AMORPHOUS POLYETHERIMIDE FILMS FOR CAPACITORS, METHODS OF MANUFACTURE, AND ARTICLES MANUFACTURED THEREFROM
A uniaxially-stretched, extruded film comprising a polyetherimide and less than 5 weight percent of fluorine, 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 13 micrometers, 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 Volts/micrometer.
1 . A uniaxially-stretched, extruded film comprising a polyetherimide and less than 5 weight percent of fluorine, 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 13 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 Volts/micrometer.
2 . The film of claim 1 , wherein the film has a length of at least 10 meters, and a width of at least 300 millimeters, and at least 80% of the area of the film is the wrinkle-free region.
3 . The film of claim 2 , wherein the film has a length of 100 to 10,000 meters, and a width of 300 to 3,000 millimeters.
4 . 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 Daltons.
5 . 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.
6 . The film of claim 1 , comprising less than 1000 ppm each of a fluorine-containing compound or a silicone-containing compound.
7 . The film of claim 1 , comprising less than 100 ppm of a fluorine-containing compound or a silicone-containing compound.
8 . The film of claim 1 , wherein the film has no observable specks or gels over an area of at least 3 square meters when viewed at a distance of 0.3 meters without magnification.
9 . The film of claim 1 , wherein the film has no observable voids over an area of at least 3 square meters when viewed at a magnification of 50×.
10 . 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.
11 . The film of claim 1 , wherein the polyetherimide has a Tg of greater than 135° C.
12 . The film of claim 1 , wherein the polyetherimide has a weight average molecular weight of 20,000 to 400,000 Daltons, as determined by gel permeation chromatography based on a polystyrene standard.
13 . The film of claim 1 , wherein the polyetherimide has a weight average molecular weight of 10,000 to 80,000 Daltons, as determined by gel permeation chromatography based on a polystyrene standard.
14 . The film of claim 1 , wherein the polyetherimide is of the formula
wherein
a is greater than 1,
V is a tetravalent aromatic group of the formula
wherein W is a divalent moiety selected from —O—, —O—Z—O—, —SO 2 —, or a combination thereof, wherein the divalent bonds of the —O—, the —O—Z—O—, and the —SO 2 — group are in the 3,3′,3,4′,4,3′, or the 4,4′ positions, and wherein Z is a monocyclic or polycyclic moiety having 6 to 24 carbon atoms and optionally substituted with 1 to 8 C 1-8 alkyl groups, 1 to 8 halogen atoms, or a combination thereof, and
R is selected from an aromatic hydrocarbon group having 6 to 20 carbon atoms, a halogenated derivative thereof, a straight or branched chain alkylene group having 2 to 20 carbon atoms, a cycloalkylene group having 3 to 20 carbon atoms, or a divalent group of the formula
wherein Q 1 is —O—, —S—, —C(O)—, —SO 2 —, —SO—, —C y H 2y — wherein y is 1 to 5, and a halogenated derivative thereof.
15 . The film of claim 14 , wherein the polyetherimide is of the formula
wherein
T is —O— or a group of the formula —O—Z—O— wherein the divalent bonds of the —O— or the —O—Z—O— group are in the 3,3′,3,4′,4,3′, or the 4,4′ positions and Z is a divalent radical of the formulae
wherein Q is —O—, —S—, —C(O)—, —SO 2 —, —SO—, or —C y H 2y — wherein y is an integer from 1 to 5; and
R is a divalent group of formula
wherein Q 1 is —O—, —S—, —C(O)—, —SO 2 —, —SO—, or —C y H 2y — wherein y is an integer from 1 to 5.
16 . The film of claim 15 , wherein R is m-phenylene, p-phenylene, diarylsulfone, or a combination thereof.
17 . An article comprising the film of claim 1 .
18 . The article of claim 17 , further comprising a layer of a conductive metal deposited on at least a portion of the wrinkle-free region.
19 . The article of claim 18 , wherein the conductive metal comprises aluminum, zinc, copper, or a combination thereof.
20 . The article of claim 18 , wherein the conductive metal layer has a thickness of 1 to 3000 Angstroms.
21 . The article of claim 18 , wherein the conductive metal layer has a thickness of 1 to 2820 Angstroms.
22 . The article of claim 17 , wherein the conductive metal layer has a resistivity of 0.1 to 100 Ohm/sq.
23 . The article of claim 17 , wherein the conductive metal layer is deposited by chemical vapor deposition, high temperature vacuum operations, or combinations thereof.
24 . A capacitor comprising a wound metallized film of claim 18 .
25 . An electronic article comprising the capacitor of claim 24 .
26 . 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 meters.
27 . An article comprising a portion of the film of claim 26 .
28 . The article of claim 27 , further comprising a layer of a conductive metal deposited on at least a portion of the surface of the wrinkle-free region.
29 . The article of claim 28 , wherein the conductive metal comprises aluminum, zinc, copper, or a combination thereof.
30 . The article of claim 28 , wherein the conductive metal layer has a thickness of 1 to 1000 Angstroms.
31 . The article of claim 28 , wherein the conductive metal layer has a resistivity of 0.1 to 100 Ohms/sq.
32 . The article of claim 28 , wherein the conductive metal layer is deposited by chemical vapor deposition, high temperature vacuum operations, or combinations thereof.
33 . A capacitor comprising the article of claim 28 .