US20140232033A1 - Porous Membrane - Google Patents
Porous Membrane Download PDFInfo
- Publication number
- US20140232033A1 US20140232033A1 US14/181,002 US201414181002A US2014232033A1 US 20140232033 A1 US20140232033 A1 US 20140232033A1 US 201414181002 A US201414181002 A US 201414181002A US 2014232033 A1 US2014232033 A1 US 2014232033A1
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- Prior art keywords
- ptfe
- extrudate
- integrated tape
- range
- stretching
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/94—Lubricating
- B29C48/95—Lubricating by adding lubricant to the moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D67/00—Processes specially adapted for manufacturing semi-permeable membranes for separation processes or apparatus
- B01D67/0002—Organic membrane manufacture
- B01D67/0023—Organic membrane manufacture by inducing porosity into non porous precursor membranes
- B01D67/0025—Organic membrane manufacture by inducing porosity into non porous precursor membranes by mechanical treatment, e.g. pore-stretching
- B01D67/0027—Organic membrane manufacture by inducing porosity into non porous precursor membranes by mechanical treatment, e.g. pore-stretching by stretching
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
- B29C48/08—Flat, e.g. panels flexible, e.g. films
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/005—Shaping by stretching, e.g. drawing through a die; Apparatus therefor characterised by the choice of materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
- B29C55/02—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets
- B29C55/10—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial
- B29C55/12—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial
- B29C55/14—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively
- B29C55/143—Shaping by stretching, e.g. drawing through a die; Apparatus therefor of plates or sheets multiaxial biaxial successively firstly parallel to the direction of feed and then transversely thereto
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/06—Organic material
- B01D71/30—Polyalkenyl halides
- B01D71/32—Polyalkenyl halides containing fluorine atoms
- B01D71/36—Polytetrafluoroethene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0012—Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
- B29K2027/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2007/00—Flat articles, e.g. films or sheets
- B29L2007/002—Panels; Plates; Sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/755—Membranes, diaphragms
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249978—Voids specified as micro
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249978—Voids specified as micro
- Y10T428/249979—Specified thickness of void-containing component [absolute or relative] or numerical cell dimension
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
- Y10T428/249981—Plural void-containing components
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/3154—Of fluorinated addition polymer from unsaturated monomers
Definitions
- the present invention is generally directed to a porous membrane.
- the present invention is directed to a porous expanded polytetrafluoroethylene membrane having improved properties and made from multiple extrudates.
- ePTFE expanded polytetrafluoroethylene
- the membranes are typically made to attain a particular property such as air permeability or moisture vapor transmission.
- the desired property can often be attained by producing a membrane with a predetermined pore size, thickness and/or unit weight.
- Previous attempts at improving membrane properties have been to coat the membrane with a polymer such as polyurethane or to use multiple membranes or intermediate membrane components to provide a composite membrane. Despite this ability to modify the ultimate resultant membrane, there is still a need to improve the membrane.
- One aspect of the invention is a membrane having at least one improved property, such as increased strength or durability.
- the membrane comprises a sheet of expanded polytetrafluoroethylene.
- the sheet is porous and has a gas permeability of at least 0.1 CFM according to ASTM D737.
- the sheet has an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751.
- Another aspect of the invention is a membrane that comprises a sheet of expanded polytetrafluoroethylene.
- the sheet includes a first extrudate made from a first PTFE fine powder resin mixed with processing lubricant at a first lube rate.
- a second extrudate is made from the first PTFE fine powder resin mixed with processing lubricant at the first lube rate.
- the first and second extrudates combined into an integrated tape structure that is bi-axially stretched.
- the sheet is porous and has a gas permeability of at least 0.1 CFM according to ASTM D737.
- the sheet has an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751.
- Another aspect of the invention is a method of making a membrane.
- the method comprises the steps of providing a first extrudate made from a first PTFE fine powder resin mixed with processing lubricant at a first lube rate.
- a second extrudate is provided and made from the first PTFE fine powder resin mixed with processing lubricant at the first lube rate.
- the first and second extrudates are overlaid.
- the overlaid first and second extrudates are calendered into an integrated tape.
- the integrated tape is stretched in the machine direction.
- the integrated tape is stretched in the transverse direction to provide a porous sheet that has a gas permeability of at least 0.1 CFM according to ASTM D737 and an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751.
- FIG. 1 is a perspective view of a portion of a sheet of membrane, constructed according to one aspect of the invention
- FIG. 2 is a cross-sectional view of the sheet of membrane illustrated in FIG. 1 , taken approximately along line 2 - 2 in FIG. 1 ;
- FIG. 3 is a schematic view of a process used to make the sheet of membrane, according to another aspect of the invention.
- FIG. 4 is an enlarged view of a calender portion of the process illustrated in FIG. 3 .
- An improved membrane 20 ( FIG. 1 ), made according to one aspect of the invention, is in the form of a sheet 22 .
- the sheet 22 ( FIG. 2 ) incorporates at least two identical layers or components.
- the components are in the form of extrudates 24 , 26 made by a paste extrusion process.
- the extrudates 24 , 26 are formed into an integrated tape structure 40 ( FIGS. 3 and 4 ).
- the integrated tape structure 40 is bi-axially stretched to form the sheet 22 .
- the resultant sheet 22 of membrane 20 is porous, and preferably microporous, with a three-dimensional matrix or lattice type structure of numerous nodes 62 interconnected by numerous fibrils 64 .
- the material that the sheet 22 is made from expanded polytetrafluoroethylene (ePTFE) that may or may not be sintered.
- the average size of the pores in the sheet 22 is sufficient to be deemed microporous, but any pore size may be used in the present invention.
- a suitable average size for the pores in the sheet 22 may be in the range of 0.01 to 1.0 micron, and preferably in the range of 0.01 to 0.25 micron and most preferably in the range of 0.01 to 0.10 micron. This porosity enables the sheet 22 to be permeable.
- the sheet has an air permeability, measured according to ASTM D737 test method, in the range of about 0.10 CFM to 0.30 CFM.
- the sheet 22 is made by mixing of polytetrafluoroethylene (PTFE) fine powder and lubricant in a mixer 100 ( FIG. 3 ).
- PTFE polytetrafluoroethylene
- the PTFE fine powder is available from DuPont as 601A or 603A TEFLON® fine powder resin.
- the lubricant is available from Exxon Mobile Corporation under the name ISOPAR® K.
- the amount of lubricant used the lube rate is in the range of 14 wt-% to 22 wt-% of lubricant to PTFE fine powder resin, preferably the lube rate is in the range of 15 wt-% to 17 wt-% of lubricant to PTFE fine powder resin and most preferably the lube rate is 16 wt.%.
- the mixer 100 may be any suitable mixing equipment, such as a PK Blender. Predetermined appropriate amounts of lubricant and PTFE fine powder resin are introduced into the mixer 100 . The mixer 100 is rotated at a speed that will not “abuse” the PTFE fine powder resin. The mixer 100 is rotated for an appropriate time that allows the lubricant to sufficiently wet and protect the PTFE fine powder resin.
- the mixture of lubricant and PTFE fine powder resin is introduced into a preformer 120 .
- the preformer 120 mechanically compresses the mixture of lubricant and PTFE fine powder resin into a billet (not shown).
- the billet has an elongated cylindrical shape that can have any suitable diameter, such as in the range of about 2 inches to 6 inches.
- the billet may be stored at this stage to allow the lubricant to better penetrate into the PTFE fine powder resin.
- the billet is placed in an extruder 140 .
- the extruder 140 is a press that forces the mixture of lubricant and PTFE fine powder resin of the billet through a die of the extruder to yield the extrudate 24 , 26 .
- fibrils are formed as raw dispersion particles of the PTFE fine powder resin move passed one another.
- the extrudates 24 , 26 have a predetermined thickness, dependent on the die configuration, in the range of about 0.035 inch to 0.045 inch and preferably about 0.040 inch.
- the extrudates 24 , 26 are substantially identical in thickness and lube rate.
- the extrudates may be wound up on a roll 142 for temporary storage.
- the extrudates 24 , 26 are trained off their respective rolls 142 and directed into a calender 160 ( FIGS. 3 and 4 ). It will be apparent that, by way of example for this aspect of the invention, two extrudates 24 , 26 are illustrated but any suitable number of extrudates of appropriate configuration may be used. As best seen in FIG. 3 , the upper or first extrudate 24 is fed in the machine direction MD against rotating upper roller 162 . The lower or second extrudate 26 is fed in the machine direction MD against rotating lower roller 164 .
- the calender 160 forms the integrated tape 40 from the extrudates 24 , 26 .
- the first and second extrudates 24 , 26 are forced into engagement with one another because the gap between the rollers 162 , 164 is less than the combined thicknesses of the extrudates 24 , 26 .
- the gap is in the range of about 0.010 inch to 0.030 inch and preferably about 0.020 inch.
- the rollers 162 , 164 are metal and each heated to a temperature in the range of about 160° F. to 320° F., depending on the number and thickness of the extrudates 24 , 26 used.
- the thickness of the integrated tape 40 is preferably in the range of about 0.010 inch to 0.030 inch and preferably about 0.020 inch.
- the first and second extrudates 24 , 26 are combined into the integrated tape structure 40 by mechanically interlocking the nodes 62 and fibrils 64 making up the first and second extrudates. That is, during the calender operation, a portion of the first extrudate 24 is forced into a portion of the second extrudate 26 .
- This provides a relatively strong integrated tape structure 40 that enables other desirable improved properties of the finished sheet 22 of membrane 20 .
- the integrated tape structure 40 is trained over a series of heated drying rollers 180 ( FIG. 3 ).
- the heated drying rollers 180 drive off any lubricant that is left in the integrated tape structure 40 .
- the removed lubricant is collected in a collection system (not shown)
- the integrated tape structure 40 is “expanded” or stretched in at least one and preferably two (bi-axially) directions to form the finished sheet 22 of membrane 20 . “Expanded” is intended to mean sufficiently stretched beyond the elastic limit of the membrane material to introduce permanent set or elongation to the fibrils 64 .
- the integrated tape structure 40 is directed to a machine direction MD stretcher 200 .
- the machine direction stretcher 200 has a first roller 202 that is rotating at a first speed.
- the machine direction stretcher 200 has a second roller 204 that is rotating at a second speed greater than the first speed of the first roller 202 .
- the rollers 202 , 204 are heated in the range of about 260° F. to 300° F. and preferably about 280° F.
- the surface speed differential of the second roller 204 rotating faster than the surface speed of the first roller 202 determines the ratio of machine direction MD stretch.
- the machine direction MD stretch ratio is in the range of about 1.0 to 6.0 and preferably in the range of about 2.0 to 3.5.
- the integrated tape structure 40 is directed to a transverse or cross direction XD stretcher 220 .
- the integrated tape structure 40 is clamped at its laterally opposite edges by parts of the cross direction XD stretcher 220 .
- the integrated tape structure 40 is stretched in a second direction, substantially orthogonal to the machine direction MD a predetermined amount to form the sheet 22 .
- the integrated tape structure 40 is stretched in the cross direction XD direction in the range of about 8 to 12 times its original cross direction dimension (width) and preferably about 10 times.
- the integrated tape structure 40 is stretched when exposed to elevated temperatures in the range of about 500° F. to 600° F. and preferably about 550° F.
- the sheet 22 is preferably heated or “sintered” to reduce and minimize residual stress in the membrane material.
- the sheet 22 is preferably heated in the cross direction stretcher 220 by exposure to elevated temperatures in the range of about 700° F. to 750° F. and preferably about 730° F.
- the sheet 22 may be unsintered or partially sintered as is appropriate for the contemplated use of the membrane 20 .
- the sheet 22 of the membrane 20 is the rolled onto roll 222 .
- the sheet 22 of membrane 20 was tested against known membranes. Results of the testing are presented in the table below. Samples 1-5 are known ePTFE membranes only made from a single extrudate. Sample 6 is a known ePTFE membrane made from a single extrudate and coated with a polyurethane material. Samples 7-9 are sheets 22 of membrane 20 made according to one aspect of the invention.
- the sheet 22 of membrane 20 according to one aspect of the invention, has significantly improved desirable properties, such as Mullen Hydrostatic, which is indicative of strength and durability.
- the sheet 22 has an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751 while retaining air permeability and preferably in the range of 135 psi to 175 psi.
Abstract
Description
- This patent application is a continuation of co-pending U.S. patent application Ser. No. 12/609,444, filed Oct. 30, 2009, the entire teachings and disclosure of which are incorporated herein by reference thereto.
- The present invention is generally directed to a porous membrane. In particular, the present invention is directed to a porous expanded polytetrafluoroethylene membrane having improved properties and made from multiple extrudates.
- Membranes made from expanded polytetrafluoroethylene (ePTFE) are known. Such known membranes are used in many applications because of their chemical inertness. Exemplary applications for ePTFE membrane use include waterproof and breathable garments, fluid filtration, medical implantation and venting.
- The membranes are typically made to attain a particular property such as air permeability or moisture vapor transmission. The desired property can often be attained by producing a membrane with a predetermined pore size, thickness and/or unit weight. Previous attempts at improving membrane properties have been to coat the membrane with a polymer such as polyurethane or to use multiple membranes or intermediate membrane components to provide a composite membrane. Despite this ability to modify the ultimate resultant membrane, there is still a need to improve the membrane.
- One aspect of the invention is a membrane having at least one improved property, such as increased strength or durability. The membrane comprises a sheet of expanded polytetrafluoroethylene. The sheet is porous and has a gas permeability of at least 0.1 CFM according to ASTM D737. The sheet has an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751.
- Another aspect of the invention is a membrane that comprises a sheet of expanded polytetrafluoroethylene. The sheet includes a first extrudate made from a first PTFE fine powder resin mixed with processing lubricant at a first lube rate. A second extrudate is made from the first PTFE fine powder resin mixed with processing lubricant at the first lube rate. The first and second extrudates combined into an integrated tape structure that is bi-axially stretched. The sheet is porous and has a gas permeability of at least 0.1 CFM according to ASTM D737. The sheet has an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751.
- Another aspect of the invention is a method of making a membrane. The method comprises the steps of providing a first extrudate made from a first PTFE fine powder resin mixed with processing lubricant at a first lube rate. A second extrudate is provided and made from the first PTFE fine powder resin mixed with processing lubricant at the first lube rate. The first and second extrudates are overlaid. The overlaid first and second extrudates are calendered into an integrated tape. The integrated tape is stretched in the machine direction. The integrated tape is stretched in the transverse direction to provide a porous sheet that has a gas permeability of at least 0.1 CFM according to ASTM D737 and an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751.
- Further features of the invention will become apparent to those skilled in the art to which the invention relates from reading the following description with reference to the accompanying drawings, in which:
-
FIG. 1 is a perspective view of a portion of a sheet of membrane, constructed according to one aspect of the invention; -
FIG. 2 is a cross-sectional view of the sheet of membrane illustrated inFIG. 1 , taken approximately along line 2-2 inFIG. 1 ; -
FIG. 3 is a schematic view of a process used to make the sheet of membrane, according to another aspect of the invention; and -
FIG. 4 is an enlarged view of a calender portion of the process illustrated inFIG. 3 . - An improved membrane 20 (
FIG. 1 ), made according to one aspect of the invention, is in the form of asheet 22. The sheet 22 (FIG. 2 ) incorporates at least two identical layers or components. The components are in the form ofextrudates extrudates FIGS. 3 and 4 ). The integratedtape structure 40 is bi-axially stretched to form thesheet 22. - The
resultant sheet 22 ofmembrane 20 is porous, and preferably microporous, with a three-dimensional matrix or lattice type structure ofnumerous nodes 62 interconnected bynumerous fibrils 64. The material that thesheet 22 is made from expanded polytetrafluoroethylene (ePTFE) that may or may not be sintered. - Surfaces of the
nodes 62 andfibrils 64 define numerous interconnecting pores that extend completely through thesheet 22 between opposite major side surfaces of the membrane in a tortuous path. Preferably, the average size of the pores in thesheet 22 is sufficient to be deemed microporous, but any pore size may be used in the present invention. A suitable average size for the pores in thesheet 22 may be in the range of 0.01 to 1.0 micron, and preferably in the range of 0.01 to 0.25 micron and most preferably in the range of 0.01 to 0.10 micron. This porosity enables thesheet 22 to be permeable. For example, the sheet has an air permeability, measured according to ASTM D737 test method, in the range of about 0.10 CFM to 0.30 CFM. - The
sheet 22 is made by mixing of polytetrafluoroethylene (PTFE) fine powder and lubricant in a mixer 100 (FIG. 3 ). The PTFE fine powder is available from DuPont as 601A or 603A TEFLON® fine powder resin. The lubricant is available from Exxon Mobile Corporation under the name ISOPAR® K. By way of example, the amount of lubricant used the lube rate is in the range of 14 wt-% to 22 wt-% of lubricant to PTFE fine powder resin, preferably the lube rate is in the range of 15 wt-% to 17 wt-% of lubricant to PTFE fine powder resin and most preferably the lube rate is 16 wt.%. Themixer 100 may be any suitable mixing equipment, such as a PK Blender. Predetermined appropriate amounts of lubricant and PTFE fine powder resin are introduced into themixer 100. Themixer 100 is rotated at a speed that will not “abuse” the PTFE fine powder resin. Themixer 100 is rotated for an appropriate time that allows the lubricant to sufficiently wet and protect the PTFE fine powder resin. - The mixture of lubricant and PTFE fine powder resin is introduced into a
preformer 120. Thepreformer 120 mechanically compresses the mixture of lubricant and PTFE fine powder resin into a billet (not shown). The billet has an elongated cylindrical shape that can have any suitable diameter, such as in the range of about 2 inches to 6 inches. The billet may be stored at this stage to allow the lubricant to better penetrate into the PTFE fine powder resin. - The billet is placed in an
extruder 140. Theextruder 140 is a press that forces the mixture of lubricant and PTFE fine powder resin of the billet through a die of the extruder to yield theextrudate extrudates extrudates roll 142 for temporary storage. - The
extrudates respective rolls 142 and directed into a calender 160 (FIGS. 3 and 4 ). It will be apparent that, by way of example for this aspect of the invention, twoextrudates FIG. 3 , the upper orfirst extrudate 24 is fed in the machine direction MD against rotatingupper roller 162. The lower orsecond extrudate 26 is fed in the machine direction MD against rotatinglower roller 164. - The
calender 160 forms theintegrated tape 40 from theextrudates second extrudates rollers extrudates rollers extrudates integrated tape 40 is preferably in the range of about 0.010 inch to 0.030 inch and preferably about 0.020 inch. - The first and
second extrudates integrated tape structure 40 by mechanically interlocking thenodes 62 andfibrils 64 making up the first and second extrudates. That is, during the calender operation, a portion of thefirst extrudate 24 is forced into a portion of thesecond extrudate 26. This provides a relatively strongintegrated tape structure 40 that enables other desirable improved properties of thefinished sheet 22 ofmembrane 20. - The
integrated tape structure 40 is trained over a series of heated drying rollers 180 (FIG. 3 ). Theheated drying rollers 180 drive off any lubricant that is left in theintegrated tape structure 40. The removed lubricant is collected in a collection system (not shown) - The
integrated tape structure 40 is “expanded” or stretched in at least one and preferably two (bi-axially) directions to form thefinished sheet 22 ofmembrane 20. “Expanded” is intended to mean sufficiently stretched beyond the elastic limit of the membrane material to introduce permanent set or elongation to thefibrils 64. - The
integrated tape structure 40 is directed to a machinedirection MD stretcher 200. Themachine direction stretcher 200 has afirst roller 202 that is rotating at a first speed. Themachine direction stretcher 200 has asecond roller 204 that is rotating at a second speed greater than the first speed of thefirst roller 202. Therollers second roller 204 rotating faster than the surface speed of thefirst roller 202 determines the ratio of machine direction MD stretch. The machine direction MD stretch ratio, according to one aspect of the invention, is in the range of about 1.0 to 6.0 and preferably in the range of about 2.0 to 3.5. - The
integrated tape structure 40 is directed to a transverse or crossdirection XD stretcher 220. Theintegrated tape structure 40 is clamped at its laterally opposite edges by parts of the crossdirection XD stretcher 220. Theintegrated tape structure 40 is stretched in a second direction, substantially orthogonal to the machine direction MD a predetermined amount to form thesheet 22. Theintegrated tape structure 40 is stretched in the cross direction XD direction in the range of about 8 to 12 times its original cross direction dimension (width) and preferably about 10 times. Theintegrated tape structure 40 is stretched when exposed to elevated temperatures in the range of about 500° F. to 600° F. and preferably about 550° F. - The
sheet 22 is preferably heated or “sintered” to reduce and minimize residual stress in the membrane material. Thesheet 22 is preferably heated in thecross direction stretcher 220 by exposure to elevated temperatures in the range of about 700° F. to 750° F. and preferably about 730° F. However, thesheet 22 may be unsintered or partially sintered as is appropriate for the contemplated use of themembrane 20. Thesheet 22 of themembrane 20 is the rolled ontoroll 222. - The
sheet 22 ofmembrane 20, according to one aspect of the invention, was tested against known membranes. Results of the testing are presented in the table below. Samples 1-5 are known ePTFE membranes only made from a single extrudate. Sample 6 is a known ePTFE membrane made from a single extrudate and coated with a polyurethane material. Samples 7-9 aresheets 22 ofmembrane 20 made according to one aspect of the invention. Thesheet 22 ofmembrane 20, according to one aspect of the invention, has significantly improved desirable properties, such as Mullen Hydrostatic, which is indicative of strength and durability. Thesheet 22 has an average Mullen Hydrostatic Burst pressure in the range of 135 psi to 175 psi according to ASTM D751 while retaining air permeability and preferably in the range of 135 psi to 175 psi. -
Mullen Hydrostatic ASTM D751 (PSI) Failure Air Permeability ASTM D737 (CFM) Sample mode Left Center Right Average Left Center Right Average 1 Leak 134 128 131 131 0.35 2 Leak 105 94 105 101 0.55 3 Leak 90 91 96 92 0.65 4 Leak 120 120 123 121 0.38 5 Leak 101 106 98 102 0.75 6 Leak 101 101 97 100 7 Burst 174 173 176 174 0.228 0.259 0.237 0.241 8 Burst 172 165 166 168 0.227 0.254 0.250 0.244 9 Burst 152 139 153 148 0.273 0.272 0.282 0.276 - From the above description of at least one aspect of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are intended to be covered by the appended claims.
Claims (18)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US14/181,002 US20140232033A1 (en) | 2009-10-30 | 2014-02-14 | Porous Membrane |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US12/609,444 US8673440B2 (en) | 2009-10-30 | 2009-10-30 | Porous membrane |
US14/181,002 US20140232033A1 (en) | 2009-10-30 | 2014-02-14 | Porous Membrane |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/609,444 Continuation US8673440B2 (en) | 2009-10-30 | 2009-10-30 | Porous membrane |
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US20140232033A1 true US20140232033A1 (en) | 2014-08-21 |
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US12/609,444 Active 2030-06-01 US8673440B2 (en) | 2009-10-30 | 2009-10-30 | Porous membrane |
US14/181,002 Abandoned US20140232033A1 (en) | 2009-10-30 | 2014-02-14 | Porous Membrane |
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US12/609,444 Active 2030-06-01 US8673440B2 (en) | 2009-10-30 | 2009-10-30 | Porous membrane |
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IT201900010113A1 (en) * | 2019-06-26 | 2020-12-26 | Flon Project S R L | Production line, and related production method, to obtain a PTFE tape stretched longitudinally and transversely |
Citations (3)
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US4478665A (en) * | 1980-11-06 | 1984-10-23 | W. L. Gore & Associates, Inc. | Method for manufacturing highly porous, high strength PTFE articles |
US20030194599A1 (en) * | 2002-04-16 | 2003-10-16 | Sassa Robert L. | Composite films for electrochemical devices |
WO2009011315A1 (en) * | 2007-07-18 | 2009-01-22 | Nitto Denko Corporation | Water-proof sound-transmitting membrane, method for production of water-proof sound-transmitting membrane, and electrical appliance using the membrane |
Family Cites Families (13)
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US4385093A (en) | 1980-11-06 | 1983-05-24 | W. L. Gore & Associates, Inc. | Multi-component, highly porous, high strength PTFE article and method for manufacturing same |
JPH078926B2 (en) | 1989-12-07 | 1995-02-01 | ダイキン工業株式会社 | Method for producing polytetrafluoroethylene multilayer porous membrane |
FR2691670B1 (en) | 1992-05-26 | 1994-08-26 | Plastic Omnium Cie | Polytetrafluoroethylene tape suitable for laser marking. |
US6500532B1 (en) | 1999-08-13 | 2002-12-31 | Bruce G. Ruefer | Expanded PTFE multilayer composite sheet |
US6342294B1 (en) | 1999-08-12 | 2002-01-29 | Bruce G. Ruefer | Composite PTFE article and method of manufacture |
JP3580790B2 (en) | 2001-10-31 | 2004-10-27 | 宇明泰化工股▲ふん▼有限公司 | Asymmetric porous polytetrafluoroethylene membrane and method for producing the same |
US7771818B2 (en) * | 2002-09-20 | 2010-08-10 | Bha Group, Inc. | Treatment of porous article |
WO2005118254A1 (en) | 2004-06-03 | 2005-12-15 | Coltec Industrial Products Llc | Multifuncton multilayer ptfe tape and method of manufacture |
US7306729B2 (en) * | 2005-07-18 | 2007-12-11 | Gore Enterprise Holdings, Inc. | Porous PTFE materials and articles produced therefrom |
JP5207694B2 (en) * | 2007-09-20 | 2013-06-12 | 日本ゴア株式会社 | Stretched porous polytetrafluoroethylene film laminated gasket sheet and gasket composed of this gasket sheet |
JP5658860B2 (en) * | 2008-05-12 | 2015-01-28 | 日東電工株式会社 | Polytetrafluoroethylene porous membrane, method for producing the same, and filter medium |
US8147936B2 (en) * | 2009-06-10 | 2012-04-03 | General Electric Company | Composite membrane for chemical and biological protection |
US20110268959A1 (en) * | 2010-04-29 | 2011-11-03 | General Electric Company | Porous membrane |
-
2009
- 2009-10-30 US US12/609,444 patent/US8673440B2/en active Active
-
2014
- 2014-02-14 US US14/181,002 patent/US20140232033A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4478665A (en) * | 1980-11-06 | 1984-10-23 | W. L. Gore & Associates, Inc. | Method for manufacturing highly porous, high strength PTFE articles |
US20030194599A1 (en) * | 2002-04-16 | 2003-10-16 | Sassa Robert L. | Composite films for electrochemical devices |
WO2009011315A1 (en) * | 2007-07-18 | 2009-01-22 | Nitto Denko Corporation | Water-proof sound-transmitting membrane, method for production of water-proof sound-transmitting membrane, and electrical appliance using the membrane |
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US20110104472A1 (en) | 2011-05-05 |
US8673440B2 (en) | 2014-03-18 |
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