Grafted Fluoropolymer Multilayer Structure for Adhesion
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Solution Overview
Problem
Existing multilayer polymer structures face challenges with chemical resistance, thermal stability, impermeability, dimensional stability, and abrasion resistance, particularly in complex configurations like automotive fuel lines and fuel tanks, due to issues with co-extrusion processes leading to delamination and weak inter-layer adhesion.
Innovation Solution
A multilayer structure comprising grafted fluoropolymer and semi-crystalline aromatic polyamide layers, with a process of co-extruding these layers to achieve improved adhesion and stability, where the grafted fluoropolymer layer provides chemical resistance and the polyamide layer offers strength and abrasion resistance, while maintaining a balanced set of properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If co-extrusion process is used to manufacture multilayer polymer structures, then productivity and manufacturing capability for complex shapes is improved, but manufacturing precision deteriorates due to delamination and weak inter-layer adhesion
Solution Approach 1:
The patent modifies the chemical parameters of the fluoropolymer by grafting carboxylic acid groups onto the polymer chain. This chemical modification changes the surface properties and reactivity of the fluoropolymer, enabling strong chemical bonding with the polyamide layer during co-extrusion, thereby preventing delamination while maintaining high productivity
Solution Approach 2:
The patent creates a composite material system where a grafted fluoropolymer (with carboxylic acid groups) is combined with polyamide in a multilayer structure. The grafting creates a chemically active interface between the two polymer layers, forming a composite with superior inter-layer adhesion compared to simple physical layering
2Reliability
If fluoropolymer and polyamide layers are combined in multilayer structure, then chemical resistance and mechanical strength are improved, but reliability deteriorates due to delamination and loss of structural integrity
Solution Approach 1:
The patent changes the chemical composition parameters of the fluoropolymer by introducing carboxylic acid grafts. This modification creates chemical compatibility and bonding capability with the polyamide layer, ensuring stable long-term adhesion and preventing delamination that would compromise structural integrity
Solution Approach 2:
The grafted carboxylic acid groups act as a chemical intermediary between the fluoropolymer and polyamide layers. These functional groups facilitate chemical bonding across the interface, serving as a bridge that ensures stable adhesion and maintains the reliability of the multilayer structure
3Ease of manufacture
If conventional co-extrusion is used for fluoropolymer and engineered thermoplastic layers, then ease of manufacture is improved, but manufacturing precision deteriorates due to unstable operating conditions and poor dimensional stability
Solution Approach 1:
The patent modifies the thermal and chemical parameters of the fluoropolymer through grafting. The introduced carboxylic acid groups enhance inter-layer bonding during co-extrusion, stabilizing the manufacturing process and improving dimensional stability of the final product without complicating the co-extrusion process
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 solution results in a multilayer structure with enhanced chemical resistance, impermeability, and mechanical strength, addressing the limitations of prior art structures by ensuring consistent performance and improved manufacturing processes for complex shapes.
Implementation Method 1
layer (L1) comprises at least one polymer composition (C1) comprising a grafted fluoropolymer material (M1) consisting of N1 grafted fluoropolymer(s) (P1), said polymer(s) (P1) being obtained by a process comprising grafting onto an ungrafted fluoropolymer (U1) at least one grafting agent (G1) chosen from ethylenically unsaturated carboxy acids, their esters, their anhydrides and their salts
Implementation Method 2
A multilayer structure comprising grafted fluoropolymer and semi-crystalline aromatic polyamide layers, with a process of co-extruding these layers to achieve improved adhesion and stability
Data Source
AI summary
Multilayer Polymer Structure Multilayer structure comprising at least one couple (L1-L2) of adjacent layers (L1) and (L2), wherein layer (L1) comprises at least one polymer composition (C1) comprising a grafted fluoropolymer material (M1) consisting of N1 grafted fluoropolymer(s) (P1), said polymer(s) (P1) obtained by a process comprising grafting onto an ungrafted fluoropolymer (U1) at least one grafting agent (G1) chosen from ethylenically unsaturated carboxy acids, their esters, their anhydrides and their salts, layer (L2) comprises at least one polymer composition (C2) comprising at least one impact modifier (I2) and a semi-crystalline aromatic polyamide material (M2) consisting of N2 semi-crystalline aromatic polyamide polymer(s) (P2), and the average melting temperature (Tav,1) of material (M1) differs by at most 45° C. from the average melting temperature (Tav,2) of material (M2), Nj being the number of polymer(s) (Pj) of material (Mj), Nj>1, Tav,j being equal to formula (T) wi,j being the weight amount of the ith polymer (Pj) of material (Mj), Ti,j being the melting temperature of the ith polymer (Pj) of material (Mj), Wj being the total weight amount of material (Mj), for j=1 and for j=2. Process for manufacturing the above multilayer structure, which comprises co-extruding polymer compositions (C1) and (C2), so as to obtain couple (L1-L2) of adjacent layers (T1) and (T2). Shaped article comprising the above multilayer structure, and process for manufacturing it.(∑i=1Njwi,jTi,j)/Wj(1)