The disclosure describes composite fibers reinforced with inorganic nanostructures of high aspect ratio with homogeneous dispersion and alignment along the fiber axis and a process for producing said composite fibers. A composite fiber comprising an array of inorganic nanowires embedded in a polymer matrix. The nanowires have a diameter <100 nm and high aspect ratio of at least 5 with homogenous dispersion and polymer chains of the polymer matrix and the nanowires are oriented along the fiber axis. The nanowire wt % in the composite fiber is in the range of 0.01 to 2 wt %. The inorganic nanowires are non conducting and include at least one of ZnO, or aluminosilicate clay tubes.

The disclosure describes composite fibers reinforced with inorganic nanostructures of high aspect ratio with homogeneous dispersion and alignment along the fiber axis and a process for producing said composite fibers. A composite fiber comprising an array of inorganic nanowires embedded in a polymer matrix. The nanowires have a diameter <100 nm and high aspect ratio of at least 5 with homogenous dispersion and polymer chains of the polymer matrix and the nanowires are oriented along the fiber axis. The nanowire wt % in the composite fiber is in the range of 0.01 to 2 wt %. The inorganic nanowires are non conducting and include at least one of ZnO, or aluminosilicate clay tubes.

Charged polymeric webs, such as electret webs, include a thermoplastic resin and a charge-enhancing additive. The additives are substituted heterocyclic thiolate salts. The heterocyclic thiolate salt has 2 nitrogen groups and a third group that may be an NH, N—NH.sub.2, O, or S group. The substituent group is an aromatic or heterocyclic aromatic group. The electret webs may be a non-woven fibrous web or a film. The electret webs are suitable for use as filter media.

Charged polymeric webs, such as electret webs, include a thermoplastic resin and a charge-enhancing additive. The additives are substituted heterocyclic thiolate salts. The heterocyclic thiolate salt has 2 nitrogen groups and a third group that may be an NH, N—NH.sub.2, O, or S group. The substituent group is an aromatic or heterocyclic aromatic group. The electret webs may be a non-woven fibrous web or a film. The electret webs are suitable for use as filter media.

A method of making nonwoven webs comprising providing a spinneret including a pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer into a region adjacent the first side of the spinneret, directing only a second stream of molten propylene polymer into a region distal to the first side of the spinneret, extruding only the first stream propylene polymer through the exit openings in a first zone where the exit opening comprises exit ports in the first zone having a first density; extruding only the second stream propylene polymer through the exit openings of a second zone where the exit opening comprises exit ports in the second zone having a second density less than the first density; and the second zone is distal to the first side with the first zone being between the second zone and the first side.

A method of making nonwoven webs comprising providing a spinneret including a pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer into a region adjacent the first side of the spinneret, directing only a second stream of molten propylene polymer into a region distal to the first side of the spinneret, extruding only the first stream propylene polymer through the exit openings in a first zone where the exit opening comprises exit ports in the first zone having a first density; extruding only the second stream propylene polymer through the exit openings of a second zone where the exit opening comprises exit ports in the second zone having a second density less than the first density; and the second zone is distal to the first side with the first zone being between the second zone and the first side.

A macro-synthetic fiber includes three or more partially fused filaments made of a polymer composition including at least one polypropylene, wherein the fiber has a multi-lobal cross-sectional shape with three or more lobes. A method produces macro-synthetic fibers, a cementitious material includes a binder and macro-synthetic fibers, and a method for forming a concrete surface uses a concrete mixture modified with the macro-synthetic fibers.

A macro-synthetic fiber includes three or more partially fused filaments made of a polymer composition including at least one polypropylene, wherein the fiber has a multi-lobal cross-sectional shape with three or more lobes. A method produces macro-synthetic fibers, a cementitious material includes a binder and macro-synthetic fibers, and a method for forming a concrete surface uses a concrete mixture modified with the macro-synthetic fibers.

A spun-blown non-woven web is disclosed which is formed from a plurality of fibers formed from a single polymer having an average fiber diameter ranging from between about 0.5 microns to about 50 microns; a basis weight of at least about 0.5 gsm; a tensile strength, measured in a machine direction, ranging from between about 20 g to about 4,200 g; a ratio of tensile strength, measured in the machine direction, to basis weight of at least about 20:1; and a ratio of percent elongation, measured in the machine direction, to fiber diameter of at least about 15.

A spun-blown non-woven web is disclosed which is formed from a plurality of fibers formed from a single polymer having an average fiber diameter ranging from between about 0.5 microns to about 50 microns; a basis weight of at least about 0.5 gsm; a tensile strength, measured in a machine direction, ranging from between about 20 g to about 4,200 g; a ratio of tensile strength, measured in the machine direction, to basis weight of at least about 20:1; and a ratio of percent elongation, measured in the machine direction, to fiber diameter of at least about 15.