Chemically adsorbed film and method of manufacturing the same

Abstract: A highly dense chemically adsorbed film is formed by repeating the alternate process of adsorption reaction and washing. Adsorption reaction is directed by contacting the substrate surface, which has or is given an alkali metal or a functional group, with a chemical adsorbent, having halosilyl or alkoxysilyl groups at the end of molecules. An unreacted chemical adsorbent is then washed away from the substrate surface. The alternate treatment of adsorption reaction and washing is repeated, thereby covalently bonding a chemically adsorbed film to the substrate surface. As a result, a chemically adsorbed film is formed in which stem molecules are directly or indirectly covalently bonded to the substrate surface via at least one element chosen from the group consisting of Si, Ge, Sn, Ti, Zr, S or C and graft molecules are covalently bonded to at least one element chosen from Si, Ge, Sn, Ti, Zr, S or C via at least one bond chosen from -SiO-, -GeO-, SnO-, -TiO-, ZrO-, -SO₂-,-SO- and -C-.

Description: The invention relates to a chemically adsorbed film and method of manufacturing the same; more particularly, the invention relates to a chemically adsorbed film and its method of manufacture, in which the molecules are, as a whole, densely connected to the substrate surface by chemically bonding graft molecules to chemically adsorbed stem molecules. Conventional methods used for manufacturing chemically adsorbed film include the procedure mentioned, for example, on page 92, volume 102 of the Journal of the American Chemical Society (J. Sagiv et al., Journal of the American Chemical Society, 92, 102 (1980)) and page 851 of the sixth volume of Langmuir (K. Ogawa et al., Langmuir, 6, 851 (1990)). In this method, a chemically adsorbed film is manufactured by a dehydrochlorination reaction between groups exposed on a substrate surface, such as hydroxyl groups, and a chlorosilane-based surface active material. The adsorption reaction is carried out for many hours until it reaches the point of saturation adsorption. To form one chemically adsorbed film, an adsorption reaction, a washing and a rinsing are performed once. However, the above-noted method is limited in improving film density; the number of functional groups of the group itself sets an upper limit on the site number for the adsorption reaction of chemically adsorbed material. As a result, based on the above-noted method, there is a problem that film density can not be improved even by significantly lengthening the time for adsorption reaction. The method of building up chemical admolecules on a chemically adsorbed film (USP-4, 673, USP-4, 992, 300) is also known as a conventional method. However, it is difficult to increase the density of molecules on the substrate surface using this method. The object of the invention is to provide a chemically adsorbed film with improved film density, while detailing its method of manufacture, thereby solving the above-noted problems. This object is achieved by a chemically adsorbed film, formed by covalent bonding of stem molecules to active hydrogens or alkali metals on the surface of a substrate via at least one element chosen from Si, Ge, Sn, Ti, Zr, S or C. Graft molecules are covalently bonded to said at least one element chosen from Si, Ge, Sn, Ti, Zr, S or C via at least one bond chosen from -SiO-, -GeO-, -SnO-, TiO-, ZrO-, -SO 2 -, -SO- and -C-. In the above-noted composition, it is preferable that direct or indirect covalent bonding between stem molecules and the substrate surface employs at least one bond chosen from the following: -SiO-,-SiN-, -GeO-, -GeN-, -SnO-, -SnN-, -TiO-, -TiN-, -ZrO- and -ZrN-. In the above-noted composition, it is preferable that a stem or graft molecule contains a hydrocarbon chain, a fluorocarbon chain, an aromatic group or a heterocyclic group. In the above-noted composition, it is preferable that an unsaturated bond is included in a stem or graft molecule. In the above-noted composition, it is preferable that a chemically adsorbed film is a monomolecular chemically adsorbed built-up film. The method of manufacturing a chemically adsorbed film of the invention, which is the method of bonding graft molecules to stem molecules, comprises the following procedures: (1) directly or indirectly contacting the chemical admolecules, containing functional groups as shown in formula [A] or formula [B] at the end of molecules, with the substrate surface, which either has or is given active hydrogens or alkali metals on the surface, thereby covalently bonding the chemical admolecules, stem molecules, to the substrate surface by condensation reaction; removing unreacted chemical admolecules; reacting the substrate surface with water, thereby substituting the halogen or alkoxyl group, or both, to a hydroxyl group. Formula [A] is provided as seen below: -AX m where X represents halogen, A represents Si, Ge, Sn, Ti, Zr, S or C, m represents 2 or 3. Formula [B] is represented by: -A(Q) m where Q represents an alkoxyl group, A represents Si, Ge, Sn, Ti, Zr, S or C, m represents 2 or 3. The method additionally comprises contacting the substrate surface with chemical admolecules containing at least one functional group at the end of molecules, chosen from formulas [C] through [G], thereby creating a condensation reaction; removing unreacted chemical admolecules; reacting the substrate surface with water. Formula [C] is designated: -AX n where X represents halogen, A represents Si, Ge, Sn, Ti, Zr, S or C n represents 1, 2 or 3. Formula [D] is designated: -A(Q) n where Q represents an alkoxyl group, A represents Si, Ge, Sn, Ti, Zr, S or C, n represents 1, 2 or 3. Formula [E] is designated: -SO 2 X where X represents halogen. Formula [F] is represented by: -SOX where X represents halogen. Formula [G] is denoted by: >N-CHO or -OCHO In the above-noted composition, it is preferable that unreacted chemical admolecules are removed by a nonaqueous solution. In the above-noted composition, it is preferable that either liquid water or steam is used in the process of reacting stem or graft molecules with water. In the above-noted composition, it is preferable that the chemical adsorbent, which contains trichlorosilane-based ends, is used as stem or graft molecules. In the above-noted composition, it is preferable that the condensation reaction due to the contact with stem or graft molecules is a dehydrochlorination, alcohol elimination or water elimination reaction. In the above-noted composition, it is preferable that a hydrocarbon chain, a fluorocarbon chain, an aromatic group or a heterocyclic group is included in stem or graft molecules. In the above-noted composition, it is preferable that an unsaturated bond is included in stem or graft molecules. Based on this invention, the density of a chemically adsorbed film is improved by increasing the number of admolecules. More specifically, the number of admolecules can be increased by the rise in the site number, which is promoted by introducing graft molecules to the roots of stem molecules. In addition, it is possible that graft molecules are directly bonded to the substrate. Based on the preferable composition of the invention, direct or indirect covalent bonding of stem molecules to the substrate surface employs at least one bond chosen from -SiO-, -SiN-, -GeO-, -GeN-, -SnO-, -SnN-, -TiO-, -TiN-, -ZrO- and -ZrN-, thus allowing a molecular adsorption film to become chemically stable. In a preferable composition of the invention - with an unsaturated bond in the hydrocarbon chain of stem or graft molecules - it is possible to polymerize stem and/or graft molecules or to introduce another molecule after the formation of a chemically adsorbed film. It is preferable that the unsaturated bond is e.g. the double bond of carbon-carbon (C=C), the double bond of carbon-nitrogen (C=N), the triple bond of carbon-carbon (C≡C), or the triple bond of carbon-nitrogen (C≡N). Furthermore, a preferable composition of the invention is a chemically adsorbed film and a monomolecular chemically adsorbed built-up film, whereby a film with increased molecular density is formed. In the method of manufacturing a chemically adsorbed film of the invention, said film with improved film density efficiently may be formed by increasing the number of admolecules, which is made possible by increasing the site number. Moreover, this method can reduce the reaction time. According to a preferable composition of the invention, the unreacted chemical admolecules are removed by a nonaqueous solution, and a film with a thickness at an angstrom or nanometer level is uniformly formed over the substrate surface. In a preferable composition of the invention, stem or graft molecules are reacted with liquid water or steam, a halogen atom can be substituted for a hydroxyl group quite efficiently. The above-noted method of using the chemical adsorbent with trichlorosilane ends as the stem or graft molecules is quite practical, providing a high adsorption reaction. A preferable composition of the present invention comprises a condensation reaction due to the contact with stem or graft molecules in a dehydrochlorination, alcohol elimination or water elimination reaction, whereby a high reaction rate is possible. Figure 1 is a model view, enlarged to a molecular level, showing the substrate of one example according to the invention. Figure 2 is a model view, enlarged to a molecular level, showing the chemically adsorbed monomolecular film of the example according to the invention. Figure 3 is a model view, enlarged to a molecular level, showing another chemically adsorbed monomolecular film of the example according to the invention. Figure 4 is a model view, enlarged to a molecular level, showing the chemically adsorbed monomolecular film of another example according to the invention. Figure 5 is a model view, enlarged to a molecular level, showing another chemically adsorbed monomolecular film of the example according to the invention. Figure 6 is a model view, enlarged to a molecular level, showing the chemically adsorbed monomolecular film of another example according to the invention. The method of manufacturing a chemically adsorbed film of the invention comprises fixing a chemical adsorbent to a substrate and chemically adsorbed film by repeating the alternate process of adsorption reaction and washing. Particularly, even in case the first adsorption reaction process is not completely directed without reaching the stage of saturated adsorption, the number of -OH groups is increased. This result is obtained by removing unreacted molecules with a nonaqueous solvent and by washing the substrate, which has only scattered admolecules on its surface, with water. After the second adsorption reaction, more than two admolecules are found where only one admolecule was originally contained. In this process, the distance between admolecules is decreased mutually and uniformly, thereby increasing the film density. However, if the time spent for the adsorption reaction is too short, the adsorbed molecules will be scattered over the substrate at wide distances from one another. As a result, the admolecules can bend, become parallel to the substrate, or cover the original sites for adsorption. In order to prevent such undesirable results, more than several minutes are required for the adsorption reaction. Under standard reaction conditions, however, it is quite likely that the reaction rate is too fast to enable control of the time for adsorption reaction. In this case, the association or collision rates between the reactive groups of the chemical adsorbent and the active hydrogen groups of a substrate can be reduced by lowering the temperature of the reaction or the concentration of adsorbent; as a result, the time for the reaction is extended and thus becomes quite manageable. In this invention, a chemical adsorbent may be provided as recited below: a molecule in which a halosilyl group as shown in formula [C] is bonded to the end of molecule - containing e.g. a hydrocarbon chain, a fluorocarbon chain, an aromatic ring, a heterocyclic ring, or a metal; a molecule in which an alkoxysilyl or aldehydesilyl group as shown in formula [D] is bonded to the end of molecule - containing e.g. a hydrocarbon chain, a fluorocarbon chain, an aromatic ring, a heterocyclic ring, or a metal; a molecule in which at least one functional group chosen from halogenated sulfonyl groups as shown in formulas [E] and [F] and an aldehyde group as shown in formula [G] is bonded to the end of molecules - containing e.g. a hydrocarbon chain, a fluorocarbon chain, an aromatic ring, a heterocyclic ring, or a metal. However, it is preferable that a halosilyl group is either a dihalosilyl or a trihalosilyl group. Similarly, an alkoxysilyl group should be either a dialkoxysilyl or a trialkoxysilyl group. In terms of reactivity, Cl is preferred to Br or I as a halogen. However, a similar chemically adsorbed film can be formed even with Br or I. When the adsorption reaction is carried out more than once, the kind of chemical adsorbent can be changed each time. In spite of the fact that the film density is affected by the change of adsorbent, the density can be controlled in many cases. The increase or control of film density is applicable not only to the case of forming one film on the substrate but to forming a multilayer film on the existing chemically adsorbed film. The following can be used as chemical adsorbents in this invention: (1) trichlorosilane-based surface active materials including CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl 3 , CF 3 CH 2 O(CH 2 ) 15 SiCl 3 , CF 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 15 SiCl 3 , CF 3 (CH 2 ) 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl 3 , CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl 3 , CF 3 COO(CH 2 ) 15 SiCl 3 , or CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl 3 (2) monochlorosilane-based surface active materials, whose lower alkyl groups are substituted, or dichlorosilane-based surface active materials including CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl n (CH 3 ) 3-n , CF 3 (CF 2 ) 7 (CH 2 ) 2 SiCl n (C 2 H 5 ) 3-n , CF 3 CH 2 O(CH 2 ) 15 SiCl n (CH 3 ) 3-n , CF 3 CH 2 O(CH 2 ) 15 SiCl n (C 2 H 5 ) 3-n , CF 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 15 SiCl n (CH 3 ) 3-n , CF 3 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 15 SiCl n (C 2 H 5 ) 3-n , CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl n (CH 3 ) 3-n , CF 3 (CF 2 ) 7 (CH 2 ) 2 Si(CH 3 ) 2 (CH 2 ) 9 SiCl n (C 2 H 5 ) 3-n , CF 3 COO(CH 2 ) 15 SiCl n (CH 3 ) 3-n , CF 3 COO(CH 2 ) 15 SiCl n (C 2 H 5 ) 3-n , CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl n (CH 3 ) 3-n , or CF 3 (CF 2 ) 5 (CH 2 ) 2 SiCl n (C 2 H 5 ) 3-n , where n represents 1 or 2. In particular, trichlorosilane-based surface active materials, in which adjacent molecules form siloxane bonds, are preferable for obtaining a stronger chemically adsorbed film. Moreover, CF 3 (CF 2 ) n CH 2 CH 2 SiCl 3 (where n represents an integer, preferably between about 3 and 25) is preferable since it is balanced with e.g. the dissolution property, chemical adsorption property, water- and oil-repelling property, and anticontamination property. By incorporating an unsaturated bond into an alkyl or alkyl fluoride chain, a bridge formation can be formed by irradiation with an electron beam at only about 5 Mrads, after formation of a chemically adsorbed film; as a result, the hardness of the film can be improved. Trichlorosilane-based surface active materials, such as the following: CH 3 (CH 2 ) 18 SiCl 3 , CH 3 (CH 2 ) 15 SiCl 3 , CH 3 (CH 2 ) 10 SiCl 3 or CH 3 (CH 2 ) 25 SiCl 3 , and monochlorosilane-based materials, whose lower alkyl groups are substituted, or dichlorosilane-based surface active materials, such as the following: CH 3 (CH 2 ) 18 SiCl n (CH 3 ) 3-n , CH 3 (CH 2 ) 18 SiCl n (C 2 H 5 ) 3-n , CH 3 (CH 2 ) 15 SiCl n (CH 3 ) 3-n , CH 3 (CH 2 ) 10 SiCl n (CH 3 ) 3-n , or CH 3 (CH 2 ) 25 SiCl n (C 2 H 5 ) 3-n are included as chlorosilane-based surface active materials containing alkyl groups. CH 3 (CH 2 ) n SiCl 3 (where n represents an integer, preferably between about 3 and 25) is most preferable among these for the dissolution property of the solvent. In order to achieve a high adsorption density, a linear chlorosilane-based surface active material is preferred. However, as said active material applied in this invention, the alkyl fluoride or hydrocarbon groups of the material can be diverged, or the silicons at the ends of the material can be substituted by alkyl fluoride or hydrocarbon groups, expressed as the formulas including R 2 SiCl 2 , R 3 SiCl, R 1 R 2 SiCl 2 or R 1 R 2 R 3 SiCl, where R, R 1 , R 2 and R 3 represent alkyl fluoride or hydroxyl groups. A nonaqueous solvent used for this invention is preferably chosen from the following solvents: fluoric solvent such as 1, 1-dichloro - 1-fluoroethane; 1, 1-dichloro - 2, 2, 2-trifluoroethane; 1, 1-dichloro - 2, 2, 3, 3,3-pentafluoropropane or 1, 3-dichloro - 1, 1, 2, 2, 3-pentafluoropropane; hydrocarbon-based solvent such as hexane, octane, hexadecane, or cyclohexane; ethers solvent such as dibutylether or dibenzylether; esters solvent such as methyl acetate, ethyl acetate, isopropyl acetate or amyl acetate. Acetone or methyl ethyl ketone can e.g. be used as ketones solvent. Metal such as Al, Cu or stainless steel, glass, ceramics, or a group which is hydrophilic but contains a comparatively small number of hydroxyl groups (-OH) - such as a plastic, whose surface is hydrophilic - are included as groups which can be used for this invention. In employing metal as said group, it is preferable to use a base metal such as Al, Cu or stainless steel since chemical adsorption is promoted between the hydrophilic groups on the substrate surface and chlorosilyl groups in this invention. If a material, such as plastic, does not have an oxide film on its surface, the surface must become hydrophilic beforehand by introducing to it carboxyl and hydroxyl groups. The introduction of such groups can be directed by treating the surface with 100W under a plasma atmosphere, containing oxygen, for 20 minutes, or by corona treatment. However, in case of nylon and polyurethane resin, which have imino groups (>NH) on their surfaces, such treatment is not necessary; a dehydrochlorination reaction is promoted between the hydrogens of the imino groups (>NH) of the substrate and the chlorosilyl groups (-SiCl) of a chemical adsorbent, thereby creating a siloxane bond (-SiO-). This invention can be applicable for various uses and materials as described in the following: (a) examples of substrates - metal, ceramics, plastic, wood, stone (the invention being applicable even when the substrate surface being coated with e.g. paint in advance); (b) examples of cutlery - kitchen and other knives, scissors, engraver, razor blade, hair clippers, saw, plane, chisel, gimlet, badkin, cutting tools, drill tip, blender blade, juicer blade, flour mill blade, lawn mower blade, punch, straw cutter, stapler, blade for can opener or surgical knife; (c) examples of needles - acupuncture needle, sewing needle, sewing-machine needle, long thick needle for making tatami, syringe needle, surgical needle or safety pin; (d) examples of products in the pottery industry - products made of pottery, glass, ceramics or enameled products, including hygienic potteries (such as a chamber pot, wash-bowl and bathtub), tableware (such as a rice bowl, plate, bowl, teacup, glass, bottle, coffee-pot, pots and pans, earthenware mortar and cup), flower vases (such as a flower bowl, flowerpot and small flower vase), water tanks (such as a breeding cistern and aquarium water tank), chemistry apparatus (such as a beaker, reactor vessel, test tube, flask, culture dish, condenser, stirring rod, stirrer, mortar, vat, syringe), roof tile, tile, enameled tableware, enameled wash bowl, and enameled pots and pans; (e) examples of mirrors - hand mirror, full-length mirror, bathroom mirror, washroom mirror, mirrors for automobile (back and side mirrors), half mirror, mirror for show window or mirrors for department store; (f) examples of molding parts - die for press molding, die for cast molding, die for injection molding, die for transfer molding, die for vacuum molding, die for blow forming, die for extrusion molding, die for inflation molding, die for fiber spinning, calender processing roll; (g) examples of ornaments - watch, jewelry, pearl, sapphire, ruby, emerald, garnet, cat's-eye, diamond, topaz, bloodstone, aquamarine, turquoise, agate, marble, amethyst, cameo, opal, crystal, glass, ring, bracelet, brooch, tiepin, earrings, necklace or glasses frames (of platinum, gold, silver, aluminium, titanium, tin, compound metals of these elements, or stainless steel); (h) examples of molds for food - cake mold, cookie mold, bread mold, chocolate mold, jelly mold, ice cream mold, oven plate or ice tray; (i) examples of cookware - pots and pans, iron pot, kettle, pot, frying pan, hot plate, net for grilling food, tool for draining off oil or plate for making takoyaki; (j) examples of paper - photogravure paper, water and oil repellent paper, paper for posters or high-quality paper for pamphlets; (k) examples of resin - polyolefin (such as polypropylene, polyethylene, etc.), polyvinylchloride, polyvinylidenechloride, polyamide, polyimide, polyamideimide, polyester, aromatic polyester, polystyrene, polysulfone, polyethersulfone, polyphenylenesulfide, phenolic resin, furan resin, urea resin, epoxide, polyurethane, silicon resin, ABS resin, methacrylic resin, ethylacrylate resin, ester resin, polyacetal or polyphenyleneoxide; (l) examples of household electric goods - television, radio, tape recorder, audio goods, CD player, refrigerator, freezer, air conditioner, juicer, blender, blade of an electric fan, lighting equipment, dial plate or hair drier for perm; (m) examples of sporting goods - skis, fishing rod, pole for pole vault, boat, sailboat, jet skis, surfboard, golf ball, bowling ball, fishing line, fishing net or fishing float; (n) examples of vehicle parts; (1) ABS resin - lamp cover, instrument panel, trimming parts, and protector for a motorcycle, (2) cellulose plastic - markings for automobile, and steering wheel, (3) FRP (Fiber Reinforced Plastics) - bumper, and engine cover, (4) phenolic resin - brake, (5) polyacetal - wiper, wiper gear, gas valve, carburetor parts, (6) polyamide - radiator fan, (7) polyarylate (polycondensation polymerization by bisphenol A and pseudo phthalic acid) - direction indicator lamp (or lens), cowl board lens, relay case, (8) polybutylene terephthalate - rear end, front fender, (9) poly amino-bismaleimide - engine parts, gear box, wheel, suspension drive system, (10) methacrylate resin - lamp cover lens, meter panel and cover, and center mark, (11) polypropylene - bumper, (12) polyphenylene oxide - radiator grill, wheel cap, (13) polyurethane - bumper, fender, instrument panel, and fan, (14) unsaturated polyester resin - body, gas tank, heater housing, meter panel, (o) examples of stationery goods - fountain pen, ballpoint pen, mechanical pencil, pencil case, binder, desk, chair, book shelf, rack, telephone base, ruler, or draftsman's outfit; (p) examples of building materials - roof materials (such as ceramic tile, slate or tin such as used in galvanized iron plate), outer wall materials (such as wood including processed wood, mortar, concrete, ceramic sizing, metallic sizing, brick, building stone, plastic material or metallic material including aluminium) or interior materials (such as wood including processed wood, metallic material including aluminium, plastic material, paper or fiber); (q) examples of stone materials - granite or marble, used for building, building material, works of art, ornament, bath, gravestone, monument, gatepost stone wall, sidewalk, or paving stone. (r) examples of musical instruments and audio apparatus - percussion instruments, string instruments, keyboard instruments, woodwind instruments or brass instruments, more specifically e.g. drum, cymbals, violin, cello, guitar, koto, piano, flute, clarinet, shakuhachi and horn, and microphone, speaker, or earphone. (s) others - high voltage insulator with good water, oil and contamination-repelling properties, including thermos bottles, vacuum apparatus, insulator for transmitting electricity or spark plugs. The method of manufacturing a chemically adsorbed film of the invention will now be explained specifically in the following examples 1-3. Example 1 Adsorption solution A was prepared by dissolving 1% by weight of a chemical adsorbent, n-nonadecyl trichlorosilane, into the mixed solvent of hexadecane, carbon tetrachloride and chloroform at a weight ratio of 80:12:8 respectively. Glass substrate 1, as a hydrophilic group, was prepared as shown in figure 1. After being washed with a organic solvent, the substrate was dipped in adsorption solution A for five minutes. Due to this treatment, a dehydrochlorination reaction was promoted between the Si-Cl groups of n-nonadecyl trichlorosilane and the -OH groups of glass substrate 1, thereby forming a chemically adsorbed film on the substrate as shown in formula [1]. A chemically adsorbed monomolecular film 2 as shown in figure 2, which had only a few horizontal bonds since the -OH groups were unaffected, was formed after washing the substrate with a organic solvent for 15 minutes and with chloroform for another 15 minutes. This monomolecular film was firmly connected to the substrate, and had excellent water-repelling properties. The formation of the film was confirmed by obtaining particular signals for this structure at 3680 (reversion: Si-OH), 2930-2840 (reversion: CH 3 , -CH 2 -), 1470 (reversion: -CH 2 -), and 1080 (reversion: Si-O)cm -1 by Fourier Transform Infrared Spectral (FTIR) measurement. As a next step, a readsorption reaction was directed. The substrate with the formed monomolecular film was dipped and held in a newly prepared adsorption solution A for one hour. The substrate was then washed with a organic solvent for 15 minutes and with water for another 15 minutes, thereby promoting a dehydrochlorination reaction between Si-Cl groups of n-nonadecyl trichlorosilane and -OH groups at the root of monomolecular film 3. As a result, a chemically adsorbed film was formed on glass substrate 1 as shown in figure 3. According to FTIR measurement, the particular signals for this structure at 2930-2840 (reversion: CH 3 , -CH 2 -), 1470 (reversion: -CH 2 -), 1080 (reversion: Si-O)cm -1 were stronger than the signals obtained after the first reaction. This result confirmed the increase of admolecules. The absorption wave number, measuring the asymmetric stretching vibration of methylene, declined from 2929cm -1 after the first adsorption reaction to 2921cm -1 after the second reaction. It is generally known that such decline in wave number occurs when the distance between molecules with a long chain alkyl part decreases. In fact, the absorption wave number of certain material decreases as the material changes from a gaseous body to a liquid body and then to a solid body. Therefore, confirmation was obtained that the film density increased due to the decrease in distance between the molecules - the composition of the film - after the readsorption reaction. Example 2 Adsorption solution B was prepared by dissolving 1% by weight of a chemical adsorbent, n-nonadecenyl trichlorosilane, into a mixed solvent of hexadecane, carbon tetrachloride and chloroform at a weight ratio of 80:12:8, respectively. As a hydrophilic group, glass substrate 1 was prepared. After being washed with organic solvent, the substrate was dipped and held in adsorption solution B for five minutes. As a result, a dehydrochlorination reaction was promoted between Si-Cl of n-nonadecenyl trichlorosilane and OH of glass substrate 1, thereby forming a chemically adsorbed film on the substrate as shown in formula [2]. After washing the substrate with a nonaqueous solvent for 15 minutes and with chloroform for another 15 minutes, chemically adsorbed monomolecular film 4 as shown in figure 4, which had few horizontal bonds since -OH groups were unaffected, was formed. This monomolecular film was firmly connected to the substrate, and possessed good water-repelling properties. Signals were obtained for this structure at 2930-2840 (reversion: -CH 2 -), 1470 (reversion: -CH 2 -), 1080 (reversion: SiO)cm -1 by FTIR measurement, thereby confirming the formation of the film. A readsorption reaction was directed as in the following procedures: dipping and holding the substrate formed with the monomolecular film in a newly prepared adsorption solution B; washing the substrate with a nonaqueous solvent for 15 minutes and with water for another 15 minutes. A dehydrochlorination reaction was then promoted between Si-Cl of n-nonadecenyl trichlorosilane and -OH groups of glass substrate 1, thereby forming a chemically adsorbed film 5 on the substrate as shown in figure 5. The particular signals obtained by FTIR measurement at 2930-2840 (reversion: -CH 2 -), 1470 (reversion: -CH 2 -), 1080 (reversion: Si-O)cm -1 for this structure were strengthened compared with the signals obtained from the first adsorption reaction, thereby confirming an increase of admolecules. Moreover, the absorption wave number of assymmetric stretching vibration of methylene declined from 2928cm -1 after the first adsorption to 2921cm -1 after the second adsorption. As in example 1, after the readsorption reaction, the distance between molecules of the film became shorter, and the film density was increased. Example 3 Adsorption solution C was prepared by dissolving 1% by weight of a chemical adsorbent, 14-bromotetradecyl trichlorosilane, into a mixed solvent of hexadecane, carbon tetrachloride and chloroform at a weight ratio of 80:12:8, respectively. A chemically adsorbed film shown in figure 2 was formed through the following procedures as detailed in example 1: promoting the first adsorption by dipping and holding glass substrate 1 in adsorption solution A; washing the substrate with a nonaqueous solution, chloroform, and then with water, thereby forming the film. This monomolecular film was firmly fixed to the substrate, and had a good water-repelling property. As in example 1, the formation of the film was confirmed by obtaining particular signals by FTIR measurement. Readsorption was directed as in the following procedures: dipping and holding the substrate formed with monomolecular film 2 in a newly prepared adsorption solution C for one hour; washing the substrate with a nonaqueous solvent for 15 minutes and with chloroform for another 15 minutes. As a result, a dehydrochlorination reaction was promoted between Si-Cl of 14-bromotetradecyl trichlorosilane and OH of glass substrate 1 or at the root of monomolecular film 2, thereby forming chemically adsorbed film 6 on the substrate as shown in figure 6. Stronger signals at 2930-2840 (reversion: CH 3 , -CH 2 -), 1470 (reversion: -CH 2 -), 1080 (reversion: Si-O)cm -1 were obtained by FTIR measurement after the second adsorption reaction. The creation of an additional particular signal at 1440 (reversion: Br-C)cm -1 was also confirmed after the second adsorption. Absorption wave number by the asymmetric stretching vibration of methylene declined from 2928cm -1 after the first adsorption to 2922cm -1 after the second adsorption. As in other examples, it was confirmed that the distance between the molecules became shorter and the film density was increased. Although a chemical adsorbent containing halosilyl groups was used for examples 1-3, the same results could be obtained by using an adsorbent having e.g. alkoxysilyl groups. For the first adsorption reaction, a chemical adsorbent comprises a functional group shown in formula [A] or formula [B]. From the second repetition onwards, however, a chemical adsorbent contains at least one group chosen from the group consisting of halosilyl, alkoxysilyl or functional groups shown in formulas [A] through [G]. As explained above, a highly dense chemically adsorbed film is formed by repeating an adsorption reaction and washing process, and by covalently bonding a chemical adsorbent to a substrate and a chemically adsorbed film. The density of the adsorbed film, in addition, can be controlled by varying the time for adsorption reaction, the number of repetitions, and the kind and combination of chemical adsorbents.

Claims: A chemically adsorbed film comprising stem molecules and graft molecules, wherein the stem molecules are covalently bonded to active hydrogens or alkali metals on the surface of a substrate using at least one element chosen from the group consisting of Si, Ge, Sn, Ti, Zr, S or C, and wherein the graft molecules are covalently bonded to said at least one element of the stem molecules, using at least one bond chosen from the group consisting of -SiO-,-GeO-, -SnO-, -SnN-, -TiO-, -ZrO-, -SO 2 - and -C-. The chemically adsorbed film according to claim 1, wherein covalent bonding between said stem molecules and said substrate surface employs at least one bond chosen from the group consisting of -SiO-, -SiN-, -GeO-, -GeN-, -SnO-, -SnN-, -TiO-, -TiN-, -ZrO-and -ZrN-. The chemically adsorbed film according to claim 1 or 2, wherein the stem molecules or graft molecules additionally comprise a hydrocarbon chain, a fluorocarbon chain, an aromatic group, or a heterocyclic group. The chemically adsorbed film according to any of claims 1 to 3, wherein an unsaturated bond is present in stem or graft molecules. The chemically adsorbed film according to any of claims 1 to 4, said chemically adsorbed film comprising a monomolecular chemically adsorbed built-up film. A method of manufacturing a chemically adsorbed film, whereby graft molecules are bonded to stem molecules, comprising: (1) providing a substrate surface, wherein said surface comprises active hydrogens or alkali metals, and contacting said surface with chemical admolecules, wherein said admolecules contain functional groups shown in formula [A] or formula [B]; promoting a dehydrochlorination or alcohol elimination reaction, thereby covalently bonding said chemical admolecules into stem molecules; removing unreacted chemical admolecules; reacting the substrate surface with water and substituting one or more members of the group consisting of a halogen group and an alkoxyl group with a hydroxyl group; wherein Formula [A] comprises the designation -AX m where X represents halogen, A represents Si, Ge, Sn, Ti, Zr, S or C, and m represents 2 or 3; further wherein Formula [B] comprises the designation -A(Q) m where Q represents an alkoxyl group, A represents Si, Ge, Sn, Ti, Zr, S or C, and m represents 2 or 3; and (2) contacting said substrate surface with chemical admolecules containing at least one functional group chosen from the group consisting of formulas [C], [D], [E], [F], or [G], thereby promoting a dehydrochlorination, water elimination or alcohol elimination reaction, and removing unreacted chemical admolecules and reacting the substrate surface with water; wherein Formula [C] comprises the designation -AX n where X represents halogen, A represents Si, Ge, Sn, Ti, Zr, S or C, and n represents 1, 2 or 3; further wherein Formula [D] comprises the designation -A(Q) n where Q represents an alkoxyl group, A represents Si, Ge, Sn, Ti, Zr, S or C, and n represents 1, 2 or 3; further wherein Formula [E] comprises the designation -SO 2 X where X represents halogen; further wherein Formula [F] comprises the designation -SOX where X represents halogen; further wherein Formula [G] comprises the designation >N-CHO or -OCHO. The method of manufacturing a chemically adsorbed film according to claim 6, wherein unreacted chemical admolecules are removed by a nonaqueous solution. The method of manufacturing a chemically adsorbed film according to claim 6 or 7, wherein stem or graft molecules are reacted with water. The method of manufacturing a chemically adsorbed film according to any of claims 6 to 8, wherein a chemical adsorbent having trichlorosilane-based ends is used as a stem or graft molecule. The method of manufacturing a chemically adsorbed film according to any of claims 6 to 9, wherein a condensation reaction is promoted by contact with stem or graft molecules in a dehydrochlorination or alcohol elimination reaction. The method of manufacturing a chemically adsorbed film according to any of claims 6 to 10, wherein said stem or graft molecules comprise a hydrocarbon chain, a fluorocarbon chain, an aromatic group or a heterocyclic group. The method of manufacturing a chemically adsorbed film according to any of claims 6 to 11, wherein an unsaturated bond is contained in said stem or graft molecules.

Inventors: MINO NORIHISA, OGAWA KAZUFUMI, OHTAKE TADASHI, MINO, NORIHISA, OGAWA, KAZUFUMI, OHTAKE, TADASHI
Applicants: MATSUSHITA ELECTRIC IND CO LTD, MATSUSHITA ELECTRIC INDUSTRIAL CO., LTD.
Application year: 1993
Main classification: B32B7
IPC codes: B05D1