US4587163A
Expired / Lapsed
US
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Preparation of ultra high molecular weight polyethylene morphologies of totally fused particles with superior mechanical performance
Assignee: International Business Machines Corp
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Filing: 1984-11-01
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Granted: 1986-05-06
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Expires: 2004-11-01
Abstract
Abstract An isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene and a method of making it. An original powder stock or a partially fused, melt-crystallized stock having a granular memory, is heated to a temperature at which the stock fuses completely to form a homogeneous melt which loses memory of the granular structure of the original stock. The resultant melt is cooled to ambient temperatures under compression to provide a novel homogeneous isotropic semicrystalline morphology. An anisotropic morphology of ultra-high-molecular-weight polyethylene may then be made by solid-state deforming that semicrystalline morphology at a temperature near but below its crystalline melting point at a deformation ratio of about 5 to 8.
Inventors
- 👤 Anagnostis E. Zachariades
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-22 22:46
CPC Classifications
B; B29; B29C; B29C43/00; B29C43/003; B29C43/32; B29C43/52; B29C55/00; B29C55/02; B29C55/18; B29C67/00; B29C67/24; A; A61; A61F; A61F2210/00; A61F2210/0014; B29K; B29K2023/00; B29K2023/04; B29K2023/06; B29K2023/0658; B29K2023/0683; B29K2105/00; B29K2105/25; B29K2105/251; B29K2995/00; B29K2995/0037; B29K2995/0041; B29K2995/0045; B29K2995/0088; B29L; B29L2031/00; B29L2031/753; B29L2031/7532; Y; Y10; Y10S; Y10S528/00; Y10S528/92; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
81 words
A method for making an isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused melt-crystallized stock having granular memory to a temperature and for a time to fuse the stock completely to form a homogeneous melt which has lost memory of its former granular structure, and cooling the resultant melt to ambient temperatures under compression to provide a homogeneous isotropic semicrystalline morphology which has no memory of the granular nature of the original stock.
Claim 2
Independent Claim
81 words
A method for making an isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused melt-crystallized stock having granular memory to a temperature and for a time to fuse the stock completely to form a homogeneous melt which has lost memory of its former granular structure, and cooling the resultant melt to ambient temperatures under compression to provide a homogeneous isotropic semicrystalline morphology which has no memory of the granular nature of the original stock.
Claim 3
Dependent Claim
18 words
The method of claim 1 wherein the heating step comprises heating to 220°-320° C. for about 10 minutes.
Claim 4
Independent Claim
124 words
A method for making an isotropic homogeneous semicrystalline morphology of ultra-high-molecular-weight polyethylene comprising; heating an original powder stock or a partially fused melt-crystallized stock having granular memory, to a temperature between 220° C. and 320° C. in the absence of oxygen at a compression load of about 1500-2000 pounds for about ten minutes, then at about 150° C. placing the material under a compression load of about 12000-14000 pounds for another ten minutes to provide a melt in which the stock fuses completely and loses memory of its former granular structure, and cooling the resultant material to ambient temperatures under a compression load of about 1500 pounds to give a semicrystalline morphology which has no memory of the granular nature of the original stock.
Claim 5
Independent Claim
124 words
A method for making an isotropic homogeneous semicrystalline morphology of ultra-high-molecular-weight polyethylene comprising; heating an original powder stock or a partially fused melt-crystallized stock having granular memory, to a temperature between 220° C. and 320° C. in the absence of oxygen at a compression load of about 1500-2000 pounds for about ten minutes, then at about 150° C. placing the material under a compression load of about 12000-14000 pounds for another ten minutes to provide a melt in which the stock fuses completely and loses memory of its former granular structure, and cooling the resultant material to ambient temperatures under a compression load of about 1500 pounds to give a semicrystalline morphology which has no memory of the granular nature of the original stock.
Claim 6
Independent Claim
99 words
A method for making an anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused melt-crystallized stock having granular memory to a temperature and for a time to fuse the stock completely and lose memory of its original granular structure, cooling the resultant material to ambient temperatures under compression to provide an initial homqgenous isotropic semicrystalline morphology which has no memory of the granular nature of the original stock, and solid-state deforming that semicrystalline morphology at a temperature near but below its crystalline melting point at a deformation ratio of about 5 to 8.
Claim 7
Independent Claim
99 words
A method for making an anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused melt-crystallized stock having granular memory to a temperature and for a time to fuse the stock completely and lose memory of its original granular structure, cooling the resultant material to ambient temperatures under compression to provide an initial homqgenous isotropic semicrystalline morphology which has no memory of the granular nature of the original stock, and solid-state deforming that semicrystalline morphology at a temperature near but below its crystalline melting point at a deformation ratio of about 5 to 8.
Claim 8
Dependent Claim
14 words
The method of claim 4 wherein the temperature of deformation is about 130° C.
Claim 9
Dependent Claim
29 words
The method of claim 4 wherein the heating step includes heating at 220° C. to 320° C. for about ten minutes under a compression load of about 1500-2000 pounds.
Claim 10
Dependent Claim
27 words
The method of claim 6 wherein the heating step also includes subsequently, at about 150° C. applying a load of about 12000-14000 pounds for about ten minutes.
Claim 11
Dependent Claim
14 words
The method of claim 4 wherein the deforming step includes at least five times.
Claim 12
Independent Claim
147 words
A method for making an anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused, melt-crystallized stock having granular memory, to a temperature between 220° C. and 320° C. in the absence of oxygen at a compression load of about 1500-2000 pounds for about ten minutes, then at about 150° C. placing the material under a compression load of about 12000-14000 pounds for another ten minutes to provide a melt in which the stock fuses completely and loses memory of its former granular structure, cooling the resultant material to ambient temperatures under a compression load of about 1500 pounds to give a semicrystalline morphology which has no memory of the granular nature of the original stock, and extruding the semicrystalline product through an extrusion rolling die at a temperature of about 130° C. at a deformation ratio of about 5 to 8.
Claim 13
Independent Claim
147 words
A method for making an anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused, melt-crystallized stock having granular memory, to a temperature between 220° C. and 320° C. in the absence of oxygen at a compression load of about 1500-2000 pounds for about ten minutes, then at about 150° C. placing the material under a compression load of about 12000-14000 pounds for another ten minutes to provide a melt in which the stock fuses completely and loses memory of its former granular structure, cooling the resultant material to ambient temperatures under a compression load of about 1500 pounds to give a semicrystalline morphology which has no memory of the granular nature of the original stock, and extruding the semicrystalline product through an extrusion rolling die at a temperature of about 130° C. at a deformation ratio of about 5 to 8.
Claim 14
Independent Claim
143 words
A method for making an anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature between 220° C. and 320° C. in the absence of oxygen at a compression load of about 1500-2000 pounds for about ten minutes, then at about 150° C. placing the material under a compression load of about 12000-14000 pounds for another ten minutes to provide a melt in which the stock fuses completely and loses memory of its former granular structure, cooling the resultant material to ambient temperatures under a compression load of about 1500 pounds to give a semicrystalline morphology which has no memory of the granular nature of the original stock, and drawing the semicrystalline product at a temperature of about 130° C. at a deformation ratio of about 5 to 8.
Claim 15
Independent Claim
143 words
A method for making an anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature between 220° C. and 320° C. in the absence of oxygen at a compression load of about 1500-2000 pounds for about ten minutes, then at about 150° C. placing the material under a compression load of about 12000-14000 pounds for another ten minutes to provide a melt in which the stock fuses completely and loses memory of its former granular structure, cooling the resultant material to ambient temperatures under a compression load of about 1500 pounds to give a semicrystalline morphology which has no memory of the granular nature of the original stock, and drawing the semicrystalline product at a temperature of about 130° C. at a deformation ratio of about 5 to 8.
Claim 16
Dependent Claim
22 words
An isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene comprising a completely fused ultra-high molecular weight polyethylene without any memory of a granular structure.
Claim 17
Dependent Claim
22 words
An isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene comprising a completely fused ultra-high molecular weight polyethylene without any memory of a granular structure.
Claim 18
Dependent Claim
31 words
An isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene obtained from a homogeneous melt of ultra-high molecular weight polyethylene with weight average molecular weight of several millions without the aid of radiation dopants.
Claim 19
Dependent Claim
31 words
An isotropic semicrystalline morphology of ultra-high-molecular-weight polyethylene obtained from a homogeneous melt of ultra-high molecular weight polyethylene with weight average molecular weight of several millions without the aid of radiation dopants.
Claim 20
Dependent Claim
31 words
A homogeneous melt crystallized ultra-high molecular-weight polyethylene morphology with an effective molecular network structure and number of physical entanglements without the aid of radiation cross linking or chemical cross linking agents.
Claim 21
Dependent Claim
31 words
A homogeneous melt crystallized ultra-high molecular-weight polyethylene morphology with an effective molecular network structure and number of physical entanglements without the aid of radiation cross linking or chemical cross linking agents.
Claim 22
Dependent Claim
77 words
An ultra-high-molecular-weight polyethylene useful for tendon fabrication, having a molecular weight of several million and made by first heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature at which the stock fuses completely and loses memory of its former granular structure, and then cooling the resultant material to ambient temperatures under compression load to give a semicrystalline morphology without memory of the granular nature of the original stock.
Claim 23
Dependent Claim
77 words
An ultra-high-molecular-weight polyethylene useful for tendon fabrication, having a molecular weight of several million and made by first heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature at which the stock fuses completely and loses memory of its former granular structure, and then cooling the resultant material to ambient temperatures under compression load to give a semicrystalline morphology without memory of the granular nature of the original stock.
Claim 24
Dependent Claim
39 words
An anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: a solid-state deformed semicrystalline morphology, having no memory of a granular nature, deformed at a temperature near but below its crystalline melting point at a deformation ratio of about 5 to 8.
Claim 25
Dependent Claim
39 words
An anisotropic morphology of ultra-high-molecular-weight polyethylene comprising: a solid-state deformed semicrystalline morphology, having no memory of a granular nature, deformed at a temperature near but below its crystalline melting point at a deformation ratio of about 5 to 8.
Claim 26
Dependent Claim
19 words
The anisotropic morphology of ultra-high-molecular-weight polyethylene in claim 15 wherein the solid state deformed morphology is filamentary or ribbon-like.
Claim 27
Dependent Claim
29 words
The anisotropic morphology of ultra-high-molecular-weight polyethylene in claim 16 wherein the filamentary or ribbon-like products exhibit resistance to fibrillation without the aid of radiation cross-linking or chemical cross-linking agents.
Claim 28
Dependent Claim
102 words
An ultra-high-molecular-weight polyethylene useful for tendon fabrication, having a molecular weight of several million and made by first heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature at which the stock fuses completely and loses memory of its former granular structure, then cooling the resultant material to ambient temperatures under compression load to give a semicrystalline morphology without memory of the granular nature of the original stock, and then extruding the semicrystalline product through an extrusion rolling die at a temperature of about 130° C. and at a deformation ratio of about 5-8.
Claim 29
Dependent Claim
102 words
An ultra-high-molecular-weight polyethylene useful for tendon fabrication, having a molecular weight of several million and made by first heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature at which the stock fuses completely and loses memory of its former granular structure, then cooling the resultant material to ambient temperatures under compression load to give a semicrystalline morphology without memory of the granular nature of the original stock, and then extruding the semicrystalline product through an extrusion rolling die at a temperature of about 130° C. and at a deformation ratio of about 5-8.
Claim 30
Dependent Claim
97 words
An ultra-high-molecular-weight polyethylene useful for tendon fabrication, having a molecular weight of several million and made by first heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature at which the stock fuses completely and loses memory of its former granular structure, then cooling the resultant material to ambient temperatures under compression load to give a semicrystalline morphology without memory of the granular nature of the original stock, and then drawing the semicrystalline product at a temperature of about 130° C. and at a deformation ratio of about 5-8.
Claim 31
Dependent Claim
97 words
An ultra-high-molecular-weight polyethylene useful for tendon fabrication, having a molecular weight of several million and made by first heating an original powder stock or a partially fused, melt-crystallized stock having a granular memory, to a temperature at which the stock fuses completely and loses memory of its former granular structure, then cooling the resultant material to ambient temperatures under compression load to give a semicrystalline morphology without memory of the granular nature of the original stock, and then drawing the semicrystalline product at a temperature of about 130° C. and at a deformation ratio of about 5-8.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-05-05 | 1989-11-04 | 1990-05-06 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-05-05 | 1993-11-04 | 1994-05-06 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-05-05 | 1997-11-04 | 1998-05-06 | $7700.00 | Window Closed / Lapsed |