TFE-PPVE Copolymer Composition for Smooth Injection Molding

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Solution Overview

Problem

Existing polymers fail to provide injection molded articles with excellent surface smoothness, uniform thin coating layers, and high productivity while maintaining good water vapor and chemical resistance, abrasion resistance, and low permeability.

Innovation Solution

A copolymer containing tetrafluoroethylene and perfluoro(propyl vinyl ether units, with specific content and melt flow rates, is used to create injection molded articles with improved surface smoothness and uniform coating layers, and exhibits excellent water vapor, air, and chemical resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional polymers are used for injection molding, then manufacturing is simple, but surface smoothness is poor

Engineering Contradiction:

Improvesurface smoothnessVSAvoidmolding difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by precisely controlling the melt flow rate (MFR) within 35-45 g/10min and functional groups within 50 or less per 10^6 carbon atoms. These parameter optimizations enable the polymer to achieve excellent surface smoothness in injection molded articles while maintaining ease of manufacturing through standardized processing conditions.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If polymer with high melt flow rate is used, then productivity increases, but coating uniformity deteriorates

Engineering Contradiction:

Improveforming speedVSAvoidcoating uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent optimizes the melt flow rate parameter to a specific range of 35-45 g/10min, which balances productivity and coating quality. This parameter setting allows the polymer to flow efficiently for high productivity while maintaining sufficient viscosity control for uniform thin coating formation with fewer defects.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If polymer with low functional groups is used, then chemical resistance improves, but processability deteriorates

Engineering Contradiction:

Improvechemical resistanceVSAvoidprocessability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent precisely controls the functional groups parameter to 50 or less per 10^6 carbon atoms, which provides excellent chemical resistance. Simultaneously, the controlled low functional group content prevents excessive polymerization and maintains appropriate melt flow properties, ensuring good processability for injection molding and extrusion coating.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4299612B1Copolymer, molded body, injection molded body, and coated electrical wire

Publication Date: 2026.03.04 DAIKIN INDUSTRIES LTD

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 4.8 to 5.7% by mass with respect to the whole of the monomer units, a melt flow rate at 372°C of 33.0 to 39.0 g/10 min, and the number of functional groups of 50 or less per 106 main-chain carbon atoms.