Melt processable perfluoropolymer forms

Abstract

Melt processable perfluoropolymer forms prepared from melt processable perfluoropolymer fibers and yarns. Filtration media and filtration support media prepared from melt processable perfluoropolymers.

1 . Textured yarns having 2 to 100 crimps/inch derived from melt processable perfluoropolymers, having individual filament deniers from about 0.5 to about 300 and total yarn deniers of about 10 to 100,000, wherein said perfluoropolymer is selected from the group consisting of copolymers of tetrafluoroethylene with 1 to 5 mole % of at least one perfluoroalkoxylvinylether where the alkyl group has from 1 to 4 carbon atoms and copolymers of tetrafluoroethylene with 2 to 20 mole % of at least one perfluoroolefin having from 3 to 8 carbon atoms.  
     
     
         2 . Staple Fibers having 0 to 50 crimps/inch derived from melt processable perfluoropolymers having individual filament deniers from about 0.5 to about 300 and total yarn deniers of about 10 to 100,000, wherein said perfluoropolymer is selected from the group consisting of copolymers of tetrafluoroethylene with 1 to 5 mole % of at least one perfluoroalkoxylvinylether where the alkyl group has from 1 to 4 carbon atoms, and copolymers of tetrafluoroethylene with 2 to 20 mole % of at least one perfluoroolefin having from 3 to 8 carbon atoms.  
     
     
         3 . Yarns and staple fibers according to claims  1  or  2  with individual filaments having a cross-sectional shape selected from the group consisting of circular, elliptical, angular, hollow, multilobal, bi-component or sheath core yarns or staple fibers made from said melt processable perfluoropolymers and any other melt processable polymer as the second component.  
     
     
         4 . Yarns and Staple fibers derived from melt processable perfluoropolymers, having individual filament deniers from about 0.5 to about 300, and total yarn deniers of about 10 to 100,000 having cross-sectional geometries of individual filaments other than single component circular, these include elliptical, angular, hollow, multilobal, bi-component, or sheath core.  
     
     
         5 . A yam according to claims  3  or  4  having residual elongation of 1 to 50%, better filament uniformity, and less brittleness.  
     
     
         6 . A high purity yarn and staple fiber according to claims  3  or  4  suitable for use in semiconductor, pharmaceutical, and other high purity applications.  
     
     
         7 . A yarn according to  claim 3  or  4  suitable for weaving, knitting, hydroentangling, flame treating, and other textile processes.  
     
     
         8 . An air entangled yarn derived from melt processable perfluoropolymers, having individual filament deniers from about 0.5 to about 300, and total yarn deniers of about 10 to 100,000.  
     
     
         9 . A twisted yarn having 1 to 20 twists per inch derived from melt processable perfluoropolymers, having individual filament deniers from about 0.5 to about 300, and total yarn deniers of about 10 to 100,000.  
     
     
         10 . Yarns made according to claims  3 ,  4 ,  5 ,  6 ,  8 , or  9 , or any combination of these claims, suitable for weaving, knitting, hydroentangling, air-jet entangling flame treating, and other textile processes.  
     
     
         11 . A woven fabric having a weight per square yard of from about 1 to about 100 ounces per square yard made from yams according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 , or any combination of these claims, suitable for use in filtration, or as a support scrim in non-woven products.  
     
     
         12 . A knitted fabric having a weight per square yard of from about 1 to about 100 ounces per square yard made from yams according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 , or any combination of these claims, suitable for use in filtration, or as a support scrim in non-woven products.  
     
     
         13 . A crimped staple fiber according to claims  3  or  4  wherein the filaments have been crimped to give an angular “saw toothed” shape with 2 to 50 crimps per inch, cut to any length, suitable for use on standard carding equipment to make nonwoven batts which can then be needled into felts or for carding into sliver for making spun yarns or for producing high loft air laid non-woven products.  
     
     
         14 . A non-woven perfluoropolymer fabric having a weight per square yard of from about 1 to about 100 ounces per square yard, made from staple fibers according to  claim 6 , having excellent strength in both the machine and cross-machine directions, and good filtration properties.  
     
     
         15 . A non-woven perfluoropolymer fabric having a weight per square yard of from about 1 to about 100 ounces per square yard produced by needlepunching of a continuous, carded staple fiber web, made from staple fibers according to  claim 13 , having excellent strength in both the machine and cross-machine directions, and good filtration properties.  
     
     
         16 . A lightly needled or un-needled carded batt made from melt processable perfluoropolymer which has been densified and/or bonded through a heated calendering process, with smooth, textured, or patterned calender rolls, to yield a fabric with increased strength and stiffness, as compared to its precursor.  
     
     
         17 . A fabric, according to claims  14  and  15 , further, including a perfluoropolymer woven supporting fabric or scrim for increased strength.  
     
     
         18 . A fabric, according to claims  14  and  15 , further including a woven supporting fabric or scrim made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or synthetic fibers for increased strength.  
     
     
         19 . A fabric according to claims  14 ,  15 ,  16 ,  17 , or  18  made from of a blend of melt processable perfluoropolymer staple fibers and fibers selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other synthetic fibers.  
     
     
         20 . A fabric according to claims  14 ,  15 ,  16 ,  17 ,  18 , or  19  where the fabric density, air permeability, and mean pore size can be controlled through needling conditions.  
     
     
         21 . A calendered fabric according to claims  14 ,  15 ,  16 ,  17 ,  18 ,  19 , or  20  where the fabric density, air permeability, and mean pore size can be controlled in a continuous fashion through the heated calendering/densification process with smooth, textured, or patterned calender rolls, or in a batch fashion in a plate press.  
     
     
         22 . Yarns, staple fibers, or fabrics according to claims  10 ,  11 ,  12 ,  13 ,  14 ,  15 ,  16 ,  17 ,  18 ,  19 ,  20 , or  21  which are thermally bonded to themselves.  
     
     
         23 . Yarns, staple fibers and fabrics according to claims  10 ,  11 ,  12 ,  14 ,  15 ,  16 ,  17 ,  18 ,  19 ,  20 , or  21  which are thermally bonded to other high temperature plastics, fabrics and other media.  
     
     
         24 . Filtration and coalescing media, support layers, drainage layers, and other components produced by winding continuous or spun yarns according to claims  3 ,  4 ,  5 ,  6 , or  8 ,  9 , or  10 .  
     
     
         25 . Filtration and coalescing media, support layers, drainage layers, and other components produced according to claims  10 ,  11 ,  12 ,  14 ,  15 ,  16 ,  17 ,  18 ,  19 ,  20 ,  21 ,  22 , or  23 .  
     
     
         26 . Filtration and coalescing components according to claims  24  or  25  with seams formed by thermal fusion.  
     
     
         27 . Filtration and coalescing components according to claims  24  or  25  which are melt fused to other components of the filter or the filter housing to form a liquid tight seal.  
     
     
         28 . Filtration and coalescing components according to claims  24  or  25  having less tendency to foul and easier cleaning by back-pulsing, rinsing, mechanical means, or other techniques.  
     
     
         29 . Filtration and coalescing components according to claims  24  or  25  having high purity suitable for semiconductor, pharmaceutical, and other high purity applications.  
     
     
         30 . Pleatable filtration and coalescing components according to claims  24  or  25 .  
     
     
         31 . Filtration and coalescing components according to claims  24  or  25  thermally bonded to other media, such as membranes, drainage layers, pleat supports and any other component of filter elements or devices.  
     
     
         32 . A self-supported non-woven fabric derived from melt processable perfluoropolymers possessing a Mullen burst strength (ASTM-D3776) between 10 and 1000 psi.  
     
     
         33 . A scrim-supported non-woven fabric possessing a Mullen burst strength between 10 and 1000 psi wherein said non-woven fabric is derived from melt processable perfluoropolymers.  
     
     
         34 . A self-supported or scrim-supported non-woven fabric derived from melt processable perfluoropolymers possessing an air permeability (ASTM D737) between 1 and 300 cfm/ft 2  at 0.5″ water pressure.  
     
     
         35 . A woven fabric having a weight per square yard of about 1 to about 100 ounces per square yard, made from a blend comprising. 1 to 99 percent by weight of melt processable perfluoropolymer yarns according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 ; and 99 to 1 percent of fibers or yarns made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyirnide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, suitable for use in filtration, as a support scrim in nonwoven products.  
     
     
         36 . A woven fabric having a weight per square yard of about 1 to about 100 ounces per square yard made from a blend of 1 to 99 percent by weight of melt processable perfluoropolyner yams according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 ; and 99 to 1 percent by weight of fibers or yarns made from polytetrafluoroethylene (PTFE), suitable for use in filtration, as a support scrim in nonwoven products.  
     
     
         37 . A knitted fabric having a weight per square yard of about 1 to about 100 ounces per square yard made from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer yarns according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 ; and 99 to 1 percent of fibers or yarns made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, suitable for use in filtration, or as a support scrim in nonwoven products.  
     
     
         38 . A knitted fabric having a weight per square yard of about 1 to about 100 ounces per square yard made from a blend comprising: 1 to 99 percent melt processable perfluoropolymer yarns or fibers according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 ; and 99 to 1 percent PTFE yarns or fibers, suitable for use in filtration, or as a support scrim in nonwoven products.  
     
     
         39 . A fabric according to claims  14 ,  15 ,  16 ,  17 , or  18  made from a blend comprising: 1 to 99 percent melt processable perfluoropolymer fibers; and 99 to 1 percent PTFE fibers.  
     
     
         40 . A fabric, according to  claim 39  where the fabric density, air permeability, and mean pore size can be controlled through needling conditions.  
     
     
         41 . A calendered fabric according to claims  39  or  40  where the fabric density, air permeability, and mean pore size can be controlled in a continuous fashion through the heated calendering/densification process with smooth, textured, or patterned calender rolls, or in a batch fashion in a plate press.  
     
     
         42 . Yams, staple fibers, or fabrics according to claims  35 ,  36 ,  37 ,  38 ,  39 ,  40  or  41  which are thermally bonded to themselves.  
     
     
         43 . Yarns, staple fibers, or fabrics according to claims  35 ,  36 ,  37 ,  38 ,  39 ,  40 , or  41  which are thermally bonded to other high temperature plastics, fabrics and other media.  
     
     
         44 . Filtration and coalescing media, support layers, drainage layers, and other components produced by winding continuous or spun yams comprising a blend of from 1 to 99 percent melt processable perfluoropolymer yarns or fibers according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 , and 99 to 1 percent by weight of fibers or yarns made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.  
     
     
         45 . Filtration and coalescing media, support layers, drainage layers, and other components produced by winding continuous or spun yarns comprising a blend of from 1 to 99 percent melt processable perfluoropolymer yarns or fibers according to claims  3 ,  4 ,  5 ,  6 ,  8 ,  9 , or  10 ; and 99 to 1 percent PTFE yarns or fibers.  
     
     
         46 . Filtration and coalescing media, support layers, drainage layers, and other components produced according to claims  35 ,  36 ,  37 ,  38 ,  39 ,  40 ,  41 ,  42 , and  43 .  
     
     
         47 . Filtration and coalescing components according to claims  44 ,  45 , or  46  with seams formed by thermal fusion.  
     
     
         48 . Filtration and coalescing components according to claims  44 ,  45 , or  46  which are melt fused to other components of the filter or the filter housing to form a liquid tight seal.  
     
     
         49 . Filtration and coalescing components according to claims  44 ,  45 , or  46  having less tendency to foul and easier cleaning by back-pulsing, rinsing, mechanical means, or other techniques.  
     
     
         50 . Filtration and coalescing components according to claims  44 ,  45 , or  46  having high purity suitable for serniconductor, pharmaceutical, and other high purity applications.  
     
     
         51 . Pleatable filtration and coalescing components according to claims  44 ,  45 , or  46 .  
     
     
         52 . Filtration and coalescing components according to claims  44 ,  45 , or  46  thermally bonded to other media, such as membranes, drainage layers, pleat supports and any other component of filter elements or devices.  
     
     
         53 . A self-supported non-woven fabric derived from a blend comprising: from 1 to 99 percent melt processable perfluoropolymer fibers and 99 to 1 percent fibers made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, said non-woven fabric possessing a Mullen burst strength (ASTM-D3776) between 10 and 1000 psi.  
     
     
         54 . A self-supported non-woven fabric derived from a blend comprising: from 1 to 99 percent melt processable perfluoropolymer fibers; and from 99 to 1 percent PTFE fibers, said non-woven fabric possessing a Mullen burst strength (ASTM-D3776) between 10 and 1000 psi.  
     
     
         55 . A scrim supported non-woven fabric possessing a Mullen burst strength between 10 and 1000 psi wherein said non-woven fabric is derived from a blend comprising: from 1 to 99 percent melt processable perfluoropolymer fibers; and 99 to 1 percent fibers made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers.  
     
     
         56 . A scrim supported non-woven fabric possessing a Mullen burst strength between 10 and 1000 psi wherein said non-woven fabric is derived from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer fibers; and 99 to 1 percent PTFE fibers.  
     
     
         57 . A self-supported or scrim supported non-woven fabric derived from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer fibers and 99 to 1 percent by weight fibers made from materials selected from the group consisting of glass, aramid, polyacrylate, polyphenylene sulfide, polyimide, polyester, polyamide, partially fluorinated polymers, carbon, or other natural or other synthetic fibers, said self supported or scrim supported non-woven fabric possessing an air permeability (ASTM D737) between 1 and 300 cfm/ft 2  at 0.5″ water pressure.  
     
     
         58 . A self-supported or scrim supported non-woven fabric derived from a blend comprising: 1 to 99 percent by weight of melt processable perfluoropolymer fibers; and 99 to 1 percent PTFE fibers, said self-supported or scrim supported non-woven fabric possessing an air permeability (ASTM D737) between 1 and 300 cfm/ft 2  at 0.5″ water pressure.  
     
     
         59 . Filtration and coalescing components according to claims  24 ,  25 ,  44 ,  45 , or  46  with seams formed by sewing, use of an adhesive, or by mechanical fasteners.  
     
     
         60 . Filtration and coalescing components according to claims  24 ,  25 ,  44 ,  45 , or  46  which are attached to other components of the filter or the filter housing, using an adhesive, to form a liquid tight seal.  
     
     
         61 . Filtration and coalescing components according to claims  24 ,  25 ,  44 ,  45 , or  46  attached to other media, such as membranes, drainage layers, pleat supports and any other component of filter element devices using an adhesive, by sewing, or by mechanical fasteners.