JP7374895B2 - ポリエチレンシート及びそれから製造される物品 - Google Patents
ポリエチレンシート及びそれから製造される物品 Download PDFInfo
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- JP7374895B2 JP7374895B2 JP2020527082A JP2020527082A JP7374895B2 JP 7374895 B2 JP7374895 B2 JP 7374895B2 JP 2020527082 A JP2020527082 A JP 2020527082A JP 2020527082 A JP2020527082 A JP 2020527082A JP 7374895 B2 JP7374895 B2 JP 7374895B2
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- monolayer
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- uhmwpe
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Classifications
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Description
(i)10.0mm以上の幅と少なくとも100N/texの弾性率を有し、
(ii)0.1Hz≦f≦1.0Hzの周波数掃引での引張応答の動的機械分析(DMA)において測定した場合に、次の不等式
tanδ<1/(f×a)+b-(f×c)
(式中、a=120、b=0.045、及びc=0.016である)
を満たすtanδを有し、
(iii)最大目付が45gsm以下である、
非繊維状配向ポリエチレン単層に関する。
ASTM D7744-11は2011年9月に発表された。
ASTM D4440-07は2007年3月に発表された。
MIL-DTL-662Fは1997年に発表された。
MIL-DTL-46593Bは2006年に発表された。
NIJ-0115.00は2000年に発表された。
各単層又はフィルムは、同じ意味で使用されている用語あり、非フィラメント状であり、高度に配向している。高度に配向とは、1つの方向(通常は配向フィルムの単層が製造される方向)の弾性率がその他の方向よりも少なくとも10倍大きいことを意味する。好ましくは、一方向の弾性率は、他のどの方向よりも少なくとも20倍大きく、より好ましくは少なくとも30倍大きい。
tanδ<1/(a×f)+b-c×f
を満たすtanδを有し、
式中、fはHz単位であり、×は掛け算の記号であり、a=120、b=0.045、及びc=0.016である。
クロスプライテープは、複数の単層、好ましくは2つ又は4つの単層を含み、単層の間に位置する5gsmの最大目付を有する接着剤を含んでいてもよい。いくつかの実施形態においては、接着剤層の重量は4.5gsm未満、又は更には4gsm未満である。
図1の任意選択的な接着剤13は、隣接する単層を一体に結合するために、各単層の表面に隣接して配置される。各接着剤層は5gsm以下の坪量を有する。
図2は、複数のクロスプライされた非繊維状超高分子量ポリエチレンテープ10を含む典型的な積層体を示す。いくつかの実施形態においては、少なくとも90%、より好ましくは少なくとも95%、最も好ましくは100%のテープが、積層体の中で、1枚の単層の配向が隣接するテープの最も近い単層の配向に対して相殺するように位置する。
(i)複数のクロスプライ非繊維状超高分子量ポリエチレンテープ10を供給する工程であって、テープが、好ましくは、1つの単層11の配向が別の単層12の配向に対して相殺するように配置された、接着剤13で隔てられたポリエチレン配向フィルム11と12の2つの単層を含み、接着剤が5gsm以下の坪量を有する工程、
(ii)少なくとも90パーセントのテープが、1枚のテープの単層の配向が隣接する単層の最も近い単層の配向に対して相殺するように位置する配置で、工程(i)の複数のUHMWPEテープ10を含むスタック20を組み立てる工程であって、スタック中のクロスプライテープと接着剤の合計重量が0.06~60kg/m2である工程、
(iii)工程(ii)のスタックに5~60分間、10~400barの圧力及び70~152℃の温度をかける工程、並びに
(iv)25℃以下の温度まで圧力を維持しながら積層体を冷却する工程、
を含む。
フィルムの引張特性
単層の引張特性は、ASTM D7744に従って決定した。単層を全幅の張力で試験することが実施困難な場合には、単層からストリップを剥がすことにより試験片を作製した。ストリップの幅は約2~4mmであり、縦方向に平行であった。これらは、単層の初めから終わりまで約1mm幅のフィレット鋼帯を静かに引っ張ることによって、単層の端を引き裂いてから配向方向に平行に単層の初めから終わりまで引き裂きを進めることにより剥がした。ストリップを指の間に軽く通すことにより、端から緩んだフィブリルを除去した。試験片はScotch(登録商標)Magic(商標)テープ(3M,Saint Paul,Minnesota)でタブ付けした。弾性率は、ASTM D7744で定義されている通りにM1とする。
別途記載がない限り、1mmを超える長さの寸法は、目で1mmまで正確に定規を用いて測定した。フィルムの厚さは、平らな面の間にフィルムを接触させ、ノギスを介してフィルムを手で自由に引っ張ることができない最大表示値として厚さを得ることで、0.01mmまで正確にノギスを用いて測定した。線形質量についてのフィルムストリップの質量及び密度測定は、0.001gまでの精度で測定した。
フィルムの線密度は、引張試験片について上述した方法を使用してストリップを形成し、上述した通りに長さと質量を測定し、線密度を計算することにより計算した。フィルム密度は、線密度をフィルムの厚さ(上述した通りに測定)及びフィルムストリップ幅で割ることにより計算した。フィルムストリップの幅は、可動ノギスのジョウの移動方向に平行にフィルムストリップの幅断面寸法を配置し、ノギスの幅をゆっくりと狭め、フィルムがノギスのジョウの間を自由に通過しない時点のフィルムの最も大きい値を幅とすることにより、0.01mmまで正確にノギスで測定した。
DMAの結果は、上述した通りに準備したストリップを使用して、延伸方向に平行な張力で測定した。RSA-III(TA Instruments,New Castle,Delaware)を使用した。フィルムは配向方向と垂直に幅1~3mmで、配向に平行に細長く切った。サンプルには、22±2℃で、及び0.1~1.0Hzの範囲の周波数で、最大0.1%の歪みの振動引張応力で負荷をかけた。虚数弾性率に対する実数弾性率の比tanδを決定した。
フィルム標的を、一連の単層の配向方向を互いに本質的に直角に重ね、十字形の標的を形成することにより、耐弾試験のために準備した。十字形の各脚の接触している層の間に薄い両面接着テープを配置して、正方形のクロスプライの中心部の構造が変化しないようにしつつ、標的をレジストリに保持し、単層が衝撃荷重下で標的の平面内を移動する傾向を緩和した。次いで、十字形の標的を前面と背面で硬い正方形の金属フレーム内にクランプ止めした。フレームは、支持されていない中心のクロスプライ部分を残したままで、互いに噛み合う溝の間に十字形の4本の脚を保持した。その後、一貫した境界条件を与えるようにフレームの2つの部分をトグルカムロックでしっかりとクランプ止めした。
式1
式2
UHMWPEポリマー(Mitsui&Co.-USA,Rye Brook,NYのHIZEX MILLION(登録商標)540RU)の連続流を、振動ホッパーを介して、シリンダーの上部近くで重力に垂直に回転する加熱されているスチールシリンダーに供給し、次いで、幅W全体で一貫した粉末厚さを確実に得るためにドクターブレードの下を通過させた。シリンダーを温度T1に加熱し、ロール表面速度V1で移動させた。粉末は、等しいサイズ、名目上等しい温度、及び等しい速度の水平に対向する逆回転スチールシリンダーにより接触及びせん断され、線圧Pまで負荷がかけられた。これにより、粉末は、厚さtrolledの半透明フィルムへと合体及びせん断され、その幅はロールに塗布されたポリマー粉末のコーティングの幅にほぼ等しく、横方向の圧力下で比DRに引き伸ばされた。フィルムを加熱されたオーブンに通し、次いでオーブンの後及び各プラテンの後の入口速度に対してフィルムの出口速度を増加させための駆動ロールを使用して、非粘着表面を有する10個の加熱プラテンの上を通過させた。最初のプラテンでの初期速度をV2として定義し、最終出口速度をVnとして定義した。プラテン温度は、熱電対によって温度T2…TNと測定した。張力を0.40~0.53N/Texに維持するように温度を調整した。総延伸比TDRは次のように定義した:
式3
実施例4を製造するために使用した単層を、身体防護具に適切な寸法の耐弾製品として更に評価した。名目上約1mmの重なりで4枚のフィルムを横に並べて配置し、米国特許第7,923,094号明細書(以降「094」)に教示の技術を使用して、固体状態で約76cm幅の連続フィルムに接合した。単層は実質的に半透明になり、手で擦っても容易にはフィブリル化しなくなる。その後、得られた単層から22.9cm×22.9cmの正方形を切り取り、各層の最大配向方向が隣接する層に対して本質的に直交するように積層した。この方法で、32枚の単層の複数の標的を積層した。その後相互貫入歯を有する硬い金属フレームで標的の周囲をクランプ止めすることで固定された標的を保持した。その後、標的を上述した通りにV50について試験した。表3は、本発明を、配向UHMWPEフィルム技術の先行技術を代表するDuPont(商標)Tensylon(登録商標)HSグレードフィルムの対照と比較している。本発明により製造したフィルムは、「094」の教示に従ってより幅が広いフィルムへと製造された場合、装甲性能が増加する。
実施例11~13から得た単層を、身体防護具に典型的な面積密度で硬質の標的と柔軟性を有する標的の両方へと変換し、V50について評価した。
それぞれ9.82kg/m2の面積密度を有しておりそれぞれ145枚のクロスプライテープを有している、上の実施例14~19と同じ方法で製造した2枚のパネルを、National Institute of Justice(米国司法省研究所)規格NIJ0101.06に準拠するように調整したRoma Plastilina No.1モデリング粘土のブロックに付けて配置し、「Wolf Classic」7.62×39mm、8.0g、鉛芯フルメタルジャケットライフル弾で射撃した。最初のパネル(実施例20)は、700~740m/sの衝撃速度で5回射撃したが、穴が開かなかった。これは、この設計が典型的なアサルトライフルから近距離で射撃された場合にこの弾丸を止めるのに、設計が効果的な可能性があることを示している。2番目のパネルである実施例21は、V50用に射撃された。表5は、本発明の結果を他の既知の材料の結果と比較している。本発明とは対照的に、比較材料は、粘土のブロックの前ではなく、周囲の硬い金属フレームに取り付けることにより試験した。境界条件のこの相違は、本発明の試験と比較して、比較材料においてより高い結果をもたらすことになる。試験条件のこの違いにもかかわらず、DSM Dyneema LLCからのものなどの他の市販材料に対するその値から明らかなように、配向UHMWPEフィルム(DuPontのTensylon(登録商標)グレードHSフィルム)で強化された従来技術の材料に対する本発明の進歩は明白である。
実施例14~21で使用した接着剤で被覆された単層の第2の部分を、クロスプライシートの接着剤が2つの単層の間に挟まれるようにクロスプライした。単層間の合計の接着剤含有量は、名目上3gsmであった。隣接するクロスプライシートを一体に結合する接着剤は存在せず、積み重ねた際に層は互いに対して容易にスライドできた。これらのプリフォームを、34Barの圧力で成形した。プレスから取り出した後、個々のクロスプライシートは隣接するクロスプライシートに接着せず、剥がれて離れた。得られた厚さ方向の構造は[0方向配向UHMWPE/接着剤/90方向UHMWPE]であり、接着剤は実施例14~21で使用したものと同じ配合であった。積層体は、低い曲げ剛性を有しており、取り扱い及び切断が容易であり、残留カールがなく、小さい圧力で他の層に擦り付けられたときに通常の取り組みで耐摩耗性を有するようであった。サンプルを35.6cm×38cmの長方形に切断し、各単層の配向方向が次の単層に対して名目上直角になるように積み重ねた。これは、本発明が、当該技術分野で公知の手段によって、人間の胴体などの柔軟な構造を保護するために使用できる柔らかい装甲構造体に容易に変換できることを実証している。
実施例11~24で使用したものと同じ単層材料のロールを部分的にほぼ正方形のシート状にした後、坪量2.8gsmのDuPont(商標)Surlyn(登録商標)1707の予め押し出したフィルムをクロスプライ間の接着剤として使用して、ダブルベルトラミネーターでクロスプライテープ材料の連続ロールへと固めた。材料を、フルオロポリマーでコーティングされた連続繊維ガラスベルトの間に積層し、約120℃で約20秒間加熱し、低圧下で一体にニップで挟み、約40℃未満に冷却されている間に一体に保持した。結果として、材料は加熱されてから圧縮され、接着剤フィルムが流動して配向UHMWPE単層を損うことなしにクロスプライテープを一体に接着し、材料が低圧下で冷却されることで構造[0方向配向UHMWPE/Surlyn(登録商標)接着剤/90方向配向UHMWPE]を有するクロスプライテープの連続ロールが製造された。得られたクロスプライの坪量は62gsmであると測定された。前と同じように、この材料は扱い易く、切断し易く、それ自体に対する耐摩耗性を有するようであった。これは、経済的であるとして当該技術分野で知られている手段により、本発明を身体防護具の製造業者に直接役立つ製品形態に容易に変換でき、その後人間の胴体などの柔軟な構造を保護するために使用できることを実証している。その後、上述したようにサンプルを連続ロールから35.6cm×38cmの長方形に切断し、フィルムの配向方向が隣接するフィルムに対して名目上直角になるように積み重ねた。
表6の実施例27の射撃標的を、引き続きナイフによる貫通に抵抗する能力について試験した。ピストルの弾丸の捕捉による損傷によってあまり乱されない周辺の領域に、National Institute of Justice(国立司法研究所標準)規格NIJ-0115.00により規定されている「P1」刃を衝突させた。サンプルは、NIJ-0115.00で規定されている一連のゴムとフォームのパッドの上に置き、1.500mから垂直自由落下で誘導された同様にNIJ-0115.00を満たす1.8758kgの質量の発射体で落下する刃を衝突させた。規定されている標的の下の確認紙にある切れ目の長さを拡大鏡とノギスで測定し、標的及び確認紙を三角形の刃が通り抜けてフォームの裏地に入る刃の貫通深さを推定するために使用した。比較のために、DuPont(商標)Kevlar(登録商標)AS450Xとして市販されている、従来技術の突き刺し抵抗性身体防護具積層体のサンプルも同様に試験した。DuPont(商標)Kevlar(登録商標)AS450Xは、浸透性エチレンコポリマーフィルムを含浸させたパラアラミド織布である。衝突直前の速度を測定した。結果を表7に示す。これから分かるように、本発明は、望まれる防弾に加えて、より低い面積密度で、その前の耐弾試験による大幅な損傷の後であっても、従来技術の実施例よりも優れた突き刺し抵抗性を示した。
上の実施例は、配向ポリマーの自己相似装甲材料について、着弾衝撃貫通が強度増加の分数冪として増加し、弾性率の増加のより小さい分数冪として減少するという先行技術の教示に、我々の発見が反することを実証した。
(i)配向UHMWPEフィルムで二軸強化された装甲材料用の積層体の典型である、2つの市販の材料(共にDuPontからのTensylon(登録商標)HSBD30A及びTensylon(登録商標)HA120)。両方とも製造されたままの状態で試験した。Tensylon(登録商標)HA120のサンプルについては、120℃、204Barの圧力で20分間、シリコーンゴムプレスパッドの間でホットプレスで更に固め、その後、加圧下で室温まで冷却することも行った。
(ii)積層された高強度生地、DuPontのKevlar(登録商標)AS450X、アイオノマーバインダーで部分的に含浸されたパラアラミドフィラメント糸の織生地、これは身体防護具用に設計されており、手持ち型武器での穴開けによる貫通に耐性を有する。
(iii)耐穴開け包装に一般的に使用されている2種のプラスチックフィルム、すなわちポリエステルテレフタレート(PET)プラスチックフィルム(DuPont Teijin Films,Hopewell,VirginiaのMylar(登録商標))及びポリカーボネートシート。
1.2,000,000以上の粘度平均分子量を有する超高分子量ポリエチレン(UHMWPE)を含む非繊維状配向ポリエチレン単層であって、
(iv)10.0mm以上の幅と少なくとも100N/texの弾性率を有し、
(v)0.1Hz≦f≦1.0Hzの周波数掃引での引張応答の動的機械分析(DMA)において測定した場合に、次の不等式
tanδ<1/(f×a)+b-(f×c)
(式中、a=120、b=0.045、及びc=0.016である)
を満たすtanδを有し、
(vi)最大目付が45gsm以下である、
非繊維状配向ポリエチレン単層。
2.テープが0.02~0.06mmの厚さを有する、上記1に記載の単層。
3.テープが、600~750kg/m 3 、又は600~720kg/m 3 、又は600~700kg/m 3 、又は600~680kg/m 3 の密度を有する、上記1に記載の単層。
4.1つの単層の最大配向の方向が次の単層の最大配向の方向に対して直交するように各単層が配置されている、上記1に記載の単層を複数含むクロスプライテープ。
5.少なくとも1つの単層の表面上にコーティングされた5gsmの最大目付を有する熱可塑性接着剤を更に含む、上記4に記載のテープ。
6.2つ又は4つの単層を含む、上記4に記載のテープ。
7.前記接着剤が織物層を更に含む、上記5に記載のテープ。
8.前記織物がスクリム又は不織生地である、上記7に記載のテープ。
9.上記4に記載のクロスプライテープを複数含む、固化された耐衝撃貫通積層体であって、前記積層体が、試験方法Aに従って試験された場合に、少なくとも63J-m 2 /kg又は少なくとも67J-m 2 /kg又は少なくとも69J-m 2 /kg又は少なくとも71J-m 2 /kgの比エネルギー吸収(SEA)を有する、耐衝撃貫通積層体。
10.マトリックス樹脂中に埋め込まれた連続フィラメント繊維の少なくとも1つの層を更に含む、上記9に記載の積層体。
11.前記連続フィラメント繊維がp-アラミド若しくはUHMWPE又は両方の組み合わせである、上記10に記載の積層体。
Claims (4)
- 2,000,000以上の粘度平均分子量を有する超高分子量ポリエチレン(UHMWPE)を含む非繊維状配向ポリエチレン単層であって、
(i)10.0mm以上の幅と少なくとも100N/texの弾性率を有し、
(ii)0.1Hz≦f≦1.0Hzの周波数掃引での引張応答の動的機械分析(DMA)において測定した場合に、次の不等式
tanδ<1/(f×a)+b-(f×c)
(式中、a=120、b=0.045、及びc=0.016である)
を満たすtanδを有し、かつ、
(iii)最大目付が45gsm以下である、
非繊維状配向ポリエチレン単層。 - 0.02~0.06mmの厚さを有する、請求項1に記載の単層。
- 1つの単層の最大配向の方向が次の単層の最大配向の方向に対して直交するように各単層が配置されている、請求項1に記載の単層を複数含むクロスプライテープ。
- 請求項3に記載のクロスプライテープを複数含む、固化された耐衝撃貫通積層体であって、前記積層体が、試験方法Aに従って試験された場合に、少なくとも63J-m2/kgの比エネルギー吸収(SEA)を有する、耐衝撃貫通積層体。
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US10773488B2 (en) | 2020-09-15 |
US20190160782A1 (en) | 2019-05-30 |
IL273673B (en) | 2022-04-01 |
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CN111542427A (zh) | 2020-08-14 |
CA3076891C (en) | 2024-03-05 |
CA3076891A1 (en) | 2019-06-06 |
AU2018375093A1 (en) | 2020-03-12 |
BR112020010510B1 (pt) | 2024-01-09 |
AU2018375093B2 (en) | 2023-09-28 |
EP3717229A1 (en) | 2020-10-07 |
BR112020010510A2 (pt) | 2020-11-10 |
JP2021504499A (ja) | 2021-02-15 |
IL273673A (en) | 2020-05-31 |
CN111542427B (zh) | 2022-07-19 |
WO2019108291A1 (en) | 2019-06-06 |
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