Fluoropolymers with shell-modified particles, and processes for their preparation

Claim 2

Aqueous polymer dispersion containing colloidal particles of a partially modified tetrafluoroethylene polymer with a multi-shell particle structure of shells of different composition, said particles consisting essentially of (a) a particle core comprising a polymer of 0.05 to 6% by weight of units of at least one modifying fluoro-olefinic comonomer of the formulae ##STR7## wherein R 1 is H, Br or Cl; R 2 is F or R f 1 , R f 1 denoting a perfluoroalkyl radical with 1 to 4 C atoms; and R 3 is R 1 or R 2 ; ##STR8## wherein R f 1 is a perfluoroalkyl radical with 1 to 4 C atoms and R f 2 is F or a perfluoromethyl radical; R.sub.f.sup.3 --O--CF═CF.sub.2 (a.sup.3) wherein R f 3 is a perfluoroalkyl radical with 1 to 5 C atoms; or R.sub.4 --O--CF═CF.sub.2 (a.sup.4) wherein R 4 is a radical XCF 2 --(CF 2 ) m -- in which X is H or Cl and m denotes an integer from 0 to 4, and units of tetrafluoroethylene, the proportion of the particle core being 5 to 20% by weight of the total particle, (b) an inner particle shell, immediately adjacent to the particle core, of a polymer consisting of tetrafluoroethylene units, and (c) an outer particle shell, immediately adjacent to the inner particle shell, of a polymer comprising 0.1 to 15% by weight of units of at least one modified, fluoro-olefinic comonomer of the formulae (a 1 ), (a 2 ), (a 3 ), and (a 4 ), these formulae being as defined under (a), and units of tetrafluoroethylene, the weight ratio of the inner particle shell to the outer particle shell being 75:25 to 99.5:0.5.

Claim 3

Aqueous fluoropolymer dispersion as claimed in claim 1 wherein the particle core consists of 0.1 to 5% by weight of units of the modifying fluoro-olefinic comonomer and of tetrafluoroethylene units.

Claim 4

Aqueous fluoropolymer dispersion as claimed in claim 1 wherein the outer particle shell comprises a polymer consisting of 0.1 to 12% by weight of units of the modifying fluoro-olefinic comonomer and tetrafluoroethylene units.

Claim 5

Aqueous fluoropolymer dispersion as claimed in claim 1 wherein the modifying fluoro-olefinic comonomer in the particle core is at least one comonomer from the group comprising perfluoropropene, perfluoro(propylvinyl)-ether, chlorotrifluoroethylene and vinylidene fluoride.

Claim 6

Aqueous fluoropolymer dispersion as claimed in claim 1 wherein the modifying fluoro-olefinic comonomer in the outer particle shell is at least one comonomer from the group comprising perfluoropropene, perfluoro(propylvinyl)-ether, chlorotrifluoroethylene and vinylidene fluoride.

Claim 7

Coagulated fluoropolymer resin powder which consists of primary particle agglomerates with an average particle diameter of 200 to 800 μm in which the primary particles are built up as claimed in any one of claims 1 to 5.

Claim 8

A process for the preparation of aqueous fluoropolymer dispersions containing colloidal particles of a partially modified tetrafluoroethylene polymer with a multi-shell particle structure of shells of different composition as claimed in claim 1 by emulsion polymerization of tetrafluoroethylene with modifying fluoro-olefinic comonomers copolymerizable with tetrafluoroethylene, in the presence of catalysts and emulsifiers which comprises (A) first preparing a colloidal seed dispersion with a polymer solids content of 3 to 18% by weight, relative to the total weight of the aqueous seed dispersion, by emulsion polymerization of tetrafluoroethylene and at least one modifying fluoro-olefinic comonomer of the formulae ##STR9## wherein R 1 is H, Br, or Cl; R 2 is F or R f 1 , R f 1 denoting a perfluoroalkyl radical with 1 to 4 C atoms; and R 3 is R 1 or R 2 ; ##STR10## wherein R f 1 is a perfluoroalkyl radical with 1 to 4 C atoms and R f 1 is F or a perfluoromethyl radical; R.sub.f.sup.3 --O--CF═CF.sub.2 (a.sup.3) wherein R f 3 is a perfluoroalkyl radical with 1 to 5 C atoms; or R.sub.4 --O--CF═CF.sub.2 (a.sup.4) wherein R 4 is a radical XCF 2 --(CF 2 ) m -- in which X=H or Cl and m denotes an integer from 0 to 4, the amount of this fluoro-olefinic comonomer being such that the proportion of its units in the seed particles formed is 0.05 to 6% by weight; discontinuing the polymerization by letting down the pressure and removing the monomer phase; (B) then continuing the emulsion polymerization in the presence of this colloidal seed dispersion from stage (A), if appropriate after reducing the solids content by dilution, by forcing in tetrafluoroethylene and continuing to feed in tetrafluoroethylene to maintain a pressure of 5 to 30 bars, until the solids content of the final dispersion has reached 8 to 40% by weight, the amount of colloidal seed dispersion present being such that the particle cores formed from the seed particles comprise 5 to 20% by weight of the particles of the final dispersion, and (C) feeding at least one modified fluoro-olefinic comonomer of the formulae (a 1 ), (a 2 ), (a 3 ), and (a 4 ) wherein these formulae are as defined under (A), into the continuing emulsion polymerization of stage (B) when a degree of conversion in the range from 75 to 99.5% by weight has been reached, relative to the consumption of tetrafluoroethylene up to the intended solids content of the final dispersion, the amount fed in being such that the proportion of comonomer units in the outer particle shell which forms is 0.1 to 15% by weight.

Claim 9

A process as claimed in claim 7 wherein the emulsion polymerization in stage (B) is continued by passing in tetrafluoroethylene until the solids content of the final dispersion reaches 12 to 30% by weight.

Claim 10

A process as claimed in claim 7 wherein the emulsion polymerization in stage (B) is continued by passing in tetrafluoroethylene until the solids content of the final dispersion reaches 15 to 25% by weight.

Claim 11

A process as claimed in claim 7 wherein the modifying fluoro-olefinic comonomer is fed into stage (C) in an amount such that the proportion of units thereof in the outer particle shell formed is 0.1 to 12% by weight.

Claim 12

A process as claimed in claim 7 wherein the colloidal seed dispersion prepared in a separate operation according to stage (A) is introduced before continuing the emulsion polymerization according to stage (B), the amount of catalyst and emulsifier required for stage (B) being added at the start of stage (B).

Claim 13

A process as claimed in claim 7 wherein the emulsion polymerization in stage (B) and (C) is carried out in the presence of dispersion stabilizers.

Claim 14

A process as claimed in claim 7 wherein the dispersion stabilizers are added approximately when feeding in of the comonomer, according to stage (C), starts.

Claim 15

A process as claimed in claim 7 wherein a non-polymerizable, non-fluorinated chain transfer agent is present in at least one of stages (A), (B), and (C).