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50 All images and content are copyright of their respective owners and.This invention relates to an apparatus and method for continuously producing a porous polytetrafluoroethylene polymer useful for making Teflon filters.
More particularly, this invention relates to an apparatus and method for continuously producing a porous polytetrafluoroethylene polymer useful for making filters for extracting particulate matter from fluids such as air and liquid.
Polytetrafluoroethylene polymers, also referred to as Teflon, PTFE, or polytetrafluoroethylene, are known in the art.
It is known that Teflon can be made by extruding a molten polymer through an annular die. See, for example, U.S. Pat. No. 2,772,444 to Holmes. While such extrusion of molten polymer through an annular die can produce a relatively smooth extruded material, it is difficult to use such an extruder in the production of porous sheets or membranes.
It is known that porous sheets can be made by calendering molten polymer to form a sheet. For example, U.S. Pat. No. 3,953,566 to Holmes discloses a calender for calendering a molten polymer to form a sheet. See also U.S. Pat. No. 3,952,788 to Yasuda. In such calendering processes, there is a tendency for the polymer to flow away from the calender nip, thus requiring an undesirably large calender nip. In addition, such calendering of molten Teflon polymer is relatively difficult, requiring very high pressures to extrude the molten polymer through the nip of the calender.
It is also known that Teflon, like most polymers, can be formed into films by casting molten Teflon into a thin film of a liquid. See, for example, U.S. Pat. Nos. 2,772,444 to Holmes and 3,952,788 to Yasuda. As far as we are aware, no one has made a Teflon polymer useful for making Teflon filters by casting molten polymer into a thin film of air.
It is known that the permeability of a polymer can be increased by “ballooning” the polymer. As used herein, the term “balloon
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