Pre-fiber gel materials and compositions, methods of manufacture and uses thereof
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 sufficient cohesiveness in the composition so that it can be spun into a fiber.
1. A method of producing a pre-fiber gel composition, consisting essentially of:
providing at least one amide-based compound;
providing at least one lactam gelling agent; and
mixing the at least one amide-based polymer and the at least one lactam gelling agent such that there is sufficient viscosity and sufficient cohesiveness in the composition so that it can be spun into a fiber.
2. The method of claim 1 , wherein the at least one amide-based polymer comprises a nylon compound.
3. The method of claim 2 , wherein the nylon compound comprises nylon-6.
4. The method of claim 1 , wherein the at least one lactam gelling agent comprises caprolactam.
5. The method of claim 1 , wherein the at least one lactam gelling agent comprises less than 50 weight percent of the composition.
6. The method of claim 5 , wherein the at least one lactam gelling agent comprises less than 40 weight percent of the composition.
7. The method of claim 6 , wherein the at least one lactam gelling agent comprises less than 30 weight percent of the composition.
8. The method of claim 6 , wherein the at least one lactam gelling agent comprises less than 20 weight percent of the composition.
9. The method of claim 1 , wherein mixing comprises blending.
10. The method of claim 1 , wherein mixing comprises extruding.
11. A spun fiber formed using the method of claim 1 .
12. A carpet product comprising the spun fiber of claim 9 .
13. A pre-fiber gel composition, consisting essentially of:
at least one amide-based polymer; and
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 polymer and the at least one lactam gelling agent that the composition can be spun into a fiber.
14. A method of producing a pre-fiber gel composition, consisting essentially of:
providing at least one amide-based compound;
providing at least one lactam gelling agent;
mixing the at least one amide-based polymer and the at least one lactam gelling agent such that there is sufficient viscosity and sufficient cohesiveness in the composition so that it can be spun into a fiber;
heating the composition; and
removing at least part of the at least one lactam gelling agent after the mixing step.