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1. WO2013159020 - DISPERSION SPUN FLUOROPOLYMER FIBER PREPARED FROM NON-MELT-PROCESSIBLE POLYTETRAFLUOROETHYLENE AND PERFLUOROALKOXY

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[ EN ]

It is claimed:

1. A method of making a fluoropolymer fiber comprising forming a mixture of an aqueous dispersion of non-melt-processible polytetrafluoroethylene particles and perfluoroalkoxy particles with an aqueous solution of a matrix polymer.

2. The method according to claim 1 further comprising extruding the mixture into a coagulation bath and forming an intermediate fiber structure by coagulating the matrix polymer in the coagulation bath.

3. The method according to claim 2 further comprising sintering the intermediate fiber structure to decompose the matrix polymer and coalesce the polytetrafluoroethylene particles and the perfluoroalkoxy particles into a blended fiber.

4. The method according to claim 1 wherein the matrix polymer is selected from the group consisting of methylcellulose, hydroxyethylcellulose, methylhydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxypropylcellulose, ethylcellulose and carboxymethylcellulose.

5. The method according to claim 1 wherein the ratio of polytetrafluoroethylene particles to perfluoroalkoxy particles in the mixture is about 3 to 1.

6. The method according to claim 1 wherein the fluoropolymer fiber includes at least about 75% polytetrafluoroethylene particles and at least about 25% perfluoroalkoxy particles.

7. The method according to claim 2 further comprising drawing the intermediate fiber structure.

8. The method according to claim 1 wherein the polytetrafluoroethylene particles have an SSG of less than about 2.4.

9. The method according to claim 1 wherein the fluoropolymer fiber has two melting points.

10. The method according to claim 1 wherein the fluoropolymer fiber has a tenacity of at least about 1.1 gpd.

11. A fluoropolymer fiber comprising a blend of non-melt-processible polytetrafluoroethylene particles and perfluoroalkoxy particles.

12. The fluoropolymer fiber according to claim 11 including up to about 25 % perfluoroalkoxy particles and up to about 75% polytetrafluoroethylene particles.

13. The fluoropolymer fiber according to claim 11 wherein the polytetrafluoroethylene particles have an SSG of less than about 2.4.

14. The fluoropolymer fiber according to claim 11 having a maximum continuous use temperature of about 260 °C.

15. The fluoropolymer fiber according to claim 11 wherein the fiber is about 1200 denier.

16. The fluoropolymer fiber according to claim 11 having a tenacity of at least about 1.1 pd.

17. The fluoropolymer fiber according to claim 11 having an elongation to break of about 60%.

18. The fluoropolymer fiber according to claim 11 having two different melting points.

19. The fluoropolymer fiber according to claim 18 wherein the two different melting points include a first melting point of about 301 °C and a second melting point of about 325 °C.

20. The fluoropolymer fiber according to claim 11 having two different crystallization points.

21. The fluoropolymer fiber according to claim 20 wherein the two different crystallization points include a first crystallization point of about 285 °C and a second crystallization point of about 312 °C.

22. The fluoropolymer fiber according to claim 11 wherein the polytetrafluoroethylene particles have an SSG of less than about 2.4 and the fluoropolymer fiber has a tenacity of at least 1.0 gpd, at least two melting points and an elongation to break of at least 50%.

23. The fluoropolymer fiber according to claim 11 having a bonding strength, when laminated with a PFA film, that is greater than a bonding strength of a dispersion spun, 100% PTFE fiber that is laminated with the PFA film.

24. A member selected from the group consisting of a bearing, a bushing, a fabric, a belt, a diaphragm, a coating, a filter and a seal, the member comprising the fluoropolymer fiber according of claim 11.

25. A fluoropolymer fiber comprising a continuous multifilament yarn including polytetrafluoroethylene particles and perfluoroalkoxy particles.

26. The fluoropolymer fiber according to claim 25 wherein the polytetrafluoroethylene particles and perfluoroalkoxy particles are coalesced and entangled.

27. The fluoropolymer fiber according to claim 25 further comprising a matrix polymer.

28. The fluoropolymer fiber according to claim 27 wherein the matrix polymer is selected from the group consisting of methylcellulose, hydroxyethylcellulose, methylhydroxypropylcellulose, hydroxypropylmethylcellulose, hydroxypropylcellulose, ethylcellulose and carboxymethylcellulose.

29. The fluoropolymer fiber according to claim 27 wherein the fluoropolymer fiber exhibits two different endotherms when observed using a differential scanning calorimeter.

30. The fluoropolymer according to claim 29 wherein the two different endotherms include a perfluoroalkoxy endotherm at about 301 °C.

31. The fluoropolymer according to claim 30 wherein the two different endotherms include a polytetrafluoroethylene endotherm at about 325 °C.

32. The fluoropolymer fiber according to claim 30 wherein the two different endotherms are observed upon second heat of the fluoropolymer fiber.

33. The fluoropolymer fiber according to claim 27 wherein the fluoropolymer fiber exhibits two different exotherms when observed using a differential scanning calorimeter.

34. The fluoropolymer according to claim 32 wherein the two different exotherms include a perfluoroalkoxy exotherm at about 287.7 °C.

35. The fluoropolymer according to claim 34 wherein the two different exotherms include a polytetrafluoroethylene exotherm at about 311.08 °C.

36. The fluoropolymer fiber according to claim 34 wherein the two different exotherms are observed upon second heat of the fluoropolymer fiber.

37. The fluoropolymer fiber according to claim 27 wherein the fluoropolymer fiber exhibits a perfluoroalkoxy endotherm at about 301 °C and a polytetrafluoroethylene endotherm at about 325 °C when observed upon second heat of the fluoropolymer fiber with a differential scanning calorimeter.

38. The fluoropolymer fiber according to claim 37 wherein the fluoropolymer fiber exhibits a perfluoroalkoxy exotherm at about 287.7 °C and a polytetrafluoroethylene exotherm at about 311.08 °C when observed upon second heat of the fluoropolymer fiber with a differential scanning calorimeter.