Applications of Fluoropolymer Films

Part I Materials, Technology, and Properties 1

1. 1 Introduction 3
2. 1.1 Definitions 5
3. 1.1.1 Polymeric Films and Sheets 5
4. 1.1.2 Fluoropolymers 6
5. 1.2 Manufacturing Methods for the Production of Films From Melt-Processible Thermoplastics 9
6. 1.2.1 Film Extrusion 9
7. 1.2.2 Film Extrusion Methods 14
8. 1.3 Secondary Processing of Thermoplastic Films 22
9. 1.3.1 Surface Preparation of Thermoplastic Films 23
10. 1.3.2 Lamination of Thermoplastic Films 26
11. 1.3.3 Heat Sealing of Thermoplastic Films 28
12. 1.3.4 Metallization of Thermoplastic Films 29
13. 1.3.5 Orientation 31

References 36

2 Materials for Fluoropolymer Films and Sheets 39

1. 2.1 Perfluoroethylene (Polytetrafluoroethylene) 39
2. 2.1.1 Industrial Process for Production of Polytetrafluoroethylene 39
3. 2.1.2 Structure and Related Properties of Polytetrafluoroethylene 41
4. 2.1.3 General Properties of Polytetrafluoroethylene 43
5. 2.1.4 Forms of PTFE Resins for Films and Sheets 46
6. 2.1.5 Modified Polytetrafluoroethylene 46
7. 2.1.6 Processing of PTFE 47
8. 2.1.7 Applications for Polytetrafluoroethylene 47

2.2 Melt-Processible Fluoropolymers 49

1. 2.2.1 Industrial Process for the Production of Melt-Processible Fluoropolymers 50
2. 2.2.2 Structure and Related Properties of Melt-Processible Fluoropolymers 54
3. 2.2.3 Processing of Melt-Processible Fluoroplastics 60
4. 2.2.4 Applications for Melt-Processible Fluoropolymers 65
5. 2.3 Other Thermoplastic Fluoropolymers 69
6. 2.3.1 Industrial Processes for the Production of Other Thermoplastic Fluoropolymers 69
7. 2.3.2 Structure and Related Properties of Other Thermoplastic Fluoropolymers 71
8. 2.3.3 Processing of Other Thermoplastic Fluoropolymers 74
9. 2.3.4 Applications for Other Thermoplastic Fluoropolymers 76

References 77

3 Polytetrafluoroethylene Films 85

1. 3.1 Manufacturing Methods for the Production of Polytetrafluoroethylene Films and Sheets 85
2. 3.1.1 Skived Polytetrafluoroethylene Films and Sheets 85
3. 3.1.2 Extruded Unsintered Polytetrafluoroethylene Films and Tapes 93
4. 3.1.3 Process for Unsupported Cast Polytetrafluoroethylene Films 99
5. 3.1.4 Process for Supported Cast Polytetrafluoroethylene Films 103
6. 3.1.5 Laminates 104

References 105

4 Films from Melt-Processible Fluoropolymers 107

1. 4.1 Production of FEP Films 107
2. 4.1.1 Materials 107
3. 4.1.2 Equipment 107
4. 4.1.3 Process Conditions 107
5. 4.2 Production of PFA and MFA Films 108
6. 4.2.1 Materials 108 4.2.2 Equipment 108
7. 4.2.3 Process Conditions 108
8. 4.3 Production of ETFE Films 109
9. 4.3.1 Materials 109
10. 4.3.2 Equipment 109
11. 4.3.3 Process Conditions 109
12. 4.4 Production of PVDF Films 109
13. 4.4.1 Materials 109
14. 4.4.2 Equipment 110
15. 4.4.3 Process Conditions 110
16. 4.5 Production of PCTFE Films 110
17. 4.5.1 Materials 110 4.5.2 Equipment 110
18. 4.5.3 Process Conditions 110
19. 4.6 Production of ECTFE Films 111
20. 4.6.1 Materials 111 4.6.2 Equipment 111
21. 4.6.3 Process Conditions 111
22. 4.7 Production of THV Films 111
23. 4.7.1 Materials 111
24. 4.7.2 Equipment 112
25. 4.7.3 Process Conditions 112
26. 4.8 Production of Films From Other Thermoplastic Fluoropolymers Films 112
27. 4.8.1 Production of Films From Fluorinated Thermoplastic Elastomers 112
28. 4.8.2 Production of Films From Amorphous Perfluoropolymers 113

References 114

5 Films from Polyvinyl Fluoride 115

1. 5.1 Properties of Polyvinyl Fluoride 115
2. 5.2 Processing Polyvinyl Fluoride 116
3. 5.3 Manufacturing of Unoriented Polyvinyl Fluoride Films 117
4. 5.4 Manufacturing of Oriented Polyvinyl Fluoride Films 118
5. 5.4.1 Polyvinyl Fluoride Dispersion in the Latent Solvent 118
6. 5.4.2 Film Extrusion 119
7. 5.4.3 Biaxial Orientation 120

References 122

6 Secondary Processing of Fluoropolymer Films 125

1. 6.1 Surface Preparation of Fluoropolymer Films 125
2. 6.1.1 Corona Treatment of Fluoropolymer Films 125
3. 6.1.2 Sodium Etching of Fluoropolymer Films 125
4. 6.1.3 Plasma Treatment of Fluoropolymer Films 126
5. 6.1.4 Flame Treatment of Fluoropolymer Films 126
6. 6.2 Lamination of Fluoropolymer Films 127
7. 6.3 Heat Sealing of Fluoropolymer Films 127
8. 6.4 Metallization of Fluoropolymer Films 127
9. 6.5 Orientation of Fluoropolymer Films 128
10. 6.6 Other Methods for Secondary Processing of Fluoropolymer Films 128
11. 6.6.1 Laser Marking of Fluoropolymer Films 128
12. 6.6.2 Laser Cutting of Fluoropolymer Films 129
13. 6.6.3 Printing on Fluoropolymer Films 129
14. 6.6.4 Thermoforming of Fluoropolymer Films 130

References 131

7 Testing of Thermoplastic Films 133

1. 7.1 Standards for Testing of Mechanical Properties 133
2. 7.2 Standards for Testing of Thermal Properties 134
3. 7.2.1 Heat Aging 134
4. 7.2.2 Thermal Stability 134
5. 7.2.3 Heat Sealability 134
6. 7.2.4 Shrinkage 134
7. 7.2.5 Linear Coefficient of Expansion 134
8. 7.2.6 Continuous Use Temperature 135 7.3 Standards for Testing of Electrical Properties 135
9. 7.4 Standards for Testing of Barrier Properties 135
10. 7.5 Standards for Testing of Optical Properties 136
11. 7.5.1 Refractive Index 136
12. 7.5.2 Optical Transmission 136
13. 7.6 Standards for Testing of Chemical Resistance 136
14. 7.7 Standards for Testing of Surface Properties 136
15. 7.7.1 Critical Surface Energy 136 7.7.2 Contact Angle 136
16. 7.8 Standards for Testing of Thermal Stability 136
17. 7.9 Standards for Testing of Weatherability 137
18. 7.9.1 Accelerated Testing Methods 137
19. 7.9.2 Outdoor Testing Methods 137

References 137

8 Safety, Hygiene, Disposal, Recycling of Fluoropolymer Films 139

1. 8.1 Safety, Hygiene, and Disposal of Fluoropolymer Films 139
2. 8.1.1 Toxicology of Fluoroplastics 139
3. 8.1.2 Thermal Behavior of Fluoroplastics 139
4. 8.1.3 Medical Applications of Fluoroplastics 141
5. 8.1.4 Food Contact 141
6. 8.1.5 Environmental Protection and Disposal Methods for Fluoroplastics 142
7. 8.2 Recycling of Fluoropolymer Films 142

References 143

Part II Typical Properties of and Applications for Fluoropolymer Films 145

9 Polytetrafluoroethylene Films—Typical Properties and Applications 147

1. 9.1 Skived Polytetrafluoroethylene Films 147
2. 9.2 Cast Polytetrafluoroethylene Films 147
3. 9.3 Unsintered Polytetrafluoroethylene Films 150
4. References 150

10 FEP Films, Typical Properties and Applications 151

References 152

11 Perfluoroalkoxy Resin Films—Typical Properties 153

11.1 PFA Films 153

11.2 MFA Films 154

References 155

12 ETFE Films—Typical Properties and Applications 157

References 158

13 PCTFE Films—Typical Properties and Applications 159

Further Reading 160

14 ECTFE Films—Typical Properties and Applications 161

References 162

15 PVDF Films—Typical Properties and Applications 163

References 164

16 THV Films—Typical Properties 165

Reference 166

17 Teflon AF Films—Typical Properties 167

Reference 168

18 DAI-EL T-530 Films—Typical Properties 169

Reference 170

19 Polyvinyl Fluoride Films—Typical Properties and Applications 171

References 173

Part III Commercial Grades of Fluoropolymer Films and Their Applications 175

20 Commercial Grades of Fluoropolymer Films 177

1. 20.1 Polytetrafluoroethylene Films 177
2. 20.1.1 Skived Films 177 20.1.2 Cast Films 177
3. 20.1.3 Unsintered Polytetrafluoroethylene Films 180
4. 20.2 Fluorinated Ethylene Propylene Films 180
5. 20.3 Perfluoroalkoxy Polymer Films 185
6. 20.3.1 Films From PFA Resins 188
7. 20.3.2 Films From MFA Resins 192
8. 20.4 Ethylene Tetrafluoroethylene Copolymer Films 198
9. 20.5 Polychlorotrifluoroethylene Films 198
10. 20.6 Ethylene-Chlorotrifluoroethylene Copolymer Films 202
11. 20.7 Polyvinylidene Fluoride Films 211
12. 20.8 THV Fluoroplastic Films 216
13. 20.9 Teflon AF Fluoroplastic Films 216
14. 20.10 Polyvinyl Fluoride Films 222
15. 20.10.1 Oriented Polyvinyl Fluoride Films 222
16. 20.10.2 Unoriented Polyvinyl Fluoride Films 222
17. 20.10.3 Classification of Polyvinyl Fluoride Films 225
18. References 233　

21 Applications for Commercial Fluoropolymer Films 235

1. 21.1 Applications for Polytetrafluoroethylene Films 235
2. 21.1.1 Applications for Skived Polytetrafluoroethylene Films 235
3. 21.1.2 Applications for Cast Polytetrafluoroethylene Films 241
4. 21.1.3 Applications for Unsintered Polytetrafluoroethylene Films 242
5. 21.2 Applications for Fluorinated Ethylene Propylene Films 242
6. 21.3 Applications for Perfluoroalkoxy Resin Films 243
7. 21.3.1 Applications to Perfluoroalkoxy Resin Films 243
8. 21.3.2 Applications for MFA Films 243
9. 21.4 Applications for Copolymer of Ethylene and Tetrafluoroethylene Films 244
10. 21.5 Applications for Polychlorotrifluoroethylene Films 245
11. 21.6 Applications for Copolymer of Ethylene and Chlorotrifluoroethylene Films 246
12. 21.7 Applications for Polyvinylidene Fluoride Films 251
13. 21.8 Applications for Terpolymer of Tetrafluoroethylene, HFP, and VDF Films 252
14. 21.9 Applications for Teflon AF Films 252 21.10 Applications for Polyvinyl Fluoride Films 253
15. 21.11 Applications for Fluoropolymer Films by Industries and Activities 256
16. References 256

Appendix 1: Major Fluoropolymer Film Manufacturers, Suppliers, and Distributors 257

Appendix 2: Trade Names of Common Commercial Fluoropolymers 261

Appendix 3: Acronyms and Abbreviations 263

Appendix 4: Glossary of Terms 267

Appendix 5: Tedlar Film Designation Guide 277

Bibliography 279

Index 281