High molecular weight poly(alpha-olefin) solutions and articles made therefrom
First Claim
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1. A process for the continuous preparation of solutions comprising up to 50 wt. % of an UHMW PO having an intrinsic viscosity from 5 to 45 dl/g measured in decalin at 135°
- C. comprising the steps of;
a) forming a slurry of UHMW PO particles in a solvent for the UHMW PO at a first temperature which is below the temperature at which said UHMW PO particles will dissolve in said solvent;
b) processing said slurry through an extruder operating such that a mixture of said solvent and said UHMW PO is formed at a second temperature above the melting temperature of said UHMW PO, and the throughput rate of UHMW PO is at least the quantity 2.5 D2 (2.5×
D×
D) grams per minute, where D represents the screw diameter of said extruder in centimeters;
c) optionally, discharging said mixture from the extruder through a positive displacement pump;
d) passing said mixture through a heated vessel at a temperature above the melting temperature of said UHMW PO in said solvent, said heated vessel having a volume such that the average residence time of the mixture in said vessel is from 2 to 120 minutes, whereby a solution of said UHMW PO is formed.
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Abstract
A robust process for the continuous preparation of solutions of high molecular weight UHMW PO that is capable of producing strong materials at high production capacity, is conservative of capital and energy requirements, and the articles made therefrom.
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Citations
36 Claims
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1. A process for the continuous preparation of solutions comprising up to 50 wt. % of an UHMW PO having an intrinsic viscosity from 5 to 45 dl/g measured in decalin at 135°
- C. comprising the steps of;
a) forming a slurry of UHMW PO particles in a solvent for the UHMW PO at a first temperature which is below the temperature at which said UHMW PO particles will dissolve in said solvent;
b) processing said slurry through an extruder operating such that a mixture of said solvent and said UHMW PO is formed at a second temperature above the melting temperature of said UHMW PO, and the throughput rate of UHMW PO is at least the quantity 2.5 D2 (2.5×
D×
D) grams per minute, where D represents the screw diameter of said extruder in centimeters;
c) optionally, discharging said mixture from the extruder through a positive displacement pump;
d) passing said mixture through a heated vessel at a temperature above the melting temperature of said UHMW PO in said solvent, said heated vessel having a volume such that the average residence time of the mixture in said vessel is from 2 to 120 minutes, whereby a solution of said UHMW PO is formed. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
- C. comprising the steps of;
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25. A process for the continuous preparation of molded articles from slurries of ultrahigh molecular weight UHMW PO comprising the steps:
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a) forming a slurry of ultrahigh molecular weight UHMW PO particles having an intrinsic viscosity measured in decalin at 135°
C. of from 5 to 45 dl/g in a solvent for the UHMW PO at a first temperature which is below the temperature which said UHMW PO will dissolve in said solvent;
b) processing said slurry through an extruder operating such that a mixture of said solvent and said UHMW PO is formed at a second temperature above the melting temperature of said UHMW PO, and the throughput rate of UHMW PO in said mixture is at least the quantity 2.5 D2 (2.5×
D×
D) grams per minute wherein D represents the screw diameter of the extruder in centimeters;
c) optionally, discharging said mixture from the extruder through a positive displacement pump;
d) passing said mixture through a heated vessel at a temperature above the melting temperature of said UHMW PO, said vessel having a volume such that the average residence time of the mixture in said vessel is from 2 to 120 minutes, whereby a solution of said UHMW PO is formed;
e) passing the thus-formed solution out of said vessel through a positive displacement pump and through a shaping orifice, said solution being at a temperature below the atmospheric boiling point of said solvent to form a molded solution article;
f) optionally, stretching the molded solution article;
g) cooling the solution article obtain a molded gel article;
h) optionally stretching the molded gel article;
i) substantially removing the solvent from said molded gel article to form a molded solid article; and
j) optionally stretching the molded solid article in one or more steps at temperatures from 25°
C. to 165°
C. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36)
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Specification