Fluoropolymer blends and multilayer articles

Abstract

Disclosed are various fluoropolymer blend combinations and multilayer articles comprising a blend in a first layer and a second layer comprising a polymer bonded to the first layer. The invention also provides an article comprising a first layer comprising a blend of two or more fluoropolymers, and a second layer bonded to the first layer, the second layer comprising a partially-fluorinated thermoplastic polymer, a perfluorinated thermoplastic polymer, or a combination thereof. The invention also provides an article comprising a first layer comprising a blend of two or more fluoropolymers, at least one of which comprises a partially-fluorinated thermoplastic polymer, and optionally at least one perhalogenated polymer, and a second layer bonded to the first layer, the second layer comprising an at least partially-fluorinated thermoplastic polymer. The invention also provides processes for preparing blended fluoropolymers and multilayer articles comprising a fluoropolymer layer.

1 . A fluoropolymer composition comprising a partially fluorinated-thermoplastic polymer in a blend with at least one additional component selected from: 
 (i) a perfluorothermoplastic, wherein the partially fluorinated-thermoplastic is substantially non-vinylidene fluoride containing;    (ii) two or more different perfluoropolymers, one or more of which may be thermoplastic;    (iii) a different partially-fluorinated thermoplastic polymer, wherein the partially fluorinated-thermoplastic polymers have interpolymerized units derived from a substantial amount of vinylidene fluoride;    (iv) two different partially-fluorinated thermoplastic polymers.    
     
     
         2 . A blend according to  claim 1  wherein the partially fluorinated-thermoplastic is derived from a combination of interpolymeiized units of tetrafluoroethylene, hexafluoropropylene, perfluoro alkyl or alkoxy vinyl ethers, and nonfluorinated olefins.  
     
     
         3 . A blend according to  claim 1  wherein the perfluorothermoplastic is selected from FEP, PFA, or a combination thereof.  
     
     
         4 . The blend of  claim 1  further comprising a fluoroelastomer and/or a perfluoroelastomer.  
     
     
         5 . A blend according to  claim 1  having at least two partially-fluorinated thermoplastic polymers with interpolymerized units derived from a substantial amount of vinylidene fluoride and further comprising a perfluoropolymer derived from interpolymerized units of two or more of tetrafluoroethylene, hexafluoropropylene, and perfluoro alkyl or alkoxy vinyl ethers.  
     
     
         6 . A blend according to  claim 1  having at least two partially-fluorinated thermoplastic polymers with interpolymerized units derived from a substantial amount of vinylidene fluoride and wherein one or more of the vinylidene fluoride-containing thermoplastic copolymer(s) further comprise(s) interpolymerized units derived from tetrafluoroethylene, hexafluoropropylene, and optionally a perfluoro alkyl or alkoxy vinyl ether.  
     
     
         7 . A blend according to  claim 1  having at least two partially-fluorinated thermoplastic polymers with interpolymerized units derived from a substantial amount of vinylidene fluoride and wherein one of the thermoplastic polymers has a vinylidene fluoride content between about 3 and 30 weight percent and wherein a second of said thermoplastic polymers has a vinylidene fluoride content between about 20 and 60 weight percent.  
     
     
         8 . A blend according to  claim 1  having at least three partially-fluorinated thermoplastic polymers wherein at least one polymer is derived from a combination of interpolymerized units of tetrafluoroethylene, hexafluoropropylene, vinylidene fluoride, perfluoro alkyl or alkoxy vinyl ethers, and/or nonfluorinated olefins.  
     
     
         9 . A blend according to  claim 1  wherein one or more polymer(s) further comprises interpolymerized units of according to the formula: —CF 2 —CF(X′)—, wherein each X′ is independently Cl, Br, R f , O(R f O) a R f , wherein each R f  is independently a C 1 -C 10  perfluoroalkyl group; or a perfluorinated polymer comprising interpolymerized units of Formula II:  
       
         
           
           
               
               
           
         
         wherein each Y is independently a bond, O, or CF 2 ; each Z is independently F or R f  wherein each R f  is independently a C 1 -C 10  perfluoroalkyl group; a is 0-20; and n is 0-3.  
       
     
     
         10 . An article comprising a blend according to  claim 1 .  
     
     
         11 . A polymer composition comprising a blend of a first polymer having a surface energy below about 20 mJ/m 2  and a second polymer having a surface energy having below about 25 mJ/m 2 , wherein the difference of the surface energy between the first polymer and the second polymer is from 1 mJ/m 2  to 5 mJ/m 2 .  
     
     
         12 . An article comprising the polymer composition of  claim 11 .  
     
     
         13 . The polymer composition of  claim 9  wherein the first polymer is provided in a layer adjacent to a layer of the second polymer.  
     
     
         14 . An article comprising the layered polymer composition of  claim 13 .  
     
     
         15 . A permeation resistant fluoropolymer composition comprising: 
 a) a perfluoropolymer; and    b) from about 5 to about 50 weight percent, based on the fluoropolymer composition, of a partially-fluorinated polymer;    wherein the fluoropolymer composition has a Permeation Constant below about 50% greater than the perfluoropolymer alone.    
     
     
         16 . The composition of  claim 15  wherein the composition has a Permeation Constant below about 25% greater than the perfluoropolymer alone.  
     
     
         17 . The composition of  claim 15  wherein the perfluoropolymer is FEP or PFA.  
     
     
         18 . The composition of  claim 15  wherein the partially-fluorinated polymer is a copolymer derived from interpolymerized units of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride, and optionally a perfluoro alkyl or alkoxy vinyl ether.  
     
     
         19 . An article comprising the composition of  claim 15 .  
     
     
         20 . A method of making a fluoropolymer composition according to  claim 1  comprising blending a partially fluorinated-thermoplastic polymer in a blend with at least one additional component selected from (i) a perfluorothermoplastic, wherein the partially fluorinated-thermoplastic is substantially non-vinylidene fluoride containing; (ii) two or more different perfluoropolymers, one or more of which may be thermoplastic; (iii) a different partially-fluorinated thermoplastic polymer, wherein the partially fluorinated-thermoplastic polymers have interpolymerized units derived from a substantial amount of vinylidene fluoride; and (iv) two different partially-fluorinated thermoplastic polymers.