Composite material of continuous fiber and ultra high molecular weight polyethylene

Abstract

A composite material composed of continuous high strength fibers such as carbon, aramid or glass, and ultra high molecular weight polyethylene (UHMW PE), wherein the UHMW PE comprises a continuous matrix among and surrounding the fibers. The resultant composite material exhibits extraordinarily high strength, stiffness and other fiber dominated properties in the directions parallel to the fibers and exhibits its lowest strength and stiffness in directions perpendicular to the fibers. It also exhibits superb abrasion resistance, good impact strength, excellent chemical resistance, a low coefficient of friction and other beneficial properties of UHMW PE.

1 . A composite material of continuous fibers and ultra high molecular weight polyethylene, the composite material comprising: 
 (a) ultra high molecular weight polyethylene; and    (b) continuous high strength fibers, wherein the ultra high molecular weight polyethylene forms a continuous matrix among and surrounding the fibers.    
   
   
       2 . The composite material of  claim 1 , wherein the molecular weight of the ultra high molecular weight polyethylene is greater than 2,000,000 daltons.  
   
   
       3 . The composite material of  claim 1 , wherein the high strength fibers comprise carbon, glass, aramid, boron, basalt, and steel.  
   
   
       4 . The composite material of  claim 1 , wherein the high strength fibers may be unidirectional continuous fibers.  
   
   
       5 . The composite material of  claim 1 , wherein the high strength fibers may be woven continuous fibers.  
   
   
       6 . The composite material of  claim 1 ,. wherein the high strength fibers may be randomly oriented continuous fibers.  
   
   
       7 . A composite material of continuous fibers and ultra high molecular weight polyethylene, the composite material comprising: 
 (a) ultra high molecular weight polyethylene;    (b) continuous high strength fibers, wherein the ultra high molecular weight polyethylene forms a continuous matrix among and surrounding the fibers; and    (c) at least one additive or filler.    
   
   
       8 . The composite material of  claim 7 , wherein the molecular weight of the ultra high molecular weight polyethylene is greater than 2,000,000 daltons.  
   
   
       9 . The composite material of  claim 7 , wherein the high strength fibers comprise carbon, glass, aramid, boron, basalt, and steel.  
   
   
       10 . The composite material of  claim 7 , wherein the high strength fibers may be woven continuous fibers.  
   
   
       11 . The composite material of  claim 7 , wherein the high strength fibers may be unidirectional continuous fibers.  
   
   
       12 . The composite material of  claim 7 , wherein the high strength fibers may be randomly oriented continuous fibers.  
   
   
       13 . The composite material of  claim 7 , wherein the additive or filler comprises other polymers.  
   
   
       14 . The composite material of  claim 7 , wherein the additive or filler comprises heat stabilizers.  
   
   
       15 . A method of manufacturing an ultra high molecular weight polyethylene composite, the method comprising: 
 (a) selecting unidirectional and continuous high strength fibers;    (b) impregnating the fibers with ultra high molecular weight polyethylene in a fine powder to form a composite;    (c) optionally adding additives or fibers to the composite; and    (d) forming a continuous matrix of the ultra high molecular weight polyethylene surrounding the fibers.    
   
   
       16 . The method of  claim 15 , wherein the molecular weight of the ultra high molecular weight polyethylene is greater than 2,000,000.  
   
   
       17 . The method of  claim 15 , wherein the high strength fibers comprise carbon, glass, aramid, boron, basalt, and steel.  
   
   
       18 . The method of  claim 15 , wherein the high strength fibers may be woven continuous fibers.  
   
   
       19 . The method of  claim 15 , wherein the high strength fibers may be randomly oriented continuous fibers.  
   
   
       20 . The method of  claim 15 , wherein the additive or filler comprises other polymers.  
   
   
       21 . The method of  claim 15 , wherein the additive or filler comprises heat stabilizers.