ULTRA-HIGH STRENGTH UHMW PE FIBERS AND PRODUCTS
1 Assignment
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Accused Products
Abstract
Multi-filament UHMW PE yarns 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 yarn having a tenacity of greater than about 45 g/d (40.5 g/dtex).
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Citations
21 Claims
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1. (canceled)
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2. A ballistic article made from a gel spun yarn, which gel spun yarn is produced by a process comprising the steps of:
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feeding a slurry that comprises an UHMW PE and a spinning solvent to an extruder to produce a liquid mixture, the UHMW PE having an intrinsic viscosity (IV) in decalin at 135°
C. of at least about 30 dl/g;
wherein a 10 wt. % solution of said UHMW PE dissolved in mineral oil at 250°
C. has a Cogswell extensional viscosity (λ
) in accordance with the formula;λ
≧
5,917(IV)0.8;passing the liquid mixture through a heated vessel to form a homogeneous solution comprising the UHMW PE and the spinning solvent; providing the solution from the heated vessel to a spinneret to form a solution yarn; drawing the solution yarn that issues from the spinneret at a draw ratio of from about 1.1;
1 to about 30;
1 to form a drawn solution yarn;cooling the drawn solution yarn to a temperature below the gel point of the UHMW PE polymer to form a gel yarn; drawing the gel yarn in one or more stages at a first draw ratio DR1 of from about 1.1;
1 to about 30;
1;drawing the gel yarn at a second draw ratio DR2; removing spinning solvent from the gel yarn in a solvent removal device to form a dry yarn; drawing the dry yarn at a third draw ratio DR3 in at least one stage to form a partially oriented yarn;
the partially oriented yarn having an intrinsic viscosity of greater than about 19 dl/g;transferring the partially oriented yarn to a post drawing operation; and drawing the partially oriented yarn 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 yarn product having a tenacity of greater than about 45 g/d (40.5 g/dtex) and a modulus of greater than about 1400 g/d.- View Dependent Claims (3, 4, 5, 6, 7, 8)
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9. A ballistic article made from a gel spun yarn, which gel spun yarn is produced by a process comprising the steps of:
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feeding a slurry that comprises an UHMW PE and a spinning solvent to an extruder to produce a liquid mixture, the UHMW PE having an average particle size from about 100 microns to about 200 microns and an intrinsic viscosity in decalin at 135°
C. of at least about 30 dl/g;passing the liquid mixture through a heated vessel having a temperature from about 220°
C. to about 320°
C. to form a homogeneous solution comprising the UHMW PE and the spinning solvent, the solution including UHMW PE in an amount from about 5% by weight to about 20% by weight of the solution;providing the solution from the heated vessel to a spinneret to form a solution yarn; drawing the solution yarn that issues from the spinneret at a draw ratio of from about 1.1;
1 to about 30;
1 to form a drawn solution yarn;cooling the drawn solution yarn to a temperature below the gel point of the UHMW PE polymer to form a gel yarn; drawing the gel yarn in one or more stages at a first draw ratio DR1 of from about 1.1;
1 to about 30;
1;drawing the gel yarn at a second draw ratio DR2; removing spinning solvent from the gel yarn in a solvent removal device to form a dry yarn; drawing the dry yarn at a third draw ratio DR3 in at least one stage to form a partially oriented yarn, the partially oriented yarn having an intrinsic viscosity of greater than about 19 dl/g; transferring the partially oriented yarn to a post drawing operation; and drawing the partially oriented yarn 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 yarn product having a tenacity of greater than about 45 g/d (40.5 g/dtex) and a modulus of greater than about 1400 g/d.- View Dependent Claims (10, 11, 12, 13, 14, 15)
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16. A ballistic article made from a gel spun yarn, which gel spun yarn is produced by a process comprising the steps of:
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feeding a slurry that comprises an UHMW PE and a spinning solvent to an extruder to produce a liquid mixture, the UHMW PE having an intrinsic viscosity in decalin at 135°
C. of at least about 30 dl/g;passing the liquid mixture through a heated vessel to form a homogeneous solution comprising the UHMW PE and the spinning solvent; providing the solution from the heated vessel to a spinneret to form a solution yarn; drawing the solution yarn that issues from the spinneret at a draw ratio of from about 1.1;
1 to about 30;
1 to form a drawn solution yarn;cooling the drawn solution yarn to a temperature below the gel point of the UHMW PE polymer to form a gel yarn; drawing the gel yarn in one or more stages at a first draw ratio DR1 of from about 1.1;
1 to about 30;
1;drawing the gel yarn at a second draw ratio DR2; removing spinning solvent from the gel yarn in a solvent removal device to form a dry yarn; drawing the dry yarn at a third draw ratio DR3 in at least one stage to form a partially oriented yarn; transferring the partially oriented yarn to a post drawing operation; and drawing the partially oriented yarn 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 yarn product having a tenacity of greater than about 45 g/d (40.5 g/dtex) and a modulus of greater than about 1400 g/d.- View Dependent Claims (17, 18, 19, 20, 21)
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Specification