Polyamide nanofiber nonwovens
A nanofiber nonwoven product is disclosed which comprises a polyamide with a relative viscosity from 2 to 330, spun into nanofibers with an average diameter of less than 1000 nanometers (1 micron). In general, the inventive products are prepared by: (a) providing a polyamide composition, wherein the polyamide has a relative viscosity from 2 to 330; (b) melt spinning the polyamide composition into a plurality of nanofibers having an average fiber diameter of less than 1 micron, followed by (c) forming the nanofibers into the product.
1. A fabric product comprising
one or more layers of a nonwoven product comprising from 0.05% to 20% of polyethylene and 80% to 99.5% of nylon,
wherein the nonwoven product comprises nanofibers having an average diameter of less than 950 nanometers.
2. The fabric product of claim 1 , wherein the fabric product is a breathable fabric.
3. The fabric product of claim 1 , wherein the polyethylene has a melt index between 5 grams/10 min and 200 grams/10 min.
4. The fabric product of claim 1 , wherein the polyethylene has density between about 0.85 grams/cc and about 1.1 grams/cc.
5. The fabric product of claim 1 , comprises from 0.1% to 1.2% polyethylene.
6. The fabric product of claim 1 , wherein the nonwoven product comprises nanofibers having an average diameter from 150 to 500 nanometers.
7. The fabric product of claim 1 , wherein the nylon comprises at least one of N6, N66, N6T/66, N612, N6/66, N61/66, N66/61/6T, N11, N12, or combinations thereof, wherein “N” means Nylon.
8. The fabric product of claim 1 , wherein the nylon is N66.
9. The fabric product according to claim 1 , wherein the product has an Air Permeability Value of less than 600 CFM/ft 2 .
10. The fabric product according to claim 1 , wherein from 1 to 20% of the nanofibers have a fiber diameter of greater than 700 nanometers.
11. The fabric product according to claim 1 , further comprising an additive in an amount from 0.01 to 49 wt. %, based on the total weight of the nanofiber nonwoven product.
12. The fabric product according to claim 1 , wherein the additive comprises a zinc compound.
13. The fabric product according to claim 1 , wherein the additive comprises zinc oxide.
14. A method for forming fabric product comprising:
blending polyethylene pellets, chips, or flakes with nylon pellets, chips, or flakes into a blended composition;
spinning the blended composition into a plurality of nanofibers having an average fiber diameter from 100 to 950 nanometers; and
forming the nanofibers into a layer for the fabric product.
15. The method claim 14 , wherein the nonwoven product is a breathable fabric.
16. The method of claim 14 , wherein the blended composition comprises from 0.05% to 20% of polyethylene and 80% to 99.5% of nylon.
17. The method of claim 14 , wherein the nylon comprises at least one of N6, N66, N6T/66, N612, N6/66, N61/66, N66/61/6T, N11, N12, or combinations thereof, wherein “N” means Nylon.
18. The method of claim 14 , wherein the nylon pellets, chips, or flakes contains up to 5% moisture.
19. The method of claim 14 , wherein the blended composition is melt spun by way of melt-blowing through a die into a high velocity gaseous stream.
20. The method of claim 14 , wherein the blended composition is melt-spun by 2-phase propellant-gas spinning, including extruding the blended composition in liquid form with pressurized gas through a fiber-forming channel.