Method and device for producing a polymer tape

Patent metadata

Field	Value
Publication number	US-9316465-B2
Application number	US-73290210-A
Country	US
Kind code	B2
Filing date	Mar 26, 2010
Priority date	Mar 31, 2009
Publication date	Apr 19, 2016
Grant date	Apr 19, 2016

Abstract

The invention relates to a method for producing a highly oriented, high molecular weight polymer tape. The method comprises forming and compression-molding a polymer powder bed at a temperature below the melting point of the polymer to form a sheet; at a temperature below the melting point of the polymer, rolling and stretching the sheet in a calendar unit to form a partially oriented polymer web; at a temperature below the melting point of the polymer, drawing the partially oriented polymer web in a drawing unit; and, optionally repeating step c) to form a more fully oriented non-fibrous high molecular weight polymer tape, the method being discontinuous in that the ingoing line speed of one of the method steps b) to d) differs from the outgoing line speed of the preceding method step.

First claim

The invention claimed is:

1. A method for producing a highly oriented non-fibrous polymer tape comprising:
a) forming and compressing a polymer powder bed at a temperature below the melting point of the polymer to form a non-fibrous polymeric sheet;
b) rolling and stretching the non-fibrous sheet formed according to step a) in a calendar unit at a temperature below the melting point of the polymer to form a partially oriented polymer web;
c) drawing the partially oriented polymer web in a drawing unit at a temperature below the melting point of the polymer to form an oriented non-fibrous polymer tape; and
d) repeating step c) to form a more oriented non-fibrous polymer tape, wherein
the method is practiced in a discontinuous manner such that an ingoing line speed of at least two of the method steps b), c) and d) are lower than an outgoing line speed of a preceding step.

2. The method of claim 1 , wherein step a) is directly followed by step b), and wherein an outgoing line speed of step a) is substantially the same as an ingoing line speed of step b).

3. The method of claim 1 , further comprising rolling and stretching the partially oriented polymer web of step b) to form a more fully oriented polymer web.

4. The method of claim 1 , which respectively comprises:
winding the non-fibrous polymeric sheet, partially oriented polymeric web or oriented non-fibrous polymer tape onto a bobbin at a winding speed which is substantially the same as an outgoing line speed of the preceding step,
breaking the non-fibrous polymeric sheet, partially oriented polymeric web or oriented non-fibrous polymer tape after being wound onto the bobbin, and then
unwinding the non-fibrous polymeric sheet, partially oriented polymeric web or oriented non-fibrous polymer tape from the bobbin to at least one of steps b) and c), respectively, at substantially the ingoing line speed thereof.

5. The method of claim 1 , wherein the polymer is selected from the group consisting of polyolefins, ultrahigh molecular weight polyolefins, polyesters, polyvinyl alcohols, polyacrylonitriles, polyamides, liquid crystalline polymers, polybenzimidazole and polybenzoxazole.

6. The method of claim 1 , wherein step c) includes uniaxially drawing the partially oriented polymer web.

7. The method of claim 1 , wherein a line speed ratio of a greater outgoing line speed of a preceding step to a lower ingoing line speed is between about 1.25 to about 20.

8. The method of claim 1 , wherein the polymer is a high or ultrahigh molecular weight polyethylene.

9. The method of claim 7 , wherein the line speed ratio is between about 1.75 to about 15.

10. The method of claim 7 , wherein the line speed ratio is between about 2.5 to about 10.

11. The method of claim 1 , wherein the polymer is an ultrahigh molecular weight polyethylene having an intrinsic viscosity as measured in decalin at 135° C. of at least 4 dl/g.

12. The method of claim 1 , wherein the polymer is an ultrahigh molecular weight polyethylene that is drawable in a solid state.

13. The method of claim 5 , wherein the polymer is poly(1,4-phenylene-2,6-benzobisoxazole) or poly(2,6-diimidazo[4,5-b-4′,5′-e]pyridinylene-1,4-(2,5-dihydroxy)phenylene).

14. The method of claim 1 , wherein the polymer is a high molecular weight polymer having a viscosity-average molecular weight of 250000 or more.

15. A method for producing a highly oriented non-fibrous polymer tape comprising:
a) forming and compressing a polymer powder bed at a temperature below the melting point of the polymer to form a non-fibrous polymeric sheet;
b) rolling and stretching said sheet in a calendar unit at a temperature below the melting point of the polymer to form a partially oriented polymer web;
b′) winding the partially oriented polymer web onto a bobbin at a winding speed which is substantially the same as an outgoing line speed of b); breaking the partially oriented polymer web; and then unwinding the partially oriented polymer web to step c) at substantially the ingoing line speed thereof;
c) drawing the partially oriented polymer web in a drawing unit at a temperature below the melting point of the polymer to form an oriented non-fibrous polymer tape;
c′) winding the oriented non-fibrous polymer tape onto a bobbin at a winding speed which is substantially the same as an outgoing line speed of c); breaking the partially oriented non-fibrous polymer tape; and then unwinding the oriented non-fibrous polymer tape to step d) at substantially the ingoing line speed thereof;
d) repeating step c) to form a more oriented non-fibrous polymer tape, wherein
the ingoing line speed of method step c) is lower than the outgoing line speed of step b); and the ingoing line speed of step d) is lower than the outgoing line speed of step c).

16. The method of claim 15 , further comprising step a′) winding the non-fibrous polymeric sheet onto a bobbin at a winding speed which is substantially the same as an outgoing line speed of a); breaking the non-fibrous polymeric sheet; and then unwinding the non-fibrous polymeric sheet to step b) at substantially the ingoing line speed thereof.

17. The method of claim 16 , wherein the ingoing line speed of step b) is lower than the outgoing line speed of step a).

18. The method of claim 15 , further comprising rolling and stretching the partially oriented polymer web of step b) to form a more fully oriented polymer web.

19. The method of claim 15 , wherein the polymer is selected from the group consisting of polyolefins, ultrahigh molecular weight polyolefins, polyesters, polyvinyl alcohols, polyacrylonitriles, polyamides, liquid crystalline polymers, polybenzimidazole and polybenzoxazole.

20. The method of claim 15 , wherein step c) includes uniaxially drawing the partially oriented polymer web.

21. The method of claim 15 , wherein a line speed ratio of a greater outgoing line speed of a preceding step to a lower ingoing line speed is between about 1.25 to about 20.

22. The method of claim 15 , wherein the polymer is a high or ultrahigh molecular weight polyethylene.

23. The method of claim 21 , wherein the line speed ratio is between about 1.75 to about 15.

24. The method of claim 21 , wherein the line speed ratio is between about 2.5 to about 10.

25. The method of claim 15 , wherein the polymer is an ultrahigh molecular weight polyethylene having an intrinsic viscosity as measured in decalin at 135° C. of at least 4 dl/g.

26. The method of claim 15 , wherein the polymer is an ultrahigh molecular weight polyethylene that is drawable in a solid state.

27. The method of claim 15 , wherein the polymer is poly(1,4-phenylene-2,6-benzobisoxazole) or poly(2,6-diimidazo[4,5-b-4′,5′,-e]pyridinylene-1,4-(2,5-dihydroxy)phenylene).

28. The method of claim 15 , wherein the polymer is a high molecular weight polymer having a viscosity-average molecular weight of 250000 or more.

Assignees

• Steeman Reinard Jozef Maria
• Dsm Ip Assets Bv

Inventors

• Steeman Reinard Jozef Maria

Classifications

• B29C43/006

  Pressing and sintering powders, granules or fibres · CPC title

• B29C43/46

  Rollers · CPC title

• F41H5/0485 Primary

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

• B29C43/228

  using endless belts feeding the material between non-rotating pressure members, e.g. vibrating pressure members · CPC title

• B29C43/22

  of articles of indefinite length · CPC title