A COMPOSITE POLYESTER FILM

Abstract: A composite polyester film comprising a major layer and a minor layer composed of a polyester having a melt resistivity of less than 5 x 10⁸ Ω.cm and lower than that of a polyester constituting the major layer and a thickness of 1/200 to 4/10 of the thickness of the composite film as a whole. The film exhibits excellent electrostatic castability and heat stability.

Description: This invention relates to a composite polyester film and particularly to a composite polyester film having an excellent electrostatic impression casting property and thermal stability. A polyester such as polyethylene terephthalate is excellent in mechanical characteristics, thermal resistance, weather-proofing and electrical insulation properties. Such polyesters have been used broadly as films and for molding articles. Preferable film forming productivity, uniform thickness and excellent transparency have been needed for polyester film. Normally, polyester film is produced by quenching a melt-extruded polyester sheet with a rotating quenching drum or the like. It is however, difficult to adhere the polyester sheet to the surface of the quenching drum so that uniform film is not readily obtained. A variety of methods of improving the adherence of polyester sheet have been proposed. For instance, JP-C-37-6142 proposes a method in which a polyester sheet is made adherent to a quenching drum by forming an electrode between an extrusion die and the quenching drum, and subsequently applying a high voltage to unsolidified polyester sheet in order to adhere the polyester sheet to the quenching drum (hereinafter referred to as an electrostatic impression casting method). When the film forming rate is increased, even this electrostatic impression casting method causes a problem of decreasing adherence between the sheet and the quenching drum. In order to solve such a problem, JP-A-53-34894 and JP-A-57-190040 propose a method of decreasing the specific resistance of the polyester by adding metal compounds to the polyester. The film containing such a compound has a uniform thickness but has decreased thermal stability. The decrease in thermal stability results in the formation of coarse protrusions derived from polymer gel formed by thermal degradation and the metal compounds. This causes a problem of increasing defects (fish eyes) on the surface of the film after stretching. Furthermore, these coarse protrusions cause a problem of decreasing insulation breakdown voltage in use of the polyester in capacitors. On the other hand, in order to improve the slipperiness of polyester film, numerous methods have been proposed which involve adding inorganic particles to the polyester; see JP-A-59-171623. In these methods, not only the electrostatic impression casting property but also uniformity of the protrusions formed on the film surface by inorganic particles are insufficient. The inventors have found that the electrostatic impression casting property is influenced by the quantity of metal present in the region of the surface of the melt polyester sheet which is in contact with the rotating quenching drum, which through extensive research, has led to the present invention. The object of the invention is to provide a composite polyester film having excellent electrostatic impression casting property as well as thermal stability, which comprises: a main layer and a sublayer. Another object of the invention is to provide a composite polyester film having excellent uniformity of thickness, transparency, and fewer fish eyes resulting from polymer gel formed by thermal degradation. Another object of the invention is to provide a composite polyester film having excellent smoothness and suitable slipperiness and a specified amount of inactive particles contained in the polyester of a sublayer. A further object of the invention is to provide a composite polyester film in which numerous protrusions, when numerous inactive particles are contained in the polyester of the sublayer, are formed on the film surface, so as to afford the film excellent smoothness and electromagnetic transfer characteristic . According to one aspect of the invention there is provided a composite polyester film comprising a main layer and a sublayer, the sublayer containing substantially spherical inactive particles selected from colloidal silica and cross-linked polystyrene particles, which particles have a diameter of up to 2.0µm and being made from a polyester having a specific resistance of the polymer in a melt state of less than 5×10 8 Ω·cm and which is lower than that of the main layer, the thickness of the sublayer being 1/200 - 4/10 of the overall thickness of the composite polyester film. Examples of polyester in the present invention include homopolymers such as polyethylene terephthalate, polyethylene-2, 6-naphthalate, polyethylene-1 and 2-bis(2-chlorophenoxy) ethane-4, 4'-dicarboxylate, copolyesters employing ethylene terephthalate as a main repeating unit and copolyesters employing ethylene-2,6-naphthalate as a main unit. It is preferable that the amounts of other dicarboxylic acid and glycol components of the copolyester are not more than 20 mole %. The copolymer components of the polyester are composed of the following acid and diol components: the acid components may be aromatic dicarboxylic acids such as isophthalic acid, aliphatic dicarboxylic acids such as adipic acid, and hydroxycarboxylic acids such as hydroxybenzoic acids; examples of diol components are propylene glycol, trimethylene glycol, neopentyl glycol and 1,4-cyclohexanedimethanol as well as ethylene glycol. The main layer and sublayer of the composite polyester film in this invention may be composed of either the same polyester or different polyesters. The main layer may be further made from either of the polyesters. The specific resistance of the polymer in a melt state in the present invention is measured in the following manner. A measuring apparatus, as shown in Fig 1, can be employed. Polyester 5 to be measured is put into a vessel with a pair of electrodes 6 inserted. This vessel is immersed into a heater 4. The polyester 5 is melted and stored at 280° C under nitrogen atmosphere. Subsequently a voltage is applied from a direct current high voltage generator 1. The specific resistance of the polymer in a melt state can be obtained by putting the values indicated with an ammeter 2 and a voltmeter 3, the electrode area and the distance between the electrodes into the following formula: ρ = V×S I×D ρ: specific resistance of the polymer in a melt state ( Ω·cm) V: applied voltage (V) S: electrode area (cm 2 ) I: measured electric current (A) D: distance between the electrodes (cm) The specific resistance of the polymer in a melt state of the composite polyester film constituting the sublayer in the first aspect of the present invention is less than 5×10 8 Ω·cm, preferably less than 3×10 8 Ω cm and more preferably less than 1×10 8 Ω·cm. When the specific resistance of the polymer in a melt state of the polyester comprising the sublayer is not less than 5×10 8 Ω·cm, the electrostatic impression casting property decreases and waviness (hereinafter referred to as impression irregularities) readily forms on the film so that film forming productivity decreases. When the specific resistance of the polymer in a melt state of the polyester constituting the sublayer is not less than 1×10 7 Ω·cm, the polyester is preferable for thermal stability. When the specific resistance of the polymer in a melt state of the polyester constituting this sublayer is in the range of 0.5×10 8 Ω·cm to 2.0×10 8 Ω·cm, the film is suitable for a base film for use in a magnetic recording medium, particularly for a base film (hereinafter referred to as a base film A) for use in metal evaporated magnetic tape or metal powder magnetic tape. When this specific resistance of the polymer in a melt state is in the range of 0.1×10 8 Ω·cm to 1.0×10 8 Ω·cm, the film is suitable as a base film for use in a capacitor or magnetic recording medium (hereinafter referred to as a base film B). In addition, the specific resistance of the polymer in a melt state of the polyester constituting the main layer may be suitably higher than that of the sublayer. If it is preferably not less than 5×10 8 Ω·cm, and more particularly not less than 1×10 9 Ω·cm, the composite film may have suitably increased thermal stability and decreased fish eyes. The specific resistance of the polymer in a melt state of the polyester is influenced by the species, existing state and amount of the metal compounds. Generally, there is a tendency that the greater the amount of the metal which is solved in the polyester and is not deactivated by phosphorus compounds and the like and the smaller the deposit of metal compound particles in the polyester, the lower the specific resistance of the polymer in a melt state. The relationship between the specific resistance of the polymer in a melt state and the metal will be explained by taking an example of polyethylene terephthalate (PET) obtained by a transesterification method. In transesterification, metal compounds such as alkaline metal compounds, alkaline earth metal compounds, zinc compounds and manganese compounds are normally employed as a reaction catalyst, and a phosphorus compound is further added when the reaction is substantially complete. The metal compound employed as the reaction catalyst is partly inactivated by the phosphorus compound. The reactant thus obtained is subjected to a polycondensation reaction to form PET in the presence of a polycondensation catalyst such as an antimony compound, titanium compound or germanium compound. Normally, PET is prepared in the above manner. The specific resistance of the polymer in a melt state is affected mainly by the alkaline metal compound, alkaline earth metal compound, zinc compound, manganese compound and phosphorus compound. These metal compounds and phosphorus compound are liable to form particles insoluble in the polyester and to decrease thermal stability. The specific resistance of the polymer in a melt state is correlated with the following formula: M + ( A/2 ) - P where M represents the number of moles of alkaline earth metal compound, zinc compound and manganese compound contained in 10 6 g of the polyester, A and P represent the number of moles of alkaline metal compound and phosphorus compound respectively, contained in 10 6 g of the polyester. The higher the value obtained by using the above formula, the greater the improvement in the specific resistance of the polymer in a melt state and the greater the improvement in the electrostatic impression casting property of the polyester. Specifically, the specific resistance of the polymer in a melt state of the polyester constituting the sublayer may preferably satisfy the following formula, M + (A/2) - P ≥ 0.5 and more particularly 10.0 M + (A/2) - P ≥ 0.5 , in which case suitable electrostatic impression casting property and thermal stability can be obtained. Metal compounds controlling the specific resistance of the polymer in a melt state in the present invention may be, for example, aliphatic carboxylates and halides of alkaline earth metals, zinc, manganese, alkaline metal compounds, and glycol-soluble metal compounds of, for example, alcoholates such as methylate, ethylate and ethylene glycolate. The aliphatic carboxylates, halides and glycol-soluble metal compounds may be added in the polyester manufacturing process. Specific examples of such metal compounds are: manganese acetate, magnesium acetate, calcium acetate, zinc acetate, lithium acetate, potassium acetate, sodium acetate, magnesium propionate, manganese propionate, potassium propionate, calcium propionate, zinc propionate, magnesium chloride, lithium chloride, manganese bromide, magnesium hydroxide, manganese hydroxide, calcium hydroxide, zinc hydroxide, lithium hydroxide, magnesium glycolate, calcium glycolate, lithium methylate and butyl potassium, and combinations of two or more of such compounds may also be employed. Particularly, magnesium compounds, manganese compounds and alkaline metal compounds are preferably employed for suppressing formation of the insoluble compounds and decrease in thermal stability. In the transesterification method, these metal compounds may be added as a catalyst before the transesterification, and they may be further added after the transesterification. In trans-esterification, it is preferable that metal compounds are added when the conversion of the esterification reaction reaches preferably not less than 90% and suitably not less than 95%. Phosphorous compounds employed may be at least one compound selected from phosphoric acid, phosphorous acid and esters of those acids. Specific examples of such phosphorus compounds are phosphoric acid, monomethyl phosphate, dimethyl phosphate, trimethyl phosphate, tributyl phosphate, phosphorous acid, trimethyl phosphite and tributyl phosphite. It is necessary that the specific resistance of the polymer in a melt state of the polyester film constituting the sublayer of the composite polyester film is lower than that of the polyester film constituting the main layer of the composite polyester film according to this invention. When the specific resistance of the polymer in a melt state of the sublayer is higher than the specific resistance of the polymer in a melt state of the main layer, the electrostatic impression casting property is low, so that the film forming productivity decreases, whereas if the film forming productivity is increased, impression irregularities would be readily formed and the thickness of the film would become uniform so that the film had insufficient smoothness and low transparency. In addition, it is necessary that the thickness of the polyester constituting the sublayer is 1/200 to 4/10 of the overall thickness of the composite film. When the thickness of the sublayer is less than 1/200, the electrostatic impression casting property decreases. Therefore, the film forming productivity decreases and the impression irregularities occur. Accordingly it is difficult to laminate the layers uniformly. On the other hand, when the thickness of the sublayer exceeds 4/10, the electrostatic impression casting property is improved. However, the thermal stability decreases so that polymer gel formed by thermal degradation is readily formed. In the base film A, the thickness of the sublayer is preferably 1/50 to 3/10, and more preferably 1/20 to 2/10. In the base film B, the thickness of the sublayer is preferably 1/200 to 1/20 and, more preferably 1/200 to 1/50. The thickness of the composite film is not particularly limited; however, it is preferably 0.5 to 100 µm, and more preferably 1 to 80 µm. The sublayer constituting the composite film in the present invention may be laminated on either surface of the main layer or the respective surfaces of the main layer. When the composite film is casted, it is preferable that the sublayer is formed on the casting drum side. The sublayer may be formed on either one surface or respective surfaces of the main layer for use in a magnetic recording medium. However, it is preferable to form the sublayer on either one surface of the main layer, considering electrical properties. In the composite polyester film according to the present invention, substantially spherical inactive particles are added to the polyester constituting the sublayer so as to increase the slipperiness. The composite polyester films suitable for use can be obtained by adjusting the size and content of the inactive particles. In general, the electromagnetic transfer characteristic depends inversely on the smoothness. Therefore, the size and content of the inactive particles may preferably be adjusted depending on the purpose. Now, the base film A, namely the composite polyester suitable for the base film for a magnetic recording medium, particularly the base film for metal evaporated magnetic tape and metal powder magnetic tape, will be described. When 0.001 to 0.5 % by weight of substantially spherical inactive particles is added to the polyester constituting the sublayer of the composite polyester, the average particle diameter being preferably 30mµm to 2.0µm, the smoothness of the film surface will be suitable. In this instance, the thickness of the polyester of the sublayer is 1/200 to 4/10, preferably 1/50 to 3/10, and more preferably 1/20 to 2/10 of the overall film thickness. In addition, the specific resistance of the polymer in a melt state of the polyester constituting the sublayer is preferably less than 5×10 8 Ω·cm and suitably 0.5×10 8 ·Ωcm to 2.0×10 8 Ω·cm. It is preferable that the specific resistance of the polymer in a melt state of the polyester constituting the main layer is higher than that of the sublayer. When this specific resistance of the polymer in a melt state is preferably not less than 5×10 8 Ω·cm, and particularly not less than 10×10 8 Ω·cm, the thermal stability may be sufficiently improved. The average particle diameter of the inactive particles to be added to the sublayer is up to 2.0µm, preferably 30mµm to 2.0µm, and suitably 50mµm to 1.0µm, and particularly 0.01 to 500 mµm. The content of the inactive particles is preferably 0.01 to 0.5 % by weight, and suitably 0.01 to 0.2 % by weight. In this instance, since the composite polyester film is excellent in electrostatic impression casting property, the film forming productivity can be improved and the uniformity of the film thickness is excellent. In addition, such composite polyester film can suppress the formation of fish eyes resulting from the polymer gel formed by thermal degradation. Now, the base film B, namely the composite polyester film for the base film for a magnetic recording medium or capacitor will be described. Inactive particles, the average particle diameter being preferably 30mµm to 1.0 µm and suitably 100 to 600mµm, may be added to the polyester constituting the sublayer of the composite polyester, the amount of inactive particles added being preferably 1.0 to 20 % by weight, and suitably 5 to 15% by weight. In such a case, the relationship between smoothness and the electromagnetic transfer characteristic will be sufficiently suitable. The specific resistance of the polymer in a melt state of the polyester constituting the sublayer is less than 5×10 8 Ω·cm, and suitably 0.1× 10 8 Ω·cm to 1.0×10 8 Ω·cm. In this instance, it is preferable that the specific resistance of the polymer in a melt state of the polyester constituting the main layer is higher than that of the sublayer. When the specific resistance of the polymer in a melt state is less than 5.0×10 9 Ω·cm, such an effect is particularly pronounced. When the sublayer is composed of the polyester having the low specific resistance of the polymer in a melt state and a high concentration of minute particles, numerous protrusions with uniform height can be formed by laminating such sublayers on the polyester of the main layer. Accordingly, the film having improved smoothness and electromagnetic transfer characteristic can be efficiently manufactured. In addition, the thermal stability of the composite film thus obtained is improved so that the formation of gel particles can be suppressed. The shape of the inactive particles is substantially a true sphere in order to maintain the uniformity of the film surface state. The inactive silica particles may be contained in the polyester constituting the main layer for improving slipperiness. However, the content, average particle diameter etc. of the inactive particles are preferably within the ranges of those of the polyester constituting the sublayer. The composite polyester film in the present invention is produced for example in the following ways. Polyester (a) containing substantially spherical inactive particles selected from colloidal silicon and cross-linked polystyrene particles and having a specific resistance of the polymer in a melt state of less than 5X10 8 Ω.cm is compounded with polyester (b) having higher specific resistance of the polymer in a melt state than (a) so as to make the layer formed from (a) occupy 1/200 to 4/10 of the overall thickness. The melt-extruded composite unstretched sheet is electrostatically made adherent to the rotating quenching drum, followed by quenching and solidifying. In another method, polyester (i) contains, in addition to substantially spherical inactive particles, the amounts of such compounds that meet the general formula (I). These compounds include phosphorus compounds, alkaline metal compounds, and at least one species of the compounds selected from magnesium compounds, manganese compounds, zinc compounds and calcium compounds. Polyester (ii) has smaller amount, as determined using the formula [ M + (A/2) -P ], than that of polyester (i). The polyester (i) is compounded with the polyester (ii) to make the layer formed from (i) occupy 1/200 to 4/10 of the overall thickness of the film. Specifically, the polyesters to form the main and the sublayers are melt-extruded to form the composite unstretched sheet. Then, this unstretched sheet is quenched by the rotating quenching drum. The electrostatic impression casting method is employed to increase the adherence of the polyester sheet to the rotating quenching drum. In this instance, the adherence is effectively further improved by contacting the polyester on the sublayer side with the rotating quenching drum. The metal content of the polyester of the sublayer can be suppressed by this method. Accordingly, such a method is more desirable with respect to electrical properties, smoothness of the film surface, thermal stability of the film etc. Embodiments of the invention will now be described in more detail with reference to the accompanying drawing, indicated as Fig. 1, which is a schematic view illustrating an apparatus for measuring the specific resistance of the polymer in a melt state of the polyester, and with reference to the following Examples of the best mode, known to the applicants, for carrying out the invention. The term "part" used in the Examples means "part by weight". The methods for measuring each characteristic are illustrated as follows. (Intrinsic viscosity) o-chlorophenol was employed as solvent, and the measurement was conducted at 25° C. (Softening point) The measurement was conducted using a penetrometer and is indicated by SP (° C) value (Determination of metal element (M,A), phosphorus element and inorganic particles). The measurements were conducted by a known method. Specifically, the metal element and inorganic particles were determined for their respective amounts by atomic absorption spectrometry after the polyester had been wet ashed. Phosphorus element was determined by the molybdenum blue colorimetry method. (Thickness of the laminated layer) Several levels of polyesters having known amounts of metal and phosphorus were prepared in advance. Then, the concentration ratios of respective metal element (M+) and phosphorus element (P+) to carbon element, namely, (M+ / +C ) and (P + / C + ) were measured by the secondary ion mass spectrometry (SIMS) method. Next, the concentration ratios (M+ / C+ ) and (P + / C + ) were measured from the polyester surface layer on the sublayer side in the inner direction of the film. The concentrations of the metal elements and phosphorus element at the respective depths can be obtained by the concentration ratios obtained. The depth measured was obtained by taking the depth of up to 50% of the overall depth of the film. The difference of the concentrations thus measured, namely, (M+ / C+ ) - (P + / C + ) showed a high value at the film surface. This value rapidly decreased when approaching the main surface, after which it reached a constant value. These two inflexion points were connected by a straight line. The midpoint of the length of the straight line to the surface of the sublayer was defined as the thickness of the stack layers. (Thermal stability) The polyester was melted at 300° C under N 2 gas atmosphere. The intrinsic viscosities were measured at 8 and 68 minutes after melting initiation, and the change in intrinsic viscosity (ΔIV) was calculated. The lower the ΔIV, the more excellent the thermal stability. (Average particle size of the inactive particles in the polymer) The average particle size was determined as a median in the cumulative distribution curve by volume measured with an electron microscope, and here the particle size was expressed as the equivalent spherical diameter. The equivalent sphere diameter is the diameter of the sphere having the same particle volume as the volume of the particle. (Electrostatic impression casting property) An electric voltage of 6 KV was applied between the rotating quenching drum and an electrode provided between the extrusion die and the rotating quenching drum. The casting speed (m/min) was gradually increased and measured when impression irregularities formed. The casting speeds were judged by the following criteria: Speeds not lower than second grade were regarded as an acceptable product. not lower than 50m/min 1st grade 40 to 49m/min 2nd grade 30 to 39m/min 3rd grade lower than 30m/min 4th grade (Insulation breakdown voltage) The test was conducted using an a.c. voltage proof tester in accordance with JIS-C-2318. (Fish eyes in the film) By employing a polarizing microscope at 100 magnifications, a bi-oriented film was measured for the positions having stretched fish eye-shaped defects of not less than 0.25µm in height caused by the polymer gel and metal compound foreign particles. The measurements were ranked as follows. rank numbers/100cm 2 1st grade The Nos of fish eyes are less than 10 2nd grade The Nos of fish eyes are 10 to 20 3rd grade The Nos of fish eyes are 21 to 50 4th grade The Nos of fish eyes are not less than 51 1st and 2nd grades were determined as acceptable products. Reference Example 1 (production of polymer I) Bis - (β- hydroxylethyl) terephthalate and its low polymers were obtained by reacting terephthalic acid and ethylene glycol (mole ratio 1.15), and were stored in a melt state in the esterification reaction vessel at 250° C. A slurry was obtained by mixing 86.5 parts of terephthalic acid with 31.7 parts of ethylene glycol (mole ratio 1.15). This slurry was continuously fed for 3.5 hours into the esterification reaction vessel, and was maintained at 250° C. The water formed by the esterification reaction was removed from the reaction mixture through a rectification column. After the supply of the slurry finished, the esterification reaction was further continued for 1.5 hours and was substantially completed. The reaction degree was 98.3%. 104.8 parts of the reaction mixture obtained was transferred to a polycondensation vessel. A solution of 0.013 parts of trimethyl phosphate and 0.5 parts of ethylene glycol were added. Next, 0.015 parts of germanium dioxide were dissolved into 0.015 parts of tetraethyl ammonium hydroxide, subsequently diluted with 0.5 parts of ethylene glycol. This resulting solution was added to the reaction mixture in the condensation reaction vessel, followed by polymerization for 3.0 hours in the conventional method. Polymer I having an intrinsic viscosity of 0.612 was obtained. The phosphorus content in the polymer I was 25 ppm (P=0.81 mol/10 6 g PET). SP was 255.3° C. Reference Example 2 (production of polymer II) 0.04 parts (M=1.86 mol/10 6 g) of magnesium acetate, 0.005 parts (A=0.5 mol/10 6 g) of lithium acetate, 0.02 parts of antimony trioxide were added to a mixture of 99.8 parts of dimethyl terephthalate and 70 parts of ethylene glycol, after which the temperature of the mixture gradually was increased from 145 to 235° C in 3.5 hours. The methanol was removed from reaction mixture and the transesterification reaction was completed. A solution of 0.010 parts of trimethyl phosphate in 0.5 parts of ethylene glycol was added to the reaction product, after which 0.2 parts of cross-linked polystyrene having an average diameter of 180 mµm was added. This resulting mixture was transferred to a polycondensation reaction vessel, and the polymer II was obtained through subsequent polycondensation reaction for 3.0 hours in the conventional method. The intrinsic viscosity of the polymer II thus obtained was 0.608. The phosphorus content was 20 ppm (P=0.65 mol/10 6 g PET). SP was 260.8° C and the average particle diameter was 180 mµm. Reference Example 3 (production of polymer III) 0.056 parts (2.29mol mol/10 6 g) of magnesium acetate and 0.02 parts of antimony trioxide were added to 90 parts of dimethyl terephthalate and 57 parts of ethylene glycol, after which the temperature of the mixture gradually was increased from 145 to 235° C in 3.5 hours. The methanol was distilled and the transesterification reaction was completed. A solution of 0.01 parts of phosphoric acid in 0.1 parts of ethylene glycol was added to the reaction product, subsequently a slurry composed of 10 parts of colloidal silica and 100 parts of ethylene glycol was continuously added in 30 minutes to distill excess glycol. The colloidal silica had an average particle diameter of 300mµm and contained 0.11 parts by weight of sodium. The resulting product was transferred to a polycondensation reaction vessel, and the polymer III was obtained through subsequent polycondensation reaction for 3.0 hours in the conventional method. The intrinsic viscosity of the polymer III thus obtained was 0.591. Phosphorus contents were 25ppm (p=0.81mol/10 6 g). SP was 262.0° C and the average particle diameter was 310 mµm. Reference Example 4 (production of polymer IV) A solution of 0.1 parts of magnesium acetate, 0.1 parts of lithium acetate (A=9.8mol/10 6 ), 0.015 parts of germanium dioxide and 0.015 parts of ammonium hydroxide were added to a mixture of 99.8 parts of dimethyl terephthalate and 70 parts of ethylene glycol, after which the temperature of the mixture gradually was increased from 145 to 235° C in 3.5 hours. The methanol was removed from the reaction mixture and the transesterification reaction was completed. A slurry of 0.7 parts of magnesium acetate (total M=37.29mol/10 6 g) and 3.5 parts of ethylene glycol was added to the reaction product. After 10 minutes, a solution composed of 0.25 parts of trimethyl phosphate and 3.5 parts of ethylene glycol was added, after which 0.2 % by weight of colloidal silica having an average particle diameter of 180mµm was added. The excess ethylene glycol was removed from the reaction mixture, after which the reaction product was transferred to a polycondensation vessel, and the polymer IV was obtained through subsequent polycondensation reaction for 3.0 hours in the conventional method. The intrinsic viscosity of the polymer IV thus obtained was 0.603. The phosphorus content was 420ppm (p=13.56 mol/10 6 g). The SP was 256.5° C and the average particle diameter was 180mµm. Reference Example 5 (production of polymer V) Polymer V was obtained in a way quite similar to Example 2 except that 5.2 parts of colloidal silica having an average particle diameter of 500mµm were substituted for the cross-linked polystyrene having an average particle diameter of 180mµm which was added in Reference Example 2. Reference Example 6 (production of polymer VI) Catalysts composed of 0.06 parts of magnesium acetate (M=2.8 mol/10 6 g), 0.01 parts of lithium acetate (A=0.98mol/10 6 g) and 0.01 parts of antimony trioxides were added to 92 parts of dimethyl 2,6-naphthalenedicarboxylate and 50 parts of ethylene glycol. The temperature of the mixture gradually was increased from 170 to 240° C in 3.5 hours. Methanol was removed from the reaction mixture and the transesterification reaction was completed. A solution of 0.015 parts of trimethylphosphate in 0.5 parts of ethylene glycol were added to the reaction product, and subsequently a slurry composed of 8 parts of colloidal silica and 80 parts of ethylene glycol was continuously added in 30 minutes. The colloidal silica had an average particle diameter of 300mµm and did not contain alkali metal. The excess ethylene glycol was removed from the reaction mixture. The resulting product was transferred to a polycondensation reaction vessel, and the polymer VI was obtained through subsequent polycondensation reaction for 2.5 hours in the conventional method. The intrinsic viscosity of the polymer VI thus obtained was 0.597. The phosphorus content was 30ppm (p=0.97mol/10 6 g). SP was 273.5° C and the average particle diameter was 300mµm. Polymer characteristics of Reference Examples are shown in Table 1. Example 1 Polymer A was obtained by melting polymer I obtained from Reference Example I at 300° C after drying at 160° C for 3 hours. 95 parts of polymer I in Reference Example 1 were mixed with 5 parts of polymer IV in Reference Example 4. This mixture was dried in a similar manner to that stated above, then melted at 300° C by the use of another melt mixture. Thus polymer B was obtained. The above two species of the melt polymer were introduced into a die. A melt composite sheet having a thickness of 150µm ( the ratio of thickness of sublayer to overall thickness =1/10) is formed by respectively laminating polymer A and polymer B as a main layer and a sublayer within a die. When cooling the melt composite sheet with a rotating quenching drum, the polymer B was contacted with the revolving drum, subsequently 6KV of d.c. voltage is applied from a wire electrode from the upper surface of the polymer A, after which the composite sheet was stretched 3.5 times lengthwise and width wise. A biaxially oriented film having a thickness of 12µm was formed by thermal fixing for 15 seconds at 210° C. The compositions of polymers constituting the main layer and the sublayer, and the species, average particle diameter and content of inactive particles are given in Table 2. The electrostatic impression casting property and characteristics of the film obtained are shown in Table 3. Examples 2 to 9 and Comparative Examples 1 to 3 A biaxially oriented film was obtained in a way quite similar to Example 1 except that the thickness ratio of the main layer and the sublayer and the mixing composition of polymers A and B comprising respectively the main layer and the sublayer were changed as illustrated in Tables 2 and 3. As shown in Table 3, when the thickness of the sublayer does not meet the range in accordance with the present invention (comparative example 1), the film formed had not only an insufficient electrostatic impression casting property but also lamination irregularities. In the case of exceeding the range of the thickness of the sublayer in accordance with this invention (comparative Example 2), insulation breakdown voltage decreases and fish eyes increase, resulting in insufficient thermal stability. In addition, when the specific resistance of the polymer in a melt state of polymer B constituting the sublayer was more than the specific resistance of the polymer in a melt state as defined in this invention (comparative example 3), the electrostatic impression casting property is insufficient and many impression irregularities formed. Example 10 and Comparative Examples 4 and 5 A biaxially oriented film as shown in Tables 2 and 3 was obtained in a way quite similar to Example 8 except that polymer I in Reference Example 1 and polymer V in Reference Example 5 were employed as polymers of the main layer and the sublayer respectively. The electrostatic impression casting property and fish eyes of the film were preferable. On the other hand, a biaxially oriented film having a thickness of 12mµm was produced by forming a monolayer composed solely of polymer obtained from Reference Example 1. This oriented film had an insufficient electrostatic impression property and many impression irregularities so that product film could not be obtained (comparative example 4). Further, a biaxially oriented film having a thickness of 12mµm was produced by forming a monolayer composed solely of polymer obtained from Reference Example 5. The biaxially orientated film had insufficient thermal stability and many fish eyes (comparative example 5). Example 11 A biaxially oriented film was obtained in a way quite similar to Example 1 except that the respective polymers constituting a main layer and a sublayer employed the polymers in Reference Examples 1 and 6 respectively, the sublayers being laminated on the respective surfaces of the main layer to occupy respectively a thickness of 1/100 of the main layer (total sublayer thickness=1/50). The electrostatic impression casting property was 2 nd grade and fish eyes were 1 st grade. ΔIV was 0.062. The electrostatic impression casting property and film characteristics were satisfactory. Example 12 A biaxially oriented film was obtained in a way similar to Example 1 except that a main layer was composed of polymer I in Reference Example 1 mixed with polymer IV in Reference Example 4 in the ratio of 98:2 (weight ratio) and a sublayer was composed of polymer III in Reference Example 3, the sublayers being formed on the respective surfaces on the main layer to occupy respectively a thickness of 1/100 of the overall thickness of the composite film. The electrostatic impression casting property and fish eyes were 2 nd grade. ΔIV was 0.065. The electrostatic impression property and film characteristic were satisfactory. The composite polyester film of the present invention is a composite product prepared from polyesters having different specific resistance of the polymer in a melt state, so that the present invention has the following effects. Though the total metal amount is small, specific resistance of the polymer in a melt state is low in the surface of the composite film. The electrostatic impression casting property is extremely preferable. The composite polyester film employed in this invention has a thin sublayer having low specific resistance of the polymer in a melt state. Consequently the total metal amount is small and thermal stability is preferable. Further, when the composite polyester has a specified amount of inactive particles contained in the sublayer, the composite polyester has excellent smoothness and suitable slipperiness. In addition, when the composite polyester film in this invention has a large amount of inactive particles in the sublayer, these particles are abundant only in the surface of the composite film so that the composite polyester film is excellent in the uniformity of the height of protrusions and slipperiness, and also excellent in electromagnetic transfer characteristics as a film for a magnetic recording medium. The composite polyester film of this invention has diversified uses such as a magnetic recording medium, a base film for metal evaporated magnetic tape and base film for metal powder magnetic tape. In its use in capacitors, the composite polyester film of this invention is excellent in insulation breakdown voltage, and particularly useful for a thin layer capacitor.

Claims: A composite polyester film comprising a main layer and a sublayer, which sublayer contains substantially spherical inactive particles selected from colloidal silica and cross-linked polystyrene particles, which particles have a particle diameter of up to 2.0µm, wherein the specific resistance of the polymer in a melt state of the polyester constituting the sublayer is less than 5x10 8 Ω.cm and is lower than the specific resistance of the polymer in a melt state of the polyester constituting the main layer, and the thickness of the sublayer is from 1/200 to 4/10 of the overall thickness of the composite film. A composite polyester film comprising a main layer and a sublayer, wherein the sublayer is composed of polymer containing (1) substantially spherical inactive particles selected from colloidal silica and cross-linked polystyrene particles, which particles have a particle diameter of up to 2.0µm, (2) a phosphorus compound, (3) an alkaline metal compound, and (4) at least one metal compound selected from magnesium compounds, manganese compounds, zinc compounds and calcium compounds, the amounts of the respective compounds satisfying the following formula (I): M + ( A/2 ) - P ≥ 0.5 wherein M is the total number of moles of magnesium compound(s), manganese compound(s), zinc compound(s) and calcium compound(s) contained in 10 6 g of the polyester; A is the number of moles of alkaline metal compound(s) contained in 10 6 g of the polyester; P is the number of moles of phosphorus compound(s) contained in 10 6 g of the polyester; the amount of the respective compounds, determined by the said formula [ M + (A/2)-P ], contained in the polyester constituting the sublayer is higher than that amount in the polyester constituting the main layer, and the thickness of the sublayer is from 1/200 to 4/10 of the overall thickness of the composite film. A composite polyester film according to Claim 1 or 2, wherein the inactive particles have a particle diameter of from 30nm to 2.0µm. A composite polyester film according to any preceding claim wherein the inactive particles are present in the polyester constituting the sublayer in an amount of from 0.001 to 0.5% by weight of the said polyester. A composite polyester film according to Claim 1, 2 or 3, wherein the inactive particles are present in the polyester constituting the sublayer in an amount of from 1.0 to 20% by weight of the said polyester and have an average particle diameter of 30mµm to 1.0µm. A method of preparing a composite polyester film comprising the steps of: compounding a polyester (a) containing substantially spherical inactive particles selected from colloidal silica particles, which particles have a particle diameter of up to 2.0µm and having a specific resistance of the polymer in a melt state of less than 5x10 8 Ω.cm with a polyester (b) having a higher specific resistance of the polymer in a melt state than that of (a) to form a melt-extruded unstretched sheet, the thickness of the layer composed of the polyester (a) being from 1/200 to 4/10 of the overall thickness of the composite film; electrostatically adhering the melt-extruded unstretched sheet to a rotating quenching drum; and quench-solidifying the sheet. A method of preparing a composite polyester film comprising the steps of: compounding a polyester (i) with a polyester (ii) to form a melt extruded sheet. the polyester (i) containing (1) substantially spherical inactive particles selected from colloidal silica and cross-linked polystyrene particles, which have a diameter of up to 2.0µm, (2) a phosphorus compound, (3) an alkaline metal compound, and (4) at least one metal compound selected from magnesium compounds, manganese compounds, zinc compounds and calcium compounds, the amounts of the respective compounds satisfying the general formula (I) shown below, M + ( A/2 ) - P ≥ 0.5 wherein M is the total number of moles of magnesium compound(s), manganese compound(s), zinc compound(s) and calcium compound(s) contained in 10 6 g of the polyester; A is the number of moles of alkaline metal compound(s) contained in 10 6 g of the polyester; P is the number of moles of phosphorus compound(s) contained in 10 6 g of the polyester; the amount of the respective compounds, as determined by equation M + (A/2)-P , in the polyester (ii) being less than that in the polyester (i) as determined by equation M + (A/2)-P , and the thickness of the layer of the polyester (i) being 1/200 to 4/10 of the overall thickness of the composite film; adhering said melt-extruded unstretched sheet to a rotating quenching drum electrostatically; and quench-solidifying the said sheet. A method according to claim 6 or 7, wherein the polyester composing the sublayer which constitutes the composite unstretched sheet is adhered to the rotating quenching drum.

Inventors: MORITA TOHRU, NAGAHAMA AKIHIKO, ONO MASAAKI, UEDA TOSHIAKI, MORITA, TOHRU, NAGAHAMA, AKIHIKO, ONO, MASAAKI, UEDA, TOSHIAKI
Applicants: TORAY INDUSTRIES, TORAY INDUSTRIES, INC.
Application year: 1990
Main classification: B32B27
IPC codes: B29C47, B32B27, G11B5