High Performance Polyethylene Fiber - An Overview
Introduction
Gel-spun polyethylene fibres are ultra-strong, high-modulus fibres that are based on the simple and
flexible polyethylene molecule. They are called high-performance polyethylene (HPPE) fibres, high-
modulus polyethylene (HMPE) fibres or sometimes extended chain polyethylene (ECPE) fibres.
The gel-spinning process uses physical processes to make available the high potential mechanical
properties of the molecule. This has been quite successful but there is still ample room for
improvement.
Polyethylene fiber
Basic Structure
The polyethylene is a long chain aliphatic hydrocarbon and it is thermoplastic. The Tg is
approximately -120ºC. Tm depends upon the structure which ranges from 108-132ºC. It has high
molecular weight alkane and has a good resistance to chemical attack. Because it is a crystalline
material and does not interact with any liquids, there is no solvent at room temperature.
Basic structure of polyethylene
Manufacturing of polyethylene fibre:
Gel-spun high-performance polyethylene fibres are produced from polyethylene with a very high
molecular weight (UHMW-PE). This material is chemically identical to normal high-density
polyethylene (HDPE), but the molecular weight is higher than the commonly used PE grades. It is in
the range that is used in abrasion-resistant engineering plastics. Different from all other high-
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performance fibres, the molecules in high performance polyethylene fibres are not ‘preformed’ to form
high tenacity and modulus fibres. In aramids and comparable fibres, the molecules tend to form rod-
like structures and these need only be oriented in one direction to form a strong fibre. Polyethylene has
much longer and flexible molecules and only by physical treatments can the molecules be forced to
assume the straight (extended) conformation and orientation in the direction of the fibre. All the
physical and chemical properties of polyethylene remain in the fibres. The differences result from the
high chain extension (stretching), the high orientation and the high crystallinity. The gel-spun fibres
have properties that are superior to those made by solid-state processes.
Gel Spinning
High performance polyethylene fibres are commercially produced under the trade names Dyneemaby
DSM High Performance Fibers in the Netherlands and by the Toyobo/DSM joint venture in Japan,
and Spectra by Honeywell (formerly Allied Signal or Allied Fibers) in the USA. The basic theory
about what a super-strong polyethylene fibre should look like was already available in the 1930s from
the ideas of Carothers, but it took almost half a century to produce HPPE fibres.1 The basic theory of
how to produce a super-strong fibre from a polymer such as polyethylene is easy to understand. In
normal polyethylene the molecules are not orientated and are easily torn apart. To make strong fibres,
the molecular chains must be stretched, oriented and crystallised in the direction of the fibre.
Furthermore, the molecular chains must be long to have sufficient interaction and for this reason
polyethylene with an ultra-high molecular weight (UHMW-PE) is used as the starting material.
Usually extension and orientation are realised by drawing. The problem is that spinning these fibres
from the melt is almost impossible due to the extremely high melt viscosity. Furthermore, the drawing
of a melt processed UHMW-PE is only possible to a very limited extent owing to the very high degree
of entanglement of the molecular chains. In the gel spinning process these two problems are solved:the
molecules are dissolved in a solvent and spun through a spinneret. In the solution the molecules
become disentangled and remain in that state after the solution is spun and cooled to give filaments.
Because of its low degree of entanglement, the gel spun material can be drawn to a very high extent.
The main steps in the process are the continuous extrusion of a solution of ultra high-molecular weight
polyethylene (UHMW-PE) Spinning of the solution, gelation and crystallization of the UHMW-PE.
This can be done either by cooling and extraction or by evaporation of the solvent. Super drawing and
removal of the remaining solvent gives the fibre its final properties but the other steps are essential in
the production of a fibre with good characteristics. In the gel-spinning process, not only do all the
starting parameters have an influence on the final properties of the fibre, the different process steps also
influence all the following stages in the production of the fibre. So, starting from the same principles,
Dyneema and Spectra may use very different equipment to produce comparable fibres.
Spinning Solution
With long-chain, flexible polymers the high orientation required can be obtained by drawing up to a
very high draw ratio (50–100 times). Melt processed UHMW-PE can be drawn up to five times only,
as the interaction between the molecular chains is too high because of the molecular entanglements. In
solution, the molecules disentangle but there remain a number of cross-overs determined by the
concentration and the length of the molecules. The flexible molecules assume a roughly spherical
shape with a diameter proportional to the cubic root of the molecular weight. For the UHMW-PE
chains the diameter of such a ball is about 1% of the total chain length. As soon as strain is applied
when the solution is pressed through the spinneret, the molecules are forced into more elongated form
For maximum fibre strength, the polyethylene molecules should be as long as possible. From an
economic point of view the concentration of the solution should be as high as possible. However, these
two factors together result in a solution that has a viscosity that is far too high to spin. Careful
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optimisation of these parameters is an essential part of the process.
Gelation and crystallization
The solvent used in the polyethylene gel-spinning process should be a good solvent at high
temperatures (>100°C) but at lower temperatures (<80°C) the polymer should easily crystallize from
the solution. After the spinneret, the solution is cooled in the quench, the solvent is removed and a gel
fibre is formed. This can be done by evaporation or by extraction of the solvent.
Drawing
The final properties of the fibre in the gel-spinning process are achieved in the super drawing stage.
All the preceding steps are needed to make this possible. The strength and modulus are directly related
to the draw ratio. The maximum attainable draw ratio appears to be related to the molecular weight and
the concentration. The attainable draw ratio increases with decreasing concentration, but for each
molecular weight there is a minimum concentration below which drawing is not possible, due to
insufficient molecular overlap.
Properties
A. Tensile properties: The primary properties of the Dyneemaand Spectra fibres are high strength and
high modulus in combination with the low density. HPPE fibres have a density slightly less than one,
so the fibre floats on water. Whereas the strength and modulus are already very high. The tenacity is 10
to 15 times that of good quality steel and the modulus is second only to that of special carbon.
Elongation at break is relatively low, as for other high-performance fibres, but owing to the high
tenacity, the energy to break is high.
B. Energy absorption: Dyneema and Spectra fibres can absorb extremely high amounts of energy.
This property is utilized in products for ballistic protection. But it makes the fibre equally suited for
products such as cut-resistant gloves and motor helmets. The fibres can also be used to improve the
impact strength of carbon or glass fibre-based composites. In these applications, not only the high
tenacity is used but also the high energy absorption.
C. Fatigue Fatigue: is very important in, for example, rope applications. HPPE fibres are the first
high-performance fibres that not only have a high tenacity but that also have tension and bending
fatigue properties comparable with the commonly used polyamide and polyester grades in ropes.
D. Abrasion resistance: Abrasion resistance is very important in ropes, also in gloves. In many of
applications it is at least one of the factors that determines wear and tear and so the service life. The
high molecular weight polyethylene used for HPPE fibres is also a well-known engineering plastic.
E. Effects of water: Polyethylene is not hygroscopic and does not absorb water.The fibres have a very
low porosity, therefore water absorption in the fibre is negligible.
F. Chemical resistance: HPPE fibres are produced from polyethylene and do not contain any aromatic
rings or any amide,hydroxylic or other chemical groups that are susceptible to attack by aggressive
agents.The result is that polyethylene and especially highly crystalline, high molecular weight
polyethylene is very resistant against chemicals.
G. Other Properties
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Specific Gravity- 0.92
Tenacity - 1.0-1.5 gpd
Elongation at Break %- 45-50
Tensile Strength psi - 15000
Softening Range: deg C- 85-90
Applications of polyethylene fibres:
1. Medical implants
2. Cable and marine ropes
3. Sail cloth
4. Composites like Pressure vessel boat hulls, sports equipment, impact shields
5. Fish netting
6. Concrete reinforcement
7. Protective clothing
8. Can be used in radar protective cover because of its low dielectric constant
9. Can be used as a lining material of a pond which collects evaporation of water and containment
from industrial plants.
10. Useful in geotextile applications
Polyethylene Manufacturers:
1. Reliance Industries Ltd.
2. Fiber Group, Inc.
3. Fibra S/A
4. Steen & Co. GmbH
5. Kemex BV
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