ULTRA-HIGH STRENGTH UHMW PE FIBERS AND PRODUCTS

• US 20110269359A1
• Filed: 06/30/2011
• Published: 11/03/2011
• Est. Priority Date: 06/08/2007
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Tam, Thomas Y., Young, John A., Hermes, John E., Aminuddin, Norman
• Granted Patent: US 9,365,953 B2
• Time in Patent Office: Days
• US Class Current: 442/181
• CPC Class Codes: B29C 48/0018 combined with shaping by orienting, stretching or shrinking, e.g. film blowing B29C48/0017 takes precedence
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/37 Gear pumps
• CPC Class Codes: B29C 48/405 Intermeshing co-rotating screws
• CPC Class Codes: B29C 48/832 Heating
• CPC Class Codes: B29C 48/90 with calibration or sizing, i.e. combined with fixing or setting of the final dimensions of the extruded article
• CPC Class Codes: B29C 48/906 using roller calibration
• CPC Class Codes: B29C 48/91 Heating, e.g. for cross linking
• CPC Class Codes: B29C 48/919 using a bath, e.g. extruding into an open bath to coagulate or cool the material
• CPC Class Codes: B29K 2023/0683 UHMWPE, i.e. ultra high molecular weight polyethylene
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2250/42 Alternating layers, e.g. ABAB(C), AABBAABB(C)
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2260/048 Natural or synthetic rubber
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2571/02 defensive, e.g. armour plates or anti-ballistic clothing
• CPC Class Codes: D01F 6/04 from polyolefins
• CPC Class Codes: D04H 3/007 Addition polymers
• CPC Class Codes: D04H 3/115 : by applying or inserting filamentary binding elements
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2933 : Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/60 : Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

Multi-filament UHMW PE fibers can be produced according to processes that result in improved properties. The UHMW PE 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).

Claims

1. A fiber comprising ultra high molecular weight polyethylene (UHMW PE) 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 UHMW PE polymer and a spinning solvent to an extruder to produce a liquid mixture, the UHMW PE polymer having an intrinsic viscosity in decalin at 135°

C. of at least about 30 dl/g;

or feeding the UHMW PE 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 UHMW PE 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 UHMW PE polymer to form a gel fiber;

f) drawing the gel fiber in one or more stages at a first draw ratio DR1 of from about 1.1;

1 to about 30;

1;

g) drawing the gel fiber at a second draw ratio DR2;

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 DR3 in at least one stage to form a partially oriented fiber;

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 DR4 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 UHMW PE polymer forming the slurry of step a) has an intrinsic viscosity of greater than about 30 dl/g, and the partially oriented fiber of step i) has an intrinsic viscosity of greater than about 17 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 UHMW PE to about 0.65 times the intrinsic viscosity of the UHMW PE 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. The fabric of claim 10 which comprises a non-woven fabric.

12. The fabric of claim 10 which comprises a woven fabric.

13. 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.

14. The fibrous composite of claim 13 which comprises a consolidated plurality of non-woven fiber plies, each fiber ply comprising a plurality of fibers of claim 1 and wherein a polymeric binder material is at least partially coated on at least some of said fibers.

15. The fibrous composite of claim 13 which comprises a consolidated plurality of non-woven fiber plies, each fiber ply comprising a plurality of fibers of claim 1, 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.

16. The fibrous composite of claim 13 wherein said polymeric binder material comprises from about 7% to about 20% by weight of said fibrous composite.

17. The fibrous composite of claim 13 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.

18. The fibrous composite of claim 17 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.

19. The fibrous composite of claim 17 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.

20. An article formed from the composite of claim 12.