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Extrusion Foaming of DuPont™ Teflon® Fluoropolymer Resins
Abstract:
 Data transmission cables fabricated from foamed fluoropolymer resins have become extremely popular in computer manufacturing and installation of network systems. The foamed-cable manufacturing process involves the continuous injection of a gas, such as nitrogen, directly into an extruder filled with molten resin. A specially designed extruder screw is typically utilized to create the polymer gas mixture while an inert nucleating package contained in the resin helps promote cell growth. Foams of up to 60% voids have been demonstrated through the use of this process.
The key electrical properties required for modern data cables include a low dielectric constant and a low dissipation factor. These properties can be enhanced by foaming the insulation. Depending on the resin used, cables having a foamed insulation can be used for cable miniaturization, weight reduction of the end product, and the transmission of clear high-quality electrical signals at high signal speeds.
DuPont™ Teflon® FEP and PFA perfluorinated resins are well suited for extrusion foaming processes. Both resins maintain their low dielectric constant and low dissipation factors which are necessary for twisted pair and coaxial cable insulations.
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