Core-Shell Fluoropolymer Coatings for Metal Adhesion and Low Dielectric Loss
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Solution Overview
Problem
Current electronic telecommunication articles face challenges in achieving high adhesion to metal substrates and optimal electrical properties due to the limitations of random fluoropolymers, which often have non-fluorinated functional groups that hinder adhesion and electrical performance.
Innovation Solution
The development of core shell fluoropolymers comprising tetrafluoroethylene with a high percentage of polymerized units and a thin shell containing functional groups such as nitrile, halogen, sulfur oxide, or perfluorinated alkyl ether, which enhances adhesion and electrical properties by minimizing non-fluorinated groups and providing cure sites for crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If random fluoropolymers with functional groups are used, then adhesion to metal substrates is improved, but electrical properties (dielectric constant and loss) deteriorate due to non-fluorinated functional groups
Solution Approach 1:
The fluoropolymer is segmented into core and shell regions with distinct compositions. The core contains fluorinated comonomers for electrical performance, while the shell contains functional groups for adhesion. This spatial segmentation allows both adhesion and electrical properties to be optimized simultaneously without compromise.
Solution Approach 2:
Different regions of the fluoropolymer particle have different functional qualities. The shell region is locally optimized for adhesion to metal substrates through functional groups, while the core region is locally optimized for electrical properties through high fluorine content. This local quality differentiation resolves the contradiction between adhesion and electrical performance.
2Strength
If functional groups are distributed throughout the fluoropolymer, then adhesion to metal substrates is improved, but the amount of non-fluorinated groups increases and deteriorates electrical properties
Solution Approach 1:
The functional groups are segmented and concentrated specifically in the shell region rather than being distributed throughout the entire polymer. This segmentation allows adhesion functionality to be maintained while minimizing the overall quantity of non-fluorinated groups in the bulk material, thereby preserving electrical properties.
Solution Approach 2:
The functional groups are localized to the shell region where they are needed for adhesion, rather than being distributed throughout the polymer. This localization minimizes the volume of non-fluorinated material, maintaining low dielectric constant and loss while providing sufficient adhesion functionality at the interface with metal substrates.
3Strength
If high content of functional comonomers is used, then adhesion and crosslinking are improved, but melt processability deteriorates
Solution Approach 1:
The polymer is segmented into core and shell with different comonomer compositions. The core uses fluorinated comonomers that maintain processability, while the shell uses functional comonomers for adhesion and crosslinking. This segmentation allows high functional group content in the shell without compromising overall melt processability of the polymer.
Solution Approach 2:
The functional comonomers are localized to the shell region where adhesion and crosslinking are needed, rather than being distributed throughout the polymer. This local concentration allows high functional group content (improving adhesion) while the fluorinated core maintains good melt processability, resolving the contradiction between adhesion performance and ease of manufacture.
Data Source
AI summary
Presently described are electronic telecommunication articles comprising core shell fluoropolymers comprising polymerized units of tetrafluoroethylene and no greater than 1 wt. % of polymerized units of comonomer comprising a functional group. The functional groups are typically selected from nitrile, halogen, sulfur oxide, perfluorinated alkyl ether, and carbonyl. The core shell fluoropolymer typically comprises at least 80, 85, 90, 95, 96, 97, 98, 99 wt. % or greater of polymerized units of tetrafluoroethylene. In some embodiments, the core shell fluoropolymer further comprises up to 20 or 25 wt. % of polymerized units of other comonomers, such as hexafluoropropylene (HFP). Also described are methods of making a coated substrate, coated substrates, and core shell fluoropolymers.