Home » News » PTFE Coated Fabric » What are the differences between PTFE emulsions produced by different polymerization processes (suspension polymerization and dispersion polymerization)?
What are the differences between PTFE emulsions produced by different polymerization processes (suspension polymerization and dispersion polymerization)?
Views: 0 Author: Site Editor Publish Time: 2026-07-21 Origin: Site
Introduction by a Teflon High-Temperature Fabric Manufacturer to the Differences Between PTFE Emulsions Produced by Different Polymerization Processes (Suspension Polymerization and Dispersion Polymerization)
I. Preliminary Clarification of Concepts
In industrial practice, suspension polymerization cannot directly produce PTFE emulsion. Genuine PTFE emulsion (dispersion) is produced solely by dispersion polymerization (which is essentially emulsion polymerization). Jiangsu Teflon High-Temperature Fabric Manufacturer notes that commercially available "suspension-method PTFE emulsion" is actually an aqueous suspension made by mechanically dispersing suspension-polymerized resin micropowders. The two differ fundamentally, from particle nature to end-use applications.
II. Dispersion Polymerization: Primary PTFE Emulsion
1. Particle Morphology and Stability
The particles are perfectly spherical, formed by the agglomeration of primary particles (0.05–0.5 μm) into secondary particles with a particle size of 0.1–0.3 μm and an extremely narrow size distribution. Stability is provided by perfluorinated surfactants (PFOA alternatives) added during polymerization. The colloidal system can remain stable without stratification for years and exhibits good resistance to mechanical shear.
2. Molecular Weight and Film-Forming Properties
The molecular weight is extremely high (up to several million), with a crystallinity exceeding 94% and very strong fibrillation capacity. After coating, high-temperature sintering at approximately 380°C is required, during which the particles fuse into a continuous, dense, and tough film with excellent anti-corrosion and non-stick properties.
3. Typical Processing and Applications
Processing is limited to paste extrusion, impregnation, or coating followed by sintering. Typical applications include non-stick cookware coatings, impregnation of fiberglass architectural membranes, microporous ePTFE membranes (breathable and waterproof), and high-end capacitor films.
III. Suspension Polymerization Micropowders: Aqueous Suspension (Often Mislabeled as Emulsion)
1. Particle Morphology and Stability
As noted by Jiangsu Teflon High-Temperature Fabric Manufacturer: The particles are produced by grinding and crushing suspension-polymerized pellets, resulting in irregular polyhedral shapes with particle sizes ranging from 2 to 20 μm and a broad size distribution. The system is thermodynamically unstable and highly prone to sedimentation and stratification. Conventional surfactants and thickeners such as xanthan gum and cellulose ethers must be added to retard sedimentation, and thorough stirring is required before use.
2. Molecular Weight and Film-Forming Properties
The molecular weight can be adjusted to a relatively low range (tens of thousands to hundreds of thousands), with greater brittleness and very weak fibrillation capacity. After coating, only ambient or low-temperature drying is required to form a dry lubricating layer; it cannot be sintered into a film.
3. Typical Processing and Applications
It can be directly incorporated into formulations or applied by coating and air-dried. Applications include industrial lubricant additives, rubber and plastic mold release agents, anti-wear and slip agents for inks and coatings, and water-repellent finishing for textiles.
IV. Quick Reference: Core Differences
Particle Origin
Dispersion polymerization particles: formed in-situ into spherical shapes via dispersion polymerization;
Suspension method particles: ground from bulk resin into irregular granules.
Particle Size
Raw dispersion emulsion: 0.1–0.3 μm with narrow particle size distribution;
Suspension liquid: 2–20 μm with broad particle size distribution.
Suspension liquid: anti-friction agents, release agents, wear-resistant additives for inks.
Conclusion from Jiangsu Teflon High-Temperature Fabric Manufacturer: If your application requires impregnation, coating sintering, or film formation, you must choose the primary PTFE emulsion produced by dispersion polymerization. If you only need to improve lubricity, release properties, or abrasion resistance without sintering, then the aqueous suspension made from suspension-polymerized micropowders is a suitable option.
If you would like to learn more about the detailed specifications, application scenarios, and customization solutions for our full range of products—including Teflon high-temperature fabrics, Teflon high-temperature tapes, Teflon high-temperature mesh belts, seam-sealing machine seamless belts, single-sided PTFE fabrics, high-temperature conveyor belts, and high-temperature fiberglass fabrics—please feel free to contact us through the following:
We always uphold a professional and integrity-driven service philosophy, and are committed to providing you with one-stop solutions and attentive service!
