I. Substrate Skeleton: Glass Fiber Weaving Texture
1. Warp-Weft Interwoven Structure
The fabric is woven from multi-strand glass fiber yarns in plain, twill, or other weaves to form a mesh skeleton, with individual monofilament diameters ranging from several microns to over ten microns, and a smooth surface.
2. High Porosity
Before coating, there are numerous micron-scale pores both within the fiber bundles and at the warp-weft intersection nodes, providing space for subsequent PTFE impregnation.
II. Coating Morphology: The "Island-Coating" Structure of PTFE
1. Full Impregnation Encapsulation
PTFE resin penetrates into the gaps between each individual filament, forming a "reinforced concrete"-type composite, where the glass fibers serve as the reinforcing phase and PTFE serves as the continuous matrix. In cross-section, the fibers can be seen evenly embedded within the resin.
2. Surface Nodular Microstructure
The pure PTFE surface exhibits a distinctive network morphology of nodules (particles) interconnected by fine fibrils, formed by the aggregation of folded-chain lamellae during the sintering process, which imparts non-stick and self-lubricating properties to the material.
3. Continuous Dense Skin Layer
The surface layer is enriched with pure PTFE, forming a dense, glass-fiber-free skin film several to tens of microns thick, which serves as the key barrier for chemical inertness, non-stick properties, and electrical insulation.
III. Key Defects: Microporosity and Interface Characteristics
1. Residual Micropores
Incomplete impregnation or shrinkage during sintering may leave micron-scale voids or cracks at the center of fiber bundles and at interweaving nodes, leading to reduced release performance and chemical resistance.
2. Interface Bonding
Glass fibers and PTFE are incompatible; microscopically, smooth pits left by fiber pull-out can be observed. Through coupling agent treatment or mechanical interlocking, PTFE tightly anchors the fibers, improving interfacial bond strength.
IV. Condensed State Characteristics: Semi-Crystalline Structure
1. Spherulites and Banded Crystals
PTFE is a semi-crystalline polymer. After normal sintering, it exhibits a coexistence of spherulites and banded crystals, with crystallinity typically ranging from 50% to 70%, and well-ordered molecular chain arrangement.
2. Effect of Crystallinity
High crystallinity endows the material with long-term heat resistance up to 260°C and extremely low high-temperature creep. Over-sintering or under-sintering can lead to abnormal crystalline states, shortening the service life.
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