Fluoroplastics, Volume 1

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ISBN: 9781884207846 | 1884207847
Cover: Hardcover
Copyright: 12/31/2000

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Today, a generational change is taking place in the fluoropolymer industry. The pioneers of PTFE developed an astonishing mass of basic and applied technical work. Now many of these experts are retiring and a new generation is taking their place. This new generation brings a plethora of skills, built upon the basic knowledge of fluoropolymer technology. Speaking to the needs of today's engineering and science students and practicing professionals, this book provides an in-depth treatment of homofluoropolymer polymerization and part fabrication technology. A comprehensive range of issues surrounding the manufacturing of the monomer; polymer, fabrication, end-use, safety, and disposal are covered. The book has been arranged to allow self-managed reading and learning. It is both a source of data and a reference.

Introduction	p. 1

Fundamentals	p. 3
Introduction	p. 3
What are Fluoropolymers?	p. 4
Fundamental Properties of Fluoropolymers	p. 4
Developmental History of Fluoropolymers	p. 5
Examples of Uses of Fluoropolymers	p. 6
References	p. 8
Fluoropolymers: Properties and Structure	p. 9
Introduction	p. 9
Impact of F and C-F Bond on the Properties of PTFE	p. 9
Disturbing the PTFE Structure: Perfluorinated Ethylene-Propylene Copolymer (FEP) and Polychlorotrifluoroethylene	p. 11
Disturbing the PTFE Structure: Perfluorinated Ethylene-Propylene Copolymer (FEP)	p. 11
Disturbing the PTFE Structure: Polychlorotrifluoroethylene	p. 12
Reaction Mechanism	p. 12
Effect of Solvents on Fluoropolymers	p. 13
Molecular Interaction of Fluoropolymers: Low Friction and Low Surface Energy	p. 14
Conformations and Transitions of Polytetrafluoroethylene	p. 15
Conformations and Transitions of Polychlorotrifluoroethylene (PCTFE)	p. 16
References	p. 17
Operational Classification of Fluoropolymers	p. 19
Introduction	p. 19
TFE Homopolymers	p. 22
TFE Copolymers	p. 23
CTFE Polymers	p. 23
Vinylidene Fluoride Polymers	p. 23
Vinyl Fluoride Polymers	p. 23
Process Classification	p. 23
References	p. 24
Fluoropolymer Monomers	p. 25
Introduction	p. 25
Synthesis of Tetrafluoroethylene	p. 25
Properties of Tetrafluoroethylene	p. 26
Synthesis of Hexafluoropropylene	p. 27
Properties of Hexafluoropropylene	p. 27
Synthesis of Perfluoroalkylvinylethers	p. 28
Properties of Perfluoroalkylvinylethers	p. 29
Synthesis of Chlorotrifluoroethylene	p. 30
Properties of Chlorotrifluoroethylene	p. 30
References	p. 31
Homofluoropolymer Polymerization and Finishing	p. 33
Introduction	p. 33
Polymerization Mechanism	p. 33
Tetrafluoroethylene Polymers	p. 33
Preparation of Polytetrafluoroethylene by Suspension Polymerization	p. 35
Preparation of Polytetrafluoroethylene by Dispersion Polymerization	p. 40
Chlorotrifluoroethylene Polymers and Polymerization	p. 46
Characterization of Polytetrafluoroethylene	p. 48
Characterization of Polychlorotrifluoroethylene	p. 54
References	p. 56
Commercial Grades of Homofluoropolymers	p. 59
Introduction	p. 59
Granular PTFE	p. 59
PTFE Dispersions	p. 59
Fine Powder PTFE	p. 59
PCTFE Dispersions	p. 60
Polychlorotrifluoroethylene Polymers	p. 60
Fluoropolymer Manufacturers	p. 60
References	p. 73

Fabrication and Processing of Granular Polytetrafluoroethylene	p. 76
Introduction	p. 76
Resin Selection	p. 76
Compression Molding	p. 78
Equipment	p. 79
Mold Design	p. 79
Presses	p. 80
Ovens	p. 81
Densification and Sintering Mechanism	p. 81
Billet Molding	p. 82
Preforming	p. 82
Sintering	p. 92
Cooling	p. 95
Sintering Cycles	p. 97
Hot Compression-Molding	p. 97
Automatic Molding	p. 97
Isostatic Molding	p. 97
Introduction to Isostatic Molding	p. 103
Comparison of Isostatic with Other Fabrication Techniques	p. 103
Basic Isostatic Process	p. 105
Complex Isostatic Molding	p. 105
Wet and Dry Bag Isostatic Molding	p. 107
Isostatic Mold Design	p. 107
Preform Shape	p. 107
Surface Finish of Preform	p. 110
Pressurization Direction	p. 110
Other Design Factors	p. 111
Mold Configuration and Dimensions	p. 111
Mold and Bag Sealing	p. 113
Tooling and Material: Rigid Part	p. 115
Tooling and Material: Flexible Bag	p. 115
Design Procedure	p. 116
PTFE Resin Selection	p. 116
Isostatic Processing of PTFE Resins	p. 116
Ram Extrusion	p. 118
Introduction to Ram Extrusion	p. 118
Ram Extrusion: Basic Technology	p. 119
Ram Extrusion: Resin Feed	p. 119
Ram Extrusion: Compaction	p. 121
Ram Extrusion: Sintering and Cooling	p. 121
Ram Extrusion: Heat Requirements of Sintering	p. 121
Ram Extrusion: Pressure Requirements	p. 123
Ram Extrusion: Cooling	p. 127
Ram Extrusion: Die Skin Formation	p. 127
Ram Extrusion Equipment Design	p. 128
Drive System	p. 130
Extrusion Ram	p. 130
Extrusion Die	p. 131
Resin Feed System	p. 131
Other Ram Extrusion	p. 131
Typical Resin, Process and Property Data	p. 132
References	p. 134
Fabrication and Processing of Fine Powder Polytetrafluoroethylene	p. 135
Introduction	p. 135
Resin Handling and Storage	p. 135
Paste Extrusion Fundamentals	p. 136
Extrusion Aid or Lubricant	p. 138
Wire Coating	p. 138
Extrusion of Tubing	p. 150
Unsintered Tape	p. 157
Expanded PTFE Manufacturing	p. 162
Fine Powder Resin Selection	p. 165
References	p. 166
Fabrication and Processing of PTFE Dispersions	p. 168
Introduction	p. 168
Applications	p. 168
Storage and Handling	p. 169
Principles of Coating Technology	p. 169
Dispersion Formulation and Characteristics	p. 173
Glass Cloth Coating	p. 175
Impregnation of Flax and Polyaramide	p. 178
Coating Metal and Hard Surfaces	p. 179
PTFE Yarn Manufacturing	p. 180
Film Casting	p. 180
Anti-Drip Applications	p. 182
Filled Bearings	p. 182
De-Dusting Powders	p. 182
Other Applications	p. 183
References	p. 183
Processing of Polychlorotrifluoroethylene	p. 185
Introduction	p. 185
Processing Considerations	p. 185
Compression Molding	p. 187
Injection Molding	p. 187
Extrusion	p. 189
Machining and Bonding	p. 189
Processing PCTFE Dispersions	p. 189
References	p. 190
Fluoroadditives	p. 191
Introduction	p. 191
Feedstock	p. 191
Degradation of Polytetrafluoroethylene	p. 191
Production Methods	p. 193
Production of Fluoroadditives by Thermal Cracking (Pyrolysis)	p. 193
Production of Fluoroadditives by Electron Beam Irradiation	p. 193
Grinding Irradiated PTFE	p. 196
Commercial Products	p. 197
Applications	p. 199
Thermoplastic Modification	p. 200
Elastomers	p. 200
Printing Inks	p. 200
Paints and Coatings	p. 201
Oils and Greases	p. 201
Dry Lubricant	p. 203
Regulatory Compliance	p. 203
References	p. 204
Filled Fluoropolymer Compounds	p. 206
Introduction	p. 206
Granular-based Compounds	p. 206
Fillers	p. 206
Polytetrafluoroethylene Selection	p. 208
Filled PTFE--Production Techniques	p. 208
Fine Powder-Based Compounds	p. 209
Fillers and Compounding Methods	p. 210
Fabrication of Reinforced Gasketing Material	p. 210
Process Background	p. 211
Process Description	p. 211
Co-Coagulated Compounds	p. 214
Processing Compounds	p. 214
Typical Properties of Filled Fluoropolymers	p. 216
Mechanical Properties	p. 217
Thermal Properties	p. 222
Electrical Properties	p. 222
Chemical Properties	p. 222
Tribological Properties of Filled PTFE	p. 223
Commercial Products	p. 227
References	p. 232

Chemical Properties of Fluoropolymers	p. 233
Introduction	p. 233
Chemical Compatibility of Polytetrafluoroethylene	p. 233
Effect of Ozone with Polytetrafluoroethylene	p. 236
Oxygen Compatibility of PTFE	p. 236
Chemical Compatibility of Polychlorotrifluoroethylene	p. 237
Permeation Fundamentals	p. 237
Permeation Measurement and Data	p. 239
Environmental Stress Cracking	p. 241
References	p. 242
Properties of Tetrafluoroethylene Homopolymers	p. 243
Introduction	p. 243
Influence of Processing	p. 243
Measurement of Flaws	p. 244
Mechanical Properties	p. 246
Deformation Under Load (Creep) and Cold Flow	p. 249
Fatigue Properties	p. 254
Impact Strength	p. 254
Hardness	p. 255
Friction	p. 255
PV Limit	p. 256
Abrasion and Wear	p. 256
Electrical Properties	p. 258
Thermal Behavior	p. 259
Thermal Stability	p. 259
Thermal Expansion	p. 259
Thermal Conductivity and Heat Capacity	p. 263
Heat Deflection Temperature	p. 263
Irradiation Behavior	p. 264
Standard Measurement Methods	p. 265
Reference	p. 266
Properties of Chlorotrifluoroethylene Homopolymers	p. 267
Introduction	p. 267
Crystallinity	p. 267
Mechanical Properties	p. 267
Electrical Properties	p. 267
Thermal Properties	p. 267
Irradiation Behavior	p. 268
Properties of PCTFE Films	p. 268
References	p. 275
Fabrication Techniques for Fluoropolymers	p. 276
Introduction	p. 276
Machining	p. 276
Sawing and Shearing	p. 277
Drilling, Tapping and Threading	p. 277
Skiving	p. 277
Adhesive Bonding Methods	p. 277
Contact Adhesives	p. 277
Bonding Adhesives	p. 278
Sodium Etching	p. 278
Plasma Treatment	p. 279
Welding and Joining	p. 281
Welding Technique	p. 281
Thermoforming	p. 283
Other Processes	p. 283
Reference	p. 284
Typical Applications of Fluoropolymers	p. 285
Chemical Processing	p. 285
Piping	p. 285
Vessels	p. 286
CPI Components	p. 288
Seals and Gaskets	p. 288
Self-Supporting Components	p. 289
Trends in Using Fluoropolymers in Chemical Service	p. 289
Semiconductor Processing	p. 289
Trends for the Use of Fluoropolymers in the Semiconductor Industry	p. 290
Electrical and mechanical	p. 290
Electrical Applications	p. 290
Mechanical Applications	p. 293
Automotive	p. 294
Safety, Disposal, and Recycling of Fluoropolymers	p. 296
Introduction	p. 296
Toxicology of Fluoropolymers	p. 296
Thermal Properties of Fluoropolymers	p. 296
Emission During Processing	p. 297
Safety Measures	p. 297
Ventilation	p. 297
Processing and Fabrication	p. 299
Sintering	p. 300
Paste Extrusion	p. 300
Dispersion Coating	p. 300
Melt Processing	p. 300
Machining	p. 300
Soldering and Melt Stripping	p. 301
Welding Fluoropolymer	p. 301
Welding and Flame-Cutting Fluoropolymer-lined Metals	p. 301
Spillage Cleanup	p. 301
Equipment Cleaning and Maintenance	p. 301
Protective Clothing	p. 301
Personal Hygiene	p. 301
Fire Hazard	p. 301
Material Incompatibility	p. 301
Food Contact and Medical Applications	p. 302
Fluoropolymer Scrap and Recycling	p. 302
Environmental Protection and Disposal Methods	p. 303
Reference	p. 304
Polytetrafluoroethylene	p. 305
Polychlorotrifluoroethylene	p. 311
Trademarks	p. 319
Glossary	p. 320
Index	p. 347
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