High tenacity high modulus UHMW PE fiber and the process of making

• US 9,169,581 B2
• Filed: 02/13/2013
• Issued: 10/27/2015
• Est. Priority Date: 02/24/2012
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Tam, Thomas, Young, John Armstrong, Klein, Ralf, Tallent, Mark, Ardiff, Henry Gerard
• Primary Examiner(s): Chriss, Jennifer
• Assistant Examiner(s): VINEIS, FRANK J
• Application Number:
  US13/766,112
• Publication Number:
  US 20130225022A1
• Time in Patent Office: 986 Days
• Field of Search: 264/103, 264/165, 264/176.1, 264/204, 264/205, 264/178.R, 264/203, 264/210.1, 264/210.7, 264/210.8, 26421112-2112, 428/357, 428/364, 428/365, 428/401, 428/375, 428/392, 428/394, 442/59, 442/60, 442/134, 442/135, 442/170, 442/327, 442/330, 442/333, 442/334, 442/366
• US Class Current: 1/1
• CPC Class Codes: D01F 6/04 from polyolefins
• CPC Class Codes: D02G 3/02 Yarns or threads characterised by the material or by the materials from which they are made
• CPC Class Codes: D04H 1/593 to layered webs
• CPC Class Codes: D04H 1/70 characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D10B 2321/0211 high-strength or high-molecular-weight polyethylene, e.g. ultra-high molecular weight polyethylene [UHMWPE]
• CPC Class Codes: Y10T 428/298 Physical dimension
• CPC Class Codes: Y10T 442/2008 Fabric composed of a fiber or strand which is of specific structural definition

Abstract

Processes for preparing ultra-high molecular weight polyethylene (“UHMW PE”) filaments and multi-filament yarns, and the yarns and articles produced therefrom. Each process produces UHMW PE yarns having tenacities of 45 g/denier to 60 g/denier or more at commercially viable throughput rates.

Claims

1. An ultra-high molecular weight polyethylene (UHMW PE) multi-filament yarn having a tenacity of at least 45 g/denier, wherein said yarn is fabricated from an UHMW PE polymer having an intrinsic viscosity of at least about 21 dl/g and a yarn intrinsic viscosity that exceeds 90% relative to the intrinsic viscosity of the UHMW PE polymer;

wherein said intrinsic viscosities are measured in decalin at 135°

C. according to ASTM D1601-99.

2. The yarn of claim 1 wherein the yarn intrinsic viscosity exceeds 95% relative to the intrinsic viscosity of the UHMW PE polymer, and wherein said yarn is fabricated from a UHMW PE polymer having an intrinsic viscosity of at least 21 dl/g.

3. The yarn of claim 1 wherein said yarn is fabricated from a UHMW PE polymer having an intrinsic viscosity of greater than 21 dl/g, and wherein the yarn intrinsic viscosity is at least 21 dl/g.

4. The yarn of claim 1 wherein said yarn is fabricated from a UHMW PE polymer having an intrinsic viscosity of from 30 dl/g to about 100 dl/g, and wherein the yarn intrinsic viscosity is at least 28 dl/g.

5. The yarn of claim 1 wherein the yarn has a tenacity of at least 50 g/denier.

6. A composite formed from a plurality of yarns of claim 1.

7. The composite of claim 6 wherein said composite is non-woven and wherein said yarns are substantially coated with a polymeric binder.

8. The yarn of claim 1 wherein the yarn is fabricated from a UHMW PE polymer having an intrinsic viscosity of from 45 dl/g to about 100 dl/g, and wherein the UHMW PE polymer has a ratio of weight average molecular weight to number average molecular weight (M_w/M_n) of 3 or less.

9. The yarn of claim 1 wherein the yarn is fabricated from a UHMW PE polymer having an intrinsic viscosity of from 50 dl/g to about 100 dl/g.