Ultra-high strength UHMW PE fibers and products

1. A ballistic article made from a gel spun yarn, which gel spun yarn is produced by a process comprising the steps of:

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.

2. The ballistic article of claim 1 wherein the UHMW PE has average particles size from 100 microns to about 200 microns and about 90% of the particles have a particle size that is within 40 microns of the average particle size.

3. The ballistic article of claim 1 wherein the highly oriented yarn 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 ballistic article of claim 1 wherein the solution comprises the UHMW PE in an amount from about 6% by weight to about 10% by weight of the solution.

5. The ballistic article 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.

6. The ballistic article of claim 1 wherein the partially oriented yarn (POY) has a tenacity from about 12 g/d (10.8 g/dtex) to about 25 g/d (22.5 g/dtex).

7. The ballistic article of claim 1 wherein the UHMW PE has an intrinsic viscosity of greater than about 30 dl/g, and the partially oriented yarn has an intrinsic viscosity of greater than about 17 dl/g.

8. A ballistic article made from a gel spun yarn, which gel spun yarn is produced by a process comprising the steps of:

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.

9. The ballistic article of claim 8 wherein the UHMW PE has average particles size from 100 microns to about 200 microns and about 90% of the particles have a particle size that is within 40 microns of the average particle size.

10. The ballistic article of claim 8 wherein the highly oriented yarn 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.

11. The ballistic article of claim 8 wherein the solution comprises the UHMW PE in an amount from about 6% by weight to about 10% by weight of the solution.

12. The ballistic article of claim 8 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.

13. The ballistic article of claim 8 wherein the partially oriented yarn (POY) has a tenacity from about 12 g/d (10.8 g/dtex) to about 25 g/d (22.5 g/dtex).

14. The ballistic article of claim 8 wherein the UHMW PE has an intrinsic viscosity of greater than about 30 dl/g, and the partially oriented yarn has an intrinsic viscosity of greater than about 17 dl/g.

15. A ballistic article made from a gel spun yarn, which gel spun yarn is produced by a process comprising the steps of:

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.

16. The ballistic article of claim 15 wherein the UHMW PE has average particles size from 100 microns to about 200 microns and about 90% of the particles have a particle size that is within 40 microns of the average particle size.

17. The ballistic article of claim 15 wherein the highly oriented yarn 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.

18. The ballistic article of claim 15 wherein the solution comprises the UHMW PE in an amount from about 6% by weight to about 10% by weight of the solution.

19. The ballistic article of claim 15 wherein the partially oriented yarn (POY) has a tenacity from about 12 g/d (10.8 g/dtex) to about 25 g/d (22.5 g/dtex).

20. The ballistic article of claim 15 wherein the UHMW PE has an intrinsic viscosity of greater than about 30 dl/g, and the partially oriented yarn has an intrinsic viscosity of greater than about 17 dl/g.