Amorphous polycarbonate films for capacitors, methods of manufacture, and articles manufactured therefrom

Abstract

A uniaxially-stretched, extruded film comprising a polycarbonate, wherein the extruded film has at least one wrinkle-free region having a first surface and a second surface, the at least one extruded wrinkle-free region comprising: an extruded thickness of more than 0 and less than 7 micrometer, and a variation of the thickness of the film of +/−10% of the thickness of the film, and a surface roughness average that is less than +/−3% of the average thickness of the film as measured by optional profilometery; and further wherein the film has a dielectric constant at 1 kHz and room temperature of at least 2.7; a dissipation factor at 1 kHz and room temperature of 1% or less; and a breakdown strength of at least 300 Volt/micrometer.

1 . A uniaxially-stretched, extruded film comprising a polycarbonate, wherein the film has
 at least one wrinkle-free region having a first surface and a second surface, the at least one extruded wrinkle-free region comprising:   a thickness of more than 0 and less than 7 micrometers, and   a variation of the thickness of the film of +/−10% or less of the thickness of the film, and   a surface roughness average of less than +/−3% of the average thickness of the film as measured by optical profilometry;   and further wherein the film has:   a dielectric constant at 1 kHz and room temperature of at least 2.7;   a dissipation factor at 1 kHz and room temperature of 1% or less; and   a breakdown strength of at least 300 Volt/micrometer.   
     
     
         2 . The film of  claim 1 , wherein the film has a length of at least 10 meter, and a width of at least 300 millimeter, and at least 80% of the area of the film is the wrinkle-free region. 
     
     
         3 . The film of  claim 1 , wherein the film has an energy density of at least 3 J/cc. 
     
     
         4 . The film of  claim 2 , wherein the film has a length of 100 to 10,000 meter, and a width of 300 to 3,000 millimeter. 
     
     
         5 . The film of  claim 1 , wherein the film has less than 1,000 ppm of a compound having a molecular weight of less than 250 Dalton. 
     
     
         6 . The film of  claim 1 , wherein the film has less than 50 ppm each of aluminum, calcium, magnesium, iron, nickel, potassium, manganese, molybdenum, sodium, titanium, and zinc. 
     
     
         7 . The film of  claim 1 , comprising less than 1000 ppm each of a fluorine-containing compound or a silicone-containing compound. 
     
     
         8 . The film of  claim 1 , comprising less than 100 ppm of a fluorine-containing compound or a silicone-containing compound. 
     
     
         9 . The film of  claim 1 , wherein the film has no observable specks or gels over an area of at least 3 square meter when viewed at a distance of 0.3 meter without magnification. 
     
     
         10 . The film of  claim 1 , wherein the film has no observable voids over an area of at least 3 square meter when viewed at a magnification of 50×. 
     
     
         11 . The film of  claim 1 , wherein at least one of the surfaces of the wrinkle-free region has a roughness value Ra of less than 3% of the average thickness of the film. 
     
     
         12 . The film of  claim 1 , wherein the polycarbonate is a polycarbonate having repeating structural carbonate units of formula (1) 
       
         
           
           
               
               
           
         
         in which at least 60 percent of the total number of R 1  groups contain aromatic moieties and the balance thereof are aliphatic, alicyclic, or aromatic. 
       
     
     
         13 . The film of  claim 12 , wherein the polycarbonate is a homopolycarbonate derived from polymerization of a bisphenol compound (3) 
       
         
           
           
               
               
           
         
         wherein 
         R a  and R b  are each independently a halogen atom or a monovalent hydrocarbon group; 
         p and q are each independently integers of 0 to 4; and 
         X a  is a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each C 6  arylene group are disposed ortho, meta, or para (specifically para) to each other on the C 6  arylene group. 
       
     
     
         14 . The film of  claim 13 , wherein each X a  is independently selected from a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, and a C 1-18  organic group. 
     
     
         15 . The film of  claim 13 , wherein each X a  is independently selected from
 a C 1-18  alkylene group,   a C 3-18  cycloalkylene group,   a fused C 6-18  cycloalkylene group,   a group of the formula —B 1 —W—B 2 — wherein B 1  and B 2  are the same or different C 1-6  alkylene group and W is a C 3-12  cycloalkylidene group or a C 6-16  arylene group;   an alkyl-substituted bisphenol (4)   
       
         
           
           
               
               
           
         
         wherein R a′  and R b′  are each independently C 1-12  alkyl, R g  is C 1-12  alkyl or halogen, r and s are each independently 1 to 4, and t is 0 to 10; and 
         a substituted C 3-18  cycloalkylidene (5) 
       
       
         
           
           
               
               
           
         
         wherein R r , R p , R q , and R t  are independently hydrogen, halogen, oxygen, or C 1-12  organic groups; I is a direct bond, a carbon, or a divalent oxygen, sulfur, or —N(Z)— where Z is hydrogen, halogen, hydroxy, C 1-12  alkyl, C 1-12  alkoxy, or C 1-12  acyl; h is 0 to 2, j is 1 or 2, i is an integer of 0 or 1, and k is an integer of 0 to 3, with the proviso that at least two of R r , R p , R q , and R t  taken together are a fused cycloaliphatic, aromatic, or heteroaromatic ring. 
       
     
     
         16 . The film of  claim 13 , wherein the C 1-18  organic bridging group is —C(R c )(R d )— or —C(═R e )—, wherein R c  and R d  are each independently a hydrogen atom or a monovalent C 1-6  linear or cyclic hydrocarbon group and R e  is a divalent hydrocarbon group, p and q is each 0 or 1, and R a  and R b  are each a C 1-3  alkyl group 
     
     
         17 . The film of  claim 13 , wherein the bisphenol compound (3) is selected from 1,1-bis(4-hydroxyphenyl)methane, 1,1-bis(4-hydroxyphenyl)ethane, 2,2-bis(4-hydroxyphenyl) propane, 2,2-bis(4-hydroxyphenyl) butane, 2,2-bis(4-hydroxyphenyl) octane, 1,1-bis(4-hydroxyphenyl) propane, 1,1-bis(4-hydroxyphenyl) n-butane, 2,2-bis(4-hydroxy-2-methylphenyl) propane, 1,1-bis(4-hydroxy-t-butylphenyl) propane, 3,3-bis(4-hydroxyphenyl) phthalimidine, 2-phenyl-3,3-bis(4-hydroxyphenyl) phthalimidine, and 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane. 
     
     
         18 . The film of  claim 12 , wherein the polycarbonate is a homopolymer. 
     
     
         19 . The film of  claim 12 , wherein the polycarbonate is copolycarbonate comprising at least two different R 1  moieties. 
     
     
         20 . The film of  claim 12 , wherein the polycarbonate is a polycarbonate copolymer comprising
 a repeating carbonate unit (1), and   a repeating unit selected from ester units, diorganosiloxane units, urethane units, arylene ether units, arylene sulfone units, arylene ketone units, and combinations thereof.   
     
     
         21 . The film of  claim 20  wherein the polycarbonate is a poly(carbonate-ester) comprising
 repeating carbonate units (1), and 
 repeating ester units (7) 
 
       
         
           
           
               
               
           
         
         wherein 
         J is selected from a C 2-10  alkylene group, a C 6-20  alicyclic group, a C 6-20  aromatic group, and a polyoxyalkylene group in which the alkylene groups contain 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms; and 
         T is selected from a C 2-10  alkylene group, a C 6-20  alicyclic group, a C 6-20  alkyl aromatic group, or a C 6-20  aromatic group. 
       
     
     
         22 . The film of  claim 21 , wherein the poly(carbonate-ester) comprises repeating aromatic carbonate-ester units (8) 
       
         
           
           
               
               
           
         
         wherein 
         Ar is divalent aromatic residue of a dicarboxylic acid or combination of dicarboxylic acids, and 
         Ar′ is a divalent aromatic residue of 
         (a) a bisphenol (3) 
       
       
         
           
           
               
               
           
         
         wherein 
         R a  and R b  are each independently a halogen atom or a monovalent hydrocarbon group; 
         p and q are each independently integers of 0 to 4; and 
         X a  is a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each C 6  arylene group are disposed ortho, meta, or para (specifically para) to each other on the C 6  arylene group, 
         or 
         (b) an aromatic dihydric compound (6) 
       
       
         
           
           
               
               
           
         
         wherein 
         each R h  is independently a halogen atom, a C 1-10  hydrocarbyl group, a halogen-substituted C 1-10  alkyl group, a C 6-10  aryl group, or a halogen-substituted C 6-10  aryl group, and 
         n is 0 to 4; and 
         x is 20 to less than 100 and y is more than 0 to 80, wherein x and y are in parts by weight based on 100 parts by weight of the poly(carbonate-ester). 
       
     
     
         23 . The film of  claim 22 , wherein Ar is the residue of isophthalic acid (9a), terephthalic acid (9b), 
       
         
           
           
               
               
           
         
         or a combination thereof. 
       
     
     
         24 . The film of  claim 23 , wherein Ar′ is the residue of bisphenol A. 
     
     
         25 . The film of  claim 21 , wherein the polycarbonate is a poly(carbonate-ester) comprising
 repeating carbonate units (1) derived from a bisphenol (3)   
       
         
           
           
               
               
           
         
         wherein 
         R a  and R b  are each independently a halogen atom or a monovalent hydrocarbon group; 
         p and q are each independently integers of 0 to 4; and 
         X a  is a bridging group connecting the two hydroxy-substituted aromatic groups, where the bridging group and the hydroxy substituent of each C 6  arylene group are disposed ortho, meta, or para (specifically para) to each other on the C 6  arylene group; and 
         repeating arylate ester units (9) 
       
       
         
           
           
               
               
           
         
         wherein each R 4  is independently a halogen or a C 1-4  alkyl, and p is 0 to 3. 
       
     
     
         26 . The film of  claim 25 , wherein the ester units are poly(isophthalate-terephthalate-resorcinol ester) units. 
     
     
         27 . The film of  claim 26 , wherein the bisphenol (3) is bisphenol A. 
     
     
         28 . The film of  claim 25 , wherein the poly(carbonate-ester) further comprises repeating carbonate units (1) derived from an aromatic dihydric compound (6) 
       
         
           
           
               
               
           
         
         wherein each R 4  is independently a halogen or a C 1-4  alkyl, and n is 0 to 3; and wherein the molar ratio of carbonate units derived from bisphenol (3) to carbonate units derived from dihydroxy compound (6) is 1:99 to 99:1. 
       
     
     
         29 . The film of  claim 28 , wherein the ester units are poly(isophthalate-terephthalate-resorcinol ester) units. 
     
     
         30 . The film of  claim 29 , wherein the poly(carbonate-ester) is a poly(bisphenol-A carbonate)-co-(resorcinol carbonate)-co(isophthalate-terephthalate-resorcinol ester). 
     
     
         31 . The film of  claim 19 , wherein the polycarbonate is a poly(carbonate-siloxane) comprising
 repeating carbonate units (1); and   repeating diorganosiloxane units (10)   
       
         
           
           
               
               
           
         
         wherein 
         each R is independently the same or different C 1-13  monovalent organic group; and 
         E has an average value of 5 to 200. 
       
     
     
         32 . The film of  claim 31 , wherein the polysiloxane units are of formula (13): 
       
         
           
           
               
               
           
         
         wherein 
         each R is independently the same or different C 1-13  monovalent organic group; 
         E has an average value of 5 to 65; 
         R 6  is a divalent C 2 -C 8  aliphatic group; 
         each M is independently a halogen, cyano, nitro, C 1 -C 8  alkylthio, C 1 -C 8  alkyl, C 1 -C 8  alkoxy, C 2 -C 8  alkenyl, C 2 -C 8  alkenyloxy group, C 3 -C 8  cycloalkyl, C 3 -C 8  cycloalkoxy, C 6 -C 10  aryl, C 6 -C 10  aryloxy, C 7 -C 12  aralkyl, C 7 -C 12  aralkoxy, C 7 -C 12  alkylaryl, or C 7 -C 12  alkylaryloxy; and 
         each n is independently 0, 1, 2, 3, or 4. 
       
     
     
         33 . The film of  claim 32 , wherein
 in the carbonate units, R 1  is derived from bisphenol A; and   in the siloxane units, M is methoxy, n is one, R 2  is a divalent C 1 -C 3  aliphatic group, and R is methyl.   
     
     
         34 . The film of  claim 19 , wherein the polycarbonate is a polycarbonate-ester-siloxane) comprising
 repeating carbonate units (1);   repeating siloxane units (10)   
       
         
           
           
               
               
           
         
         wherein 
         each R is independently the same or different C 1-13  monovalent organic group; and 
         E has an average value of 5 to 200; and 
         repeating ester units (7) 
       
       
         
           
           
               
               
           
         
         wherein 
         J is selected from a C 2-10  alkylene group, a C 6-20  alicyclic group, a C 6-20  aromatic group, and a polyoxyalkylene group in which the alkylene groups contain 2 to 6 carbon atoms, specifically 2, 3, or 4 carbon atoms; and 
         T is selected from a C 2-10  alkylene group, a C 6-20  alicyclic group, a C 6-20  alkyl aromatic group, or a C 6-20  aromatic group. 
       
     
     
         35 . The film of  claim 3 , wherein
 in the polycarbonate units, R 1  is derived from a bisphenol A;   the siloxane units are polysiloxane blocks (13):   
       
         
           
           
               
               
           
         
         wherein 
         each R is independently the same or different C 1-13  monovalent organic group; 
         E has an average value of 5 to 65; 
         R 6  is a divalent C 2 -C 8  aliphatic group; 
         each M is independently a halogen, cyano, nitro, C 1 -C 8  alkylthio, C 1 -C 8  alkyl, C 1 -C 8  alkoxy, C 2 -C 8  alkenyl, C 2 -C 8  alkenyloxy group, C 3 -C 8  cycloalkyl, C 3 -C 8  cycloalkoxy, C 6 -C 10  aryl, C 6 -C 10  aryloxy, C 7 -C 12  aralkyl, C 7 -C 12  aralkoxy, C 7 -C 12  alkylaryl, or C 7 -C 12  alkylaryloxy; and 
         each n is independently 0, 1, 2, 3, or 4; and 
         the ester units are of formula (9) 
       
       
         
           
           
               
               
           
         
         wherein each R 4  is independently a halogen or a C 1-4  alkyl, and p is 0 to 3. 
       
     
     
         36 . The film of  claim 34 , wherein
 in the carbonate units, R 1  is derived from bisphenol A;   in the polysiloxane blocks, M is methoxy, n is one, R 2  is a divalent C 1 -C 3  aliphatic group, and R is methyl; and   the ester units are (isophthalate-terephthalate-resorcinol) ester units   
     
     
         37 . An article comprising the film of  claim 1 . 
     
     
         38 . The article of  claim 37 , further comprising a layer of a conductive metal deposited on at least a portion of the wrinkle-free region. 
     
     
         39 . The article of  claim 38 , wherein the conductive metal comprises aluminum, zinc, copper, or a combination thereof. 
     
     
         40 . The article of  claim 39 , wherein the conductive metal layer has a thickness of 1 to 3000 Angstroms. 
     
     
         41 . The article of  claim 40 , wherein the conductive metal layer has a thickness of 1 to 2000 Angstroms. 
     
     
         42 . The article of  claim 41 , wherein the conductive metal layer has a resistivity of 0.1 to 100 Ohm/sq. 
     
     
         43 . The article of  claim 38 , wherein the conductive metal layer is deposited by chemical vapor deposition, high temperature vacuum operations, or combinations thereof. 
     
     
         44 . A capacitor comprising a wound, metallized film of  claim 37 . 
     
     
         45 . An electronic article comprising the capacitor of  claim 44 . 
     
     
         46 . The film of  claim 1  wound on a roll, wherein the roll has no observable wrinkles or die lines when viewed without magnification at a distance of 0.3 meter. 
     
     
         47 . An article comprising a portion of the film of  claim 46 . 
     
     
         48 . The article of  claim 47 , further comprising a layer of a conductive metal deposited on at least a portion of the surface of the wrinkle-free region. 
     
     
         49 . The article of  claim 48 , wherein the conductive metal comprises aluminum, zinc, copper, or a combination thereof. 
     
     
         50 . The article of  claim 49 , wherein the conductive metal layer has a thickness of 1 to 1000 angstrom. 
     
     
         51 . The article of  claim 50 , wherein the conductive metal layer has a resistivity of 0.1 to 100 Ohm/sq. 
     
     
         52 . The article of  claim 48 , wherein the conductive metal layer is deposited by chemical vapor deposition, high temperature vacuum operations, or combinations thereof. 
     
     
         53 . A capacitor comprising a wound metallized film of  claim 46 . 
     
     
         54 . An electronic article comprising the capacitor of  claim 53 .