Introduction to Fluoropolymers: Materials, Technology, and Applications (Plastics Design Library)

✍ Scribed by Sina Ebnesajjad

• Publisher: William Andrew
• Year: 2020
• Tongue: English
• Leaves: 408
• Edition: 2
• Category: Library

✦ Synopsis

Introduction to Fluoropolymers, Second Edition, provides a comprehensive overview of the history, principles, properties, processing and applications of fluoropolymers, supporting their development and utilization in high-performance applications, components, and products. This second edition has been updated and expanded to include new in-depth chapters on manufacturing and applications of PTFE and melt processible fluoropolymers.

The book begins by demonstrating the role of fluoropolymers in everyday life, before introducing the history and basic principles of fluoropolymers. This is followed by detailed coverage of the main fluoropolymer types. Properties and applications are illustrated by real-world examples as diverse as waterproof clothing, vascular grafts and coatings for aircraft interiors. The different applications of fluoropolymers show the benefits of a group of materials that are highly water-repellant and flame-retardant, with unrivalled lubrication properties and a high level of biocompatibility. Health and safety and environmental aspects are also covered throughout the book, with a final chapter examining safety, disposal, and recycling in detail.

This book is an essential resource for anyone looking to understand or use fluoropolymer materials in their products. This includes engineers, product designers, manufacturers, scientists, researchers, and other professionals, across industries such as automotive, aerospace, medical devices, food and beverages, high performance apparel, oil and gas, renewable energy, solar photovoltaics, electronics and semiconductors, pharmaceuticals, and chemical processing. This is also a valuable introductory guide for academic researchers and advanced students in plastics engineering, polymer science, and materials science.

✦ Table of Contents

Front-matter
Copyright
Dedication
Contents
List of Contributors
Introduction
1 Fluorine, Fluorocarbons, and Fluoropolymers in Human Life—A Day With the Smiths
References
2 From Fundamentals to Applications
2.1 Introduction
2.2 What Makes Fluorine Unique?
2.3 Fluorine Characteristics
2.3.1 Fluorination
2.3.2 Reactivity—An Extreme Element
2.3.3 Preparation of Fluorine
2.3.4 Organic Chemistry
2.3.5 Fluorine and Nature
2.4 What Are Fluoropolymers?
2.5 Fundamental Properties of Fluoropolymers
2.6 Developmental History of Fluoropolymers
2.7 Examples of Uses of Fluoropolymers
References
3 Fluoropolymers—Discovery, History, Evolution, and Consumption
3.1 Roy Plunkett’s Story
3.2 Commercialization of Polytetrafluoroethylene
3.3 Developmental History of Fluoropolymers
3.4 State of Fluoropolymers
3.4.1 Energy
3.4.2 Economy
3.4.3 Resource Limitation
3.4.4 Market Demand and Growth
3.4.5 State of Technology
3.5 Summary
References
Further Reading
4 History of Expanded Polytetrafluoroethylene and W.L. Gore & Associates
4.1 Early History of W.L. Gore & Associates
4.2 Discovery of Expanded Polytetrafluoroethylene
4.3 Who Invented Expanded Polytetrafluoroethylene?
4.3.1 Summary
4.4 Other Expanded Polytetrafluoroethylene Players
4.4.1 Gore EU and Japan
References
5 Introduction to Thermoplastic Fluoropolymers
5.1 Introduction
5.2 Fluoropolymer Classifications
5.3 Fluoropolymer Products
5.4 Monomer Synthesis
5.4.1 Synthesis of Tetrafluoroethylene
5.4.2 Synthesis of Hexafluoropropylene
5.4.3 Synthesis of Perfluoroalkylvinylethers
5.4.4 Synthesis of Chlorotrifluoroethylene
5.4.5 Synthesis of Vinylidene Fluoride
5.4.6 Synthesis of Vinyl Fluoride
5.5 Monomer Properties
5.5.1 Properties of Tetrafluoroethylene
5.5.2 Properties of Hexafluoropropylene
5.5.3 Properties of Perfluoroalkylvinylethers
5.5.4 Properties of Chlorotrifluoroethylene
5.5.5 Properties of Vinylidene Fluoride
5.5.6 Properties of Vinyl Fluoride
5.6 Polymerization and Finishing
5.6.1 Polytetrafluoroethylene (CAS number 9002-84-0)
5.6.2 Perfluoroalkoxy Polymer (CAS number 26655-00-5)
5.6.3 Perfluorinated Ethylene–Propylene Copolymer (CAS number 25067-11-2)
5.6.4 Ethylene-co-tetrafluoroethylene Polymers (CAS number 68258-85-5)
5.6.5 Ethylene-co-chlorotrifluoroethylene Polymers (CAS number 25101-45-5)
5.6.6 Polychlorotrifluoroethylene (CAS number 9002-83-9)
5.6.7 Polyvinylidene Fluoride (CAS number 24937-79-9)
5.6.8 Polyvinyl Fluoride (CAS number 24981-14-4)
5.7 Structure Property Relationship
5.8 Properties of Polytetrafluoroethylene
5.8.1 Polytetrafluoroethylene Properties
5.8.2 Perfluoroalkoxy Copolymer Properties
5.8.3 Fluorinated Ethylene–Propylene Copolymer Properties
5.8.4 Polychlorotrifluoroethylene Properties
5.8.5 Ethylene–Tetrafluoroethylene Copolymer Properties
5.8.6 Ethylene–Chlorotrifluoroethylene Copolymer Properties
5.8.7 Polyvinylidene Fluoride Properties
5.8.8 Polyvinyl Fluoride Properties
5.9 Fabrication Techniques
5.10 Applications
5.11 Safety
5.12 Polymerization Surfactant
5.13 Economy
5.14 Summary
References
6 Manufacturing and Properties of Polytetrafluoroethylene
6.1 Introduction
6.2 Tetrafluoroethylene Polymers
6.3 Tetrafluoroethylene Polymerization Regimes
6.4 Tetrafluoroethylene Polymerization Mechanism
6.5 Suspension Polymerization Regimes
6.6 Polymerizing Tetrafluoroethylene by Suspension Method
6.6.1 High-Temperature Polymerization
6.6.2 Low-Temperature Polymerization
6.7 Comminution of Suspension Reactor Bead
6.7.1 Fluid Energy Milling
6.7.2 Hammer Milling
6.7.3 Comminution of Wet Reactor Bead
6.8 Pelletized (Free Flow) Granular PTFE
6.8.1 Processes for Agglomeration (Pelletization) of PTFE
6.9 Presintered Granular PTFE
6.10 PTFE Filled Compounds
6.10.1 Granular PTFE Compounds
6.10.1.1 Fillers
6.10.1.2 Selection of PTFE Grade
6.10.2 Filled PTFE Production Techniques
6.10.3 Fine Powder-Based Compounds
6.10.4 Fabrication of Reinforced Gasketing Material
6.11 Preparation of Polytetrafluoroethylene by Dispersion Polymerization
6.12 Dispersion Polymerization of TFE with APFO Replacements
6.13 Dispersion Polymerization Reactor
6.14 Preparation of Dispersion Grade PTFE
6.15 Preparation of Fine Powder PTFE
6.16 Characterization of Polytetrafluoroethylene by Properties
6.16.1 Granular PTFE Resins
6.16.2 Fine Powder PTFE Resins
6.16.3 Dispersions of PTFE
6.17 Commercial PTFE Resins
References
Further Reading
7 Processing and Fabrication of Granular Polytetrafluoroethylene
7.1 Introduction
7.2 Resin Selection
7.3 Compression Molding
7.3.1 Mold and Tooling
7.3.2 Presses
7.3.3 Ovens
7.3.4 Densification and Sintering Mechanism
7.3.5 Billet Molding
7.3.5.1 Preforming
7.3.5.2 Degassing
7.3.5.3 Sintering
7.3.5.4 Cooling
7.4 Automatic Molding
7.5 Introduction to Isostatic Molding
7.5.1 Description of Isostatic Molding
7.5.2 Wet- and Dry-Bag Isostatic Molding
7.6 Ram Extrusion
7.6.1 Ram Extrusion Types
7.6.2 Description of Four Steps of Ram Extrusion
7.6.3 Typical Resin
7.7 Summary
References
Further Reading
8 Fabrication and Processing of Fine Powder Polytetrafluoroethylene
8.1 Introduction
8.2 Resin Handling and Storage
8.3 Paste Extrusion Fundamentals
8.4 Extrusion Aid or Lubricant
8.5 Wire Coating
8.5.1 Blending the Resin with Lubricant
8.5.2 Pigment Addition
8.5.3 Preforming
8.5.4 Extrusion Equipment and Process
8.5.4.1 Extruder
8.5.4.2 Die
8.5.4.3 Drying
8.5.4.4 Sintering and Cooling
8.5.5 Reduction Ratio
8.5.6 Conductor
8.6 Extrusion of Tubing
8.6.1 Pressure Hoses
8.6.2 Extrusion, Sintering, and Cooling
8.6.3 Quality Control of Pressure Hoses
8.7 Liner Extrusion
8.8 Fine Powder Resin Selection
References
9 Fabrication and Processing of Polytetrafluoroethylene Dispersions
9.1 Introduction
9.2 Applications
9.3 Storage and Handling
9.4 Surfactants
9.5 Principles of Coating Technology
9.5.1 Coating Processes
9.5.2 Rheology
9.5.3 Surface Energy
9.6 Dispersion Formulation and Characteristics
9.6.1 Formulation
9.7 Glass Cloth Coating
9.7.1 Equipment
9.7.2 Processing
9.8 Impregnation of Flax and Polyaramide
9.8.1 Processing
9.8.2 Impregnation of Porous Metals and Graphite
9.9 Coating Metal and Hard Surfaces
9.9.1 Unfilled Polytetrafluoroethylene Coatings
9.9.2 Filled Polytetrafluoroethylene Coatings
9.10 Polytetrafluoroethylene Yarn Manufacturing
9.11 Film Casting
9.12 Antidrip Applications
9.13 Filled Bearings
9.14 Dedusting Powders
9.15 Other Applications
References
10 Manufacturing Melt-Processible Copolymers of Tetrafluoroethylene
10.1 Introduction
10.2 Molecular and Crystalline Structure
10.3 Preparation of Perfluoroalkoxy Polymers
10.3.1 Nonaqueous Polymerization of Perfluoroalkoxy Polymers
10.3.2 Aqueous Polymerization of Perfluoroalkoxy Polymers
10.4 Preparation of Perfluorinated Ethylene Propylene Polymers
10.4.1 End Group Stabilization
10.5 Preparation of Ethylene Tetrafluoroethylene Polymers
References
11 Introduction to Vinylidene Fluoride Polymers
11.1 Synthesis of Vinylidene Fluoride
11.2 Properties of Vinylidene Fluoride
11.3 Preparation of Vinylidene Fluoride Polymers
11.3.1 Emulsion Polymerization of Vinylidene Fluoride
11.3.2 Suspension Polymerization of Vinylidene Fluoride
11.3.3 Solution Polymerization of Vinylidene Fluoride
11.4 Characterization of Polyvinylidene Fluoride
11.5 Properties of Polyvinylidene Fluoride
11.5.1 Conformations and Transitions of Polyvinylidene Fluoride
11.6 Processing Polyvinylidene Fluoride
11.7 Applications
References
Further Reading
12 Processing and Fabrication of Parts from Melt-Processible Fluoropolymers
12.1 Introduction
12.2 General Considerations
12.3 Materials of Construction
12.4 Rheology of Fluoropolymers
12.4.1 Characterization of Rheology of Fluoropolymers
12.5 Processing of Fluoropolymers
12.6 Injection Molding
12.6.1 Process Conditions and Operations
12.6.2 Dimensional Stability of Parts
12.7 Extrusion
12.7.1 Introduction
12.7.2 Extrusion Processes
12.7.3 Fluoropolymer Wire Coating
12.7.4 Processing Equipment
12.8 Fluoropolymer Tube Extrusion
12.8.1 Sizing of Tubes
12.8.2 Film Extrusion
12.8.2.1 Cast Film
12.8.2.2 Blown Film
12.8.2.3 Biaxially Oriented Film
12.8.2.4 Fluoropolymer Film Extrusion
References
13 Manufacturing and Properties of Polychlorotrifluoroethylene
13.1 Introduction
13.2 Chlorotrifluoroethylene Polymers
13.3 Polymerization of Chlorotrifluoroethylene
13.3.1 Bulk Polymerization of Chlorotrifluoroethylene
13.3.2 Suspension polymerization of Chlorotrifluoroethylene
13.3.3 Emulsion Polymerization of Chlorotrifluoroethylene
13.4 Copolymerization of Chlorotrifluoroethylene
13.5 Properties of Polychlorotrifluoroethylene
13.6 Characterization of Polychlorotrifluoroethylene
13.7 Commercial Polychlorotrifluoroethylene Resins
References
14 Processing and Fabrication of Polychlorotrifluoroethylene
14.1 Introduction
14.2 Processing Considerations
14.2.1 Zero Strength Time
14.2.2 Crystallinity
14.2.3 Stress
14.3 Compression Molding
14.4 Injection Molding
14.5 Extrusion
14.6 Machining and Joining
References
15 Applications of Fluoropolymers
15.1 Chemical Processing
15.2 Piping
15.3 Vessels
15.4 Chemical Process Industry Components
15.5 Self-Supporting Components
15.6 Trends in Using Fluoropolymers in Chemical Service
15.7 Semiconductor Processing
15.8 Trends for the Use of Fluoropolymers in the Semiconductor Industry
15.9 Electrical Applications
15.10 Mechanical Applications
15.11 Automotive and Aerospace
15.12 Medical Devices
15.13 Summary
References
16 Fluoroelastomers
16.1 Introduction
16.2 Fluorocarbon Elastomers
16.2.1 Manufacturing Process
16.2.1.1 Emulsion Polymerization
16.2.1.1.1 Continuous Emulsion Polymerization
16.2.1.1.2 Semibatch Emulsion Polymerization
16.2.1.1.3 Suspension Polymerization
16.2.2 Properties Related to the Polymer Structure
16.2.3 Cross-Linking Chemistry
16.2.3.1 Cross-Linking by Ionic Mechanism
16.2.3.2 Cross-Linking by Free Radical Mechanism
16.2.3.3 Cross-Linking by Ionizing Radiation
16.2.3.3.1 Cross-Linking of Fluorocarbon Elastomer Type of Elastomers
16.2.3.3.2 Cross-Linking of Perfluoroelastomer Type of Elastomers
16.2.4 Formulation of Compounds From Fluorocarbon Elastomers
16.2.4.1 Fillers
16.2.4.2 Acid Acceptor Systems
16.2.4.3 Curatives
16.2.4.4 Plasticizers and Processing Aids
16.2.4.5 Examples of Formulations
16.2.5 Mixing and Processing of Compounds From Fluorocarbon Elastomers
16.2.5.1 Mixing
16.2.5.2 Processing
16.2.5.2.1 Calendering
16.2.5.2.2 Extrusion
16.2.5.2.3 Compression Molding
16.2.5.2.4 Transfer Molding
16.2.5.2.5 Injection Molding
16.2.6 Solution and Latex Coating
16.2.7 Curing
16.2.8 Physical and Mechanical Properties of Cured Fluorocarbon Elastomers
16.2.8.1 Heat Resistance
16.2.8.2 Compression Set Resistance
16.2.8.3 Low-Temperature Flexibility
16.2.8.4 Resistance to Automotive Fuels
16.2.8.5 Resistance to Solvents and Chemicals
16.2.8.6 Steam Resistance
16.2.9 Applications of Fluorocarbon Elastomers
16.2.9.1 Typical Automotive Applications
16.2.9.2 Typical Aerospace and Military Applications
16.2.9.3 Chemical and Petrochemical Applications
16.2.9.4 Other Industrial Applications
16.2.10 Applications of Perfluoroelastomers
16.2.11 Applications of Fluorocarbon Elastomers in Coatings and Sealants
16.2.12 Applications of Fluorocarbon Elastomers as Polymeric Processing Additives
16.3 Fluorosilicone Elastomers
16.3.1 Polymerization
16.3.2 Processing
16.3.3 Properties of Cured Fluorosilicones
16.3.3.1 Fluid and Chemical Resistance
16.3.3.2 Heat Resistance
16.3.3.3 Low-Temperature Properties
16.3.3.4 Electrical Properties
16.3.3.5 Surface Properties
16.3.4 Applications of Fluorosilicone Elastomers
16.4 Fluorinated Thermoplastic Elastomers
16.4.1 Applications of Fluorinated Thermoplastic Elastomers
16.4.1.1 Chemical and Semiconductor Industries
16.4.1.2 Electrical and Wire and Cable
16.4.1.3 Other Applications
16.5 Phosphazenes
16.6 Safety, Hygiene, and Disposal
16.6.1 Polymerization and Finishing
16.6.2 Compounding, Mixing, and Processing
16.6.3 Hazardous Conditions During Use
16.6.4 Disposal of Used Products
16.7 New Developments and Current Trends
16.7.1 New Developments in Chemistry and Processing
16.7.2 New Products
16.7.3 Other Development
References
Further Reading
Acronyms and Abbreviations
Glossary of Terms
17 Fluoropolymer and Fluorinated Additives
17.1 Polymeric Fluorinated Additives
17.1.1 Polytetrafluoroethylene Homopolymer Additives
17.1.2 Fluoroelastomer Additives (Polymer Processing Additives)
17.1.3 Vinylidene Fluoride Polymer Additives
17.2 Perfluoropolyether Additives
17.3 Polytetrafluoroethylene Modified Waxes
17.4 Fluorinated Graphite
17.5 Fluorination
17.6 Market Size
References
Further Reading
18 Polyvinyl Fluoride: The First Durable Replacement for Paint
18.1 Introduction
18.2 Basic Properties
18.3 Attribute–Application Relationships
18.4 Development and Applications of Polyvinyl Fluoride—A Chronological Treatise
References
19 Fluorinated Coatings; Technology, History, and Applications
19.1 Introduction
19.2 Fluoropolymers Used in Coatings
19.2.1 Polytetrafluoroethylene
19.2.2 Fluorinated Ethylene Propylene Copolymer
19.2.3 Perfluoroalkoxy Polymers
19.2.4 Ethylene-Tetrafluoroethylene Copolymers
19.2.5 Polyvinylidene Fluoride
19.2.6 Ethylene-Chlorotrifluoroethylene Copolymer
19.3 Fluorocoating Compositions
19.3.1 Fluoropolymer
19.3.2 Pigments and Fillers
19.3.3 Solvents
19.3.4 Additives
19.3.5 Nonfluoropolymer Binders
19.3.5.1 Polyamide-imide
19.3.5.2 Polyether Sulfone
19.3.5.3 Polyphenylene Sulfide
19.4 Liquid and Powder Coatings
19.4.1 Liquid Coatings
19.4.2 Powder Coatings
19.5 Application of Fluorocoatings
19.5.1 Substrate
19.5.2 Liquid Coating Application
19.5.3 Powder Coating Application
19.5.4 Baking/Curing
19.6 Commercial Fluorocoating Producers
19.7 A Historical Chronology of Fluoropolymer Finish Technology
19.8 Food Contact
19.9 Commercial Applications of Fluorocoatings
19.9.1 Housewares—Cookware, Bakeware, Small Electrical Appliances
19.9.2 Commercial or Industrial Bakeware
19.9.3 Fuser Rolls
19.9.4 Light Bulbs
19.9.5 Automotive
19.9.6 Chemical Processing Industry
19.9.7 Chemical Reactors
19.9.8 Ducts for Corrosive Fumes, Fire Resistance
19.9.9 Commercial Dryer Drums
19.9.10 Industrial Rollers
19.9.11 Medical Devices
19.9.12 Oil Production and Refining
19.9.13 Razor Blade Coatings
19.9.14 Architectural Coatings
19.10 Summary
References
20 Fluorinated Ionomers: History, Properties, and Applications
20.1 History
20.2 Composition
20.3 Properties
References
21 Functional Fluoropolymers
21.1 Introduction
21.2 Functional Groups
21.3 Functional Fluoropolymers—Partly Fluorinated
21.3.1 Ethylene/Tetrafluoroethylene
21.3.2 Polyvinylidene Fluoride
21.4 Functional Fluoropolymers—Fully Fluorinated
21.4.1 Perfluoroalkoxy Alkanes
21.5 Processing
21.6 Applications
21.6.1 Multilayer Hoses
21.6.2 Surface Lamination
21.6.3 Polymer Modification
21.6.4 Polymer Compatibilizing
21.6.5 Composites
21.6.6 Adhesive Dielectric Interlayer—5G Technology
21.7 Summary
References
Index