Melt Electrospun Fibers Containing Micro and Nanolayers and Method of Manufacturing

Abstract

Fibers having two or more alternating polymer layers are formed by co-extrusion followed by electroprocessing. The fibers can be used as a non-woven mat or other substrate for a variety of applications. Delamination of the fibers using ultrasonication yields separated, micro and nanolayer, fiber ribbons which may also be used a non-woven mat or other substrate.

1 - 27 . (canceled) 
     
     
         28 . A method of producing ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers, comprising the steps of:
 co-extruding two or more polymers;   producing a fiber containing a plurality of alternating layers of two or more different polymers from the co-extruded polymers; and   delaminating the fiber to yield fiber ribbons of individual polymers co-extruded in said co-extruding step.   
     
     
         29 . The method of  claim 28 , wherein the co-extruded polymers are electroprocessed in said producing step to produce said fiber containing a plurality of alternating layers of two or more different polymers and wherein said fiber has a diameter of 50 μm or less. 
     
     
         30 . The method of  claim 29 , wherein said electroprocessing and delaminating steps are performed under conditions which produce a fibrous substrate configured as a non-woven. 
     
     
         31 . The method of  claim 28 , wherein said fiber has a diameter of 10 μm or less. 
     
     
         32 . The method of  claim 28 , wherein said fiber has at least three layers. 
     
     
         33 . The method of  claim 28 , wherein said fiber has at least 50 layers. 
     
     
         34 . The method of  claim 28 , wherein said delaminating step is performed by sonication of said fiber. 
     
     
         35 . The method of  claim 28 , wherein said delaminating step is performed by chemical exposure of said fiber. 
     
     
         36 . The method of  claim 28 , wherein said delaminating step is performed by sonication and chemical exposure of said fiber. 
     
     
         37 . The method of  claim 28 , further comprising depositing a bioactive agent on said fiber ribbons. 
     
     
         38 . The method of  claim 28 , further comprising depositing a catalytic agent on said fiber ribbons. 
     
     
         39 . The method of  claim 28 , further comprising depositing a fire or flame retardant on said fiber ribbons. 
     
     
         40 . Ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers, produced by the process of:
 co-extruding two or more polymers;   producing a fiber containing a plurality of alternating layers of two or more different polymers from the co-extruded polymers; and   delaminating the fiber to yield fiber ribbons of individual polymers co-extruded in said co-extruding step.   
     
     
         41 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40 , wherein the co-extruded polymers are electroprocessed in said producing step to produce said fiber containing a plurality of alternating layers of two or more different polymers and wherein said fiber has a diameter of 50 μm or less. 
     
     
         42 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40 , wherein said delaminating step is performed by sonication of said fiber. 
     
     
         43 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40 , wherein said delaminating step is performed by chemical exposure of said fiber. 
     
     
         44 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40 , wherein said delaminating step is performed by sonication and chemical exposure of said fiber. 
     
     
         45 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40  configured as a non-woven. 
     
     
         46 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40  further comprising a bioactive agent deposited on said ribbon shaped fibers or said substrate. 
     
     
         47 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40  further comprising a catalytic agent deposited on said ribbon shaped fibers or said substrate. 
     
     
         48 . The ribbon shaped fibers or a fibrous substrate which includes ribbon shaped fibers of  claim 40  further comprising a fire or flame retardant deposited on said ribbon shaped fibers or said substrate.