A
polymerization process for producing a
tetrafluoroethylene copolymer, and the
copolymer produced thereby, are provided. The
copolymer is of the dispersion /
fine powder type and contains polymerized
tetrafluoroethylene monomer units and co-polymerized higher homologous
comonomer units having the formula (CnF(2n+1))CH═CH2, wherein 6≦n<10, in which the primary particles are believed to have a core and shell structure and the polymerized
comonomer units are present in an amount from 0.01 mol % to 0.3 mol %, based upon total
copolymer composition. The copolymer has a raw dispersion primary particle size (RDPS) of less than 0.210 microns coupled with a standard
specific gravity (SSG) of less than 2.143. Preferably the copolymer has
comonomer units present in an amount from 0.05 mol % and 0.25 mol % and the RDPS is within the range between 0.178 microns and 0.200 microns, coupled with a SSG of less than 2.140. Copolymers produced according to the invention, (perfluorohexyl)
ethylene (PFHE) and (perfluorooctyl)
ethylene (PFOE), may be shaped into the form of 0.1 inch
diameter expanded beading, which expanded beading can have a break strength of at least 10.0 lbs, and which may exceed 13.0 lbs.