Pre-fiber gel compositions and materials, methods of manufacture and uses thereof
View Patent ↗A pre-fiber gel material is described herein that includes: a) at least one amide-based and/or polyamide-based composition; and b) at least one lactam gelling agent, wherein the gel composition has sufficient viscosity and sufficient cohesiveness upon the mixing of the at least one amide-based or polyamide-based polymer and the at least one lactam gelling agent that the composition can be spun into a fiber. In addition, methods are provided herein that teach that the production of a pre-fiber gel composition, including: a) providing at least one amide-based compound; b) providing at least one lactam gelling agent; and c) mixing the at least one amide-based polymer and the at least one lactam gelling agent such that there is sufficient viscosity and to sufficient cohesiveness in the composition so that it can be spun into a fiber.
1. A pre-fiber gel composition, comprising:
at least one amide-based polymer; and
from 5 to at least 50 weight percent of at least one lactam gelling agent in the composition to form a polymer gel material, wherein the polymer gel material has sufficient viscosity and sufficient cohesiveness upon the mixing of the at least one amide-based polymer and the at least one lactam gelling agent that the material can be spun into a fiber.
2. The pre-fiber composition of claim 1 , wherein the at least one amide-based polymer comprises a nylon compound.
3. The pre-fiber composition of claim 2 , wherein the nylon compound comprises nylon-6.
4. The pre-fiber composition of claim 1 , wherein the at least one lactam gelling agent comprises caprolactam.
5. The pre-fiber composition of claim 1 , wherein the at least one lactam gelling agent comprises less than 50 weight percent of the composition.
6. The pre-fiber composition of claim 5 , wherein the at least one lactam gelling agent comprises less than 40 weight percent of the composition.
7. The pre-fiber composition of claim 6 , wherein the at least one lactam gelling agent comprises less than 30 weight percent of the composition.
8. The pre-fiber composition of claim 7 , wherein the at least one lactam gelling agent comprises less than 20 weight percent of the composition.
9. A spun fiber comprising the gel composition of claim 1 .
10. A carpet product comprising the spun fiber of claim 9 .
11. A method of producing a pre-fiber gel composition, comprising:
providing at least one amide-based compound;
providing from 5 to at least 50 weight percent of at least one lactam gelling agent; and
mixing the at least one amide-based polymer and the at least one lactam gelling agent to form a polymer gel material, such that there is sufficient viscosity and sufficient cohesiveness in the material so that it can be spun into a fiber.
12. The method of claim 11 , wherein the at least one amide-based polymer comprises a nylon compound.
13. The method of claim 12 , wherein the nylon compound comprises nylon-6.
14. The method of claim 11 , wherein the at least one lactam gelling agent comprises caprolactam.
15. The method of claim 11 , wherein the at least one lactam gelling agent comprises less than 50 weight percent of the composition.
16. The method of claim 15 , wherein the at least one lactam gelling agent comprises less than 40 weight percent of the composition.
17. The method of claim 16 , wherein the at least one lactam gelling agent comprises less than 30 weight percent of the composition.
18. The method of claim 17 , wherein the at least one lactam gelling agent comprises less than 20 weight percent of the composition.
19. The method of claim 11 , wherein mixing comprises blending.
20. The method of claim 11 , wherein mixing comprises extruding.
21. The method of claim 11 , further comprising removing at least part of the at least one lactam gelling agent after the mixing step.