JP2019506315A - 組成物及び作製方法 - Google Patents
組成物及び作製方法 Download PDFInfo
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Abstract
Description
ガラス繊維織布とPTFEフルオロポリマーコーティングとの複合材料を、浸漬コーティングプロセスによって製造する。ガラス繊維織布基材は、スタイル128である。最終複合材の重量は16.5oz/平方ヤード(560グラム/平方メートル)であり、最終厚さは0.010インチである。長さ110ヤードのこの材料の一部を、連続ロールツーロールプロセスで4MPa(40バール)の圧力及び536°F(280℃)の温度に曝露する実施形態2に記載した方法で加工した。元の複合材(すなわち、「対照」、実施形態2によって加工されていない)と、加工された材料の両方を、表面突起の数、表面粗さ、及び摩耗特性について評価する。
ガラス繊維織布とPTFEフルオロポリマーコーティングとの別の例もまた、浸漬コーティングプロセスによって製造する。このプロセスは、第1の実施例とわずかに異なり、高度に亀裂が入った表面を有する複合材をもたらす。ガラス繊維織布基材は、スタイル128である。最終複合材の重量は16.5oz/平方ヤード(560グラム/平方メートル)であり、最終厚さは0.010インチである。この材料は、2.3MPa(23バール)の圧力及び689°F(365℃)の温度を使用して、実施形態2に記載のように加工される。表面亀裂の程度を、光学顕微鏡法によって評価し、対照サンプルと加工サンプルとの比較を図5に示す。加工サンプルは、表面亀裂の90%以上の減少を示す。
Claims (15)
- 複合材であって、
第1のフルオロポリマーの第1の層と、
前記第1の層の上に重なっている補強織物の少なくとも1つのプライの第2の層と、
前記第1の層とは反対の前記第2の層の上に重なっている第2のフルオロポリマーの第3の層であって、前記第1の層、前記第3の層、またはそれらの組み合わせが、実質的に欠陥の無い外面を有する、第3の層と、を含み、
前記複合材が、少なくとも約3メートルの連続長を有する、複合材。 - 前記複合材が、ピンオンディスク摩耗試験において200回転を受けた後に、摩擦係数の10%未満の変化として定量化された初期摩耗抵抗性を有する、請求項1に記載の複合材。
- 前記複合材が、織物ナックルの100サイクル後または1%未満の曝露後に、1%未満の質量損失の耐摩耗性を有する、請求項1に記載の複合材。
- 前記第1の層及び前記第3の層が、前記第1の層及び前記第3の層の厚さにわたって亀裂及びボイドが実質的に無い、請求項1に記載の複合材。
- 前記第1の層、前記第3の層、またはそれらの組み合わせが、0.5平方インチ当たり50未満の表面亀裂と、100平方メートル当たり高さ寸法における0.1mmの最大3つの表面突起と、を有する外面を有する、請求項1に記載の複合材。
- 前記複合材が、10ミルの総厚を有する前記複合材に関して、少なくとも1200ボルト/ミルの絶縁耐力を有する、請求項1に記載の複合材。
- 前記第1の層の外面及び前記第3の層の外面が、20マイクロインチ以下の表面粗さRaを有する、請求項1に記載の複合材。
- 前記第1のフルオロポリマー及び前記第2のフルオロポリマーが、非溶融加工性である、請求項1に記載の複合材。
- 前記非溶融加工性フルオロポリマーが、ポリテラフルオロエチレン(PTFE)、変性ポリテトラフルオロエチレン(mPTFE)、またはそれらの組み合わせを含む、請求項8に記載の複合材。
- 前記第1のフルオロポリマー、前記第2のフルオロポリマー、またはそれらの組み合わせが、充填材をさらに含む、請求項1に記載の複合材。
- 前記補強織物の主表面と直接接触する少なくとも1つの中間層をさらに含む、請求項1に記載の複合材。
- 複合材を製造する方法であって、
第1のフルオロポリマーの第1の層を提供することと、
前記第1の層の上に補強織物の少なくとも1つのプライの第2の層を重ねることと、
第2のフルオロポリマーの第3の層を、前記第1の層とは反対の前記第2の層の上に重ねてスタックを形成することと、
前記スタックを、2つの実質的に平行な面によって、約0.5MPa〜約8MPaの圧力で連続的に圧縮し、約200℃〜約400℃の温度で加熱して、少なくとも3メートルの連続長の前記複合材を形成することと、を含む、方法。 - 前記第1の層及び前記第3の層が、キャスト、スカイビング、または押出される、請求項12に記載の方法。
- 前記第1の層及び前記第3の層が、乾燥粉末コーティングされる、請求項12に記載の方法。
- 前記第2の層上に乾燥粉末コーティングをさらに含み、前記乾燥粉末コーティングが、非溶融加工性フルオロポリマーを含む、請求項12に記載の方法。
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