Ultra-high strength UHMWPE fibers and products

Patent metadata

Field	Value
Publication number	US-9365953-B2
Application number	US-201113173919-A
Country	US
Kind code	B2
Filing date	Jun 30, 2011
Priority date	Jun 8, 2007
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

Multi-filament ultra high molecular weight polyethylene fibers can be produced according to processes that result in improved properties. The ultra high molecular weight polyethylene can have an intrinsic viscosity in decalin at 135° C. of at least about 30 dl/g, and can be processed under optimal conditions to achieve a gel spun fiber having a tenacity of greater than about 45 g/denier (40.5 g/dtex).

First claim

What is claimed is:

1. A fiber comprising ultra high molecular weight polyethylene (UHMWPE) having a tenacity of at least about 45 g/denier (40.5 g/dtex) and a tensile modulus of at least about 1400 g/denier, said fiber being produced by a process comprising the steps of:
a) feeding a slurry that comprises an UHMWPE polymer and a spinning solvent to an extruder to produce a liquid mixture, the UHMWPE polymer having an intrinsic viscosity (IV) in decalin at 135° C. of at least about 30 dl/g; or feeding the UHMWPE polymer and spinning solvent into an extruder and forming both a slurry and a liquid mixture inside the extruder; wherein a 10 wt. % solution of said UHMWPE dissolved in mineral oil at 250° C. has a Cogswell extensional viscosity (λ) in accordance with the formula:
λ≧5,917( IV ) 0.8 ;

b) passing the liquid mixture through a heated vessel to form a homogeneous solution comprising the UHMWPE polymer and the spinning solvent;
c) providing the solution from the heated vessel to a spinneret to form a solution fiber;
d) drawing the solution fiber that issues from the spinneret at a draw ratio of from about 1.1:1 to about 30:1 to form a drawn solution fiber;
e) cooling the drawn solution fiber to a temperature below the gel point of the UHMWPE polymer to form a gel fiber;
f) drawing the gel fiber in one or more stages at a first draw ratio DR 1 of from about 1.1:1 to about 30:1;
g) drawing the gel fiber at a second draw ratio DR 2 ;
h) removing spinning solvent from the gel fiber in a solvent removal device to form a dry fiber;
i) drawing the dry fiber at a third draw ratio DR 3 in at least one stage to form a partially oriented fiber; the partially oriented fiber having an intrinsic viscosity of greater than about 19 dl/g;
j) transferring the partially oriented fiber to a post drawing operation; and
k) drawing the partially oriented fiber at a post drawing temperature in the post drawing operation to a fourth draw ratio DR 4 of from about 1.8:1 to about 15:1 to form a highly oriented fiber product having a tenacity of at least about 45 g/denier (40.5 g/dtex).

2. The fiber of claim 1 wherein the UHMWPE polymer forming the slurry of step a) has an intrinsic viscosity of greater than about 30 dl/g.

3. The fiber of claim 1 wherein the highly oriented fiber product has an intrinsic viscosity that is from about 0.2 times the intrinsic viscosity of the UHMWPE to about 0.65 times the intrinsic viscosity of the UHMWPE polymer.

4. The fiber of claim 1 wherein the spinning solvent is selected from the group consisting of halogenated hydrocarbons, mineral oil, decalin, tetralin, naphthalene, xylene, toluene, dodecane, undecane, decane, nonane, octene, cis-decahydronaphthalene, trans-decahydronaphthalene, low molecular weight polyethylene wax, and mixtures thereof.

5. The fiber of claim 1 wherein the spinning solvent is selected from the group consisting of mineral oil, decalin, and mixtures thereof.

6. The fiber of claim 1 wherein the partially oriented fiber has a tenacity from about 12 g/denier (10.8 g/dtex) to about 25 g/denier (22.5 g/dtex).

7. The fiber of claim 1 wherein said fiber has a tensile modulus of at least about 1400 g/denier.

8. A multi-fiber yarn comprising a plurality of fibers of claim 1 .

9. A fiber ply comprising a plurality of fibers of claim 1 aligned in a substantially parallel array.

10. A fabric formed from a plurality of fibers of claim 1 .

11. A fibrous composite comprising a plurality of fibers of claim 1 and a polymeric binder material at least partially coated on at least some of said fibers.

12. The fibrous composite of claim 11 which comprises a consolidated plurality of non-woven fiber plies, each fiber ply comprising a plurality of said fibers and wherein a polymeric binder material is at least partially coated on at least some of said fibers.

13. The fibrous composite of claim 11 which comprises a consolidated plurality of non-woven fiber plies, each fiber ply comprising a plurality of said fibers, wherein each fiber ply comprises a plurality of substantially parallel fibers, and wherein a polymeric binder material is at least partially coated on at least some of said fibers.

14. The fibrous composite of claim 11 wherein said polymeric binder material comprises from about 7% to about 20% by weight of said fibrous composite.

15. The fibrous composite of claim 11 wherein said composite has a top outer surface and a bottom outer surface, and wherein said composite further comprises at least one layer of a polymer film attached to at least one of said surfaces.

16. The fibrous composite of claim 15 wherein said at least one layer of a polymer film comprises at least one polyolefin, polyamide, polyester, polyurethane, vinyl polymer, fluoropolymer, a copolymer thereof, or a combination thereof.

17. The fibrous composite of claim 15 wherein said polymeric binder material comprises a polybutadiene, polyisoprene, polystyrene-polyisoprene-polystrene-block copolymer, a styrene-isoprene-styrene block copolymer, natural rubber, ethylene-propylene copolymers, ethylene-propylene-diene terpolymers, polysulfide polymers, polyurethane elastomers, chlorosulfonated polyethylene, polychloroprene, plasticized polyvinylchloride, butadiene acrylonitrile elastomers, poly(isobutylene-co-isoprene), polyacrylates, polyesters, polyethers, fluoroelastomers, silicone elastomers, copolymers of ethylene, or a combination thereof.

18. An article formed from the composite of claim 1 .

19. A fiber comprising ultra high molecular weight polyethylene (UHMWPE) having a tenacity of at least about 45 g/denier (40.5 g/dtex) and a tensile modules of at least about 1400 g/denier, said fiber being produced by a process comprising the steps of:
a) feeding a slurry that comprises an UHMWPE polymer and a spinning solvent to an extruder to produce a liquid mixture, the UHMWPE polymer having an intrinsic viscosity (IV) in decalin at 135° C. of at least about 30 dl/g; or feeding the UHMWPE polymer and spinning solvent into an extruder and forming both a slurry and a liquid mixture inside the extruder;
b) passing the liquid mixture through a heated vessel to form a homogeneous solution comprising the UHMWPE polymer and the spinning solvent;
c) providing the solution from the heated vessel to a spinneret to form a solution fiber;
d) drawing the solution fiber that issues from the spinneret at a draw ration of from about 1.1:1 to about 30:1 to form a drawn solution fiber;
e) cooling the drawn solution fiber to a temperature below the gel point of the UHMWPE polymer to form a gel fiber;
f) drawing the gel fiber in one or more stages at a first draw ratio DR 1 of from about 1.1:1 to about 30:1;
g) drawing the gel fiber at a second draw ratio DR 2 ;
h) removing spinning solvent from the gel fiber in a solvent removal device to form a dry fiber;
i) drawing the dry fiber at a third draw ratio DR 3 in at least one stage to form a partially oriented fiber; the partially oriented fiber having an intrinsic viscosity of greater than about 19 dl/g;
j) transferring the partially oriented fiber to a post drawing operation; and
k) drawing the partially oriented fiber at a post drawing temperature in the post drawing operation to a fourth draw ration DR 4 of from about 1.8:1 to about 15:1 to form a highly oriented fiber product having a tenacity of at least about 45 g/denier (40.5 g/dtex).

20. A fiber comprising ultra high molecular weight polyethylene (UHMWPE) having a tenacity of at least about 45 g/denier (40.5 g/

Assignees

• Tam Thomas Y
• Young John A
• Aminuddin Norman
• Hermes John E
• Honeywell Int Inc

Inventors

• Tam Thomas Y
• Young John A
• Aminuddin Norman
• Hermes John E

Classifications

• B29C48/05

  Filamentary, e.g. strands · CPC title

• B29C48/919

  using a bath, e.g. extruding into an open bath to coagulate or cool the material · CPC title

• B32B2571/02

  defensive, e.g. armour plates or anti-ballistic clothing · CPC title

• B32B2260/048

  Natural or synthetic rubber · CPC title

• B29C48/0018

  combined with shaping by orienting, stretching or shrinking, e.g. film blowing (B29C48/0017 takes precedence) · CPC title