Multiple calender process for forming non-fibrous high modulus ultra high molecular weight polyethylene tape

A process for continuously producing a highly oriented non-fibrous ultra high molecular weight polyethylene tape comprising:

• feeding particles of ultra high molecular weight polyethylene into a forming device, said forming device including an upper and lower rotating belt;
• applying pressure from said upper and lower rotating belts to said polyethylene particles between said upper and lower rotating belts to remove a substantial amount of air from said polyethylene particles and to bond said polyethylene particles into a continuous sheet;
• heating said continuous sheet to a temperature near the melting point of said polyethylene;
• rolling and stretching said heated sheet in a first calender unit to form a partially oriented polyethylene web;
• rolling and stretching said partially oriented polyethylene web in at least one additional calender unit to form a fully oriented polyethylene web;
• and
• drawing said fully oriented polyethylene web to form said highly oriented non-fibrous ultra high molecular weight polyethylene tape, said UHMWPE polyethylene tape including a modulus of at least 1,400 grams per denier.