High tenacity high modulus UHMWPE fiber and the process of making
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.
1. An ultra-high molecular weight polyethylene (UHMW PE) multi-filament yarn fabricated from a UHMW PE polymer having an intrinsic viscosity of at least about 21 dl/g and having 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 is fabricated from a UHMW PE polymer having a ratio of weight average molecular weight to number average molecular weight (M w /M n ) of 3 or less.
3. 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.
4. 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.
5. 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.
6. 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.
7. 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.
8. The yarn of claim 1 wherein the yarn comprises a plurality of filaments and has a denier per filament of 1.4 dpf or greater.
9. A composite formed from a plurality of yarns of claim 1 .
10. The composite of claim 9 wherein said composite is non-woven and wherein said yarns are substantially coated with a polymeric binder.