Ultra thin polymer film electret and method of manufacturing the same

Abstract: The invention concerns an ultra thin polymer film electret (7) comprising a polymer and a substrate (3) having a surface electric charge, wherein a side chain of the polymer and the substrate (3) are physically or chemically bonded. A method of manufacturing an ultra thin polymer film electret (7) comprising: adsorbing a monomolecular film comprising a unsaturated group or a laminated film comprising the monomolecular film on to a substrate surface, irradiating the monomolecular film or the laminated film with an energy beam to polymerize the unsaturated groups and applying a high voltage to the film is also disclosed. Further, a method of manufacturing an ultra thin polymer film electret (7) comprising: physically bonding a side chain of the polymer to a substrate surface to form a thin film and applying a high voltage to the thin film is also disclosed.

Description: The present invention relates to a monomolecular or monomolecular laminated polymer film electret having a dipole. In the past, in manufacturing an ultra thin polymer film electret, a thin polymer film was formed by a melt extrusion method, a coating method, a physical deposition method and by applying an electric field directly to the thin polymer film together with light, heat or mechanical strength. In the prior art, a thin polymer film having a thickness of about a dozen µm was formed. However, the orientation at the molecular level was not high. For that character of the thin polymer film it was difficult to obtain an electret which had a sufficient surface electric charge even though high voltage was applied. In the prior method of forming a thin polymer film, it was also difficult to control the thickness of the film at the molecular level. Thus, if the thickness of the film was only at the molecular level, it could not be applied uniformly thin. The result was that the film had pin-holes and an island-state structure. Further, in order to control orientation of a polymer, a film was drawn. However, in that case, there was a limitation as to how thin a film could be drawn, and the orientation of molecules could not be controlled sufficiently. Thus, in the prior art, only an electret which had a film layer more than about several hundred to several thousand angstroms in thickness could be obtained. In addition, the orientation of molecules was not high. Thus, if the thickness of the film was decreased, the surface electric charge became small. JP-A-1232038 discloses an electret-converted high polymer sheet composed of a high polymer sheet and a film of e.g. a silane compound of crosslinked structure, said film having a thickness of from 0.03 to 0.5 µm. The film is provided by a coating process. JP-A-1010611 discloses a method for producing capacitors using the LB-method. The object of the present invention was to provide ultra thin polymer film electrets which are much thinner than prior polymer electrets and also have a sufficient surface electric charge. This object has been solved by providing the following polymer film electrets (a) and (b) described below. (a) A monomolecular polymer film electret, obtainable by: (1) adsorbing a monomolecular film onto a substrate surface by dehydrochlorination reaction of an active hydrogen group on the substrate surface, and a chloro group in a polymerizable compound comprising an unsaturated group and at least one group selected from the group consisting of a chlorosilyl group, a chlorotitanyl group and a chlorostannyl group, (2) irradiating the surface of the thus formed monomolecular film with an energy beam to polymerize the unsaturated groups, and (3) applying an electric field of 10 4 to 10 7 V/cm to said film. It is preferable that the bonds between the substrate and the monomolecular film are selected from the group consisting of -SiO-, -TiO- and -SnO- bonds. It is preferable that the substrate is selected from quartz glass, fluoride glass, metallic glass, aluminum, iron, stainless steel, titanium, silicon and germanium. (b) A monomolecular laminated polymer film electret, obtainable by: (1) adsorbing a monomolecular film onto a substrate surface by dehydrochlorination reaction of an active hydrogen group on the substrate surface, and a chloro group in a polymerizable compound comprising an unsaturated group and at least one group selected from the group consisting of a chlorosilyl group, a chlorotitanyl group and a chlorostannyl group, (2) substituting the unsaturated group of the thus formed monomolecular film by an active hydrogen group, (3) adsorbing a further monomolecular film onto the previously formed monomolecular film by dehydrochlorination reaction of said substituted active hydrogen group on the surface of the previously formed monomolecular film, and a chloro group in a polymerizable compound comprising an unsaturated group and at least one group selected from the group consisting of a chlorosilyl group, a chlorotitanyl group and a chlorostannyl group, (4) optionally repeating steps (2) and (3) at least once, (5) irradiating the surface of the thus formed monomolecular laminated film with an energy beam to polymerize the unsaturated groups, and (6) applying an electric field of 10 4 to 10 7 V/cm to said film. It is preferable that the bonds between the substrate and the monomolecular film and the bonds between the monomolecular films are selected from the group consisting of -SiO-, -TiO- and -SnO- bonds. It is preferable that the substrate is selected from quartz glass, fluoride glass, metallic glass, aluminum, iron, stainless steel, titanium, silicon and germanium. In the invention, the side chain of the polymer has a high orientation at the molecular level. For the above reason, the dipole of the whole film can be made uniform and thus can provide an electret which has a high surface electric charge. In the invention, the ultra thin polymer film electret is formed by adsorbing at least one monomolecular film onto a substate surface. According to the invention, an ultra thin polymer film having a high orientation is formed by a chemical adsorption method. The ultra thin polymer film electret is formed by converting the film to an electret. Thus, according to the invention, there is a practical merit to form an ultra thin polymer film electret having an ultra thin film thickness and also a sufficient surface electric charge. Figure 1 shows an ultra thin polymer film electret in an example of the invention. Figure 2 shows a chemical adsorption step in an example of the invention. Figure 3 shows a chemically adsorbed monomolecular film in an example of the invention. Figure 4 shows a polymerization step of a molecular film in an example of the invention. Figure 5 shows a voltage-applying step in an example of the invention. The invention relates to an ultra thin polymer film electret which has a sufficient surface electric charge. According to the invention, e.g. a monomolecular film comprising an adsorptive reagent is formed on a substrate using e.g. trichlorosilane as an adsorptive reagent. After, for example, irradiating the monomolecular film with an electron beam of about 10 Mrads, for example, applying a 200 KeV/cm electric field at 120 °C, an ultra thin monomolecular polymer film electret having a dipole was formed. An electret which has a high surface electric charge can be obtained by converting an ultra thin polymer film having a high orientation into an electret. An adsorbing molecule which can be used for the chemical adsorption method comprises at least a chloro group which reacts with an active hydrogen, and a polymerizable unsaturated group. A compound having an active chloro group such as a chlorosilyl group, a chlorotitanyl group or a chlorostannyl group is preferably used. A vinylene group or an ethynylene group is used as a polymerizable unsaturated group. Any substrate which has an active hydrogen group such as -OH group, -COOH group, >NH group, -NH 2 group on its surface can be used for the chemical adsorption method. For example, glass such as quartz glass, fluoride glass, metallic glass and metallic materials such as aluminum, iron, stainless steel and titanium and semiconductor materials such as silicon and germanium are used as a substrate for the chemical adsorption method. A substrate which has few active hydrogen groups on its surface can be made into an appropriate substrate by increasing the numbers of active hydrogen groups on its surface by conventional chemical treatment such as by ozone oxidation or irraddiating it with an electron beam. The molecules to be chemically adsorbed can be used alone or they can be diluted with a solvent. Any solvent which is a non-aqueous organic solvent containing as little moisture as possible to prevent the molecules from reacting with the hydroxyl groups and to not substantially corrode the substrate and to dissolve the adsorbing molecule sufficiently can be used. Examples of organic solvents are long chain alkyl-based solvents, aromatic hydrocarbon-based solvents, aliphatic hydrocarbon-based solvents and halogen-containing solvents. In adsorbing a monomolecular film or a laminated film onto a substrate by a chemical adsorption method, a film is chemically bonded to a substrate and the thermomechanical stability of the film is increased and a substantially pin-hole free film can be formed. The orientation of film molecules can be controlled and at the same time the film has a voltage-proof property and a high voltage can be applied to the film. Thus, according to the invention, an electret having a sufficient surface electric charge can be provided. A monomolecular film can be formed easily by washing with a non-aqueous organic solution such as chloroform to remove unreacted adsorbing molecules after the adsorption step. A monomolecular film or a monomolecular laminated film of an ultra thin polymer film electret is excellent for controlling the orientation of molecules. It is preferable in the invention to achieve an electret which has sufficient surface electric charge by controlling the orientation of the molecules. According to the invention, an energy beam which is used for polymerization depends on the molecules of the film. Particularly, it depends on the kinds and numbers of the polymerizable unsaturated groups. Examples of those are X-rays, electron beams, ultraviolet rays, and gamma rays. The strength of the energy beam also depends on the molecules of the film or the unsaturated groups. High voltage is applied to a film in order to provide a surface electric charge. The strength of the direct electric field depends on the molecules of the film. According to the invention, a monomolecular film or a laminated film, which is formed by the above mentioned chemical adsorption method, has a high orientation at the molecular level as a chain portion of the polymer is filled densely on the surface substrate. Thus, an ultra thin polymer layer electret, having a thickness on the molecular order, which has sufficient electric charge, can be formed. In addition, since the chemical adsorption polymer film is an ultra thin film, in the order of nanometers or Angstroms, it does not spoil the characteristics of the substrate such as mechanical strength. Subsequently, a detailed description of the invention will be described with concrete examples. Example 1 The case of forming a polymer ultra thin film by a chemical adsorption method will described. A chemical adsorption step is illustrated in Figure 2. Nonadecenyl trichlorosilane comprising a vinyl group as a polymerizable unsaturated group was used as an adsorbing reagent 1. It was dissolved in a non-aqueous organic solvent 2 containing 10 mmol/ℓ of nonadecenyl trichlorosilane. The non-aqueous organic solvent 2 contains 80 % by weight of normal hexadecane, 12 % by weight of chloroform and 8 % by weight of carbon tetrachloride. The substrate 3 was dipped and held in the solution at 30 °C to start the chemical adsorption reaction. An aluminum substrate was used in the example of the invention as substrate 3. The substrate 3 was dipped and held in the solution for about five hours and washed with a non-aqueous organic solution, followed by washing with pure water, thus, the monomolecular film 4 illustrated in Figure 3 was formed. As illustrated in Figure 4, a vinyl group was polymerized by irradiating the chemically adsorbed monomolecular film above with an electron beam 5 of about 5 Mrads in a vacuum atmosphere at normal temperature. According to an analysis of the pre-polymerized chemically adsorbed monomolecular film 4 and the polymerized film 6 by FT-IR, the vinyl group vanished after irradiating with the electron beam 5 and polymerization of the vinyl group was confirmed. As illustrated in Figure 5, an electric field of 200 kV/cm was applied to the polymerized film 6 at 120 °C. Thus, an ultra thin polymer film electret 7, illustrated in Figure 1, was formed. The formed ultra thin polymer film electret had a surface electric charge of about 10 -8 C/cm 2 . The formation of the chemically adsorbed polymer film was measured by FTIR. The thickness was about 2.3 nanometers (nm) by ESCA. In the example of the invention, nonadecenyl trichlorosilane was used as an adsorbing reagent. The ultra thin polymer film electret was formed by experiments with the same condition except using nonadecenyl methyldichlorosilane or nonadecenyl dimethylchlorosilane or nonadecenyl trichlorotitanium or nonadecenyl trichlorostannum as an adsorbing reagent. Example 2 Subsequently, the example of forming a chemically adsorbed laminated film will be described. In the example of the invention, 18-dimethylsilyl-14-octadecenyltrichlorosilane which has a vinyl group as an unsaturated group was used as an adsorbing reagent. The same kind of non-aqueous organic solvent as in Example 1 comprising 10 mmol/ℓ of 18-dimethylsilyl-14-octadecenyltrichlorosilane was used. An aluminum substrate was dipped and held in the solution at 30 °C to start the chemical adsorption reaction for about five hours and washed with chloroform as in Example 1, followed by washing with pure water. Subsequently, a substrate comprising the chemically adsorbed monomolecular film was dipped and held in a methanol solvent containing 2.5 % by weight of tetramethylammonium hydroxide solution for three hours. Thus after forming hydroxyl groups at the molecular ends to treat the substrate for lamination, the above mentioned chemical adsorption reaction was made to form a second layer molecular film and was, therefore, laminated. Repeating the above mentioned laminating steps, 10 layers of laminated film were formed. The vinyl groups were polymerized by irradiating the thus formed laminated film with an electron beam of about 10 Mrads in a vacuum atmosphere at normal temperature. According to an analysis of the pre-polymerized laminated film and the laminated film by FT-IR, the vinyl group vanished and polymerization of the vinyl group was confirmed. At the final step, a high electric field of 200 kV/cm at 120 °C was applied to the laminated film and an ultra thin polymer film electret was formed. The thus formed ultra thin polymer film electret had about a 10 -7 C/cm 2 surface electric charge. The formation of the chemically adsorbed polymer film was measured by FTIR. The thickness was about 25 nanometers (nm) by ESCA. According to the example of the invention, polymerization was initiated after forming the laminated film. However, the same kind electret was formed after each film layer was adsorbed. Comparative example 1 An electret having about a 10 -8 C/cm 2 surface electric charge was formed by irradiating a polytetrafluoroethylene film having a 10 µm thickness with an electron beam of 20 kV for several seconds at an electric current density of 0.05 µA/cm 2 . According to the invention, the ultra thin polymer film electret had a thickness of about 1/1000 as that of prior electrets. The ultra thin polymer film electret of the invention had the same amount of surface electric charge as that of prior electrets. The laminated form of the ultra thin polymer film electret had a greater surface charge than that of prior electrets. The ultra thin polymer film electret in the example of the invention is put to practical use in the manufacture of super small-size microphones and speakers and motors. Further, the ultra thin polymer film electret in the invention is put to practical use in manufacturing small-size transformer devices utilizing electric proof property and artificial blood vessels in which blood is not substantially congealed. As has been shown, the invention is greatly beneficial to industry.

Claims: A monomolecular polymer film electret, obtainable by: (1) adsorbing a monomolecular film onto a substrate surface by dehydrochlorination reaction of an active hydrogen group on the substrate surface, and a chloro group in a polymerizable compound comprising an unsaturated group and at least one group selected from the group consisting of a chlorosilyl group, a chlorotitanyl group and a chlorostannyl group, (2) irradiating the surface of the thus formed monomolecular film with an energy beam to polymerize the unsaturated groups, and (3) applying an electric field of 10 4 to 10 7 V/cm to said film. A monomolecular laminated polymer film electret, obtainable by: (1) adsorbing a monomolecular film onto a substrate surface by dehydrochlorination reaction of an active hydrogen group on the substrate surface, and a chloro group in a polymerizable compound comprising an unsaturated group and at least one group selected from the group consisting of a chlorosilyl group, a chlorotitanyl group and a chlorostannyl group, (2) substituting the unsaturated group of the thus formed monomolecular film by an active hydrogen group, (3) adsorbing a further monomolecular film onto the previously formed monomolecular film by dehydrochlorination reaction of said substituted active hydrogen group on the surface of the previously formed monomolecular film, and a chloro group in a polymerizable compound comprising an unsaturated group and at least one group selected from the group consisting of a chlorosilyl group, a chlorotitanyl group and a chlorostannyl group, (4) optionally repeating steps (2) and (3) at least once, (5) irradiating the surface of the thus formed monomolecular laminated film with an energy beam to polymerize the unsaturated groups, and (6) applying an electric field of 10 4 to 10 7 V/cm to said film. The monomolecular polymer film electret according to claim 1, wherein the bonds between the substrate and the monomolecular film are selected from the group consisting of -SiO-, -TiO- and -SnO- bonds. The monomolecular laminated polymer film electret according to claim 2, wherein the bonds between the substrate and the monomolecular film and the bonds between the monomolecular films are selected from the group consisting of -SiO-, -TiO- and -SnO- bonds. The monomolecular polymer film electret according to claim 1, wherein said substrate is selected from quartz glass, fluoride glass, metallic glass, aluminum, iron, stainless steel, titanium, silicon and germanium. The monomolecular laminated polymer film electret according to claim 2, wherein said substrate is selected from quartz glass, fluoride glass, metallic glass, aluminum, iron, stainless steel, titanium, silicon and germanium.

Inventors: MINO NORIHISA, OGAWA KAZUFUMI, YAMAGATA YOSHIKAZU, MINO, NORIHISA, OGAWA, KAZUFUMI, YAMAGATA, YOSHIKAZU
Applicants: MATSUSHITA ELECTRIC IND CO LTD, MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.
Application year: 1992
Main classification: H01G7
IPC codes: B29L9, C08J5, H01G7, B29L31, B29C41, C08J7