System and Method for Forming NonWoven Nanofiber Material

Abstract

A system and method for forming non-woven fibers includes an extruder for melting a substance, a nozzle on an end of the extruder for outputting the melted substance, and a gas source in fluid communication with the nozzle. The nozzle may be configured to output the substance in a melted form at atmospheric pressure proximate an output of the gas source. The system may be configured to output a gas stream at lower temperature.

The invention claimed is: 
     
         1 . A system for forming non-woven fibers, comprising:
 an extruder for melting a substance;   a nozzle on an end of the extruder; and   a gas source in fluid communication with the nozzle,   wherein the nozzle is configured to output the substance in a melted form at atmospheric pressure proximate an output of the gas source.   
     
     
         2 . The system of  claim 1 , wherein the system is configured to output the gas at a temperature below 200 degrees Celcius. 
     
     
         3 . The system of  claim 1 , wherein the nozzle comprises a substance aperture for outputting the substance and a gas aperture for outputting the gas, wherein the substance aperture is proximate the gas aperture. 
     
     
         4 . The system of  claim 3 , wherein the substance aperture is above the gas aperture. 
     
     
         5 . The system of  claim 3 , wherein the substance aperture has a rectangular shape. 
     
     
         6 . The system of  claim 3 , wherein the system is configured such that the gas stream is output at a pressure of 80 psi to 100 psi. 
     
     
         7 . The system of  claim 6 , wherein the system is configured such that the output gas stream is between 20 and 60° C. at a distance 15 centimeters from a front face of the nozzle. 
     
     
         8 . The system of  claim 3 , wherein the nozzle comprises a plurality of substance apertures. 
     
     
         9 . The system of  claim 3 , wherein the substance aperture and gas aperture are flush with the nozzle face and are defined as passages through an integral and monolithic nozzle face.