Patent ID: 8795561

Claim:
A process for forming a nanofiber non-woven comprising, in order: a) mixing a plurality of particles, a first thermoplastic polymer and a second thermoplastic polymer, wherein the first polymer and second polymer are in a softened state, wherein the second polymer is at least partially soluble in a first solvent, and optionally cooling the mixture; b) subjecting the mixture of step a) to elongational forces and heat forming nanofibers comprising the first polymer; c) bringing the mixture of step b) to a condition where the temperature is below the softening temperature of the first polymer forming a first intermediate; d) consolidating the first intermediate with pressure and a temperature greater than the glass transition temperature of the second polymer forming a second intermediate, wherein at least 70% of the nanofibers are fused to other nanofibers, and e) removing at least a portion of the second polymer from the second intermediate forming the nanofiber non-woven, wherein after step e) at least 50% of the particles are positioned outside of the nanofibers, adjacent to a surface of the nanofibers.