Melt-Fabricable Fluororesin Coating for Low-Loss High-Frequency Wire
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Solution Overview
Problem
Tetrafluoroethylene-based resin molding materials proposed for high-frequency applications are non-melt-processable, limiting their fabrication to conventional processing devices like extruders or injection molding machines, which restricts their use in producing materials with excellent high-frequency electrical properties.
Innovation Solution
A melt-fabricable fluororesin material with a dielectric constant of 2.1 or less and a dielectric loss tangent of 0.00030 or less at 12 GHz, achieved through copolymerization of tetrafluoroethylene with perfluoro(alkyl vinyl ether) or hexafluoropropylene, and subsequent irradiation to inhibit crosslinking reactions and reduce functional groups, allowing for superior high-frequency electrical properties and melt-fabricability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If tetrafluoroethylene-based resin molding material is used to achieve low dielectric constant and low dielectric loss tangent, then high-frequency electrical properties are improved, but melt-processability deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters of the fluororesin by controlling the content of CF2H groups and COF groups through copolymerization and irradiation processing. Specifically, it limits CF2H groups to 1 mol% or less and COF groups to 5 mol% or less, which enables both excellent high-frequency electrical properties and melt-processability by adjusting the molecular structure parameters
Solution Approach 2:
The patent uses composite fluororesin materials containing specific copolymers (tetrafluoroethylene/(per)fluoro(alkyl vinyl ether) copolymer and/or tetrafluoroethylene/hexafluoropropylene copolymer) combined with controlled functional groups. This composite approach allows the material to achieve both low dielectric constant (2.1 or less) and melt-processability through synergistic composition design
2Ease of manufacture
If conventional processing devices are used for fabrication, then manufacturing process is simplified, but material performance deteriorates due to non-melt-processability
Solution Approach 1:
The patent modifies the thermal and rheological parameters of the fluororesin through controlled copolymerization and irradiation, achieving a balance where the material becomes melt-processable (can be processed in conventional extruders or injection molding machines) while maintaining excellent high-frequency electrical properties (dielectric constant ≤2.1, dielectric loss tangent ≤0.00030 at 12 GHz)
3Reliability
If irradiation is applied to reduce functional groups, then high-frequency electrical properties are improved, but crosslinking reactions may occur causing molding defects
Solution Approach 1:
The patent applies preliminary anti-action by controlling the irradiation dose and conditions to reduce functional groups (COF and CF2H) to specific levels (COF ≤5 mol%, CF2H ≤1 mol%) before molding, while preventing excessive crosslinking. This preliminary control of functional group content prevents subsequent molding defects like foaming while achieving the desired low dielectric properties
Solution Approach 2:
The patent precisely controls the irradiation parameters and subsequent processing conditions to achieve the optimal balance between reducing functional groups (for low dielectric constant and loss tangent) and preventing excessive crosslinking (which would cause molding defects). The functional group content is controlled within specific ranges to eliminate harmful effects
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting fluororesin material exhibits reduced high-frequency signal attenuation, improved mechanical strength, and prevents molding defects like foaming, enabling the production of high-frequency transmission components with minimized transmission loss.
Implementation Method 1
having a dielectric constant of 2.1 or less and a dielectric loss tangent of 0.00030 or less at 12 GHz
Implementation Method 2
having a dielectric constant of 2.1 or less and a dielectric loss tangent of 0.00030 or less at 12 GHz
Data Source
AI summary
A fluororesin material including a melt-fabricable fluororesin, the fluororesin material having a dielectric constant of 2.1 or less and a dielectric loss tangent of 0.00030 or less at 12 GHz. Also disclosed is a fluororesin material for high-frequency transmission including the fluororesin material and a coated electric wire for high-frequency transmission including a solid insulating coating layer made of the fluororesin material.