PROCESS FOR PRODUCING COPOLYMER FILMS

Abstract: A process for producing polyamide-polyimide block copolymer films or polyamide-polyimide copolymer films having excellent thermal resistance and mechanical strength, which comprises casting a solvent solution of a polyamide-polyamide acid block copolymer or a polyamide-polyamide acid copolymer on a substrate, con­ verting the deposited thin layer of the solution into a self-­ supporting film, regulating the residual solvent content of the film by heating or other means, if necessary, and then heating the film at a temperature of 320° to 500°C for a specified period of time.

Description: SPECIFICATION Title of the Invention: Process for Producing Copolymer Films Background of the Invention: 1. Field of the Invention This invention relates to a process for producing polyamide-polyimide block copolymer films or polyamide-polyimide copolymer films having excellent thermal resistance and mechanical strength according to the solution casting technique. 2. Description of the Prior Art With the recent widening of application of electronics to apparatus and equipment, flexible printed circuits which can be bent at will have found an increasingly greater variety of uses because they can be mounted in apparatus and equipment with a high degree of freedom and they permits the size and weight of the latter to be reduced easily. As a result, increasingly higher performance has come to be required of plastic films which constitute the base of such circuits. Moreover, the size and weight reduction of electrical apparatus and equipment has posed a vital problem concerning their temperature rise due to the evolution of heat. In order to solve this problem, electrical insulating films having more excellent thermal resistance have come to be used in such electrical apparatus and equipment. Heat-resisting films such as aromatic polyimide films, polyester films and the like are known to be useful as base films for flexible printed circuits and electrical insulating films. However, these films are disadvantageous in that aromatic polyimide films are very expensive and the polyester films are poor in thermal resistance. In order to solve these problems, polyamidepolyimide block copolymer films and polyamide-polyimide copolymer films have been proposed in Japanese Patent Publication Nos. 28077/'78 and 44891/'81, respectively. However, these polyamide-polyimide block copolymer films and polyamide-polyimide copolymer films are markedly inferior in thermal resistance to aromatic polyimide films and, moreover, do not have satisfactorily high mechanical strength. Summary of the Invention: It is an object of the present invention to provide a process for producing polyamide-polyimide block copolymer films or polyamide-polyimide copolymer films which have excellent thermal resistance and mechanical strength and, therefore, are useful as base films for printed circuits or as electrical insulating films. According to the present invention, there is provided a process for producing polyamidepolyimide block copolymer films or polyamide-polyimide copolymer films which comprises (1) casting on a substrate (a) a solvent solution of a polyamidepolyamide acid block copolymer having repeating structural units of the formula EMI3.1 where n represents a whole number of 1 to 500, A represents a polyamide block having structural units of the formula EMI3.2 and E represents a polyamide acid block having structural units of the formula EMI4.1 or (b) a solvent solution of a polyamidepolyamide acid copolymer obtained by reacting a polyamide acid of the formula EMI4.2 or EMI5.1 with a dicarboxylic acid dichloride of the formula EMI5.2 and a diamine of the formula H2N-R2-NH2 (X) where, in the formulas (II) to (X), a and b independently represent whole numbers of 2 to 100, R2 and R4 independently represent monocyclic aromatic groups which may be substituted with one or more halogen atoms, alkyl groups of 1 to 4 carbon atoms, or alkoxy groups of 1 to 4 carbon atoms, unfused bicyclic aromatic groups in which the aromatic nuclei are linked together by the bridge member -0-, -CH2-, -CO- or 502 and they may be substituted with one or more halogen atoms, alkyl groups of 1 to 4 carbon atoms or alkoxy groups of 1 to 4 carbon atoms, heterocyclic groups, alkylene groups of 2 to 12 carbon atoms, or dicyclohexylmethane groups, R1 represents an aromatic group, a heterocyclic group or an alkylene group of 2 to 8 carbon atoms in which the carbonyl groups are bonded to different carbon atoms, R3 represents a five- or six-membered cycloalkyl group, a benzene ring or an unfused bicyclic aromatic group in which the aromatic nuclei are linked together by the bridge member -0-, -CO- or -CONH- and the carbonyl groups are bonded to different ring carbon atoms that are adjacent in pairs, and X represents a hydrogen atom or an alkyl group of 1 to 4 carbon atoms; (2) converting the deposited thin layer of the solution into a self-supporting film; (3) separating the selfsupporting film from the substrate; and (4) heating the self-supporting film having a residual solvent content of 40% by weight or less at a temperature of 320 to 5000C for a period of time ranging from 5 seconds to 90 minutes. Detailed Description of the Invention: The polyamide-polyimide block copolymer films to which the present invention is directed are those comprising a resin having repeating structural units of the formula EMI6.1 where A1 is a polyamide block having structural units of the formula EMI7.1 and E1 is a polyimide block having structural units of the formula EMI7.2 In the above formulas XI to XIV, n, a, b, R1, R2, R3 and R4 have the same meanings as given for formulas I to X. The polyamide-polyimide copolymer films to which the present invention is directed are those comprising a resin obtained by reacting a polyamide acid of the above formula (VI) or (VII) with a dicarboxylic acid dichloride of the above formula CIX) and a diamine of the above formula (X) and then cyclizing the resulting polyamide-polyamide acid copolymer. The polyamide-polyamide acid block copolymers and the polyamide-polyamide acid copolymers which are useful in the practice of the present invention can be prepared, for example, by the processes described in Japanese Patent Publication Nos. 28077/'78 and 44891/'81, respectively. In the practice of the present invention, polyamide-polyimide block copolymer films or polyamide-polyimide copolymer films are produced according to the so-called solution casting technique. More specifically, a polyamide-polyamide acid block copolymer or a polyamide-polyamide acid copolymer is dissolved in a suitable solvent. Useful solvent include, for example, N,N-dimethylacetamide, N,Ndiethylacetamide, N,N-dimethylformamide, N,N dimethylmethoxyacetamide, N-methyl-2-pyrrolidone, N-acetyl-2-pyrrolidone, N-methyl-e-caprolactam, acid hexamethylphosphoric/triamide (commonly known as hexametapol), N,N,N',N'-tetramethylurea, tetrahydrothiophene dioxide (commonly known as sulfolane), dimethyl sulfoxide, m-chlorophenol, p-chlorophenol, 3-chloro-6-hydroxytoluene, sulfuric acid and the like, as well as mixtures of the foregoing. The resulting solution is cast or coated on a substrate to deposit a thin layer of the solution, which is converted into a self-supporting film. This selfsupporting film is then separated from the substrate. The substrate used for this purpose usually comprises a metal roll, a metal belt or a solventresistant resin film. However, there may be used any other substrate, such as a glass plate, a metal plate, a solvent-resistant resin plate or the like, that is not deformed by applying thereto the solvent solution of the copolymer. Moreover, such a film can be continuously be produced by using a combination of revolving metal rolls and a metal belt, or a continuous solventresistant resin film. The thin layer of the polyamide-polyamide acid block copolymer or polyamide-polyamide acid copolymer solution deposited on the substrate can be converted into a self-supporting film by using any of various techniques such as heating, cyclization with a cyclizing agent, extraction, exposure to electromagnetic waves or radiation, evaporation under reduced pressure, air-drying and the like. In the case of heating, the self-supporting property is imparted to the thin layer by heating it in a vacuum or under atmospheric pressure at a temperature usually ranging from 500 to 2500C. The self-supporting film so formed can now be separated from the substrate. Where it is desired to form a self-supporting film by cyclization with a cyclizing agent, the polyamide-polyamide acid block copolymer or polyamidepolyamide acid copolymer can be readily cyclized into a polyamide-polyimide block copolymer or polyamidepolimide copolymer, respectively, by adding a cyclizing agent alone or a mixture of a cyclizing agent and a catalyst (such as a tertiary amine or the like) to the thin layer, or bringing the thin layer into contact with a solution containing a cyclizing agent alone or a mixture of a cyclizing agent and a catalyst, and then heat-treating the thin layer at a temperature of 20" to 2000C Examples of the cyclizing agent include acetic anhydride, propionic anhydride and dicyclohexylcarbodiimide, Typical examples of the mixture of a cyclizing agent and a catalyst include mixtures of acetic anhydride and pyridine, picoline or triethylamine. The thin layer of the polyamide-polyamide acid block copolymer or polyamide-polyamide acid copolymer solution can also be converted into a selfsupporting film by using the so-called extraction technique in which the thin layer is brought into contact with an extractant (such as water or an extraction solvent) to remove the solvent from the thin layer. A particularly important step of the process of the present invention is the step of heat-treating the self-supporting film separated from the substrate. This step is carried out by reducing the residual solvent content of the film to 40% by weight or less, preferably 20% by weight or less and most preferably 5% by weight or less by heating at relatively low temperatures, evaporation under reduced pressure, extraction or air drying, if necessary, and then heating the film at a temperature of 3200 to 5000C for a period of time ranging from 5 seconds to 90 minutes. This treatment provides the film not only with such a degree of thermal resistance as can prevent the film from being deformed in a solder bath at 2600C, but also with excellent mechanical properties such as tensile break strength, tensile elongation and the like. If this treatment is omitted, the resulting film will be insufficient in thermal resistance to be useful as a base film for flexible printed circuits in that it will have a low glass transition temperature (hereinafter referred to as T ) as measured by the penetration method (herein g after referred to as the TMA method) using a thermophysical tester and will undergo deformation upon contact with molten solder at 2600C. The reason why the thermal resistance, mechanical strength and like properties of the selfsupporting film are improved by heat treatment at a temperature of 320C to 5000C has not been completely elucidated. However, if electron spin resonance spectra (hereinafter refereed to as ESR spectra) are recorded with an electron spin resonance absorption apparatus and compared, it will be recognized that that greater number of radicals are formed in the films produced by the process of the present invention than in conventional polyamide-polyimide block copolymer films and polyamide-polyimide copolymer films. Moreover, conventional films have a fraction soluble in solvents such as sulfuric acid and the like, but the films of the present invention are completely insoluble. Thus, the films of the present invention also show an improvement in chemical resistance. On the basis of these facts, the films of the present invention are considered to have a threedimensional network structure in which cross-linking has occurred within or among the molecular chains constituting the film. In contrast, it seems that, at temperatures lower than 3200C, no adequate number of radicals are formed and no sufficient degree of cross-linking reaction for the improvement of properties takes place, resulting in a failure to achieve an improvement in thermal resistance and mechanical properties. It is generally known that a similar improvement in properties may be brought about by cyclization of polymers. However, the cyclization of polyamide-polyamide acid block copolymers and polyamide-polyamide acid copolymers into polyamide po lyimide block copolymers and polyamide-polyimide copolymers, respectively, is usually completed to a substantial degree at temperatures lower than 3000C, whether it may be carried out according to a conventional thermal method or a chemical method using a cyclizing agent. Accordingly, such improvement in properties are substantially different from that obtained by heating the film at a temperature of 320 to 5000C in accordance with the present invention. As described above, the heating temperature may range from 3200 to 5000C and preferably from 3400C to 4500C. At higher temperatures within this range, satisfactory results can be obtained in a short period of time, while at lower temperatures within this range, it is necessary to heat the film for a relatively long period of time. If the heating temperature is lower than 3200C, the effect of improving thermal resistance and the like will be insufficient, and if it is higher than 5000C, the performance of the film will undergo a marked degree of deterioration by heat. The heating at a temperature of 320 to 5000C is preferably carried out in a vacuum or in an inert gas such as nitrogen or the like. Where the heating is carried out in air, the performance of the film may be deteriorated by oxidation. Accordingly, it is desirable to heat the film rapidly by exposure to electromagnetic waves (such as infrared rays or microwaves) or radiation and then cool it rapidly so that the film may be exposed to high temperatures for as short a period of time as possible. However, hot air may be used so long as care is taken to heat and cool the film in a short period of time, for example, by blowing the hot air against the film at high velocity. Where the heating step is carried out by means of a high-temperature fluid (such as hot air, a heated inert gas, combustion gas or the like), electromagnetic waves (such as infrared rays, microwaves or the like) or radiation, a substantially satisfactory effect can be obtained by heating the film for a period of time usually ranging from 5 seconds to 90 minutes and preferably 30 seconds to 30 minutes, though it depends on the structure of the film, the heating temperature and the like. If th-e heating time is shorter than 5 seconds, the effects of the present invention cannot be obtained, and if it is longer than 90 minutes, deterioration of the film will result. The residual solvent content of the self-supporting film separated from the substrate is usually greater than 0.1% by weight. If it is greater than 40% by weight, the solvent present in the film is vigorously evaporated by exposure to a temperature of 320"C or above, resulting in a film having irregular surfaces or, in the worst case, a porous film. Such films show a reduction in mechanical strength, electrical properties and the like, so that they are unsuitable for use in applications other than some special ones Accordingly, if the residual solvent content of the self-supporting film is greater than 40% by weight, it is desirable, as described above, to reduce the residual volatile content to 40% by weight or less, preferably 20% by weight or less and most preferably 5% by weight or less by heating at temperatures lower than 3200C, evaporation under reduced pressure, extraction, air drying or other means, prior to the heat treatment of the present invention. Conveniently, the step of heating the self supporting film at a temperature of 3200 to 5000C to improve its properties is carried out immediately following the preceding film-forming step. However, it is also possible to produce a semi-finished film in one stage and then heat it in another stage. It is efficient to heat the self-supporting film simultaneously on both sides, though it may be heated on a single side. From an operational point of view, this heating step is facilitated by holding two or four edges of the self-supporting film at a constant width with fabric fasteners such as pin sheets, clips and the like. However, it is also possible to heat the self-supporting film while increasing or decreasing the width gradually. The polyamide-polyamide acid block copolymers and polyamide-polyamide acid copolymers which are useful in the practice of the present invention should preferably have a logarithmic viscosity number ( inn) of 0.1 to 3.0, more preferably 0,5 to 2.0, as measured by a 0.5 g/100 ml solution in N,N-dimethylacetamide at 350C. The film-forming conditions and the like are controlled by utilizing the logarithmic viscosity number as a guide. As described in detail hereinabove, the process of the present invention makes it possible to produce polyamide-polyimide block copolymer films and polyamide-polyimide copolymer films having such a high degree of thermal resistance as has never been achieved by conventional processes and, moreover, showing an improvement in mechanical properties such as tensile break strength, tensile elongation and the like. The process of the present invention is further illustrated by the following examples. In these examples, the logarithmic viscosity number (#inh) of a polymer as measured by a 0.5 g/100 ml solution in N,N-dimethylacetamide at 35 OC is defined by the following equation: ln (#/#0) #inh C where t is the viscosity of the solution, gO is the viscosity of the solvent, and C is the polymer concentration (in g/100 ml3 in the solution. In these examples, the apparent electron spin (S ) of a film as measured with an ESR apparatus p is defined by the following equation: S sp = A . W where S is the area bounded by the ESR spectrum and the horizontal axis indicating the intensity of the magnetic field, A is the measuring sensitivity, and W is the amount of sample used. Besides the logarithmic viscosity number and apparent electron spin, the glass transistion temperature (Tg) of a film was determined according to the TMA method, and the tensile break strength and tensile elongation of a film were determined according to the methods described in JIS P-8113. Example 1 A. Preparation of an amino-terminated polyamide: Within a l-liter reactor fitted with a stirrer, an internal thermometer, a dropping funnel having a pressure equalizing tube, and a nitrogen inlet tube, 6.84 g of 4,4f-diaminodiphenyl ether was completely dissolved in 40 g of anhydrous N,Ndimethylacetamide. while the internal temperature of the reactor was kept within the range of -5 to OOC by passing a coolant through the jacket, a solid mixture of 2.46 g (0.0121 mole) of isophthaloyl dichloride and 2.46 g (0.0121 mole) of terephthaloyl dichloride was added to the above solution, little by little, under an atmosphere of nitrogen. After completion of the addition, the resulting viscous reaction mixture was warmed to 10 0C and stirred for 1 hour. Then, while this reaction mixture was kept at a temperature of 50 to lO0C, 3.09 g (0.0532 mole) of propylene oxide diluted with 6 g of anhydrous N,Ndimethylacetamide was added thereto drop by drop. After completion of the addition, the reaction mixture was stirred at 5-10 C for 1 hour to obtain an aminoterminated polyamide having an average molecular weight of 1,000 as calculated on a theoretical basis. B. Preparation of an acid anhydride-terminated polyamide acid: Within the same reactor as described in the above procedure A, 27.1 g (0.124 mole) of pyromellitic acid dianhydride was suspended in 41 g of anhydrous N,N-dimethylacetamide. While this suspension was kept at a temperature of 50 to 200C, 22.9 g (0.114 mole) of 4,4'-diaminodiphenyl ether dissolved in 92 g of anhydrous N,N-dimethylacetamide was added thereto, drop by drop, under an atmosphere of nitrogen. The viscosity of the mixture rose as the amine solution was added. Accordingly, when 75% of the amine solution was added, 67 g of anhydrous N,N-dimethylacetamide was added in order to control the viscosity of the mixture. After completion of the addition, the resulting reaction mixture was stirred at 20-250C for 1 hour to obtain an acid anhydride-terminated polyamide acid having an average molecular weight of 5,000 as calculated on a theoretical basis. C. Preparation of a polyamide-polyamide acid block copolymer: The amino-terminated polyamide solution obtained by the procedure A was added to the acid anhydride-terminated polyamide acid solution obtained by the procedure B. This addition was carried out under an atmosphere of nitrogen at 15-200C over a period of about 30 minutes. Moreover, 89 g of N,Ndimethylacetamide was added and the resulting mixture was stirred at 20-250C for 2 hours. Thus, there was obtained a viscous solution containing 15.0% by weight of a polyamide-polyamide acid block copolymer having an inherent viscosity of 1.62 (as measured by a 0.5 g/ 100 ml solution in N,N-dimethylacetamide at 350C). D. Formation of a polyamide-polyimide block copolymer film: The polyamide-polyamide acid block copolymer solution obtained by the procedure C was cast on a glass plate by means of an applicator having a clearance of 0.7 mm, and then dried in a stream of air at 1500C for 30 minutes. The self-supporting film so formed was separated. This film was stretched over a metal frame having pins set therein, dried in a stream of air at 2000C for 60 minutes to reduce the residual solvent content to 0.4% by weight, and then heated at 3500C for 60 minutes. Properties of the polyamidepolyimide block copolymer film thus obtained are shown in Table 2. Example 2 A film was produced by employing the same procedures and conditions as described in Example 1, except that the heating was carried out at 4500C for 1 hour. Properties of the film thus obtained are shown in Table 2. Comparative Examples 1 and 2 Films were produced by employing the same procedures and conditions as described in Example 1, except that the heating was carried out at 3000C for 60 minutes in Comparative Example 1 and at 3400C for 100 minutes in Comparative Example 2. Properties of the films thus obtained are shown in Table 2. Example 3 32.1 g (0.100 mole) of benzophenonetetracarboxylic acid dianhydride was suspended in 48 g of N,N-dimethylacetarnide. While this suspension was kept at a temperature of 50 to 200C, 17.9 g (0.0896 mole) of 4,4'-diaminodiphenyl ether dissolve in 72 g of N,N-dimethylacetamide was added thereto drop by drop. Since the viscosity of the mixture rose as the amine solution was added, 80 g of N,N-dimethylacetamide was added thereto upon occasion. After completion of the addition, the resulting reaction mixture was stirred at 5-200C for 1 hour to obtain a polyamide acid solution. To this solution was added 31.1 g (0.156 mole) of 4,4'-diaminodiphenyl ether dissolved in 180 g of N,N-dimethylacetamide - The resulting mixture was cooled to a temperature of -5" to 0 C. Then, while the above reaction mixture was kept at a temperature of -5 to OOC, a solid mixture of 14.8 g (0.0729 mole) of isophthaloyl dichloride and 14.8 g (0.0729 mole) of terephthaloyl dichloride was added thereto little by little, and the resulting reaction mixture was stirred for an additional hour. Thereafter, while this reaction mixture was kept at a temperature of 50 to 100C, 18.6 g (0.320 mole) of propylene oxide diluted with 37 g of N,N-dimethyl- acetamide was added thereto drop by drop. After the addition of 120 g of N,N-dimethylacetamide, the reaction mixture was stirred at 5-100C for 2 hours to obtain a viscous solution containing 15% by weight of a polyamide-polyamide acid copolymer having an inherent viscosity of 1.60. Using this polymer solution, a film was produced according to the procedure D of Example 1. Properties of the polyamide-polyimide copolymer film thus obtained are shown in Table 2. Example 4 According to the procedures A, B and C of Example 1, a polyamide-polyamide acid block copolymer solution having a polymer concentration of 15.0% by weight was prepared by using the starting material formulation shown in Table 1. Acetic anhydride and ss-picoline were added to and mixed with the above polymer solution in such amounts that the -COOH groups of the polymer, acetic anhydride and 6-picoline were present in a molar ratio of 1:2:0.25. The resulting mixture was cast on a glass plate by means of an applicator having a clearance of 0.7 mm. This glass plate was placed on a hot plate and heated at 1000C for 1 minute.. The self-supporting gel-like film so formed was separated from the glass plate. This film was stretched over a metal frame having pins set therein, and dried in a stream of nitrogen at 1500C for 5 minutes. At this time, the residual solvent content of the film was 15% by weight. Then, the film was heated at 3500C for 60 minutes. Properties of the film thus obtained are shown in Table 2. Example 5 According to the procedures A, B and C of Example 1, a polyamide-polyamide acid block copolymer solution having a polymer concentration of 15.0% by weight was prepared by using the starting material formulation shown in Table 1. This polymer solution was cast on a glass plate by means of an applicator having a clearance of 0.7 mm, and dried in a stream of air at 1500C for 30 minutes. The self-supporting film so formed was separated. This film was stretched over a metal frame having pins set therein, dried in a stream of air at 2000C for 60 minutes, and then heated at 3200C for 15 minutes. Properties of the film thus obtained are shown in Table 2. Example 6 According to the procedures A, B and C of Example 1, a polyamide-polyamide acid block copolymer solution having a polymer concentration of 15.0% by weight was prepared by using the starting material formulation shown in Table 1. This polymer solution was cast on a glass plate by means of an applicator having a clearance of 0.7 mm. This glass plate was placed on a hot plate and heated at 600C for 15 minutes to remove a part of the solvent. Then, the glass plate carrying the polymer film was soaked in water at 200C for 4 hours and the self-supporting film so formed was separated. This film was stretched over a metal frame having pins set therein, dried in a stream of nitrogen at 1500C for 30 minutes and then 2000C for 60 minutes, and then heated under an atmosphere of nitrogen for 15 minutes by means of an infrared heater controlled in such a way that a thermocouple positioned in contact with a surface of the film indicated a temperature of 3200C. Properties of the film thus obtained are shown in Table 2. Example 7 According to the procedures A, B and C of Example 1, a polyamide-polyamide acid block copolymer solution having a polymer concentration of 15.0% by weight was prepared in a 100-liter reactor by using the starting material formulation shown in Table 1. This polymer solution was filtered, vacuum defoamed and fed, by means of a gear pump, to a T-die having a slit width of 0.4 mm and a slit length of 300 mm. Through this T-die, the polymer solution was continuously cast on a steel belt traveling at a speed of u.3 m/min. Then, the steel belt was passed through a drying oven having a length of 3 meters, in which the steel belt was exposed to a stream of nitrogen whose temperature gradually rose from 1000C at the entrance to 1500C at the exit. At the exit of the oven, the self-supporting film so formed was separated from the steel belt. This film was held on a pin tenter, exposed to a stream of nitrogen at 200 C in a drying oven having a length of 1 meter, and then heated in an infrared heater oven having a length of 3 meters and controlled in such a way that a thermocouple positioned in contact with a surface of the film indicated a temperature of 350"C. An atmosphere of nitrogen was maintained in the infrared heater oven. Properties of the continuous film thus obtained are shown in Table 2. Comparative Examples 3 to 7 Films were produced by employing the same procedures and conditions as described in Comparative Examples 3-7, respectively, except that the heating was carried out at 2500C. Properties of the films thus obtained are shown in Table 2. Comparative Example 8 A polymer solution was prepared in the same manner as described in Examples 1 and cast on a glass plate. This glass plate was placed on a hot plate and dried at 100C until the volatile content of the film was reduced to 35% by weight. The self-supporting film so formed was separated from the glass plate, stretched over a metal frame having pins set therein, and then heated in a stream of air at 3500C for 60 minutes. The film thus obtained was porous and brittle. Table 1 EMI28.1 Starting <SEP> material <SEP> formulation <tb> <SEP> Polyamide <SEP> moiety <SEP> Polyamide <SEP> acid <SEP> moiety <tb> Copolymerization <tb> Dicarboxyl- <SEP> Tetracarboxmethod <tb> ic <SEP> acid <SEP> Diamine <SEP> MPA <SEP> ylic <SEP> acid <SEP> Diamine <SEP> MPAA <tb> dichloride <SEP> dianhydride <tb> (g) <SEP> (g) <SEP> (g) <SEP> (g) <tb> I/TPC, <SEP> DAE, <SEP> PMDA, <SEP> DAE, <SEP> Block Example <SEP> 1 <SEP> 1,000 <SEP> 5,000 <tb> 4.91 <SEP> 6.84 <SEP> 27.1 <SEP> 22.9 <SEP> block <tb> I/TPC, <SEP> DAE, <SEP> PMDA, <SEP> DAE, <SEP> Block Example <SEP> 2 <SEP> 1,000 <SEP> 5,000 <tb> 4.91 <SEP> 6.84 <SEP> 27.1 <SEP> 22.9 <SEP> block <tb> I/TPC, <SEP> DAE, <SEP> BTDA, <SEP> DAE, <SEP> Monomer Example <SEP> 3 <SEP> 5,000 <SEP> 5,000 <tb> 29.6 <SEP> 31.1 <SEP> 32.1 <SEP> 17.9 <SEP> block <tb> I/TPC, <SEP> DAE, <SEP> BTDA, <SEP> DAE, <SEP> Block Example <SEP> 4 <SEP> 1,000 <SEP> 5,000 <tb> 4.91 <SEP> 6.84 <SEP> 32.1 <SEP> 17.9 <SEP> block <tb> IPC, <SEP> DAE, <SEP> PMDA, <SEP> DAE, <SEP> Block Example <SEP> 5 <SEP> 5,000 <SEP> 5,000 <tb> 29.6 <SEP> 31.1 <SEP> 27.1 <SEP> 22.9 <SEP> block <tb> I/TPC, <SEP> MPD, <SEP> PMDA, <SEP> DAE, <SEP> Block Example <SEP> 6 <SEP> 5,000 <SEP> 5,000 <tb> 41.7 <SEP> 23.3 <SEP> 27.1 <SEP> 22.9 <SEP> block <tb> I/TPC, <SEP> DAE, <SEP> PMDA, <SEP> DAE, <SEP> Block Example <SEP> 7 <SEP> 5,000 <SEP> 5,000 <tb> 2,954 <SEP> 3,110 <SEP> 2,712 <SEP> 2,288 <SEP> block <tb> Table 1 (Cont'd) EMI29.1 Heating <SEP> conditions <tb> Residual <tb> Logarith- <SEP> Method <SEP> of <tb> solvent <tb> mic <SEP> conversion <tb> Casting <SEP> content <tb> viscosity <SEP> into <SEP> a <SEP> self- <SEP> Temperamethod <SEP> before <SEP> Time <SEP> Atmos- <SEP> Heating <tb> number <SEP> supporting <SEP> ture <tb> heating <SEP> (min.) <SEP> phere <SEP> means <tb> #inh <SEP> film <SEP> ( C) <tb> (wt.%) <tb> 1.56 <SEP> Batchwise <SEP> Heating <SEP> 0.4 <SEP> 250 <SEP> 60 <SEP> Air <SEP> Hot <SEP> air <tb> 1.56 <SEP> Batchwise <SEP> Heating <SEP> 0.4 <SEP> 450 <SEP> 1 <SEP> Air <SEP> Hot <SEP> air <tb> 1.07 <SEP> Batchwise <SEP> Heating <SEP> 0.4 <SEP> 350 <SEP> 60 <SEP> Air <SEP> Hot <SEP> air <tb> Cycliz1.20 <SEP> Batchwise <SEP> 15.0 <SEP> 350 <SEP> 60 <SEP> N2 <SEP> Hot <SEP> air <tb> ation <tb> 1.10 <SEP> Batchwise <SEP> Heating <SEP> 0.4 <SEP> 320 <SEP> 15 <SEP> Air <SEP> Hot <SEP> air <tb> Extrac- <SEP> Infrared <tb> 1,01 <SEP> Batchwise <SEP> 0.3 <SEP> 320 <SEP> 15 <SEP> N2 <tb> tion <SEP> heater <tb> Infrared <tb> 1.62 <SEP> Continuous <SEP> Heating <SEP> 3.0 <SEP> 350 <SEP> 10 <SEP> N2 <tb> heater <tb> Table 1 (Cont'd) EMI30.1 Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <tb> Example <SEP> 1 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <tb> Example <SEP> 2 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 3 <tb> Example <SEP> 3 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 4 <tb> Example <SEP> 4 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 5 <tb> Example <SEP> 5 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 6 <tb> Example <SEP> 6 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 7 <tb> Example <SEP> 7 <tb> Comparative <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <tb> Example <SEP> 8 <tb> Table 1 (Cont'd) EMI31.1 Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <SEP> 300 <SEP> 60 <tb> Example <SEP> 1 <tb> Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <SEP> 340 <SEP> 100 <tb> Example <SEP> 1 <tb> Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 3 <SEP> 250 <SEP> 60 <tb> Example <SEP> 3 <tb> Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 4 <SEP> 250 <SEP> 60 <tb> Example <SEP> 4 <tb> Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 5 <SEP> 250 <SEP> 15 <tb> Example <SEP> 5 <tb> Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 6 <SEP> 250 <SEP> 15 <tb> Example <SEP> 6 <tb> Same <SEP> as <SEP> in <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 7 <SEP> 250 <SEP> 10 <tb> Example <SEP> 7 <tb> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <SEP> 42 <SEP> Same <SEP> as <SEP> in <SEP> Example <SEP> 1 <tb> (Notes) The abbreviations used in Table 1 have the following meanings: I/TPC = a 50:50 mixture of isophthaloyl bichloride and terephthaloyl dichloride. IPC = isophthaloyl dichloride. DAE = 4,4t-diaminodiphenyl ether. MPD = m-phenylenediamine. PMDA = pyromellitic acid dianhydride. BTDA = 3,3',4,4'-benzophenonetetracarboxylic acid dianhydride. The molecular weights of polymer blocks are expressed as follows: MPA = average molecular weight of polyamide blocks. MPAA = average molecular weight of polyamide acid blocks. Table 2 EMI33.1 Tensile <SEP> Thermal <SEP> Glass <SEP> Residual <tb> Tensile <SEP> Electron <tb> break <SEP> resistance <SEP> transition <SEP> solvent <tb> elongation <SEP> spin <tb> strength <SEP> to <SEP> solder <SEP> temperature <SEP> content <tb> (260 C, <tb> (kg/mmê) <SEP> (%) <SEP> Tg( C) <SEP> SP(-) <SEP> (wt.%) <tb> 30 <SEP> sec.) <tb> Example <SEP> 1 <SEP> 17.4 <SEP> 78 <SEP> Unchanged <SEP> 345 <SEP> 2.5 <SEP> 0.004 <tb> Example <SEP> 2 <SEP> 17.8 <SEP> 72 <SEP> Unchanged <SEP> 350 <SEP> 3.3 <SEP> 0.05 <tb> Example <SEP> 3 <SEP> 11.4 <SEP> 29 <SEP> Unchanged <SEP> 272 <SEP> 2.4 <SEP> 0.004 <tb> Example <SEP> 4 <SEP> 12.8 <SEP> 37 <SEP> Unchanged <SEP> 275 <SEP> 2.4 <SEP> 0.004 <tb> Example <SEP> 5 <SEP> 9.2 <SEP> 18 <SEP> Unchanged <SEP> 270 <SEP> 2.3 <SEP> 0.009 <tb> Example <SEP> 6 <SEP> 8.6 <SEP> 15 <SEP> Unchanged <SEP> 271 <SEP> 2.3 <SEP> 0.009 <tb> Example <SEP> 7 <SEP> 14.0 <SEP> 64 <SEP> Unchanged <SEP> 284 <SEP> 2.4 <SEP> 0.005 <tb> Comparative <tb> 14.7 <SEP> 63 <SEP> Wrinkled <SEP> 278 <SEP> 2.1 <SEP> 0.02 <tb> Example <SEP> 1 <tb> Comparative <tb> 13.8 <SEP> 41 <SEP> Unchanged <SEP> 341 <SEP> 2.4 <SEP> 0.004 <tb> Example <SEP> 2 <tb> Comparative <tb> 9.5 <SEP> 18 <SEP> Wrinkled <SEP> 266 <SEP> 1.6 <SEP> 0.10 <tb> Example <SEP> 3 <tb> Table 2 (Cont'd) EMI34.1 Tensile <SEP> Thermal <SEP> Glass <SEP> Residual <tb> Tensile <SEP> Electron <tb> break <SEP> resistance <SEP> transition <SEP> solvent <tb> elongation <SEP> spin <tb> strength <SEP> to <SEP> solder <SEP> temperature <SEP> content <tb> (260 C, <tb> (kg/mmê) <SEP> (%) <SEP> Tg( C) <SEP> SP(-) <SEP> (wt.%) <tb> 30 <SEP> sec.) <tb> Comparative <tb> 9.8 <SEP> 21 <SEP> Wrinkled <SEP> 269 <SEP> 1.6 <SEP> 0.10 <tb> Example <SEP> 4 <tb> Comparative <tb> 8.5 <SEP> 12 <SEP> Wrinkled <SEP> 251 <SEP> 1.6 <SEP> 0.11 <tb> Example <SEP> 5 <tb> Comparative <tb> 6.1 <SEP> 6 <SEP> Wrinkled <SEP> 264 <SEP> 1.6 <SEP> 0.11 <tb> Example <SEP> 6 <tb> Comparative <tb> 12.9 <SEP> 55 <SEP> Wrinkled <SEP> 274 <SEP> 1.5 <SEP> 0.08 <tb> Example <SEP> 7 <tb> Comparative <tb> <SEP> Porous <SEP> and <SEP> brittle <tb> Example <SEP> 8 <tb>

Claims: What is claimed is: 1. A process for producing polyamidepolyimide block copolymer films or polyamide-polyimide copolymer films which comprises (1) casting on a substrate (a) a solvent solution of a polyamidepolyamide acid block copolymer having repeating structural units of the formula EMI35.1 where n represents a whole number of 1 to 500, A represents a polyamide block having structural units of the formula EMI35.2 and E represents a polyamide acid block having structural units of the formula EMI36.1 or (b) a solvent solution of a polyamide polyamide acid copolymer obtained by reacting a polyamide acid of the formula EMI36.2 or EMI37.1 with a dicarboxylic acid dichloride of the formula EMI37.2 and a diamine of the formula H2N-R2-NH2 (X) where, in the formulas (II) to (X), a and b independently represent whole numbers of 2 to 100, R2 and R4 independently represent monocyclic aromatic groups which may be substituted with one or more halogen atoms, alkyl groups of 1 to 4 carbon atoms, or alkoxy groups of 1 to 4 carbon atoms, unfused bicyclic aromatic groups in which the aromatic nuclei are linked together by the bridge member -0-, -CH2-, -COor 502 and they may be substituted with one or more halogen atoms, alkyl groups of 1 to 4 carbon atoms or alkoxy groups of 1 to 4 carbon atoms, heterocyclic groups, alkylene groups of 2 to 12 carbon atoms, or dicyclohexylmethane groups, R1 represents an aromatic group, a heterocyclic group or an alkylene group of 2 to 8 carbon atoms in which the carbonyl groups are bonded to different carbon atoms, R3 represents a five- or six-membered cycloalkyl group, a benzene ring or an unfused bicyclic aromatic group in which the aromatic nuclei are linked together by the bridge member -0-, -CO- or -CONH- and the carbonyl groups are bonded to different ring carbon atoms that are adjacent in pairs, and X represents a hydrogen atom or an alkyl group of 1 to 4 carbon atoms; (2) converting the deposited thin layer of the solution into a self-supporting film; (3) separating the selfsupporting film from the substrate; and (4) heating the self-supporting film having a residual solvent content of 40% by weight or less at a temperature of 3200 to 5000C for a period of time ranging from 5 seconds to 90 minutes. 2. A process as claimed in claim 1 wherein the solvent is N,N-dimethylacetamide, N,N-diethyl ace tamide, N,N-dimethylformamide, N,N-dimethylmethoxy- acetamide, N-methyl-2-pyrrolidone, N-acetyl-2pyrrolidone, N-methyl-ç-caprolactam, hexamethylphosphoric triamide (commonly known as hexametapol), N,N,N',N'-tetramethylurea, tetrahydrothiophene dioxide (commonly known as sulfolane), m-chlorophenol, pchlorophenol, 3-chloro-6-hydroxytoluene or sulfuric acid. 3. A process as claimed in claim 1 wherein the self-supporting film is formed by heating the thin layer of the polyamide-polyamide acid block copolymer or polyamide-polyamide acid copolymer solution at a. temperature of 50 to 2500C, 4. A process as claimed in claim 1 wherein the self-supporting film is formed by cyclizing the thin layer of the polyamide-polyamide acid block copolymer or polyamide-polyamide acid copolymer solution in the presence of a cyclizing agent. 5. A process as claimed in claim 1 wherein the self-supporting film is formed by bringing an extractant into contact with the thin layer of the polyamide-polyamide acid block copolymer or polyamidepolyamide acid copolymer solution to extract and remove the solvent from the thin layer. 6. A process as claimed in claim 1 wherein the self-supporting film separated from the substrate is heated at a temperature of 3400 to 4500C. 7. A process as claimed in claim 1 wherein. the self-supporting film separated from the substrate is heated at a temperature of 3200 to 5000C in a vacuum or in an atmosphere of an inert gas. 8. A process as claimed in any of claims 1, 6 and 7 wherein the self-supporting film separated from the substrate is heated on both sides. 9. A process as claimed in claim 1 wherein, prior to heating the self-supporting film separated from the substrate at a temperature of 3200 to 5000C, the residual solvent content of the film is reduced to 40% by weight or less by heating at relatively low temperatures, evaporation under reduced pressure, extraction or air-drying. 10. A process as claimed in claim 9 wherein the residual solvent content is 20% by weight or less. 11. A process as claimed in claim 9 wherein the residual solvent content is 5% by weight or less. 12. A process as claimed in claim 1 wherein the polyamide-polyamide acid block copolymer or polyamide-polyamide acid copolymer has a logarithmic viscosity number of 0.1 to 3 as measured by a 0.5 g/ 100 ml solution in N,N-dimethylacetamide at 350C. 13. A process as claimed in claim 12 wherein the logarithmic viscosity number is in the range of 0.5 to 2.

Inventors: IBI, AKIRA MITSUI TOATSU APAATO 4-37, KAWAMATA, MOTOO, NAITO, MITUYUKI, SATO, TAKUSHI, SHINDO, KAZUMI, SHISHIDO, SHIGEYUKI, TAKAHASHI, SHIGERU
Applicants: MITSUI TOATSU CHEMICALS, INCORPORATED
Application year: 1984
Main classification: C08J5
IPC codes: B29C41, H05K1, C08G18, H01B3, B32B15, B29B7, C08J5, B29C31, C08G73, C08J3, B29D7, B29C47, C08J7