FLUID TREATED POLYTETRAFLUOROETHYLENE PRODUCTS AND THEIR MANUFACTURE

Abstract: Porous materials suitable for a variety of uses including waterproof/breathable fabrics, air filters, liquid filters, liquid/liquid separation membranes, vascular grafts, mechanical seals, etc. which comprises an intimate combination of about 50 to 99.9 wt % polyetrafluoroethylene polymer and about 0.1 to 50 wt % of a fluorinated organic polymer which is liquid under ambient conditions, such as the perfluoroether fluids, wherein the material has a microstructure characterized by nodes interconnected by fibrils.

Description: FLUID TREATED POLYTETRAFLUOROETHYLENE PRODUCTS AND THEIR MANUFACTURE Field of the Invention The invention broadly relates to porous materials produced by expanding paste-formed polytetra- fluoroethylene and methods of manufacturing such materials. Specifically, the invention relates to porous materials produced by either (i) expanding paste- formed polytetrafluoroethylene which has been treated with a fluorinated organic polymer fluid, or (ii) treating expanded paste-formed polytetrafluoroethylene with a fluorinated organic polymer fluid, and methods of manufacturing such materials. Background of the Invention Polytetrafluoroethylene is a unique compound commonly employed when one or more of the associated characteristics of chemical inertness, water repellency, and/or electrical insulating value are desired. Polytetrafluoroethylene can be processed to form a highly porous breathable material which continues to retain the characteristics of chemical inertness, water repellency, and electrical insulating value. Briefly, such porous materials are generally produced by heating and expanding (stretching) a paste-formed body of the polytetrafluoroethylene. Expanded porous polytetrafluoroethylene films may be used alone or laminated to an assortment of substrates to produce a variety of products including specifically, but not exclusively, sealing thread, breathable/water-repellant fabrics, air filters, liquid filters, vascular grafts (United States Patent Nos. 3,953,566, 3,962,153, 4,208,745, 4,234,535, 4,321,711, 4,332,035, 4,550,447, 4,647,416, 4,742,480, and 4,955,899), and numerous others. Expanded porous polytetrafluoroethylene films have commanded wide acceptance since their introduction because of their unique combination of properties. However, efforts continue in an attempt to improve upon these properties and thereby increase the potential uses of expanded porous films of polytetrafluoroethylene. One area of concentrated research has been with respect to efforts to increase the radiation resistance of the films, which are notoriously susceptible to degradation by radiation. Efforts to improve upon the properties and/or uses of porous polytetrafluoroethylene materials by blending an additional component into the polytetra¬ fluoroethylene prior to expansion have met with limited success. In fact, common wisdom in the art advises against incorporation of a matrix interactive component into the polytetrafluoroethylene prior to expansion, except in trace amounts, as a high degree of crystallinity is thought to be necessary to achieve proper expansion of polytetrafluoroethylene and the addition of a matrix interactive component tends to adversely affect the crystallinity. A singular success in this area is described in United States Patent No. 4,764,560, wherein incorporation of a silicone elastomer into polytetra¬ fluoroethylene resin prior to expansion, followed by polymerization of the silicone elastomer, produces a porous silicone/polytetrafluoroethylene interpenetrating polymeric network having enhanced properties. Because of the exceptional potential for further unique uses of polytetrafluoroethylene- containing materials, research continues in an effort to improve upon the properties and/or uses of the material. Summary of the Invention Various properties of expanded polytetrafluoro¬ ethylene may be created or improved by treating the polytetrafluoroethylene with a fluorinated organic polymer fluid either before or after expansion. The treated expanded porous polytetrafluoroethylene materials possess a microstructure of nodes interconnected by fibrils characteristic of untreated expanded porous polytetrafluoroethylene materials but with fibrils which are substantially free of fissures. As with untreated expanded porous polytetrafluoro¬ ethylene materials, the treated materials may be formed in any of a number of desired shapes including films and tubes. The treated porous polytetrafluoroethylene materials have enhanced resistance to degradation by radiation, enhanced fine particle filtration efficiency, the ability to prevent the passage of methanol, the ability to delay the passage of isopropanol, and an increased elongation to break. Such treated expanded porous polytetrafluoro¬ ethylene materials are suitable for the same uses as untreated expanded porous polytetrafluoroethylene materials including specifically, but not exclusively, waterproof/breathable fabrics for raincoats and tents, air filters for vehicles and computer disk drives, mechanical seals such as bushings and O-rings, liquid filters, and vascular grafts. In addition, the improved properties of the treated porous polytetrafluoroethylene materials permits the treated materials to be used in additional areas such as liquid/liquid separation membranes, and wherever the material would be subject to high levels of radiation. Specifically, the invention is treating poly¬ tetrafluoroethylene with about 0.1 to 50 wt% (preferably 2 to 20 wt.) of a fluorinated organic polymer fluid, such as a perfluoroether fluid, either before or after expansion. Brief Description of the Drawings Figure 1 is a picture of untreated expanded porous polytetrafluoroethylene film stretched 1.25 times in the machine direction and 20 times in the transverse direction taken with an electron microscope at a magnification of X10,000. Figure 2 is a picture of the expanded porous polytetrafluoroethylene film of Figure 1 after the film was treated with the perfluoroether fluid Fomblin Y 1200™ in accordance with the procedure of Example 2. The picture was taken with an electron microscope at a magnification of X10,000. Figure 3 is a picture of expanded porous poly- tetrafluoroethylene which was treated with 9 wt% of the perfluoroether fluid Fomblin Y 1200™ prior to stretching and then stretched 1.25 times in the machine direction and 20 times in the transverse direction. The picture was taken with an electron microscope at a magnification of X10,000. Detailed Description of the Invention Including a Best Mode As utilized herein, including the claims, the phrase "fluorinated organic polymer fluid" or "fluorinated fluid" means an organic polymer which is normally liquid under ambient conditions and has a carbon to fluorine mole ratio of less than 2si and preferably less than 1.2:1. As utilized herein, including the claims, the phrase "matrix interactive component" means a component which interacts with and becomes incorporated into the polymeric matrix. As utilized herein, including the claims, the term "nodule" means a roughly spherical microstructural element from which the nodes of porous expanded poly¬ tetrafluoroethylene are formed. Referring to Figures 1- 3, nodules are independently distinguishable by means of electron scanning microscopy in porous expanded polytetrafluoroethylene. As utilized herein, including the claims, the phrase "radiation tolerance" refers to the ability to resist degradation when subjected to radiant energy capable of effecting degradation. As utilized herein, including the claims, the phrase "ultra-fine filtration efficiency" refers to filtration efficiency with respect to particles having a particle size of approximately 0.1 microns as measured in accordance with the aerosol testing protocol described in Barris, M.A. , Weik, T.M. , Liu, B.Y., A Measurement System for High Purity Air Filter Media, 1986 Institute of Environmental Sciences Proceedings, p. 551. For purposes of counting the number of separate and distinct nodes in a given area of expanded porous polytetrafluoroethylene, as defined in a photograph of the material taken through electron scanning microscopy, separate and distinct nodes means nodes having at least two physically proximate nodules and no apparent common nodule. Polytetrafluoroethylene CF (CF 2 CF 2 ) n CF 4 is an unusual material commonly manufactured on a commercial scale by dispersion polymerization. Various grades of polytetrafluoroethylene are available from Dupont under the trademark Teflon and ICC Chemicals under the trademark Fluon ® . Some resins have been found to be more suitable for use in the manufacture of expanded porous materials than others. It is generally acknowledged within the art that those grades providing the largest average molecular weight and the highest percentage of crystallinity are preferred for use in the formation of expanded porous materials. In addition, it is generally preferred to utilize a homopolymer of polytetrafluoroethylene. However, it is believed that copolymers of tetrafluoroethylene and another ethylenically unsaturated monomers, such as ethylene, chlorotrifluoroethylene (CTFE), hexafluoropropylene (HFP), perfluoroether containing carboxylic acids, perfluoroether containing sulfonic acids, and the like. may also be suitable for use in the invention when such comonomer is included as a minor component of about 0.001 to about 2 wt. of the polymer matrix. Because polytetrafluoroethylene has a melt temperature which is above its decomposition temperature, polytetrafluoroethylene may not -be melted for molding and shaping as is the common practice for other hydrocarbon resins. For this reason polytetra¬ fluoroethylene is commonly molded and shaped in accordance with a well recognized technique known as paste-forming. Briefly, the paste-forming technique involves mixing the polytetrafluoroethylene resin with a lubricant, typically a volatile hydrocarbon solvent such as kerosene, with subsequent compaction and forming of the mixture to define a cohesive shaped article. The lubricant may be subsequently removed by heating. The invention is directed to the discovery that a unique porous material with improved properties can be produced by expanding paste-formed polytetrafluoro- ethylene which has been treated with a fluorinated organic polymer fluid (hereinafter fluorinated fluid) to the polytetrafluoroethylene before or after expansion. The treated polymeric matrix of polytetra¬ fluoroethylene has the typical microstructure characterized by nodes interconnected by fibrils. However, referring to Figures 1-3, a number of significant differences exist between the treated and untreated materials which become clearly discernable when the materials are viewed at a magnification of ten thousand with electron scanning microscopy. The differences include (i) substantially smooth, void-free, continuous surfaces on the fibrils (treated*) v. plurality of voids throughout the fibrils (untreated) , (ii) multiple parallel strands within each -fibril which extend continuously from node to node (treated) v. multiple parallel strands within each fibril which are discontinuous from node to node so as to farm voids within the fibril (untreated), and (iii) a substantial increase in the number of independent nodes and fibrils discernable by electron scanning microscopy for a given volume. Without intending to be limited thereby, I believe that the individual strands are separate crystalline structures bonded together through amorphous regions and that the discontinuity within a strand is the result of a separation along a crystalline interface caused by expansion of the material. Figures 1-3 clearly indicate that treatment of a polytetrafluoroethylene polymer matrix with a fluorinated fluid prior to expansion produces a substantial increase in the density of nodes and fibrils with significantly smaller nodes and significantly shorter fibrils. For example, based upon the method set forth above for counting nodes viewed through electron scanning microscopy. Figures 1 (untreated) and 2 (treated after expansion) depict only a fraction of a single node while Figure 2 (treated before expansion) depicts at least twenty separate and distinct nodes even though the materials were otherwise processed in identical fashion and the pictures were taken at the same magnification and angle. Generally, it is convenient to incorporate the fluorinated fluid into the polytetrafluoroethylene resin during the paste-forming process along with the lubricant. While the lubricant is subsequently driven from the porous expanded material, it is believed that the fluorinated fluid remains as a matrix interactive component in the final product as infra red spectra of porous expanded material which has been treated with a fluorinated fluid shows the characteristic peaks associated with the fluorinated fluid. It is theorized that the fluorinated organic polymer can be most effectively blended with the polytetrafluoroethylene by using a supercritical fluid mixing method. For example. it is believed that treatment of polytetrafluoroethylene with a combination of a perfluoroether fluid and C0 2 , maintained under supercritical conditions, would readily produce an intimate mixture of the polytetrafluoro- ethylene and the perfluoroether fluid. The intimately blended mixture may then be treated in accordance with the paste-forming technique. The treated polytetrafluoroethylene may be expanded to form porous materials in accordance with the procedure commonly employed for expanding untreated polytetrafluoroethylene. It is generally believed that the porosity range for materials produced by expanding treated polytetrafluoroethylene will be similar to the porosity range associated with materials produced by expanding untreated polytetrafluoroethylene. The polytetrafluoroethylene may be treated with about 0.1 to 50 wt% (preferably 2 to 20 wt%) of the fluorinated fluid prior to expansion in order to achieve the desired improved properties. However, the ability to prevent the passage of methanol and isopropanol appears to increase with increasing concentration of the fluorinated fluid such that a fluorinated fluid concentration of at least about 4 wt% is preferred when the porous material is intended for preventing passage of methanol and a fluorinated fluid concentration of at least about 8 wt% is preferred when the porous material is intended for retarding the passage of isopropanol. Specific fluorinated fluids suitable for use in the invention include: perfluoroether fluids, such as Fomblin available from Montefluous and Krytox available from E.I. Dupont DeNemurs; and fluorinated polyalkylene fluids such as Fluoronert available from Minnesota Mining and Manufacturing Company. The general chemical formulas of the specified fluids are set forth below: (Krytox® (Fombl±iT) F ( CFCF 2 0) n (CF 2 CF 3 ) -and- CF 3 (C 3 F 6 0) m (CF 2 0) n CF 3 CF 3 wherein n = 20 to 60. wherein m = 5 to 50 n = 10 to 100. (Fluoronert ) F(C 2 F a F wherein n = 4 to 40. Without intending to be limited thereby, I believe that the fluorinated fluid functions on the molecular level to lubricate the crystalline lattice structure of the polytetrafluoroethylene polymeric matrix so as to permit enhanced intercrystalline slippage and thereby achieve improved maintenance of intercrystalline contact when the polytetrafluoro¬ ethylene is expanded to form the porous material. The treated porous polytetrafluoroethylene materials have enhanced resistance to degradation by radiation, enhanced fine particle filtration efficiency, the ability to prevent the passage of methanol, the ability to delay passage of isopropanol, and an increased elongation to break. The treated expanded porous polytetrafluoro¬ ethylene materials are generally suitable for the same uses as untreated expanded porous polytetrafluoro¬ ethylene materials. As mentioned previously, such uses include specifically, but not exclusively, waterproof/ breathable fabrics, air filters, liquid filters, vascular grafts, and mechanical seals. It is believed that the treated expanded porous polytetrafluoroethylene materials can be formulated to have a critical surface tension of less than about 26 dynes/cm (the critical surface tension of homogeneous polytetrafluoroethylene) and generally less than about 23 dynes/cm, so as to be useful for preventing the passage of various hydrocarbons such as methanol. One of the unique aspects of treated expanded porous polytetrafluoroethylene materials is the ability of the material to permit the passage of gaseous and vaporized substances as well as a variety of liquids having a low critical surface tension, such as acetylene and isopentane, while preventing the passage of a variety of liquids having a relatively high critical surface tension, such as water and methanol. Tubes formed from the treated expanded porous polytetrafluoroethylene for use as a vascular graft should have an average pore diameter of about 2 to 100 u , a porosity of about 70% to 95%, an inside diameter of 1 to 40 mm, and a wall thickness of about 0.3 to 2 mm. This description is provided to aid in a complete nonlimiting understanding of the invention. Since many variations of the invention may be made without departing from the spirit and scope of the invention, the breadth of the invention resides in the claims hereinafter appended. 11 EXAMPLES Expanded Porous Polytetrafluoroethylene Film Treated with Perfluoroether Fluid Example 1 Into a V-shaped solid-liquid blender manufactured by Patterson Kelly (model #LB-7073) was placed 15 lbs (6.8 kg) Fluon ® 123, a finely powdered polytetrafluoroethylene manufactured by ICI. Into the polytetrafluoroethylene was added 1.4 kg kerosene (CAS 64742-47-8) through a side tube in the blender). The combination of finely powdered polytetrafluoroethylene and kerosene was blended for three minutes and then pressed into plugs in accordance with the standard practice for formation of such plugs. The plugs were ram-extruded into a sheet at a reduction ration of 122.7, calendared to a thickness of 3 mil, and the kerosene volatilized using a series of drying cans. The resultant formed sheet of polytetrafluoro¬ ethylene was transversely stretched approximately 2000% in a tentor frame at a stretch rate of less than 10%/second at a temperature below the melt point of the polytetrafluoroethylene. Example 2 Expanded porous polytetrafluoroethylene film was manufactured in accordance with the procedure set forth in Example 1. Circular samples having a 4 in (10.2 cm) diameter were cut from the expanded porous polytetrafluoroethylene film and retained between a pair of flexible rings having a three inch (7.6 cm) inside diameter and a four inch (10.2 cm) outside diameter. The retained sample is placed between an air chamber and the atmosphere and air forced through the retained sample from the air chamber to the atmosphere at a rate of 10.5 ft 3 /min. An aerosol spray of a 50/50 mixture of Fomblin Y 120™, a perfluoroether fluid available from Montefluos, and Freon 113™, a fluorocarbon available from E.I. DuPont DeNemurs, is dispersed within the air chamber at a rate of 0.01 grams/minute for the purpose of exposing the retained sample to the mixture. The retained samples were exposed to the aerosol spray for 5, 10, 30 and 60 minutes. The aerosol particles were sized and counted with a Laser Aerosol Spectrometer LAS-X™, manufactured by Particle Measurements Systems, Inc. The aerosol was found to contain particles of which more than 90% were found to have a particle size of between 0.1 and 0.4 micrometers. Example 3 Expanded porous polytetrafluoroethylene film treated with a perfluoroether fluid was manufactured in general accordance with the procedure set forth in Example 1. Into a V-shaped solid-liquid blender manufactured by Patterson Kelly (model #LB-7073) was placed 6.7 kg CD-123, a finely powdered polytetrafluoro¬ ethylene manufactured by ICI United States Inc. Into a separate blender was placed 0.14 kg Fomblin Y 120™, a perfluoroether fluid available from Montefluos, and 1.4 kg kerosene (CAS 64742-47-8) to form a liquid premix. The combination of Fomblin Y 120™ and kerosene was thoroughly agitated and then added to the polytetra¬ fluoroethylene retained within the blender through a side tube in the blender. The combination of finely powdered polytetrafluoroethylene and liquid premix was blended for eight minutes and then pressed into plugs in accordance with the standard practice for formation of such plugs. The ratio of polytetrafluoroethylene to perfluoroether fluid being about 48:1. The plugs were ram-extruded into a sheet at a reduction ratio of 122.7, calendared to a thickness of 3 mil, and the kerosene volatilized using a series of drying cans. The resultant formed sheet of perfluoroether fluid treated polytetrafluoroethylene was transversely stretched approximately 2000% in a tentor frame at a stretch rate of less than 10%/second at a temperature below the melt point of the polytetrafluoroethylene. Example 4 The procedure of Example 2 was repeated using 6.44 kg polytetrafluoroethylene and 0.35 kg Fomblin Y 120™ so as to create a polytetrafluoroethylene to perfluoroether fluid ration of about 18:1. Example 5 The procedure of Example 2 was repeated using 6.44 kg polytetrafluoroethylene and 0.675 kg Fomblin Y 120™ so as to create a polytetrafluoroethylene to perfluoroether fluid ratio of about 10:1. Filtration Efficiency The filtration efficiency of the expanded porous films manufactured in accordance with Examples 1- 5 were measured in accordance with the aerosol testing protocol described in Barris, M.A., Weik, T.M. , Liu, B.Y., A Measurement System for High Purity Air Filter Media, 1986 Institute of Environmental Sciences Proceedings, p. 551. The testing was conducted at a flow rate of 10.5 ft 3 /ft 2 /min using liquid DOP particles formed from an alcohol solution. Test results are set forth in Table One below wherein the data represents the average of ten separately tested samples. Fluid Resistance The ability of the expanded porous films of Examples 1, 4 and 5 to resist penetration by various test fluids was measured by covering the opening of a container with a sample of each of the films and placing identically sized drops of test fluids onto the upper surface of each sample using a Pipetman P-1000™ digital microliter pipet manufactured by Rainin Instruments Company. The spread of the test fluid was visually observed and recorded one minute and fifteen minutes after application of the drop. Test fluids included distilled water (73.05 dynes/cm) , reagent grade methanol (22.61 dynes/cm) , and reagent grade isopropanol (21.7 dynes/cm) . Test results are set forth in Table Two below. Matrix Tensile Strength The tensile strength of expanded porous films manufactured in accordance with the general procedures of Examples 1, 3, 4 and 5 were measured in accordance with ASTM D 882-67 using 1 inch • 6 inch samples tested on an Instron model 1000™ tensile tester with a grip separation of 4 inches and a grip separation speed of 2 inches/minute. The matrix tensile strength of the samples was then calculated in accordance with equation 1 set forth below: (breaking force (lbs f )) (213.36 grams/in 2 ) * Eq (#1) (specimen weight (grams)) The constant 213.36 grams/in 2 is obtained by multiplying together the specific gravity of polytetra¬ fluoroethylene (2.17 grams/cm 3 ), the length of the test sample (6 inches), and the conversion factor for converting cubic inches to cubic centimeters (16.39 Test results are set forth in Table Three below. Table Three Matrix Total Tensile Expansion Mass Strength Sample (%) (grams) (psi) Example 1 14.0 8670 Example 1 14.0 7470 Example 1 17.8 4380 Example 1 19.4 6030 Example 1 32.6 15780 Example 1 14.0 13200* Example 3 14.0 7470 Example 3 14.0 6420 Example 3 17.8 4220 Example 3 19.4 7030 Example 3 32.6 9470 Example 3 14.0 11400* Example 4 17.8 4080 Example 4 19.4 4940 Example 5 14.0 5020 Example 5 14.0 3200 Example 5 32.6 5200 Example 5 14.0 8650* * =_ Sintered by heating above the melt temperature of polytetrafluoroethylene. 19 Differential Scanning Calorimeter The melt characteristics of the expanded porous polytetrafluoroethylene films of Examples 1-5 were obtained using a Perkin Elmer DSC-7™ unit with a heating rate of 10°C/minute. Test results are set forth in Table Four below. It is surprisingly noted that the average melt temperature of the treated expanded porous polytetra¬ fluoroethylene films decreased as the amount of perfluoroether fluid increased and that a single melt temperature peak was obtained for all samples indicating that the perfluoroether fluid was homogeneously dispersed throughout the polytetrafluoroethylene. Radiation Resistance The radiation resistivity of films manufactured in accordance with the procedures of Examples 1 (untreated) and 5 (treated) were evaluated by mounting samples onto hollow 8 inch by 10 inch wooden picture frames, exposing the mounted samples to radiation at a level of 2.5 Mrad or 5 Mrad in a Van der Graff-type accelerator for *** hours, and then visually examining the condition of the samples. Test results are set forth in Table Five below. Table Five Sample 2.5 Mrad 5.0 Mrad Example 1 Large Hole Sample Completely Dissipated Example 5 Split in the Large Hole Middle

Claims: I claim: 1. A porous material comprising a polymeric matrix of a polytetrafluoroethylene polymer and an effective filtration efficiency enhancing amount of a fluorinated organic polymer fluid wherein the material has a microstructure characterized by nodes interconnected by fibrils. 2. A porous material of a polytetrafluoro¬ ethylene polymer having a microstructure of nodes interconnected by fibrils wherein the polymer has been treated with an amount of a fluorinated organic polymer fluid effective for increasing the ultra-fine filtration efficiency of the material by a multiple of at least three. 3. The porous material of claim 2 wherein the ultra-fine filtration efficiency of the material has been increased by a multiple of at least five. 4. The porous material of claim 2 wherein the ultra-fine filtration efficiency of the material has been increased by a multiple of at least ten. 5. The porous material of claim 2 wherein the polytetrafluoroethylene polymer is a homopolymer of polytetrafluoroethylene. 6. The porous material of claim 2 wherein the material is in the shape of a film. 7. The porous material of claim 2 wherein the material is in the shape of a tube. 8. The tube of claim 7 wherein the tube has an inside diameter of about 1 to 40 mm and a wall thickness of about 0.3 to 2 mm. 9. A porous material comprising an expanded body of a polytetrafluoroethylene polymer treated with a fluorinated organic polymer fluid wherein the body has a microstructure characterized by nodes interconnected by fibrils and the body has been expanded in at least one direction to a final length which is at least twice the original length in that direction. 10. The porous material of claim 9 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 11. The porous material of claim 9 wherein the body has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 12. The porous material of claim 9 wherein the body has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 13. The porous material of claim 9 wherein the body has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 14. The porous material of claim 9 wherein the body has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 15. A porous material comprising a polytetra¬ fluoroethylene polymer treated with an amount of a fluorinated organic polymer fluid effective for increasing the radiation tolerance of the material. 16. The porous material of claim 15 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 17. The porous material of claim 15 wherein the fluorinated organic polymer fluid is effective for increasing the radiation tolerance of the porous material by a multiple of at least three. 18. The porous material of claim 15 wherein the fluorinated organic polymer fluid is effective for increasing the radiation tolerance of the porous material by a multiple of at least five. 19. The porous material of claim 15 wherein the fluorinated organic polymer fluid is effective for increasing the radiation tolerance of the porous material by a multiple of at least ten. 20. The porous material of claim 15 wherein the material is in the shape of a film. 21. The porous material of claim 15 wherein the material is in the shape of a tube. 22. The tube of claim 21 wherein the tube has an inside diameter of about 1 to about 40 mm and a wall thickness of about 0.3 to about 2 mm so as to be configured and arranged for use as a vascular graft. 23. A porous material comprising (i) a poly¬ tetrafluoroethylene polymer with a microstructure characterized by nodes interconnected by fibrils, and (ii) an amount of a perfluoroether fluid, intimately associated with the polytetrafluoroethylene polymer, effective for preventing liquid methanol from wetting the porous material. 24. A porous material comprising a polytetra¬ fluoroethylene polymer with a microstructure characterized by nodes interconnected by fibrils and an amount of a fluorinated organic polymer fluid, intimately associated with the polytetrafluoroethylene polymer, effective for inhibiting liquid isopropanol from wetting the porous material. 25. A porous material comprising a polytetra¬ fluoroethylene polymer treated with an amount of a fluorinated organic polymer fluid effective for decreasing the critical surface tension of the material to less than 23 dynes/cm. 26. A porous material produced by stretching a composition comprising an intimate combination of about 50 to 99.9 wt% polytetrafluoroethylene polymer and about 0.1 to 50 wt% fluorinated organic polymer fluid. 27. The porous material of claim 26 wherein the polytetrafluoroethylene polymer is a homopolymer of polytetrafluoroethylene. 28. The porous material of claim 26 wherein the perfluoroether fluid has the general formula: F(C 2 F 4 ) n F wherein n = 4 to 40. 29. The porous material of claim 26 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 30. The porous material of claim 29 wherein the porous material comprises about 80 to 98 wt% poly¬ tetrafluoroethylene polymer and about 2 to 20 wt% perfluoroether fluid. 31. The porous material of claim 29 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) n (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 32. The porous material of claim 29 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0) m (CF 2 0) n CF 3 wherein m = 5 to 50 and n = 10 to 100. 33. The porous material of claim 26 wherein the porous material has a critical surface tension of less than 23 dynes/cm. 34. The porous material of claim 26 wherein the material is in the shape of a film. 35. The porous material of claim 26 wherein the material is in the shape of a tube. 36. The tube of claim 35 wherein the tube has an inside diameter of about 1 to about 40 mm with a wall thickness of about 0.3 to about 2 mm and is configured and arranged for use as a vascular graft. 37. A waterproof breathable fabric operable for permitting passage of water vapor while preventing passage of liquid water comprising a porous film of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected fibrils which has been treated with an effective ultra-filtration efficiency enhancing amount of a fluorinated organic polymer fluid and laminated onto a breathable fabric. 38. The fabric of claim 37 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 39. A waterproof breathable fabric operable for permitting passage of water vapor while preventing passage of liquid water comprising a porous film of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected fibrils which has been treated with an effective radiation tolerance enhancing amount of a fluorinated organic polymer fluid and laminated onto a breathable fabric. 40. The fabric of claim 39 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 41. A waterproof breathable fabric operable for permitting passage of water vapor while-preventing passage of liquid water comprising a porous film of a polytetrafluoroethylene polymer laminated to a breathable fabric wherein the porous film of polytetrafluoroethylene polymer has a microstructure characterized by nodes interconnected fibrils and contains about 0.1 to 50 wt% of a fluorinated organic polymer fluid. 42. The fabric of claim 41 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 43. The waterproof breathable fabric of claim 42 wherein the porous film contains about 2 to 20 wt% of the perfluoroether fluid. 44. The waterproof breathable fabric of claim 42 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) n (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 45. The waterproof breathable fabric of claim 42 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0) ffi (CF 2 0) I1 CF 3 wherein m = 5 to 50 and n = 10 to 100. 46. An air filter including a filtration media which comprises a laminate of (i) a porous film of expanded polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils which has been treated with about 0.1 to about 50 wt% of a fluorinated organic polymer fluid, and (ii) a porous structural substrate. 47. An air filter including a filtration media which comprises at least a porous particulate-entrapping film laminated to a porous structural substrate wherein the porous particulate-entrapping film comprises at least a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils containing about 0.1 to 50 wt% of a perfluoroether fluid. 48. The air filter of claim 47 wherein the porous particulate-entrapping film comprises at least 80 to 98 wt% polytetrafluoroethylene polymer and about 2 to 20 wt% of a perfluoroether fluid. 49. The air filter of claim 47 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) π (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 50. The air filter of claim 47 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0)-.(CF 2 0) n CF 3 wherein m = 5 to 50 and n = 10 to 100. 51. A liquid filter including a filtration media which comprises a laminate of (i) a porous film of expanded polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils which has been treated with about 0.1 to about 50 wt% of a fluorinated organic polymer fluid, and (ii) a porous structural substrate. 52. A liquid filter including a filtration media which comprises at least a porous particulate- entrapping film laminated to a porous structural substrate wherein the porous particulate-entrapping film comprises at least a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils containing about 0.1 to 50 wt% of a perfluoroether fluid. 53. The liquid filter of claim 52 wherein the porous particulate-entrapping film comprises at least 80 to 98 wt% polytetrafluoroethylene polymer and about 2 to 20 wt% of a perfluoroether fluid. 54. The liquid filter of claim 52 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) n (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 55. The liquid filter of claim 52 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0) m (CF 2 0) n CF 3 wherein m = 5 to 50 and n = 10 to 100. 56. A liquid/liquid separation device including a separation membrane which comprises a porous liquid-discriminatory film laminated to a porous structural substrate wherein the porous liquid- discriminatory film comprises at least a polytetra- fluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils and about 0.1 to 50 wt% of a fluorinated organic polymer fluid, intimately associated with the polytetrafluoro¬ ethylene polymer. 57. The liquid/liquid separation device of claim 56 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 58. The liquid/liquid separation device of claim 57 wherein the porous liquid-discriminatory film contains about 2 to 20 wt% of the perfluoroether fluid. 59. The liquid/liquid separation device of claim 57 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) n (CF 2 CF 3 ) CF 3 wherein n * = 20 to 60. 60. The liquid/liquid separation device of claim 57 wherein the perfluoroether fluid has the general formula: wherein m = 5 to 50 and n = 10 to 100. 61. A liquid/liquid separation device including a separation membrane which comprises a porous liquid-discriminatory film laminated to a porous structural substrate wherein the porous liquid- discriminatory film comprises at least a polytetra¬ fluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils and an amount of a fluorinated organic polymer fluid, intimately associated with the polytetrafluoroethylene polymer, effective for preventing methanol from passing through the film. 62. The liquid/liquid separation device of claim 61 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 63. The liquid/liquid separation device of claim 62 wherein the separation film comprises about 80 to 96 wt% polytetrafluoroethylene polymer and about 4 to 20 wt% of a perfluoroether fluid. 64. A liquid/liquid separation device including a separation membrane which comprises a porous liquid-discriminatory film laminated to a porous structural substrate wherein the porous liquid- discriminatory film comprises at least a polytetra¬ fluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils and an amount of a fluorinated organic polymer fluid, intimately associated with the polytetrafluoroethylene polymer, effective for retarding the passage of isopropanol through the film. 65. The liquid/liquid separation device of claim 64 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 66. The liquid/liquid separation device of claim 65 wherein the separation film comprises about 80 to 92 wt% polytetrafluoroethylene polymer and about 8 to 20 wt% of a perfluoroether fluid. 67. A mechanical seal comprising a porous shaped article of an expanded polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils which contains an amount of a fluorinated organic polymer fluid effective for increasing the radiation tolerance of the seal. 68. The mechanical seal of claim 67 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 69. A mechanical seal comprising a porous shaped article of an expanded polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils containing about 0.1 to 50 wt% of a fluorinated organic polymer fluid. 70. The mechanical seal of claim 67 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 71. The mechanical seal of claim 70 wherein the shaped article comprises about 80 to 98 wt% poly- tetrafluoroethylene polymer and about 2 to 20 wt% of the perfluoroether fluid. 72. The mechanical seal of claim 70 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) n (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 73. The mechanical seal of claim 70 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0) m (CF 2 0) n CF 3 wherein m = 5 to 50 and n - 10 to 100. 74. A process for the manufacture of a porous article of commerce which comprises the steps of: (-) combining a polytetrafluoroethylene polymer with an effective radiation tolerance enhancing amount of a fluorinated organic polymer fluid to form a shaped body; (-) expanding the shaped body to form a porous material having a microstructure of nodes interconnected by fibrils. 75. The process of claim 74 wherein an effective paste forming amount of a lubricant is combined with the polytetrafluoroethylene polymer to form the shaped body. 76. The process of claim 74 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 77. The process of claim 76 wherein the shaped body contains about 2 to 20 wt% of the perfluoroether fluid. 78. The process of claim 76 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) n (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 79 . The process of claim 76 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0) B (CF 2 0) n CF 3 wherein m = 5 to 50 and n = 10 to 100. 80. The process of claim 74 wherein the shaped body has been expanded in at least one direction to a final length which is at least twice the original length in that direction. 81. The process of claim 74 wherein the shaped body has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 82. The process of claim 74 wherein the shaped body has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 83. The process of claim 74 wherein the shaped body has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 84. The process of claim 74 wherein the shaped body has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 85. The process of claim 74 wherein the porous material is in the shape of a film. 86. The process of claim 74 wherein the porous material is in the shape of a tube. 87. A porous material comprising a polymeric matrix of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the fibrils appear to have -e smooth. continuous surface when viewed with electron scanning microscopy at a magnification αf up to 10,000. 88. A porous material comprising a polymeric matrix of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the fibrils appear to have a substantially smooth, continuous surface when viewed with electron scanning microscopy at a magnification of up to 10,000. 89. The porous material of claim 88 wherein the polytetrafluoroethylene polymer is treated with a fluorinated organic polymer fluid. 90. The porous material of claim 89 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 91. The porous material of claim 87 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 92. The porous material of claim 88 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 93. The porous material of claim 87 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 94. The porous material of claim 88 wherein the porous material- comprises a body which has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 95. A porous material comprising a polymeric matrix of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the fibrils appear to be free of voids when viewed with electron scanning microscopy at a magnification of up to 10,000. 96. A porous material comprising a polymeric matrix of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the fibrils appear substantially free of voids when viewed with electron scanning microscopy at a magnification of up to 10,000. 97. The porous material of claim 95 wherein the polytetrafluoroethylene polymer is treated with a fluorinated organic polymer fluid. 98. The porous material of claim 97 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 99. The porous material of claim 95 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 100. The porous material of claim 96 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 101. The porous material of claim 95 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 102. The porous material of claim 96 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 103. A porous material comprising an expanded polymeric matrix of a crystalline polytetrafluoro¬ ethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the poly- tetrafluoroethylene polymer has been treated with an amount of a crystalline lubricant effective for permitting enhanced intercrystalline slippage so as to maintain intercrystalline contact in the porous material. 104. The porous material of claim 103 wherein the crystalline lubricant is a fluorinated organic polymer fluid. 105. The porous material of claim 104 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 106. The porous material of claim 103 wherein the material comprises an intimate combination of about 50 to 99.9 t% polytetrafluoroethylene polymer and about 0.1 to 50 wt% fluorinated organic polymer fluid. 107. The porous material of claim 104 wherein the material comprises about 80 to 98 wt% polytetra¬ fluoroethylene polymer and about 2 to 20 wt% perfluoroether fluid. 108. The porous material of claim 104 wherein the perfluoroether fluid has the general formula: F(C 2 F 4 ) n F wherein n = 4 to 40. 109. The porous material of claim 104 wherein the perfluoroether fluid has the general formula: F(CFCF 2 0) a (CF 2 CF 3 ) CF 3 wherein n = 20 to 60. 110. The porous material of claim 104 wherein the perfluoroether fluid has the general formula: CF 3 (C 3 F 6 0) m (CF 2 0) n CF 3 wherein m = 5 to 50 and n = 10 to 100. 111. The process of claim 103 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 112. The process of claim 103 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 113. The process of claim 103 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 114. The process of claim 103 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 115. A porous material comprising a polymeric matrix of a polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the fibrils are characterized by a plurality of adjoining parallel continuous strands. 116. The porous material of claim 115 wherein the polytetrafluoroethylene polymer is treated with a fluorinated organic polymer fluid. 117. The porous material of claim 116 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 118. The porous material of claim 115 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 119. The porous material of claim 115 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 120. The porous material of claim 115 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 121. The porous material of claim 115 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 122. A porous material comprising a polymeric matrix of a crystalline polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the fibrils are substantially free of interrupted intercrystalline contact. 123. The porous material of claim 122 wherein the polytetrafluoroethylene polymer is treated with a fluorinated organic polymer fluid. 124. The porous material of claim 123 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 125. The porous material of claim 123 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 126. The porous material of claim 123 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 127. The porous material of claim 123 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 128. The porous material of claim 123 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction. 129. A porous material comprising a polymeric matrix of a crystalline polytetrafluoroethylene polymer having a microstructure characterized by nodes interconnected by fibrils wherein the polytetrafluoro- ethylene polymer has been treated such that the number of independent nodes discernable by electron scanning microscopy for a given volume is at least twice that for an untreated but otherwise identically processed porous material. 130. The porous material of claim 129 wherein the number of independent nodes discernable by electron scanning microscopy for a given volume is at least three times that for an untreated but otherwise identically processed porous material. 131. The porous material of claim 129 wherein the number of independent nodes discernable by electron scanning microscopy for a given volume is at least four times that for an untreated but otherwise identically processed porous material. 132. The porous material of claim 129 wherein the number of independent nodes discernable by electron scanning microscopy for a given volume is at least five times that for an untreated but otherwise identically processed porous material. 133. The porous material of claim 129 wherein the number of independent nodes discernable by electron scanning microscopy for a given volume is at least seven times that for an untreated but otherwise identically processed porous material. 134. The porous material of claim 129 wherein the polytetrafluoroethylene polymer is treated with a fluorinated organic polymer fluid. 135. The porous material of claim 134 wherein the fluorinated organic polymer fluid is a perfluoroether fluid. 136. The porous material of claim 129 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least three times the original length in that direction. 137. The porous material of claim 129 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least five times the original length in that direction. 138. The porous material of claim 129 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least ten times the original length in that direction. 139. The porous material of claim 129 wherein the porous material comprises a body which has been expanded in at least one direction to a final length which is at least twenty times the original length in that direction.

Inventors: CHUNG HOO YOUNG, CHUNG, HOO, YOUNG
Applicants: DONALDSON CO INC, DONALDSON COMPANY, INC.
Application year: 1992
Main classification: D04H3
IPC codes: A61L27, B01D39, B01D67, B01D71, C08J5, C08J9, C08L27, C08L71, D04H1, D04H13, D06N3