High performance fibres composite sheet

Patent metadata

Field	Value
Publication number	US-11149122-B2
Application number	US-201615765548-A
Country	US
Kind code	B2
Filing date	Oct 7, 2016
Priority date	Oct 9, 2015
Publication date	Oct 19, 2021
Grant date	Oct 19, 2021

Abstract

The invention relates to a method for manufacturing a composite sheet comprising high performance polyethylene fibres and a polymeric resin comprising the steps of assembling HPPE fibres to a sheet, applying an aqueous suspension of a polymeric resin to the HPPE fibres, partially drying the aqueous suspension, optionally applying a temperature and/or a pressure treatment to the composite sheet wherein the polymeric resin is a homopolymer or copolymer of ethylene and/or propylene. The invention further relates to composite sheets obtainable by said method and articles comprising the composite sheet such as helmets, radomes or a tarpaulins.

First claim

The invention claimed is:

1. A method for manufacturing a composite sheet comprising high performance polyethylene fibres and a polymeric resin comprising the steps of:
a) providing high performance polyethylene (HPPE) fibres with a tenacity of at least 1.0 N/tex;
b) assembling the HPPE fibres to form a sheet;
c) applying an aqueous suspension of the polymeric resin to the HPPE fibres before, during or after assembling;
d) at least partially drying the aqueous suspension of the polymeric resin applied in step c);
to obtain a composite sheet upon completion of steps a), b), c) and d);
e) optionally applying a temperature in the range from the melting temperature of the resin to 153° C. to the sheet of step c) before, during and/or after step d) to at least partially melt the polymeric resin; and
f) optionally applying a pressure to the composite sheet before, during and/or after step e) to at least partially compact the composite sheet, wherein
the polymeric resin comprises a functionalized polymer which is a copolymer of ethylene and/or propylene with an ethylenically unsaturated monomer comprising a carboxylic acid group or derivative thereof, and wherein
the polymeric resin has a density as measured according to ISO1183 in the range from 860 to 930 kg/m 3 , a peak melting temperature in the range from 40 to 140° C. and a heat of fusion of at least 5 J/g.

2. The method according to claim 1 wherein the HPPE fibres are selected from the list consisting of tapes, filaments and staple fibres.

3. The method of claim 1 , wherein the HPPE fibres are prepared by a melt spinning process, a gel spinning process or solid state powder compaction process.

4. The method according to claim 1 , wherein the concentration of polymeric resin in the aqueous suspension is between 4 and 60 wt %, wherein the weight percentage is the weight of polymeric resin in the total weight of aqueous suspension.

5. The method according to claim 1 , wherein the HPPE fibres have a tenacity of at least 1.5 N/tex.

6. The method according to claim 1 , wherein the HPPE fibres comprise ultra high molecular weight polyethylene (UHMWPE).

7. The method according to claim 1 , wherein the amount of polymeric resin in the composite sheet is between 1 and 25 wt %, wherein the weight percentage is the weight of polymeric resin in the total weight of the composite sheet.

8. The method according to claim 1 , wherein the ethylenically unsaturated monomer is selected from the group consisting of acrylic, methacrylic, cinnamic, crotonic, and maleic, fumaric, and itaconic reactants.

9. The method according to claim 1 , wherein the peak melting temperature is in the range from 60 to 120° C.

10. The method according to claim 1 , wherein the heat of fusion is at least 20 J/g.

11. The method according to claim 6 , wherein the HPPE fibres comprise more than 95 wt. % of the UHMWPE.

12. The method of claim 7 , wherein the amount of polymeric resin in the composite sheet is between 4 and 18 wt %.

13. The method according to claim 1 , wherein the heat of fusion is at least 50 J/g.

Assignees

• Dsm Ip Assets Bv

Inventors

• Marissen Roelof
• Wilms Johannes
• Nielaba Leonard

Classifications

• F41H5/0485

  all the layers being only fibre- or fabric-reinforced layers · CPC title

• F41H5/0471

  Layered armour containing fibre- or fabric-reinforced layers (in combination with ceramic layers F41H5/0428, with metal layers F41H5/0457) · CPC title

• D06M15/227 Primary

  of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated · CPC title

• C08J2323/10

  Homopolymers or copolymers of propene · CPC title

• C08J2323/04

  Homopolymers or copolymers of ethene · CPC title