A material comprising unique nanofiber layers, and more particularly, this invention relates to a method for creating a material that is made from multiple unique nanofiber layers that can be utilized as filter media among other applications. The nanofiber layers have a plurality of fine fibers with an average diameter of less than 1 micron. In embodiments, the fine fibers are formed from a polymer. The material can be created according to a method in which the fine fiber strands are formed from a polymer melt or a polymer solution. The fine fibers can then be layered on top of one another to form materials such as filter media.

A material comprising a fine fiber pulp is provided. The fine fiber pulp has a plurality of fine fibers have an average diameter of less than 1 micron and an average length of less than 1 millimeter. In embodiments, the fine fibers formed of a polymer. The material can be created according to a method in which the fine fiber strands are formed from a polymer melt or a polymer solution, the fine fiber strands are cooled to a temperature of less than −25° C. to increase brittleness of the fine fibers, and the fine fiber strands are granulated into the fine fiber pulp.

A material deposition device includes a solution supply component, a gas supply component, and a co-axial discharge mechanism. The co-axial discharge mechanism includes a solution discharge mechanism, and a gas discharge mechanism co-axial with the solution discharge mechanism. The material deposition device further includes an alignment component that aligns the solution discharge mechanism in a center of the gas discharge mechanism; and an orifice plate with a number of turbulence inducing structures that induce turbulence in gas exiting the gas discharge mechanism.

A method includes applying pressure to a liquid feed of nanofiber material at a first nozzle of an array of nozzles having a first electrode voltage applied to a first electrode within an array of nozzles to form a first enlarged meniscus having a nanofiber attached, applying pressure to the liquid feed at a second nozzle having a second electrode voltage applied to a second electrode and adjacent the first nozzle within the array to form a second enlarged meniscus, increasing the second electrode voltage applied to the second electrode to a voltage level equal to voltage applied to the first electrode when the first and second enlarged menisci meet and form a combined meniscus with the nanofiber attached, decreasing the first electrode voltage to zero, and decreasing pressure on the liquid feed at the first nozzle to separate the first enlarged meniscus at the first nozzle from the second enlarged meniscus at the second nozzle having the nanofiber attached.

The invention concerns spunbond nonwoven fabrics comprising a plurality of bicomponent filaments, the bicomponent filaments having a segmented pie cross-sectional configuration including a polycarbonate component and a polypropylene component, wherein a ratio of the polypropylene component to the polycarbonate component is between about 5:95 and about 95:5.

A multi-angle spinneret for forming hollow fibers is provided. The multi-angle spinneret includes a body defining a dope chamber, a bore needle channel, and multiple dope channels being oriented at a minimum of two distinct dope channel angles relative to the dope chamber. The body includes a bore needle disposed in the bore needle channel and oriented substantially perpendicular relative to the dope chamber. The bore needle extends though the dope chamber, such that a bore fluid flow through the bore needle is kept separate from a dope flow through the dope channels. A bore fluid outlet is positioned within a dope outlet of the dope chamber, such that a bore fluid flow out of the bore fluid outlet is substantially coaxial with and substantially centered within a dope flow out of the dope outlet.

Systems for producing M yarns, wherein M≥1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a thermoplastic polymer having a color, hue, and/or dyability characteristic, which are different from each other. Each spin station produces one yarn comprising at least one bundle of filaments. Each spin station comprises at least one spinneret through which filaments are spun from at least two molten thermoplastic polymer streams received by the respective spin station and N spin pumps upstream of the spinneret for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in each M yarn.

A method for forming filaments that utilizes a die assembly having a single uninterrupted open area and a fluid supplied by a fluid flow path within the die assembly that is divided into at least two different fluid cavities, one of the fluid cavities present between a nozzle plate comprising the plurality of filament forming nozzles and an air plate, and another fluid cavity of the at least two different fluid cavities present between the air plate and an enclosure plate that defines the single uninterrupted open area is provided.

In an embodiment, a spinning head includes a head main body and a nozzle, and a storage cavity storing a material liquid is formed inside the head main body. The nozzle projects from an outer peripheral surface of the head main body, and an ejection port ejecting a material liquid is formed at a projection end. A flow path communicating with the storage cavity extends through an inside of the nozzle to the ejection port. The ejection port is located on an upper side of a vertical direction relative to the connecting part to the storage cavity, and at least a part of the flow path is tilted relative to a horizontal plane. An upper end of the connecting part of the flow path to the storage cavity is located at the same height as or on the upper side relative to an upper end of the storage cavity.

A melt blowing apparatus and method includes a melt blowing die and at least one louver. The melt blowing die has a nosepiece comprising at least one aperture and at least one air slot adjacent the aperture. The at least one louver is movably positioned adjacent a face of the melt blowing die forming a zone through which can pass air and molten filaments from the air slots and nosepiece of the melt blowing die.