Process for forming a film of a polymer.

Abstract: A process for forming a built-up thin film of a high polymer which is inherently difficult of film formation by the Langmuir-­ Blodgett process. A high polymer is modified so as to enable film formation by the Langmuir-Blodgett process by introducing a substituent group for imparting a hydrophobic nature to a recur­ ring unit of the high polymer, and the thus-modified high polymer is mixed with a known Langmuir-Blodgett film compound for film formation by the Langmuir-Blodgett process. A high polymer used in the present invention includes linear recurring units each of which is composed of an at least divalent first organic group R₁ having at least two carbon atoms and an at least divalent second organic group R₂ having at least two carbon atoms, the first organic group R₁ and the second organic group R₂ being connected with each other by a divalent bonding group; and at least one hydrocarbon-containing group R₃ which have 10 to 30 carbon atoms and optionally contain a substituent group, and which is covalently bonded to the same recurring units.

Description: The present invention relates to a process for forming a film of a polymer of molecular weight at least 2000 and a known Langmuir-Blodgett film compound by the Langmuir-Blodgett process. It was found by Langmuir and Blodgett in 1930s that fatty acids having ca. 16 to 22 carbon atoms can form a monomolecular film on the surface of water and such a film can be built up or laminated on a substrate. However, it is only in recent years that investigation of their technical application was started. The outline or investigations hitherto made has been reviewed in "Kotai Butsuri (Physics of Solids)," 17 (12), p.45 (1982); "Thin Solid Film," 68 , No. 1 (1980); ibid., 99 , Nos. 1, 2 and 3 (1983); G. L. Gains, "Insoluble Monolayers at Liquid-gas Interface," Intersciene Publishers, New York (1966); etc. However, the conventional Langmuir-Blodgett films (hereinafter referred to as "LB film") of straight chain saturated carboxylic acids are not satisfactory in such points as heat resistance and mechanical strength and, so there is a problem that they can find no practical application as they are. In order to overcome the above disadvantages, investigations have been made on polymeric films of unsaturated fatty acids, such as ω-tricosenic acid, ω - heptadecenic acid and α -octadecylacrylic acid; and unsaturated esters of fatty acids, such as vinyl stearate, octadecyl acrylate; as well as derivatives of diacetylene. Those films, however, are not sufficiently heat-resistant and have only poor electrical properties. It is also known that some hydrophilic group-containing polymers, such as polyacrylic acids, polyvinyl alcohols, polyethyl acrylates and polypeptides, also have film-forming properties. However, any sort of polymer suitable for LB materials has not as yet been investigated, and there are no excellent materials for LB film worthy of the name. On the other hand, heat-resistant films have been produced from polyimides. However, polyimide films prepared by the spin coat method or the like usually have a thickness greater than 1 µm, or at best 100 um (1,000 Å). It is therefore very difficult to produce a heat-resistant film having a thickness of 100 um (1,000 Å) or less and, at the same time, free from pin holes. It was found by the inventors of the present invention that a film of a polymer having a molecular weight (MW) of at least 2000 as used according to the present invention can be formed alone (EP-A2-0218114) and that the film-forming property can be improved by mixing said polymer with a known compound capable of forming a Langmuir-Blodgett film (see EP-A-0230539 which was published after the priority date of the present application). The present application is directed to films which are subjected to a partial or complete ring closing treatment in order to improve the heat resistance of the thin film formed on the substrate. Accordingly, it is an object of the present invention to provide a process for forming a film according to claim 1. In the process of the present invention a known Langmuir-Blodgett film compound is used in addition to a polymer having an MW of at least 2000 which is provided with presursor structures for producing five-membered or six-membered rings containing a hetero atom. Accordingly, it is an object of the present invention to provide a polymer thin film which has a thickness conventionally difficult to obtain and which has improved heat resistance, chemical resistance and mechanical properties such as adhesive strength. To achieve the object, a process for forming a film according to the present invention comprises the step of mixing the polymer of µW at least 2000 with a known Langmuir-Blodgett film compound for film formation by the Langmuir-Blodgett process. According to the present invention, a process for forming a built-up film is provided according to claim 1. Fig. 1 shows the infrared absorption spectrum of a polymer obtained in Preparation 1; Fig. 2 shows she result of the thermal analysis of the polymer shown in Fig. 1; Fig. 3 shows the surface pressure vs. area curves obtained when the polymer of Preparation 1 is mixed with stearyl alcohol in the molar ratio of 1 : 1; Fig. 4 shows the relationship between surface pressure and area per recurring unit or the precursor obtained in Comparative Example 1. Fig. 5 shows the IR spectrum of the polymer obtained in Example 6, and Fig. 6 shows the result of the thermogravimetric analysis (TGA). Fig. 7 shows the weight change (TGA) and the heat change, measured by differential thermal analysis (DTA) when the polymer was heated from room temperature to 450°C and maintained at that temperature for one hour. Fig. 8 shows the relationship between surface pressure and area per recurring unit in the case where the polymer obtained in Example 6 was spread on the surface of water, and Fig. 9 shows the surface pressure-area curve of said polymer mixed with an equimolar amount of stearyl alcohol. Figs. 10 and 11 show respectively the Proton nuclear magnetic resonance (¹H-NMR) and infrared (IR) spectra of the polymer obtained in Example 7, and Fig. 12 shows the result of the thermogravimetric analysis. Fig. 13 shows the weight change (TGA) and the heat change (DTA) when said polymer was heated from room temperature to 500°C and maintained at that temperature for one hour. Fig. 14 shows the IR spectrum of the ring closure product obtained by heating at 500°C for one hour, Fig. 15 shows the relationship between surface pressure and area per recurring unit in the case where the polymer obtained in Example 10 was spread on the surface of water, and Fig. 16 shows the surface pressure-area curve of said polymer mixed with an equimolar amount of stearyl alcohol. Fig. 17 shows the IR spectrum of the polymer obtained in Example 8, and Fig. 18 shows the result of the thermogravimetric analysis. Fig. 19 shows the weight change (TGA) and the heat change (DTA) when said polymer was heated from room temperature to 400°C and maintained at that temperature for one hour. Fig. 20 shows the relationship between surface pressure and area per recurring unit in the case where the polymer obtained in Example 8 was spread on the surface of water, and Fig. 21 shows the surface pressure-area curve of said polymer mixed with an equimolar amount of stearyl alcohol. A material of an LB film used in the present invention is a polymer of µW at least 2000 which includes linear recurring units composed of an at least divalent first organic group R₁ having at least two carbon atoms and an at least divalent second organic group R₂ having at least two carbon atoms, said first organic group R₁ and said second organic group R₂ being connected with each other by a divalent bonding group; and at least one hydrocarbon-containing group R₃ which has 10 to 30 carbon atoms which optionally contains a substituent group, with the proviso that when R₃ has less than 14 carbon atoms, R₃ unit contain fluorine atoms, and which is covalently bonded to each recurring unit, and wherein said recurring unit is provided with a precursor structure for producing a five-membered or six-membered ring containing a hetero-atom. To be more specifc, the polymer used in this invention comprises as a basic skeleton a linear recurring unit represented by one of the following formulae: ( A - R₁ - AB - R₂ - B ) (1) ( A - R₁ - BA - R₂ - B ) (2) ( B - R₁ - BA - R₂ - A ) (3) wherein R₁ represents an organic group having a valency of at least two and containing at least two carbon atoms, and R₂ represents an organic group having a valency of at least two and containing at least two carbon atoms, at least one of the groups R₁ and R₂ being preferably a group comprising a benzenoid structure. In the above formulae (1) to (3), AB and BA represent a divalent connecting group formed by a reaction between acidic group A and basic group B wherein both groups contain hetero atoms such as O, N, S, P and B. Examples of such groups are: A: -COOR (R represents alkyl group or hydrogen atom), -COX (X represents Cl or Br), -NCO, -NCS, -CN, -CONHR, -SO₂NHR, etc. B: -NHR, -OR, -SR, -X, etc. AB: etc. BA: etc. The polymer used in this invention is modified by introducing into any basic skeleton of the recurring units (1) to (3) at least one, preferably two, covalently bonded hydrocarbon-containing groups R₃ containing 10 to 30, preferably 14 to 22 carbon atoms, in order to make it possible to form a thin film in accordance with Langmuir-Blodgett technique. Such a modification can be effected by: [I] Substituting one or more atoms contained in AB and/or BA groups of said linear recurring unit (1), (2) or (3) by one or more R₃ groups; [II] Directly substituting R₁ and/or R₂ groups by one or more R₃ groups; or [III] Introducing one or more R₃ groups into R₁ and/or R₂ through the substituent which is not involved in the formation of the linear recurring structure. It is a matter or course that the above modification methods [I], [II], and [III] can be applied in combination. In the case where more than one R₃ group is introduced into one recurring unit, the R₃ groups can be either the same or different. The modification methods will be further explained hereinbelow. Specific examples of [I], are: In the modification method [I] shown above, the hydrogen atom attached to the nitrogen atom contained in group AB or BA is substituted by R₃ groups. In the modification method [II], R₃ is directly introduced into R₁ and/or R₂ to form, for example, recurring units as shown below. The above-described modification method [III] comprises much more possibilities. To be more specific, in the case of [III], at least one of the groups R₁ and R₂ must be an organic group having a valency of at least three, and one or more substitutional groups R₃ are introduced into group R₁ or R₂ through the substituent which is not involved for the formation of the recurring structure. Examples of combinations of R₁ and R₂ where R₁ has a valency equal to, or greater than, that of R₂, and both of them nave a valency not greater than 6, are: Valence of R₁ Valance of R₂ 1 3 2 2 4 2 3 5 2 4 6 2 5 3 3 6 4 3 7 5 3 8 6 3 9 4 4 10 5 4 11 6 4 12 5 5 13 6 5 14 6 6 Of the above combinations, those comprising R₁ and R₂ groups having a valency of up to 4 can be particularly preferable, although the valencies of the groups are not limited thereto. Specific examples of linear recurring units comprising combinations of R₁ and R₂ groups having the following valencies are shown hereinbelow: R₁ = 3, R₂ = 2 R₁ = 4, R₂ = 2 R₁ = 3, R₂ = 3 R₁ = 4, R₂ = 3 R₁ = 4, R₂ = 4. When R₁ = 3 valent and R₂ = 2 valent, When R₁ = 4 valent and R₂ = 2 valent, When R₁ = 3 valent and R₂ = 3 valent, When R₁ = 4 valent and R₂ = 3 valent, When R₁ = 4, R₂ = 4, In the above formulae (4) to (75), there are groups A and B not involved in the formation of the recurring structure. In the modification method [III] mentioned hereinbefore, R₃ is introduced into such groups, for example, by substituting atoms or groups contained in A by such groups as -COOR₃, -CONHR₃, -NHCOOR₃ and -NHCSOR₃, etc. or by substituting atoms or groups contained in B by such groups as -NHR₃, -OR₃ and -SR₃ etc. Explanations will be given hereinbelow on R₁ and R₂. R₁ is a group having a valency of at least 2 and containing at least 2, preferably 5 to 20, carbon atoms. It may be an aromatic group; an aliphatic group; an alicyclic group; a group in which an aromatic group is combined with an aliphatic group; a group in which one of the above-mentioned groups is combined with a monovalent group having 1 to 30 carbon atoms selected from the group consisting of an aliphatic group, an alicyclic group, an aromatic group and a group in which an aliphatic group is combined with an alicyclic group or an aromatic group; or a group wherein each of the preceding groups is substituted by a monovalent group such as a halogen atom, nitro group, amino group, cyano group, methoxyl group or acetoxyl group, or by a group in which the above monovalent group bonds to -O-, -COO-, -NHCO-, -CO-, -S-, -CSS-, -NHCS-, -CS-, or the like. Groups comprising a benzenoid structure can be preferred as R₁ or R₂, with regard to heat resistance, chemical resistance, physical properties, etc. The term "benzenoid structure" refers herein to the structure of carbocyclic compounds as contained in ordinary aromatic compounds, in contrast to quinoid structures. Examples of R₁ and R₂ are: wherein R₄ represents -(CH₂) n - (n=1-3), -O-, -CO-, -S-, -SO₂-, (in which R₅ represents an alkyl group or an aryl group). (wherein R₄ is as defined before) (wherein R₄ is as defined before) More preferred examples of R₁ and R₂ are: (R₄ is as defined before) R₃ may be a hydrocarbon containing group having 10 to 30, preferably 14 to 22, carbon atoms. A preferred example thereof is a monovalent group selected from an aliphatic group, an aliphatic group bonded to an alicyclic group, aliphatic group bonded to an aromatic group, or a substituted group thereof. Specific examples of R₃ are: CH₃(CH₂) n-1 , CH₂=CH(CH₂) n-2 , (CH₃)₂CH(CH₂) n-3 , CH₃(CH₂)₂C≡C-C≡C(CH₂) m , (CH₃)₃C(CH₂) n-4 , (in which ℓ+m=n-5 , n is an integer of 10 to 30, preferably 14 to 22). These groups may be substituted with substituent groups, such as a halogen atom, nitro group, an amino group, a cyano group, a methoxyl group and an acetoxyl group and the like, however, these are not critical. Fluorine can be preferable as a substituent in some cases since it is capable of imparting stronger hydrophobicity to the polymer than hydrogen. In other words, alkyl groups having a shorter chain can be employed when fluorine atoms are contained therein. For example, in the case of C₈F₁₇(CH₂) k -, k=2 will be sufficient to obtain a polymer capable of forming a film. Specific examples of polymers employable in the process for forming a film of this invention will become apparent by applying the examples of R₁, R₂, R₃, A, B, AB and BA, as well as the modes of substitution of R₃, to formulae (1) to (75). Although no copolymers are included in formulae (1) to (75), it is a matter of course that copolymeric derivatives and mixtures thereof are included within the scope of this invention. Furthermore, although it is not indispensable, the polymer used in the present invention may be substituted by groups containing 1 to 9 carbon atoms according to the processes of [I], [II] or [III]. A film can be formed in accordance with the process for forming a film of this invention even when its molecular weight is relatively small. In such a case, however, it may not be possible to attain good heat resistance, mechanical strength and chemical resistance. On the other hand, an excessively high molecular weight is undesirable since it may become difficult to form a film because of increase of viscosity. Accordingly, the weight average molecular weight is from at least 2,000 to 300,000 preferably from 10,000 to 150,000. Specific examples which can be advantageous in costs and easiness of synthesizing monomers and polymers, are shown below. However, these are not restrictive. In the above formulae, "→" indicates isomerism. For instance, formula (76) stands for formulae (76-1) and (76-2) shown below. and The present invention includes both cases in which each of (76-1) and (76-2) exists alone or in combination. Other examples may be found in books such as "Heat Resistance of High Polymer" (published by Baifukan, March 5, 1970) and "Thermal Decomposition and Heat Resistance or High Polymer" (published by Baifukan, March 15, 1974) edited by Hirotaro Kambe. The process for producing thin films of the polymer will be explained hereinbelow, referring to the case where R₃ = CH₃(CH₂)₁₇-in formula (78). The following compound: which is obtained by the alcoholysis of pyromellitic acid dianhydride is acylated with thionyl chloride at a temperature of from not lower than -10°C to a temperature up to near the boiling point of the acid halide preferably from 0° to 40°C in an organic polar solvent under substantially anhydrous conditions, followed by reacting the resulting product with diaminodiphenyl ether at a temperature of not lower than -10°C, preferably of from -10°C to +20°C, more preferably from 0° to +10°C. However, in the latter stage of the reaction, the use of reaction temperature over 20°C is favorable to complete the reaction. The acylation and the amidation are usually carried out at a temperature between about 0°C to -10°C, but as the substituent groups such as long chain alkyl groups, etc. have the tendency of freeze solidifying in this invention, they should preferably be carried out at a temperature of not lower than -10°C. In the above case, of course, either raw materials having different substituent groups may also be mixed to give copolymers, or tetracarboxylic acid dianhydride or diamine having no substituent group or having substituent groups having not more than 10 carbon atoms may be mixed in an amount of about 0 to 50%. The thus prepared amphiphilic polyimide precursor can be used as a material for forming a film after having been isolated and purified, or can be added with a solvent, such as chloroform and benzene, so as to directly make a spreading solution for forming a polymeric film. Explanations will be given hereinbelow on the process for forming Langmuir-Blodgett films to be used in this invention. In a process for forming a Langmuir-Blodgett film, a film-forming material is spread on the surface of water, and the thus spread material is compressed at a certain surface pressure to form a monomolecular film, which is then transferred or laminated onto a substrate by passing the substrate through the film. This is known as the vertical dipping method. Other known processes for forming a Langmuir-Blodgett film include the horizontal dipping method, the revolving cylindrical method, etc. (See "Shin Jikken Kagaku Koza", Vol.18, (Surface and Colloids), pp. 498-508. Any conventional processes can be applied to this invention without any particular restrictions. The Langmuir-Blodgett process is an excellent method for forming oriented thin film of less than 100 um (1000 Å), e.g. of several tens um (hundreds Å) or several um (tens Å). The thickness of the thin films can be controlled with an accuracy of some um (tens Å) and the films formed on a substrate in accordance with this invention also have the same characteristic. However, it is possible to form a film according to this invention having a thickness greater than 1000nm (10,000 Å). "The known Langmuir-Blodgett film compound" disclosed herein is a compound known to those skilled in the art which is described in the above-described literatures. A compound consisting of a hydrocarbon group which has about 14 to 22 carbon atoms and a hydrophilic group being represented by one of the following formulae is preferred: CH₃(CH₂) n-1 Z CH₂=CH(CH₂) n-2 Z CH₃(CH₂) ℓ C≡C-C≡C(CH₂) m Z wherein n is an integer of from 14 to 22, ℓ+m=n-5 , and Z = OH, NH₂, COOH or COOR' (R'represents a lower aliphatic hydrocarbon group). Compounds represented by the formula CH₃(CH₂) n-1 Z are preferred in terms of cost, while among the formulae, in order to improve the film-forming property, a compound containing an unsaturated bond is preferable since it can be polymerized by irradiation by light, radiation. The mixing ratio of at least one of the above mentioned compounds and the high polymer is not limited. For the formation of films according to the Langmuir-Blodgett process, there is used, in general, a solvent, such as benzene, chloroform and the like, which is insoluble to water and vaporizable into the gaseous phase. However, in the case of the polymer used in this invention, it is preferred to use a polar organic solvent in combination with a volatile solvent, in order to attain an increased solubility. Examples of preferable polar organic solvents are N,N-dimethylformamide, N,N-dimethylacetamide, N,N-diethylform-amide, N,N-diethylacetamide, N,N-dimethylmethoxy-acetamide, dimethylsulfoxide, N-methyl-2-pyrrolidone, pyridine, dimethylsulfone, hexamethylphosphoramide, tetramethylenesulfone, dimethyltetramethylenesulfone. In the case where an organic polar solvent is used in combination with a volatile solvent, such as benzene and chloroform, the latter, it is presumed, vaporizes into the gaseous phase during the spreading, whereas the former dissolves into the large quantity of water. There is no particular limitation on the kind of substrate to be used in this invention. It depends only on the use or application of the film. Examples of substrates usable in this invention include those made of ordinary inorganic substances such as glass, alumina and quarz; those made of metals, plastics, and semiconductors of, e.g., Groups IV, III-V and II-VI of the Periodic Table, such as Si, GaAs and ZnS; and those made of magnetic materials or ferroelectric materials, such as PbTiQ₃, BaTiO₃, LiNbO₃, and LiTaO₃. It is also possible to use a substrate subjected to a conventional surface treatment. The adhesion between the polymer film formed by the process of this invention and the substrate can also be improved by applying a silicone coupling agent (in particular, a silicone coupling agent containing amino and epoxy groups) or an aluminium chelate to a substrate and then subjecting it to a heat treatment. The substrate may be treated in a plurality of layers with metal salts of fatty acids as conventionally applied in this field. It is a characteristic feature of this invention that the films formed on a substrate in accordance with the Langmuir-Blodgett process are subjected to a partial or complete ring-closing treatment, in order to further improve the heat resistance of the thin film formed on the substrate. The polymers (76)' to (88)' can be produced through partial or complete rang closure of a five-membered or six-membered ring containing a hetero-atom. The structures of the polymers (76)' to (88)' after the complete ring closure will be as shown below. There are no particular limitations on the treatment to be employed for the ring closure. In the case of imidation of a sample represented by (78), the following reaction takes place when heated at a temperature of around 200 to 400°C. At this time, the group which has been introduced for the purpose of increasing the hydrophobic nature is eliminated as an alcohol, but since the eliminated alcohol can be removed at a temperature of about 200 to 400°C, if necessary, under a gas flow or a vacuum, a polyimide thin film having a very high heat resistance can be obtained.. In order to obtain a thin film having a high heat resistance by such a ring closure process, it is preferable to select a known Langmuir-Blodgett film compound from the above-described examples which is able to be removed under the condition of a ring closure reaction. The use applications of such a thin film will now be described. A thin film formed by the process of the present invention is characterized in that it is a very thin film having efficient heat resistance, chemical resistance and mechanical properties. Owing to such characteristics, it is applicable to various fields such as electronics, energy conversion and material separation. In the field of electronics, in which the electric conductivity, photo-conductivity, optical characteristics, insulation characteristics, thermal characteristics and chemical reactivity of a thin film formed by the process of the present invention are utilized, the film may be used as an optical recording film, resist film, insulating film, thin film for a capacitor, liquid crystal orientation film, polarizing film, sensor film, etc. As an insulating film, it can be used as an insulation layer in the electrical and electronic elements having the structure of MIS, MIM, etc. in which various kinds of semiconductors or metals have been intended therewith as an insulation layer of an integrated circuit (IC) or an large scale integrated circuit (LSI), and a field effect transistor device, photoelectric device, light emitting device, light receiving device, light detecting device, hot electron transistor, etc. Especially, a thin film formed by the process of the present invention is effective for Metal/insulator/substrate (MIS) and metal/insulator/metal (MIM) which utilize a tunnelling effect, and is also usable as the insulating film of a |Josephson Junction|(JJ). Furthermore, the film may be applied to a cladding material or an optical circuit element for a waveguide. The film may also be suitable as a protective coating material in various fields. The use of a mixed material in the present invention in place of a fatty acid in the technique of forming a mixed film or a laminated film of a functional LB material and a fatty acid, which technique is generally adopted in the field of an LB film, brings about various functions, and such a mixed film and a laminated film are considered to have many uses. For instance, it is possible to produce a photoelectric device and a biosensor by preparing a film containing a dye and an enzyme, respectively. In addition, the use of such a film in the field of material separation will also be possible. The process for preparing a polymer used in the present invention and the process for forming a film according to the present invention will be explained in the following with reference to Examples. Preparation 1 10.91 g of pyromellitic acid dianhydride and 27.05 g of stearyl alcohol were reacted at 120°C for 3 hours, and the reaction product was recrystallized from 200 mℓ of ethanol to obtain distearyl pyromellitate having a melting point of 133 to 137°C. 3.79 g of distearyl pyromellitate was dissolved in 60 cc of hexamethylene phosphoramide and cooled to 5°C. 1.19 g of thionyl chloride was added dropwise thereto at about 5°C. After dropping, the reaction was continued for about one hour. Thereafter, 1.2 g of diaminodiphenyl ether dissolved in 30 cc of dimethylacetamide was added dropwise to the reaction mixture at about 10°C, and the reaction temperature was raised to about 20°C to react the mixture for 2 hours. The reaction mixture was poured into 400 cc of ethanol to separate the reaction product. The separated product was filtered and dried at 40°C to obtain about 3.4 g of pale yellow powder. IR spectrum analysis, thermal analysis (TGA-DTA) and measurement of molecular weight by gel permeation chromatographic (GPC) were carried out. The results are as follows: IR Spectrum Analysis The IR chart taken by the KBr disc process is as shown in Fig. 1, in which the characteristic absorptions of esters, amides I, II and III, alkyl chains and ethers are seen. Thermal Analysis (TGA-DTA) Thermal analysis was carried out in a nitrogen flow (30 m/min) by using an (H) type of radioisotope thermoelectric generator differential thermal (RTG-DTA) analyzer manufactured by Rigaku Denki with a full scale of 10 mg (H) for TGA and 100 V for DTA under the condition that the temperature was raised up to 1,000°C at a rate of 10°C/min. The result is as shown in Fig. 2. In the TGA inflection points are seen at 203, 270, 354, 403 and 580°C, while in the DTA no characteristics peak appears. Measurement of Molecular Weight by GPC The number-average molecular weight which was measured in a mixed solvent of chloroform and N,N-dimethylacetamide (8 : 2) was about 15,000 calculated in terms of polystyrene. EXAMPLE 1 25 mℓ of spreading solution for an LB film was prepared by dissolving 55.1 mg of the product of Preparation 1 in a mixed liquid of distilled chloroform/dimethylacetamide = 8 : 2 in volume ratio. The relationship between the surface pressure and the area per repeating unit was measured on the surface of redistilled water at 20°C. The result is as shown in Fig. 3. The surface pressure rose rapidly at around 65x10⁻²⁰m² (65 Å²) unit, and a good condensed film was formed. The limiting area was about 55x10⁻²⁰m² (55 Å²) unit and the collapsing pressure was about 45x10⁻³N/m (45 dyne/cm) (Fig. 3 - A). To the spreading solution the same volume of stearyl alcohol having the same molar concentration as that or the solution was mixed so that the sum of the number of the recurring units of the product of Preparation 1 and the number of the molecules of the stearyl alcohol may become equal to the number of the recurring units of Fig. 3-A. The relationship between the surface pressure and the area indicated by B in Fig. 3 is obtained. It is clear that the addition of stearyl alcohol makes the rise of the curve steeper and also rises the collapsing pressure 60x10⁻³ N/m (60 dyne/cm) in other words, makes the film more stable. A built-up film on a glass substrate with aluminum deposited thereon was a good Y-type film whether stearyl alcohol had been added or not. When a mixture of the product of Preparation 1 and stearyl alcohol in a molar ratio of 1 : 1 was built up on a germanium substrate and was heated for one hour at 400°C in a nitrogen gas flow, the disappearance of the stearyl group and the appearance of a five-membered imide ring at 1790 and 1710 cm⁻¹ was observed by an Fourier transfer attenuated total refraction infrared (FT-ATR-IR) spectrum analysis. EXAMPLE 2 The pressure surface vs. area curves were evaluated in the same way as in Example 1 by using stearic acid, ω-heptadecenic acid, and octadecane in place of stearyl alcohol, respectively. It was found that the rise of the curve was steep and the collapsing pressure rose in any case. The collapsing pressures in the case of using stearic acid and ω-heptadecenic acid were approximately the same and higher than that in the case of using octadecan. The films formed by adding stearic acid, ω-heptadecenic acid and octadecane, respectively, were built up in the form of a Y-type on a glass substrate with aluminum deposited thereon, whereby good built-up films were obtained. COMPARATIVE EXAMPLE 1 A polyimide precursor was synthesized in the same manner as in Preparation 1, except that n-decyl alcohol (n-C₁₀H₂₁OH) was used instead of stearyl alcohol. As far as IR spectrum, thermal analysis and molecular weight measured by GPC are concerned, the polyimide precursor showed the same characteristics as those of the polyimide obtained in Preparation 1. However, the surface pressure-area curve or the precursor, shown in Fig. 4, indicates the presence of a liquid expansion phase and denies the existence of a condensed phase. It would, therefore, be apparent that an alkyl group containing only 10 carbon atoms would be too short to give a polymer capable of forming a stable condensed film. No good built-up film was obtained even adding prior known Langmuir-Blodgett film compound. EXAMPLES 3, 4 AND 5 A polyimide precursor was synthesized in the same manner as in Preparation 1, except that straight chain alcohols, having 14, 16 and 22 carbon atoms respectively, were used instead of stearyl alcohol. As far as IR spectrum, thermal analysis, molecular weight measured by GPC and the surface pressure-area curve are concerned, the polyimide precursor showed the almost same characteristics as those of the polyimide obtained in Preparation 1. The polyimide precursors having 14 and 22 carbon atoms also formed stable condensed film and were capable of forming built-up films according to an LB process. Especially, good built-up film of Y-type was obtained simultaneously using straight chain alcohol. EXAMPLE 6 Synthesis of a Polymer from Trimellitic Acid Monostearyl Ester and 2,5-Diaminobenzamide In a 200 mℓ four neck flask an acid chloride was prepared from trimellitic acid monostearyl ester (2.31 g, 5.00 millimoles) Hexamethylene phosphoramide (HMPA) (30 mℓ), and thionyl chloride (1.19 g, 10.0 millimoles). Thereto was dropwise added 2,5-diaminobenzamide (0.756 g, 5.00 milimoles) at about 5°C with stirring by the use of a mechanical stirrer. Stirring was further continued for more than one hour, and the temperature was slowly restored to room temperature. The resulting red-brown reaction liquid was poured in 500 mℓ of ethanol, while stirring by the use of a mechanical stirrer, when a white precipitate was formed. The precipitate was filtered, washed first with water and then with ethanol, and dried under a reduced pressure, whereby polyamide 5 (2.30 g, yield 80%) was obtained as a pale yellow solid. The structure was identified by ¹H-NMR and IR spectrum. The results of ¹H-NMR, IR spectrum analysis, thermal analysis (TGA-DTA), and the measurement of molecular weight by GPC are as follows: ¹H-NMR Analysis The proton NMR spectrum obtained in dimethyl formamide (DMF)-d₇ + CDCℓ₃ was assigned as follows. δ0.7 - 1.7 (m, 35H CO₂CH₂C₁₇H₃₅) δ4.25 (t, 2H CO₂CH₂C₁₇H₃₅) δ7.90 - 8.40 (m, 6H, aromatic) The proton of CONH could not be observed. IR Spectrum Analysis As the IR chart obtained by KBr disc methods is shown in Fig. 5, there appeared the absorption peak characteristic of esters, amides I, II, and III, and alkyl chains. Thermal Analysis (TGA-DTA) The result obtained by measuring by the use of an RTG-DTA of type H, manufactured by Rigaku Denki Co., Ltd., under the conditions: TGA full scale, 10 mg, DTA full scale, 100 µV; maximum temperature, 1000°C; rate of heating, 10°C/min; and nitrogen stream of 30 mℓ/min is as shown in Fig. 6. In the TGA were observed inflection points at 230, 288, 360, 400, 460, and 507°C and a characteristic peak in the vicinity of 525°C. On the other hand, Fig. 7 shows the result obtained when the product was heated up to 450°C at rate of 10°C/min, and maintained at 450°C for one hour. Although the weight slowly decreases by heating at 450°C for one hour, heat-resistant at around 400 to 450°C may be expected. In the IR spectrum of the compound which was obtained by the ring closure of the polymer in this example as above it was confirmed that the absorption resembling that of the imide linkage is observed and the alkyl group disappears. Also, the weight decrease after the heating at 450°C for one hour is 48.4%, which is in good agreement with the theoretical decrease 50.1% in the case where a ring closure structure is formed by the elimination of stearyl alcohol and water. Measurement of Molecular Weight by GPC By GPC measured in a mixture of N,N-dimethylacetamide and chloroform a number average molecular weight of about 16,000 (reduced to polystyrene) was obtained. The product obtained in this example was dissolved in a 5 : 5 mixture (volume ratio) of distilled chloroform and distilled dimethylacetamide to prepare 25 mℓ of LB film spreading solution. The relationship between surface pressure and area per recurring unit was measured at 20°C on the surface of redistilled water. The result obtained is shown in Fig. 8. The surface pressure rose steeply from ca. 50 x 10⁻²⁰m² (50 Å²) unit, forming a good condensed film. The collapse pressure was 30 x 10⁻³ N/m (30 dyne/cm). When stearyl alcohol was mixed in an equimolar amount, a good surface pressure-area curved was obtained (Fig. 9). It was brought to light that when the polymer in this example mixed with an equimolar amount of stearyl alcohol is built up on the glass substrate on which aluminum was evaporated, a deposited film of Y type was obtained. In addition the 61 layers deposited film obtained in the above described way had a thickness of ca. 180 um (1800 Å), and the electrical insulation characteristic was found to be excellent by the measurement of capacitance. Further, it was also confirmed from the peaks at 1790 cm⁻¹ and 1710 cm⁻¹ by FT-IR analysis that when said deposited film was heated at 450°C for one hour a linkage resembling the imide linkage was formed. EXAMPLE 7 10.91 g of pyromellitic acid dianhydride and 27.05 g of stearyl alcohol were allowed to react at 120°C for three hours, and the product was recystallized from 200 mℓ of ethanol to give pyromellitic acid distearyl ester of m.p. 133 - 137°C. Synthesis of a Polymer from Pyromellitic Acid Distearyl Ester and 2,5-Diaminobenzamide In a 200 mℓ four neck flask, an acid chloride solution was prepared at room temperature from pyromellitic acid distearyl ester (3.80 g, 5.00 millimoles), thionyl chloride (1.19 g, 10.0 millimoles), and HMPA (50 mℓ), and thereto was dropwise added 2,5-diaminobenzamide (0.765 g, 5.00 millimoles) dissolved in dimethylacetamide (30 mℓ) at about 5°C with stirring by the use of a mechanical stirrer, and stirring was further continued for more than one hour, and then the temperature was slowly restored to room temperature. After the reaction liquid was filtered through a Kiriyama filter, similar to a Buchner funnel, the filtrate was poured in 500 mℓ of ethanol, in which a pale yellow precipitate was formed. The precipitate was filtered off, washed first with water and then with ethanol, and dried under a reduced pressure, whereby polyamide (3.55 g, yield 81%) was obtained as a yellow solid. The results of the measurement of molecular weight by ¹H-NMR, IR spectrum analysis, thermal analysis (TGA-DTA) and GPC are as follows. ¹H-NMR Analysis The proton NMR spectrum obtained in a solution of DMF-d₇ - CDCℓ₃ is as shown in Fig. 10. IR Spectrum Analysis As the IR chart obtained by KBr disc method is shown in Fig. 11, there appeared the absorption peak characteristic of esters, amides I, II, and III, and alkyl chains. Thermal Analysis (TGA-DTA) The result obtained by measuring by the use of an RTG-DTA of type H, manufactured by Rigaku Denki Co., Ltd., under the conditions: TGA full scale, 10 mg; DTA full scale, 1000 µV; maximum temperature, 1000°C; rate of heating, 10°C/min; and nitrogen stream of 30 mℓ/min is shown in Fig. 12. In the TGA were observed inflection points at 238, 292, 355, 400, 485, and 592°C, and in the DTA was observed no characteristic peak. On the other hand, Fig. 13 shows the result obtained when the product was heated up to 500°C at a rate of 10°C/min, and maintained at 500°C for one hour. Even when heating was made at 500°C for one hour, there was found almost no decrease in the weight, indicating the heat stability, so that heat resistance can be expected at a temperature above 500°C. Although the IR spectrum of the compound obtained by the ring closure of the polymer in this example as above is low in the percent transmission as shown in Fig. 14, the absorption resembling that of the imide linkage can be observed. Also, the weight decrease observed after the heating at 500°C for one hour is 64.7%, which is well in conformity with the theoretical decrease 64.1% in the case where polyimidoisoindoquinazolinedione is formed by the elimination of stearyl alcohol and water. Measurement of Molecular Weight by GPC By GPC measured in a mixture of N,N-dimethylacetamide and chloroform a number average molecular weight (reduced to polystyrene) of about 42,000 was obtained. 55.1 g of the product obtained in this example was dissolved in an 8 : 2 mixture (volume ratio) of distilled chloroform and distilled dimethylacatamide to prepare 25 mℓ of LB film spreading solution. The relationship between surface pressure and area per recurring unit was measured at 20°C on the surface of redistilled water. The result obtained is shown in Fig. 5. The surface pressure rose steeply from about 90 x 10⁻²⁰m² (90 Å²)/unit, forming a good condensed film. The limiting area was 75 x 10⁻²⁰m² (75 Å²)/unit , and the collapse pressure was 30 x 10⁻³N/m (30 dyne/cm). When mixed with an equimolar amount of stearyl alcohol, an extremely good surface pressure-area curve was obtained (Fig. 16). It was brought to light that when the polymer in this example mixed with an equimolar amount of stearyl alcohol was deposited on the glass substrate on which aluminum was vacuum evaporated a deposited film of Y type was obtained. In addition, the 61 layers accumulated film obtained in the above described way had a thickness of ca. 180 nm (1800 Å), and the electric insulation characteristic was found to be excellent by the measurement of capacitance. Further, it was also confirmed from the peaks at 1790 cm⁻¹ and 1710 cm⁻¹ by FT-IR analysis that when said accumulated film is heated at 500°C for one hour, a linkage resembling the imide linkage is formed. EXAMPLE 8 10.91 g of pyromellitic acid dianhydride and 27.05 g of stearyl alcohol were allowed to react at 120°C for three hours, and the product was recrystallized from 200 mℓ of ethanol to give pyromellitic acid distearyl ester of m.p. 133 - 137°C. Synthesis of a Polymer from Pyromellitic Acid Distearyl Ester and 3,3-Diaminobenzidin In a 200 mℓ four neck flask an amount (2.84 g, 3.74 millimoles) of pyromellitic acid distearyl ester was weighed out and dissolved in hexamethylphosphoric triamide (HMPA, 30 mℓ). When thionyl chloride (0.87 g, 7.48 millimoles) was dropwise added at 5°C under a stream of nitrogen with stirring by the use of a mechanical stirrer, and further the stirring was continued for one hour, a pale yellow pasty acid chloride was obtained. By adding 30 to 40 mℓ of methylene chloride (dried with calcium chloride) the solution was made homogeneous. In a separate 200 mℓ four neck flask, tetraaminobenzidin (0.800 g, 3.74 millimoles) was dissolved in dimethylacetamide (30 mℓ), and the above described solution of acid chloride was dropped in this solution over about 30 minutes at about 5°C in a stream of nitrogen with stirring by the use of a mechanical stirrer. After stirring for an additional three hours the temperature was slowly restored to room temperature. After the reaction was complete, by pouring the reaction mixture in 500 mℓ of ethanol was stirring by the use of a mechanical stirrer, a pale yellow precipitate was deposited. When the precipitate was filtered through a Kiriyama filter, washed with water and then with ethanol, and dried under a reduced pressure, 0.91 g (yield 26%) of a polymer was obtained. The results or ¹H-NMR, IR spectrum analysis, thermal analysis (TGA-DTA), and the measurement of molecular weight by GPC are as follows: ¹H-NMR Analysis The proton NMR spectrum was obtained in a solution of DMF-d₇ +CDCℓ₃ was assigned as follows: δ1.20 (m, 70H, CO₂CH₂C₁₇H₃₅) δ4.25 (t, 4H CO₂CH₂C₁₇H₃₅) δ7.95 - 8.25 (m, 8H aromatic) The proton of CONH could not be observed. IR Spectrum Analysis As the IR chart obtained by KBr disc method is shown in Fig. 17, the characteristic absorptions of esters, amides I, II, and III, and alkyl chains appeared. Thermal Analysis (TGA-DTA) The result obtained by measuring by the use of an RTG-DTA of type H, manufactured by Rigaku Denki Co., Ltd., under the conditions: TGA full scale, 10 mg; DTA full scale, 100 µV; maximum temperature, 1000°C; rate of heating, 10°C/min; and the nitrogen stream of 30 mℓ/min is as shown in Fig. 18. In the TGA inflection points were observed at 200, 275, 330, 385, and 605°C, and in the DTA was observed no characteristic peak. On the other hand Fig. 19 shows the result obtained when the product was heated up to 400°C at a rate of 10°C/min, and maintained at 400°C for one hour. By heating at 400°C for one hour an almost constant weight was attained. Heat resistance may be expected up to 400 to 450°C. In the IR spectrum of the compound which was obtained by the ring closure of the polymer in this example as above it was confirmed that the absorption resembling that of the imide linkage is observed and the alkyl group disappears. Also, the weight decrease after the heating at 400°C for one hour is 65.0%, which is substantially in conformity with the theoretical decrease 61.7% in the case where a ring closure structure is formed by the elimination of stearyl alcohol and water. Measurement of Molecular Weight by GPC By GPC measured in a mixture of N,N-dimethylacetamide and chloroform a number average molecular weight (reduced to polystyrene) of about 28,000 was obtained. The product obtained in this example was dissolved in an 8 : 2 mixture (volume ratio) of distilled chloroform and distilled dimethylacetamide to prepare 25 mℓ of LB film spreading solution. The relationship between surface pressure and area per recurring unit was measured at 20°C on the surface of twice-distilled water, and the result obtained is as shown in Fig. 20. The surface pressure rose steeply from about 75 x 10⁻²⁰m² (75 Å²)/unit, forming a good condensed film. The limiting area was 63 x 10⁻²⁰m² (63 Å²)/unit and the collapse pressure was 35 x 10⁻³ N/m (35 dyne/cm). When mixed with an equimolar amount of stearyl alcohol an extremely good surface pressure-area curve was obtained (Fig. 21). It was brought to light that when the polymer in this example mixed with an equimolar amount of stearyl alcohol was deposited on the glass substrate on which aluminum was vacuum evaporated an deposited film of Y type was obtained. In addition, the 61 layers accumulated film obtained in the above described way had a thickness of ca. 180 nm (1800 Å), and the insulation characteristic was found to be excellent by the measurement of capacitance. Further, it was also confirmed from the peaks at 1790 cm⁻¹ and 1710 cm⁻¹ by FT-IR analysis that when said accumulated film is heated at 400°C for one hour, a linkage resembling the imide linkage is formed.

Claims: A process for forming a film comprising the step of forming a built-up film of a mixture of -a polymer having a molecular weight of at least 2000 and -a known Langmuir-Blodgett film compound by the Langmuir-Blodgett process, said polymer including linear recurring units each of which is composed of an at least divalent first organic group R₁ having at least two carbon atoms and an at least divalent second organic group R₂ having at least two carbon atoms, said first organic group R₁ and said second organic group R₂ being connected with each other by a divalent bonding group, and at least one hydrocarbon-containing group R₃ which has 10 to 30 carbon atoms and which optionally contains a substituent group, with the proviso that when R₃ has less than 14 carbon atoms, R₃ must contain fluorine atoms and which is covalently bonded to each recurring unit, and wherein said recurring unit is provided with a precursor structure for producing a five-membered or six-membered ring containing a hetero-atom, said known Langmuir-Blodgett film compound consisting of a hydrocarbon group having 14 to 22 carbon atoms and a hydrophilic group, and the step of heating said built-up film to produce said five-membered or six-membered ring containing a hetero-atom. A process according to Claim 1, wherein said polymer includes two hydrocarbon-containing groups R₃ per recurring unit. A process according to Claim 1 or 2, wherein one or both of said first and second organic groups R₁ and R₂ are benzenoid groups. A process according to Claim 1 or 2, wherein said hydrocarbon-containing group R₃ comprises an aliphatic group, an aliphatic group bonded to an alicyclic group, or an aliphatic group bonded to an aromatic group, or substituted such groups. A process according to any one of Claims 1 to 4, wherein said hydrocarbon-containing group R₃ has 14 to 22 carbon atoms.

Inventors: AWAJI, HIROSHI, UEKITA, MASAKAZU
Applicants: KANEGAFUCHI KAGAKU KOGYO KABUSHIKI KAISHA
Application year: 1987
Main classification: B05D1
IPC codes: C08L101, C08L79, B01D69, C08J5, C08L67, B05D1, C08L77