# US 10,119,214 B2 · Force spun sub-micron fiber and applications > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,119,214 B2 - Document ID: US10119214B2 - Status: Granted - Kind: B2 - Application number: 14/329,801 - Filed: 2014-07-11 - Published: 2015-01-22 - Granted: 2018-11-06 - Earliest claimed: 2013-07-17 - Assignees: Sabic Global Technologies B.V. - Applicants: Sabic Global Technologies B.V. - Inventors: Jacob Labelle; Richard Peters; Erich Teutsch - Web page: https://patentgrep.com/patent/US10119214B2 ## CPC - D04H 3/009: Condensation or reaction polymers - B29C 48/301: {having reciprocating, oscillating or rotating parts} - D04H 3/105: by needling (needling machines D04H18/00) - D04H 3/11: by fluid jet - Y10T 428/24149: Honeycomb-like - Y10T 442/681: Spun-bonded nonwoven fabric - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A process of forming a non-woven web including spinning continuous polymeric filaments including one selected from a poly(phenylene ether) component, a poly(phenylene ether)-polysiloxane block copolymer, and combinations thereof. The filaments can have a length to diameter ratio that is more than 1,000,000, and a diameter ranging from 50 nanometers to 5 microns. The spinning can include passing a polymer through a spinneret having a plurality of orifices in a non-electrospinning environment. The process can further include chopping the plurality of continuous filaments and obtaining a plurality of chopped nano-fibers and forming the nano-fibers into a nonwoven web. The spinning can be conducted at a rate of at least 300 grams/hour/spinneret. ## Claims ### Claim 1 A process comprising: spinning a plurality of continuous polymeric filaments by passing a mixture of at least one polymeric component and a solvent through a rotating spinneret having a plurality of orifices, wherein the at least one polymeric component comprises one selected from the group consisting of a poly(phenylene ether) component, a poly(phenylene ether)-polysiloxane block copolymer, and combinations thereof, wherein the solvent comprises benzene, toluene, xylene, chlorobenzene, chloroform, carbon tetrachloride, alcohols, ketones, anisole, veratrole, dichloroethane, trichloroethane or a combination thereof, wherein the mixture has a viscosity greater than 100 centipoise, wherein each of the plurality of continuous polymeric filaments has a length to diameter ratio that is more than 1,000,000, wherein each of the plurality of continuous polymeric filaments has a diameter ranging from 50 nanometers to 5 microns, wherein the spinning is conducted in a non-electrospinning environment and at greater than or equal to 6000 rotations per minute, wherein the spinning is conducted at a rate of at least 300 grams/hour/spinneret; and producing a non-woven web comprising the plurality of continuous polymeric filaments, wherein the non-woven web has a width of at least 150 mm. ### Claim 2 (depends on 1) The process of claim 1, wherein producing the non-woven web comprises depositing the plurality of continuous filaments onto one selected from the group consisting of a carrier substrate, a functional sheet, a film, a non-woven, a rolled good product, and combinations thereof. ### Claim 3 (depends on 2) The process of claim 2, wherein the carrier substrate is a reciprocating belt. ### Claim 4 (depends on 2) The process of claim 2, further comprising solidifying the plurality of continuous polymeric filaments before the depositing step. ### Claim 5 (depends on 1) The process of claim 1, wherein the non-woven web is unconsolidated. ### Claim 6 (depends on 1) The process of claim 1, further comprising consolidating the non-woven web. ### Claim 7 (depends on 1) The process of claim 1, further comprising consolidating the non-woven web under pressure. ### Claim 8 (depends on 1) The process of claim 1, wherein the spinning is conducted at a rate of at least 7000 grams/hour/spinerret. ### Claim 9 (depends on 1) The process of claim 1, wherein each of the plurality of continuous polymeric filaments is provided with at least one additional functionality imparting at least one selected from the group consisting of therapeutic activity, catalytic activity microelectronic activity, micro-optoelectronic activity, magnetic activity, biological activity, and combinations thereof. ### Claim 10 (depends on 1) The process of claim 1, wherein none of the plurality of continuous polymeric filaments are bonded to adjacent filaments. ### Claim 11 (depends on 1) The process of claim 1, wherein a portion of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. ### Claim 12 (depends on 1) The process of claim 1, wherein each of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. ### Claim 13 (depends on 1) The process of claim 1, further comprising entangling the the plurality of continuous polymeric filaments. ### Claim 14 (depends on 13) The process of claim 13, wherein the entangling is one of needle-punching and fluid hydroentangement. ### Claim 15 (depends on 1) The process of claim 1, wherein the poly(phenylene ether) component comprises repeating structural units having the formula: wherein each occurrence of Z1 is independently halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms; and wherein each occurrence of Z2 is independently hydrogen, halogen, unsubstituted or substituted C1-C12 hydrocarbyl provided that the hydrocarbyl group is not tertiary hydrocarbyl, C1-C12 hydrocarbylthio, C1-C12 hydrocarbyloxy, or C2-C12 halohydrocarbyloxy wherein at least two carbon atoms separate the halogen and oxygen atoms. ### Claim 16 (depends on 1) The process of claim 1, wherein the poly(phenylene ether)-polysiloxane block copolymer is prepared by an oxidative copolymerization method. ### Claim 17 (depends on 1) The process of claim 1, wherein the poly(phenylene ether) component comprises a homopolymer or copolymer of monomers selected from the group consisting of 2,6 dimethylphenol, 2,3,6 trimethylphenol, and combinations thereof. ### Claim 18 (depends on 1) The process of claim 1, further comprising at least partially removing the solvent from the plurality of continuous polymeric filaments before the plurality of continuous polymeric filaments are deposited. ### Claim 19 (depends on 1) The process of claim 1, wherein the solvent is a chlorinated solvent. ### Claim 20 (depends on 1) The process of claim 1, wherein the non-woven web contains less than 10 wt % of a material selected from the group consisting of polyvinyl pyrrolidine, polymethyl methacrylate, polyvinylidence fluoride, polypropylene, polycarbonate, polyethylene oxide, agarose, polyvinylidene fluoride, polylactic glycolic acid, nylon 6, polycaprolactone, polylactic acid, polybutylene terepthalate, polyetherimide homopolymers, polyetherimide co-polymers, polyetherether ketones homopolymers, polyetherether ketones copolymers, polyphenylene sulfones homopolymers, polyphenylene sulfones copolymers, polycarbonate homopolymers, polycarbonate copolymers, and combinations thereof. ### Claim 21 (depends on 1) The process of claim 1, wherein the process excludes any detectable amount of a material selected form the group consisting of polyvinyl pyrrolidine, polymethyl methacrylate, polyvinylidene fluoride, polypropylene, polycarbonate, polyethylene oxide, agarose, polyvinylidene fluoride, polylactic glycolic acid, nylon 6, polycaprolactone, polylactic acid, polybutylene terepthalate, and combinations thereof. ### Claim 22 A process of forming a non-woven web, said process comprising: spinning a plurality of continuous polymeric filaments comprising one selected from the group consisting of a poly(phenylene ether) component, a poly(phenylene ether)-polysiloxane block copolymer, and combinations thereof, the plurality of continuous polymeric filaments having a length to diameter ratio that is more than 1,000,000, and a diameter ranging from 50 nanometers to 5 microns; said spinning comprising passing a mixture of at least one polymer and a solvent through a rotating spinneret having a plurality of orifices at greater than or equal to 6000 rotations per minute in a non-electrospinning environment; chopping the plurality of continuous filaments and obtaining a plurality of chopped nano-fibers; forming the plurality of chopped nano-fibers into a non-woven web; the spinning being conducted at a rate of at least 300 grams/hour/spinneret, and wherein the solvent comprises benzene, toluene, xylene, chlorobenzene, chloroform, carbon tetrachloride, alcohols, ketones, anisole, veratrole, dichloroethane, trichloroethane or a combination thereof, wherein the mixture has a viscosity greater than 100 centipoise. ### Claim 23 (depends on 22) The process of claim 22, wherein none of the plurality of continuous polymeric filaments are bonded to adjacent filaments. ### Claim 24 (depends on 22) The process of claim 22, wherein a portion of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. ### Claim 25 (depends on 22) The process of claim 22, wherein each of the plurality of continuous polymeric filaments are at least partially bonded to adjacent filaments. ### Claim 26 (depends on 22) The process of claim 22, further comprising entangling the plurality of continuous polymeric filaments. ### Claim 27 (depends on 22) The process of claim 22, wherein the non-woven web contains less than 10 wt % of a material selected from the group consisting of polyvinyl pyrrolidine, polymethyl methacrylate, polyvinylidene fluoride, polypropylene, polycarbonate, polyethylene oxide, agarose, polyvinylidene fluoride, polylactic glycolic acid, nylon 6, polycaprolactone, polylactic acid, polybutylene terepthalate, polyetherimide homopolymers, polyetherimide co-polymers, polyetherether ketones homopolymers, polyetherether ketones copolymers, polyphenylene sulfones homopolymers, polyphenylene sulfones copolymers, polycarbonate homopolymers, polycarbonate copolymers, and combinations thereof.