Graft polymer based on ultrahigh molecular weight polyethylene

Claim 2

A graft polymer consisting essentially of 95 to 99.9 parts by weight of polyethylene having a mean average molecular weight of at least 1,000,000 g/mol as a base polymer, and 5 to 0.1 parts by weight of a graft monomer selected from the group consisting of alkenecarboxylic acid and alkenecarboxylic anhydride.

Claim 3

The polymer of claim 1 wherein said molecular weight is not more than 10,000,000 g/mol.

Claim 4

The polymer of claim 2 wherein said molecular weight is 2,000,000 to 8,500,000 g/mol.

Claim 5

The polymer of claim 3 wherein said molecular weight is 3,000,000 to 8,000,000 g/mol.

Claim 6

The polymer of claim 1 wherein said polyethylene is present in an amount of 96.0 to 99.5 parts by weight.

Claim 7

The polymer of claim 1 comprising 0.5 to 4 parts by weight of said graft monomer.

Claim 8

The polymer of claim 6 comprising 1.0 to 3.5 parts by weight of said graft monomer.

Claim 9

The graft polymer of claim 1 wherein said graft monomer is selected from the group consisting of maleic acid, fumaric acid, itaconic acid, crotonic acid, acrylic acid, methacrylic acid, maleic anhydride, itaconic anhydride, crotonic anhydride, acrylic anhydride, and methacrylic anhydride.

Claim 10

The graft polymer of claim 8 wherein said graft monomer is selected from the group consisting of acrylic acid and maleic anhydride.

Claim 11

The graft polymer of claim 9 comprising 1 to 3 parts by weight of said maleic anhydride per 100 parts by weight of said maleic anhydride and said polyethylene.

Claim 12

A process for the preparation of the graft polymer of claim 1 comprising mixing said polyethylene, said graft monomer, 0.1 to 2.0 mols of a free radical forming initiator per mol of said graft monomer to form an initial mixture, subjecting said initial mixture to a high prepressure to form a pressed mixture, sintering said pressed mixture, in the substantial absence of shear forces causing uncontrolled degradation of said polyethylene, at a sintering temperature of 200° C. to 250° C. and a sintering pressure of 4.0 to 20 MPa to form a sintered mixture, and allowing said sintered mixture to cool under said sintering pressure.

Claim 13

The process of claim 11 wherein said sintering temperature is 210° C. to 240° C. and said sintering pressure is 5 to 15 MPa.

Claim 14

The process of claim 11 wherein said graft monomer is selected from the group consisting of maleic acid, fumaric acid, itaconic acid, crotonic acid, acrylic acid, methacrylic acid, maleic anhydride, itaconic anhydride, crotonic anhydride, acrylic anhydride, and methacrylic anhydride.

Claim 15

The process of claim 13 wherein said graft monomer is selected from the group consisting of acrylic acid and maleic anhydride.

Claim 16

The process of claim 11 wherein said initiator is selected from the group consisting of organic peroxides and organic hydroperoxides.

Claim 17

The process of claim 11 wherein said graft monomer and said initiator are dissolved in a solvent to form a blend, said blend is mixed with said polyethylene, and said solvent evaporated.

Claim 18

The process of claim 16 wherein said solvent is selected from the group consisting of low boiling polar organic solvent, aliphatic esters, and cyclic ethers.

Claim 19

The process of claim 17 wherein said solvent is selected from the group consisting of aliphatic ketones having 3 to 5 carbon atoms, tetrahydrofuran, dioxane, acetone, methyl isobutyl ketone, propylene carbonate, formamide, acrylic acid esters, and methyl acetate.

Claim 20

The process of claim 18 wherein said solvent is acetone.

Claim 21

The process of claim 15 wherein said initiator is taken from the class consisting of diacyl peroxides, peroxydicarbonates, alkyl peresters, perketals, dialkyl peroxides, dialkyl hydroperoxides, and ketone peroxides.

Claim 22

The process of claim 20 wherein said initiator is selected from the group consisting of 2,5-dimethyl-2,5-bis(ter.-butylperoxy)hexane and 3,3,6,6,9,9-hexamethyl-1,2,4,5-tetraoxacyclononane.

Claim 23

The process of claim 11 wherein said prepressure is 1 to 50 MPa.

Claim 24

The process of claim 11 wherein said sintering is carried out for 30 to 180 minutes.

Claim 25

The process of claim 11 wherein there is 0.3 to 1.8 mols of said initiator per mol of said graft monomer.