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Teflon

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Fundamental Structures and Properties of Teflon and Its Applications in Industry 1. Introduction
Polytetrafluoroethylene (PTFE) also known as Teflon is a thermoplastic polymer. It is formed by addition polymerization using the monomer tetrafluroethylene (TFE). Teflon is a strong, waxy and non-flammable resin which is used in many applications especially in corrosive industries due to its resistance to chemicals. In addition, it is able to maintain its physical properties over a wide range of temperatures.
Teflon was invented by accident by a research chemist named Roy J. Plunkett at DuPont’s Jackson Lab in New Jersey on 6 April 1938. Plunkett and his technician assistant, Jack Rebok, were testing on the chemical reactions of the refrigerant gas TFE, he noticed one of the pressurized cylinders failed to discharge when its valve was opened. Rebok suggested cutting the cylinder open to see what went wrong. They discovered the gas inside the cylinder had solidified into a white powder. Plunkett began to test the properties of the white powder.
The white powder was found to be more lubricant than other slippery solids. In addition, it proved to be inert to almost other chemicals and had extremely high melting point at 335°C. Plunkett discovered that the gas had polymerized to become a PTFE resin and thus, invented a way to produce the TFE to PTFE polymerization in the lab. 2. Analysis of Fundamental Structures and Properties
PTFE exhibits many useful properties. It is resistant to many chemicals, weather and UV resistance, non-stick, low coefficient of friction, a good insulator, excellent optical properties and can withstand extreme temperatures from as low as 240°C to up to as high as 260°C without changes to its physical or chemical properties. Also, it is hydrophobic and oleophobic hence, it is easier to clean it.
The monomer TFE (-CF2=CF2-) undergoes free radical addition polymerization. PTFE are made up of only carbon and fluorine atoms only hence, it is a linear polymer with no configuration and conformation. This caused the fluorine atoms to be arranged regularly and ensure close-packing chains across the polymer which promotes the degree of crystallinity. However, the polymer is rigid due to fluorocarbon chain, even small rotations hindered by slightly overcrowded fluorine atoms.
The high degree of crystallinity ensures it has a low chance to creep and also promotes the tensile strength due to the regularity of the fluorine atoms on the polymer chain. In addition, PTFE polymer has a high molecular weight ranging from (5-100) x 106 g/mol. Since the repeating unit (-CF2CF2-) has a molecular weight of 100.02 g/mol, the degree of polymerization is high. Due to this, mechanical properties such as ductility, tensile strength and hardness are at its peak.
When it crystallizes from a melt, it formed a spherulite structure. Each spherulite consists of crystalline region which acts as a nucleus, an amorphous region and tie molecules. The crystalline part makes PTFE strong but the amorphous region gives PTFE its toughness as it is able to bend without breaking. Also, spherulite can reflect light and therefore gave PTFE its optical property.
The fluorine atoms in PTFE has high electronegativity, thus having more electrons which formed an impenetrable shield which lock onto and protect the compound’s string of carbon atoms. Also, it contributes to the size of the polymer orbital formed and the number of electrons present in the polymer orbital. This allows it to repel the polar water molecules and gave its property as hydrophobic.
In addition, the CF2 groups are equally spaced along the chain which is twisted to form a helix to accommodate the large fluorine atoms to relieve overcrowding and having the shortest F-F distance. It provides stability to the fluorine to carbon bonds. As such, it is difficult to break a stable bond and this makes PTFE unreactive to many chemicals. This stable bonding structure also contributes to good dielectric properties. It prevents the transmission of electrons through the molecular orbital of PTFE and due to the strength of the carbon to fluorine bonds, electrons are not released easily from the polymer orbital. 3. Description of Industrial Applications of Teflon
Teflon is widely used in many industries due to its unique properties. In the petrochemical industries and chemical processing industries, Teflon is used for vessel linings, seals, gaskets, spacers, pump interiors, washers, dip tubes and well-drilling components. This is due to PTFE is chemically inert, resistant to corrosion and functions in environments of 500 degrees Fahrenheit. Also, PTFE are used in refrigeration systems and steams line. PTFE hoses are used to transfer chemicals and connectors and lines for product interchange. Teflon replaces the typical corrugated, stainless steel hoses.
For the electrical industries, PTFE are used as an insulator in wire, cable wrap, spacers and tubings. It is used to separate conductive surfaces in capacitors. It is machined into standoff insulators and many different types of high voltage encapsulation devices for electrical components.
For the food, beverage, cosmetics and pharmaceutical industries, only virgin PTFE is used as it is approved by Food and Drug Administration (FDA). Thin sheets and film of PTFE make an inert, no-toxic slide surface without microscopic depressions so microbes cannot grow. Conveyancing components such as profiles, guides, rails and slides, are able to withstand high temperatures inside baking and drying oven and other heated components.
In addition for pharmaceutical industries, PTFE coatings are used to provide over braid seals, strength and ease when cleaning and purging the system. It can be shaped as a bottle to contain dangerous chemicals such as phenol which is used to deactivate bacteria after fermentation process.
In the automotive industries, air brake systems in which constructions made of over-braided are needed. It is used on the outside edge of air compressors as PTFE are able to withstand extremely high temperatures. It is able to reduce deposits of carbon particles which are essential to the automotive industry due to the burning of fuel.
PTFE is usually used for tubing, hydraulic and fuel hoses in the aerospace industry. It is fused with Kevlar for added protection since it is used in applications that require the tempering of heat. It is normally found in pneumatic and hydraulic systems.
PTFE not only can withstand high temperatures but also extremely low temperatures used within cryogenics industry. Therefore, it is mostly used for hydraulic hoses, piston rings, fuel lines and air liquid systems. Due to PTFE’s resistance to weather degradation, glass filled PTFE are stamped into bearing pads as it remained an inert interface between disparate construction materials.
Semiconductors used PTFE as an insulator in the production of discrete components such as capacitors in chip manufacturing. This is due it able to withstand a wide temperature range of -350°F to 550°F. 4. Prospective Improvement of Teflon
Teflon is being studied to be used in the medical industries as Tennenbaum type stents. The study compares the improved duration of patency between Teflon Tannenbaum stent and conventional Cotton-Leung Polyethylene stent.
Biliary stent insertion is a standard palliative treatment for obstructive jaundice caused by malignancy of the pancreas and biliary system. Currently, Amsterdam type polyethylene stent are used with a median patency of 3-6 months. Studies found that a direct relation between the frictional coefficient of the polymer and amount of encrusted material and therefore, Teflon was picked to be the best polymer for biliary stents.
Plastic stents are less expensive and it is much popular compared to metallic stents. However, plastic stents are prone to clogging, causing often repeated stent changes in order to maintain biliary drainage. Stent blockage is a major limitation in palliative treatment of malignant biliary obstruction.
In the study of patency, stent diameter of 10 Fr wide and length of 9cm long were kept constant but both stent designs and material used were different. Teflon was used as an inner coating separated by stainless steel mesh from an outer polyamide layer, following a Tennenbaum design which consists of a thin stainless steel mesh between an inner Teflon coating and an outer polyamide layer without side holes and four side flaps at each end so as not to penetrate the lumen of the stent. On the other hand, polyethylene uses the standard Amsterdam design stent which consists of one side flap and one side hole at each end.
The stents are placed in patients suffering from malignant biliary obstruction and the results do not proved the improved duration of patency. However, it showed an excess incidence of proximal stent migration thus additional design modifications are needed. 5. References 1) http://web.mit.edu/invent/iow/plunkett.html 2) http://www.chemguide.co.uk/organicprops/alkenes/polymerisation.html 3) http://aerostudents.com/files/materialsAndStructures/MaterialsScienceBookSolutions/CH14.pdf 4) Callister, William D. (2007). Materials Science and Engineering: An Introduction (7th Edition). New York: John Wiley & Sons, Inc. 5) http://www.polytech.mat.ethz.ch/research/diss/visjager.pdf 6) http://pslc.ws/macrog/crystal.htm 7) http://www.polymer-search.com/teflon.html 8) http://www.apexpolymers.net/ptfe.htm 9) http://toefco.com/ptfe-history-and-common-applications 10) http://dare.uva.nl/document/86654 11) http://fluoropolymerproducts.com/ptfe_applications.htm 12) http://www.agcchem.com/documentation/technical-data/finish/13-fluon-ptfe-resins/46-processing-note-f12-13-physical-properties-of-unfilled-filled-ptfe.html

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