EP4031589A1 - Low molecular weight polytetrafluoroethylene micropowder and process for preparing the same - Google Patents
Low molecular weight polytetrafluoroethylene micropowder and process for preparing the sameInfo
- Publication number
- EP4031589A1 EP4031589A1 EP20866024.1A EP20866024A EP4031589A1 EP 4031589 A1 EP4031589 A1 EP 4031589A1 EP 20866024 A EP20866024 A EP 20866024A EP 4031589 A1 EP4031589 A1 EP 4031589A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- ptfe
- molecular weight
- low molecular
- micropowder
- polymerization
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F14/00—Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
- C08F14/18—Monomers containing fluorine
- C08F14/26—Tetrafluoroethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J3/00—Processes of treating or compounding macromolecular substances
- C08J3/12—Powdering or granulating
- C08J3/16—Powdering or granulating by coagulating dispersions
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F114/00—Homopolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen
- C08F114/18—Monomers containing fluorine
- C08F114/26—Tetrafluoroethene
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/12—Polymerisation in non-solvents
- C08F2/16—Aqueous medium
- C08F2/18—Suspension polymerisation
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/12—Polymerisation in non-solvents
- C08F2/16—Aqueous medium
- C08F2/22—Emulsion polymerisation
- C08F2/24—Emulsion polymerisation with the aid of emulsifying agents
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/12—Polymerisation in non-solvents
- C08F2/16—Aqueous medium
- C08F2/22—Emulsion polymerisation
- C08F2/24—Emulsion polymerisation with the aid of emulsifying agents
- C08F2/28—Emulsion polymerisation with the aid of emulsifying agents cationic
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F2/00—Processes of polymerisation
- C08F2/38—Polymerisation using regulators, e.g. chain terminating agents, e.g. telomerisation
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F4/00—Polymerisation catalysts
- C08F4/28—Oxygen or compounds releasing free oxygen
- C08F4/32—Organic compounds
- C08F4/34—Per-compounds with one peroxy-radical
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F6/00—Post-polymerisation treatments
- C08F6/008—Treatment of solid polymer wetted by water or organic solvents, e.g. coagulum, filter cakes
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F6/00—Post-polymerisation treatments
- C08F6/14—Treatment of polymer emulsions
- C08F6/18—Increasing the size of the dispersed particles
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F6/00—Post-polymerisation treatments
- C08F6/14—Treatment of polymer emulsions
- C08F6/22—Coagulation
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F6/00—Post-polymerisation treatments
- C08F6/24—Treatment of polymer suspensions
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2327/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
- C08J2327/02—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
- C08J2327/12—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
- C08J2327/18—Homopolymers or copolymers of tetrafluoroethylene
Definitions
- the present invention pertains to a process for preparing a polymeric material. More particularly, the present invention relates to low molecular weight polytetrafluoroethylene. More particularly, the invention also relates to a process for preparing low molecular weight Polytetrafluoroethylene also known as “PTFE micropowders”. BACKGROUND OF THE INVENTION
- PTFE micropowders are low molecular weight PTFE, mainly used as an additive in polymers, coatings, paints, rubbers, cosmetics, waxes, inks, adhesives, greases and lubricants.
- PTFE Micropowders exhibit impressive array of following properties that make them the material of choice for various demanding applications:
- low molecular weight PTFE powders have been produced typically from high molecular weight PTFE powders by degradation methods like irradiation with high energy electrons from either a gamma source or an electron beam, or high temperature treatment.
- ECHA European Chemical Agency
- EU 2020/784 EU 2019/1021, Annex -XVII to REACH, Entry 68
- PFOA Perfluorooctanoic acid
- US7176265B patent titled “Directly polymerized low molecular weight granular polytetrafluoroethylene” discloses direct polymerized low molecular weight PTFE.
- Low molecular weight granular polytetrafluoroethylene or modified polytetrafluoroethylene having a melt viscosity of less than about lxlO 6 Pa-S powder is isolated directly from the reaction vessel.
- the low molecular weight polytetrafluoroethylene or modified polytetrafluoroethylene powder in this patent has a melt viscosity of less than about lx 10 6 Pa-S, a specific surface area of less than about 8 m / g, an extractable fluoride level of about 3 ppm or less by weight, and a narrow molecular weight distribution as indicated by a polydispersity index of about 5 or less.
- the particles of low molecular powder have a weight average particle size of about 2 to about 40 micrometers and the powder is substantially free of particles having a particle size of less than about 1 micrometer.
- the low molecular weight polytetrafluoroethylene or modified polytetrafluoroethylene powder in this patent has a melt viscosity of less than about lxlO 6 Pa-S,
- US8754176B2 patent titled “Low molecular weight polytetrafluoroethylene powder and preparation method therefore” discloses Low molecular weight polytetrafluoroethylene powder.
- a low-molecular weight polytetrafluoroethylene powder has been disclosed.
- the low molecular weight PTLE micropowder has been used as an additive in a coating material, etc., can form a coating with excellent texture and gliding properties, while also improving dispersibility and viscosity; and a production process therefor.
- It discloses a process for producing a low-molecular weight polytetrafluoroethylene powder comprising: an emulsion polymerization step of polymerizing at least tetrafluoroethylene in the presence of a polymerization initiator and an aqueous medium to produce emulsified particles thereof; an agglomeration step of agglomerating the emulsified particles to form an agglomerated powder thereof; and a suspension polymerization step of polymerizing at least tetrafluoroethylene in the presence of the agglomerated powder, a polymerization initiator, and an aqueous medium.
- the low-molecular weight polytetrafluoroethylene powder satisfies a melt viscosity of 700,000 Pa-s or less has been disclosed.
- melt viscosity was only found ranging from 1.0x10 to 7.0xl0 5 Pa-s, at 380°C.
- the present invention relates to production of low molecular weight PTFE micropowder by direct polymerization technology and overcomes limitation of the melt viscosities over prior art and that is devoid of the step of irradiation or thermal degradation and complies with regulations on PFOA restriction in substances.
- the main objective of this invention is to provide low molecular weight PTFE powder and a process of direct polymerization for preparing low molecular weight Polytetrafluoroethylene (PTFE) micropowder that overcomes limitations of the melt viscosities over prior art.
- Another objective of this invention is to provide a low molecular weight PTFE powder and a process for preparing low molecular weight Polytetrafluoroethylene (PTFE) micropowder that may be devoid of the step of exposure to high temperature or ionizing radiations.
- Still another objective of this invention is to provide a low molecular weight PTFE micropowder and a process for producing the same employing direct polymerization.
- the present invention relates to low molecular weight PTFE powder and a process for preparing a low molecular weight polytetrafluoroethylene (PTFE) micropowder.
- PTFE polytetrafluoroethylene
- the present invention relates to production of low molecular weight PTFE micropowder by direct polymerization technology and overcomes limitation of the melt viscosities over prior art and that is devoid of the step of irradiation or thermal degradation and complies with regulations on PFOA restriction in substances.
- the low molecular weight PTFE micropowder may be produced by direct polymerization technology and it may be devoid of the degradation steps like irradiation or high temperature treatment.
- the low molecular weight PTFE micropowder may have particle size is in the range from 2 pm to 600 pm.
- the low molecular weight PTFE micropowder may have specific surface area (SSA) ranging from 3.0 to 20.0 m /g.
- the low molecular weight PTFE micropowder may have standard gravity ranges from 2.145-2.212.
- the low molecular weight PTFE micropowder may have molecular weight less than or equal to 6,00,000.
- a process for preparing a low molecular weight polytetrafluoroethylene (PTFE) micropowder having melt viscosity of range melt viscosity of 1,000,001- 999,999,999 Pascal at 380°C at 21.6 Kg load is disclosed.
- the process for preparing a low molecular weight polytetrafluoroethylene (PTFE) micropowder may comprises the steps of:
- TFE Tetrafluoroethylene
- the step of polymerizing TFE may comprises:
- the aqueous emulsion may comprise an initiator for initiating the polymerization process, selected from the group consisting of Disuccinic Acid Peroxide (DSAP), Ammonium Persulphate (APS), Potassium Persulphate (KPS) and combinations thereof.
- an initiator for initiating the polymerization process selected from the group consisting of Disuccinic Acid Peroxide (DSAP), Ammonium Persulphate (APS), Potassium Persulphate (KPS) and combinations thereof.
- the aqueous emulsion may comprise chain transfer agents selected from the group consisting of alcohols, hydrocarbons and combinations thereof.
- the step of polymerizing TFE may comprise suspension polymerisation.
- the process for polymerizing TFE may be carried out at a temperature of 20 to 1201C, pressure of 8 to 25 Bar, and for a polymerization reaction period of 60 to 400 minutes.
- the step of coagulation is induced by adding organic acids or inorganic acids.
- the organic acids comprises of group consisting of phosphoric acid, oxalic acid, nitric acid, sulphuric acid, hydrochloric acid and combination thereof
- wet PTFE micropowder After washing the coagulated particles with water and steam, the drying of wet PTFE micropowder may be carried out.
- a low molecular weight PTFE micropowder produced by direct polymerization and devoid of any degradation steps like irradiation or high temperature treatment.
- the particle size of PTFE micropowder may varies from a range of 2 pm to 600 pm, the melt viscosity may ranges from 1,000,001- 999,999,999 Pascal at 380°C at 21.6 Kg load.
- Figure 1 Flowchart for the process for preparing a low molecular weight Polytetrafluoroethylene micropowder.
- the present invention relates to low molecular weight PTFE powder and a process for preparing a low molecular weight polytetrafluoroethylene (PTFE) micropowder.
- the present invention relates to production of low molecular weight PTFE micropowder by direct polymerization technology and overcomes limitation of the melt viscosities over prior art and that is devoid of the step of irradiation or thermal degradation and complies with regulations on PFOA restriction in substances
- the melt viscosity may be also measured according to ASTM D 1238 using a flow tester(make: Dynisco) die diameter of 2.095 and is a value measured by preheating 3 g of test sample for 5 min at 380°C. and measuring the same with a load of 21.6 kg while maintaining that temperature
- the low molecular weight PTFE micropowder may have particle size is in the range from 2 pm to 600 pm.
- the particle size may be measured by Dynamic light scattering system.
- the particle size may be measured by D50 analysis.
- the particle size analysis may be done by laser diffraction method as per ASTM D4894.
- the low molecular weight PTFE micropowder may have specific surface area (SSA) ranging from 3.0 to 20.0 m /g,
- the specific surface area may be measured by BET using a surface analyzer with a mixed gas of 30% nitrogen and 70% helium as the carrier gas and liquid nitrogen. Standard Gravity
- the low molecular weight PTFE micropowder may have standard gravity ranges from 2.145-2.212.
- the melt viscosity may be measured at 380°C at 21.6 Kg load.
- the temperature may be measured by using ASTM D 4591 by using differential scanning calorimeter.
- approximately 3 mg of the low-molecular weight PTFE powder may be placed in an aluminum pan (crimped container) and the temperature is raised 10°C./min in the 240 to 380°C at 21.6 Kg load under a 50 mF/min air flow.
- the melting point may be defined as the minimum point of required melting heat within the above range.
- the low molecular weight PTFE micropowder may have extractable fluoride level which may range from 1 ppm or less by weight .
- low molecular weight PTFE micropowder is made by direct polymerization process that is devoid of any further degradation step like irradiation or high temperature treatment.
- a process for preparing a low molecular weight polytetrafluoroethylene (PTFE) micropowder having melt viscosity of range melt viscosity of 1,000,000- 999,999,999 Pascal at 380°C at 21.6 Kg load is disclosed.
- Figure 1 illustrates process for producing low molecular weight polytetrafluoroethylene micropowder from high molecular weight PTFE composition.
- a process for preparing a low molecular weight polytetrafluoroethylene (PTFE) micropowder comprising the steps of: (a) polymerizing Tetrafluoroethylene (TFE);
- fluoromonomers may comprises of Tetrafluoroethylene. It may be in gas form and condensed at high pressure into liquid form. The monomer may be stored in metering tank for further adding it for further process in to required quantity.
- the fluoromonomer may be passed through silica gel absorber to remove moisture prior to feeding it into polymerization reactor.
- the reactor may be made free from any oxygen content. DI water may be further added to reactor as media at specified RPM to control reaction rate.
- reaction additives added into reactor may comprise of following: a. Inorganic sulphates as initiator, used as a positive catalyst for initiation of monomer during reaction b. Ammonia to maintain basic pH c. Surfactant system which reduces surface tension between media and monomer by micelles formation required for growth of polymer to make stable dispersion d. Organic Chain transfer agents(CTA) which helps in required size chain formation
- polymerization step is step 1 where fluoromonomers are polymerized into various process conditions
- the temperature for polymerization may range from 20-120 deg C.
- Pressure The pressure during polymerization may range from 8-25 bar
- Reaction Time The total reaction time varies from 60-400 mins After consumption of defined quantity of fluoromonomers and down polymerization to certain pressure gets completed, pressure eventually may be released to atmosphere and polymer may be formed in latex form (solid and liquid mixture). All solid particles present in primary particles may ranges from 50-200 nm.
- Coagulation leads to an increase in the particle size distribution of the polymer from nanometer range to micrometers.
- the wet powder may be subjected to drying systems.
- powder may be dried with help of hot air to moisture level less than 0.1%.
- Maximum air temperature may be 450°C.
- powder coming may be free flowing low molecular weight PTFE in form of final product.
- the process for polymerizing TFE may comprises the steps of:
- the aqueous emulsion formed in the present invention may comprise of surfactant system, fluoromonomers, initiators and chain transfer agents.
- the step of polymerizing TFE may comprise suspension polymerisation.
- the process of the present invention is preferably carried so that the contents of the reaction vessel are essentially free of surfactant, i.e., the amount of surfactant is less than 0.010% based on the amount of water present.
- surfactant means a type of molecule which has both hydrophobic and hydrophilic, portions, which allows it to stabilize and disperse hydrophobic molecules and aggregates of hydrophobic molecules in aqueous systems.
- a preferred group of surfactant system for fluoropolymer synthesis according to the embodiments of the present invention include fluorinated surfactants, non- fluorinated surfactant and a combination of these.
- surfactants for the present invention may include Ammonium or potassium or sodium salts of perfluoro alkyl ether carboxylic acids.
- fluoromonomer or the expression “fluorinated monomer” means a polymerizable alkene which contains at least one fluorine atom, fluoroalkyl group, or fluoroalkoxy group attached to the double bond of the alkene that undergoes polymerization.
- fluoropolymer means a polymer formed by the polymerization of at least one fluoromonomer, and it is inclusive of homopolymers, copolymers, terpolymers and higher polymers.
- the fluoromonomer is tetrafluoroethylene (TFE) and the fluoropolymer is polytetrafluoroethylene (PTFE).
- the aqueous emulsion may further comprise an initiator for initiating the polymerization process.
- Initiators for initiating the polymerization process.
- initiator and the expressions “radical initiator” and “free radical initiator” refer to a chemical that is capable of providing a source of free radicals, either induced spontaneously, or by exposure to heat or light.
- suitable initiators include peroxides, peroxydicarbonates and azo compounds. Initiators may also include reduction-oxidation systems which provide a source of free radicals.
- radical and the expression “free radical” refer to a chemical species that contains at least one unpaired electron.
- the radical initiator is added to the reaction mixture in an amount sufficient to initiate and maintain the polymerization reaction rate. Preferably, the addition of the initiator into the reaction vessel or reactor is carried out in one shot.
- the radical initiator may comprise a persulfate salt, such as sodium persulfate, potassium persulfate, or ammonium persulfate and combinations thereof .
- the radical initiator may comprise a redox system.
- Redox system is understood by a person skilled in the art to mean a system comprising an oxidizing agent, a reducing agent and optionally, a promoter as an electron transfer medium.
- the radical initiator is selected from the group consisting of Disuccinic Acid Peroxide (DSAP), Ammonium Persulphate (APS) and combinations thereof.
- DSAP Disuccinic Acid Peroxide
- APS Ammonium Persulphate
- the initiator may be used from 50-3000 ppm. Chain transfer agents
- Chain transfer agents also referred to as modifiers or regulators, comprises of at least one chemically weak bond.
- a chain transfer agent reacts with the free -radical site of a growing polymer chain and halts an increase in chain length. Chain transfer agents are often added during polymerization to regulate chain length of a polymer to achieve the desired properties in the polymer.
- chain transfer implies the stopping of growth of one polymer chain and the initiation of growth of another such that the number of growing polymer radicals remains similar and the polymerization proceeds at a similar rate without the introduction of more initiator.
- the new radical formed by the reaction of the growing polymer chain with a CTA does not always initiate a new polymer chain.
- chain transfer agents examples include, but not limited to, halogen compounds, hydrocarbons in general, aromatic hydrocarbons, thiols (mercaptans), alcohols and so forth; each of which can be used individually or in combination.
- the chain transfer agent may varies from 50-3,000 ppm.
- the temperature used for polymerization may vary, for example, from 20 to 120 °C, depending on the initiator system chosen and the reactivity of the fluoromonomer(s) selected. In a preferred embodiment, the polymerization is carried out at a temperature in the range of 50 to 85 °C.
- the pressure used for polymerization may vary from 2-200 bar, depending on the reaction equipment, the initiator system, and the monomer selection. In preferred embodiment the reaction is carried out at a pressure in the range of 8 to 25 bar.
- the polymerization occurs under stirring or agitation.
- the stirring may be constant, or may be varied to optimize process conditions during the course of the polymerization. In one embodiment, both multiple stirring speeds and multiple temperatures are used for controlling the reaction.
- a pressurized polymerization reactor equipped with a stirrer and heat control means is charged with water, preferably deionized water, surfactant system in accordance with the invention, chain transfer agents and at least one fluoromonomer.
- the surfactant is added in an amount in the range from 2000 to 7000 ppm, more preferably from 2500 to 5000 ppm, based on the weight of fluoropolymer dispersion.
- the surfactant is added in one shot into the reaction vessel.
- the reaction mixture comprises chain transfer agents in an amount in the range from 50 to 3000 ppm.
- the mixture may optionally contain paraffin wax.
- the reactor is then heated up to the reaction temperature and pressure. Thereafter initiators are added into the reaction vessel to initiate the polymerization reaction.
- the initiator is introduced into the reaction vessel in one shot.
- the initiator is added in an amount in the range from 50 to 3000 ppm, based on the weight of de-ionized water.
- air is removed from the reactor in order to obtain an oxygen-free environment for the polymerization reaction.
- the oxygen is removed from the reaction vessel until its concentration is less than 10 ppm.
- the reactor may also be purged with a neutral gas such as, for example, nitrogen.
- the reactor Upon completion of the polymerization reaction, the reactor is brought to ambient temperature and the residual unreacted monomer is vented to atmospheric pressure.
- the aqueous reaction medium containing the fluoropolymer is then recovered from the reaction vessel.
- the latex content ranges from 10 to 30%, and the particle size of the fluoropolymer particles ranges from 50 to 200 nm.
- coagulation is one of the vital processes that determines the particle size distribution of a product made by emulsion polymerization. Coagulation leads to an increase in the particle size distribution of the polymer from nanometer range to micrometers. Preferably coagulation is carried out till the particle size distribution of the fluoropolymer particles is in the range of 2 to 600pm.
- the coagulation of polymer particles is achieved by using inorganic or organic acids. Examples of acids that can be used in the present invention include, but not limited to phosphoric acid, oxalic acid, nitric acid, sulphuric acid, hydrochloric acid and so forth, each of which can be used alone or in combination.
- the polymer particles having micrometer sized particle distribution are separated from the mother liquor, and washed with hot and cold water with high speed stirring to remove remaining surfactant, unreacted substances and byproducts.
- the resulting powder is further subjected to steam treatment to remove volatile impurities to afford wet low molecular weight PTFE micropowder.
- the wet low molecular weight PTFE micropowder is dried in an oven to afford low molecular weight PTFE micropowder.
- drying of the wet low molecular weight PTFE micropowder is carried out at a temperature of less than or equal to 450 C.
- the polymerization process was carried out in a 150 L reactor with 100 L of de-ionized water. Oxygen was removed from the reactor until its concentration was less than 10 ppm. After that, the surfactant(s), 3200 ppm, was added in one shot into the reactor. Further, chain transfer agent, 60 ppm (aqueous based), was added into the reactor. Thereafter, the addition of Tetrafluoroethylene (TFE) caused an increase in the pressure to 15 bar and the temperature was increased to 65°C. After attaining the operating pressure and temperature a solution comprising an initiator Ammonium Persulphate (APS) was added into the reactor in one shot for initiating the polymerization process.
- TFE Tetrafluoroethylene
- APS Ammonium Persulphate
- the PTFE particles were coagulated, using nitric acid.
- the coagulated particles were separated from the mother liquor and washed with hot and cold water, steam treated and dried at a temperature of 240°C to get low molecular weight PTFE micropowder.
- the advantages of the present invention are as following: a) The invention discloses a low molecular weight PTFE powder by direct polymerization overcoming melt viscosity limitation over prior art. b) The present invention discloses a process for producing low molecular weight PTFE micropowder that complies with various regulations on restriction of PFOA, its salts and related compounds in substances. c) The present invention discloses a process for producing low molecular weight Polytetrafluoroethylene (PTFE) micropowder by using methods which may be devoid of the step of irradiating or other degradation methods.
- PTFE Polytetrafluoroethylene
- Low molecular weight polytetrafluoroethylene can be advantageously used as an additive in other materials for improving sliding properties, increasing release, improving wear resistance, conferring increased stain and mar resistance, enhancing flame retardancy, and increasing water repellency.
- These low molecular weight powders are advantageously added to thermoplastics, paints, coatings, lacquers, greases, oils, lubricants, thermoset resins, and elastomers.
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- Dispersion Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
- Polymerisation Methods In General (AREA)
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Abstract
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Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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IN201911037462 | 2019-09-17 | ||
PCT/IB2020/058608 WO2021053531A1 (en) | 2019-09-17 | 2020-09-16 | Low molecular weight polytetrafluoroethylene micropowder and process for preparing the same |
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Publication Number | Publication Date |
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EP4031589A1 true EP4031589A1 (en) | 2022-07-27 |
EP4031589A4 EP4031589A4 (en) | 2023-10-04 |
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EP20866024.1A Pending EP4031589A4 (en) | 2019-09-17 | 2020-09-16 | Low molecular weight polytetrafluoroethylene micropowder and process for preparing the same |
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EP (1) | EP4031589A4 (en) |
JP (1) | JP2023501048A (en) |
KR (1) | KR20220065003A (en) |
CN (1) | CN114450317A (en) |
GB (1) | GB2604463B (en) |
WO (1) | WO2021053531A1 (en) |
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JP7385150B2 (en) * | 2022-04-18 | 2023-11-22 | ダイキン工業株式会社 | Method for producing purified polytetrafluoroethylene powder and low molecular weight polytetrafluoroethylene powder |
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US6395848B1 (en) * | 1999-05-20 | 2002-05-28 | E. I. Du Pont De Nemours And Company | Polymerization of fluoromonomers |
US7176265B2 (en) * | 2002-11-22 | 2007-02-13 | E. I. Du Pont De Nemours And Company | Directly polymerized low molecular weight granular polytetrafluoroethylene |
US8071198B2 (en) * | 2006-11-17 | 2011-12-06 | E.I. Du Pont De Nemours And Company | Glass articles with adhesion and stain resistant non-stick coatings |
RU2478654C2 (en) * | 2008-04-14 | 2013-04-10 | Асахи Гласс Компани, Лимитед | Method of producing fine polytetrafluorethylene powder |
JP5569519B2 (en) * | 2009-03-31 | 2014-08-13 | ダイキン工業株式会社 | Low molecular weight polytetrafluoroethylene powder and method for producing the same |
US9309335B2 (en) * | 2010-09-30 | 2016-04-12 | Daikin Industries, Ltd. | Process for producing polytetrafluoroethylene fine powder |
US9175110B2 (en) * | 2012-05-09 | 2015-11-03 | The Chemours Company Fc, Llc | Fluoropolymer resin treatment employing melt extrusion and exposure to oxygen source to reduce discoloration |
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2020
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EP4031589A4 (en) | 2023-10-04 |
GB2604463A (en) | 2022-09-07 |
GB2604463B (en) | 2024-02-28 |
KR20220065003A (en) | 2022-05-19 |
CN114450317A (en) | 2022-05-06 |
GB202205473D0 (en) | 2022-05-25 |
WO2021053531A1 (en) | 2021-03-25 |
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