Fluoropolymer Wire Coating Composition for Thick Uniform Extrusion
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Solution Overview
Problem
Existing polymers deform easily in a melt state, making it difficult to form uniform, thick coatings on large-diameter core wires and resulting in inadequate abrasion resistance, oxygen permeability, chemical solution permeability, creep resistance, and rigidity at high temperatures.
Innovation Solution
A copolymer composed of tetrafluoroethylene and perfluoro(propyl vinyl ether) units, with specific content ratios and melt flow rates, minimizing deformation in the melt state and enhancing abrasion resistance, oxygen and chemical solution impermeability, and high-temperature creep resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional polymers are used for coating large-diameter core wires, then the coating process is simpler, but the coating layer deforms and cannot maintain uniform thickness
Solution Approach 1:
The patent applies parameter changes by precisely controlling the compositional parameters of the copolymer (perfluoro(alkyl vinyl ether) unit content at 2-10 mass%, melt flow rate at 372°C between 2.0-5.0 g/10min, and number of functional groups at 20 or less per 10^6). These parameter optimizations enable the coating material to maintain appropriate viscosity and flow characteristics during extrusion, preventing deformation while achieving uniform thickness on large-diameter core wires.
2Ease of manufacture
If the copolymer has higher melt flow rate, then the coating can be formed more easily, but the coating layer deforms in the melt state
Solution Approach 1:
The patent resolves this contradiction through parameter optimization of the melt flow rate at 372°C, specifying it should be between 2.0-5.0 g/10min. This controlled range ensures the material has sufficient flowability for easy coating formation while maintaining enough viscosity to prevent deformation in the melt state, achieving both ease of manufacture and shape stability.
3Strength
If the copolymer has higher content of perfluoro(alkyl vinyl ether) unit, then the abrasion resistance improves, but the rigidity at high temperature deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the content of perfluoro(alkyl vinyl ether) units to 2-10 mass%. This controlled composition provides sufficient abrasion resistance while maintaining adequate rigidity at high temperatures. The patent further refines this by controlling the number of functional groups to 20 or less per 10^6, which helps maintain structural integrity and rigidity at elevated temperatures while still achieving the desired abrasion resistance.
4Strength
If the coating layer is made thicker, then the abrasion resistance and chemical solution impermeability improve, but the coating material deforms before solidification
Solution Approach 1:
The patent resolves this contradiction through comprehensive parameter optimization: controlling the perfluoro(alkyl vinyl ether) unit content at 2-10 mass%, melt flow rate at 372°C between 2.0-5.0 g/10min, and number of functional groups at 20 or less per 10^6. These parameter combinations enable the material to maintain stable shape in the melt state even for thick coating layers, while providing sufficient abrasion resistance and chemical solution impermeability once solidified.
Data Source
AI summary
There is provided a copolymer containing tetrafluoroethylene unit and perfluoro(propyl vinyl ether) unit, wherein the copolymer has a content of perfluoro(propyl vinyl ether) unit of 3.9 to 5.5% by mass with respect to the whole of the monomer units, a melt flow rate at 372°C of 2.8 to 4.0 g/10 min, and the number of functional groups of 20 or less per 106 main-chain carbon atoms.