Capacitor films, methods of manufacture, and articles manufactured therefrom

1. A uniaxially-stretched, high yield extruded polyetherimide film comprising:

an extruded polyetherimide comprising units derived from polymerization of an aromatic dianhydride with a diamine selected from a meta-phenylene diamine, a para-phenylene diamine, and a combination thereof, wherein the polyetherimide is endcapped with a substituted or unsubstituted aromatic primary monoamine selected from substituted and unsubstituted anilines, substituted and unsubstituted naphthyl primary amines, and substituted, unsubstituted heteroaryl primary amines, and a combination thereof, wherein substituents are optionally halogenated C 6-12 aryl groups, optionally halogenated C 1-12 alkyl groups, sulfone groups, C 1-12 ester groups, C 1-12 amide groups, halogens, C 1-12 alkyl ether groups, C 6-12 aryl ether groups or C 6-12 aryl keto groups bonded to the aromatic ring; and

wherein the high yield extruded polyetherimide film comprises at least 90 weight percent of the polyetherimide before extrusion.

2. The film of claim 1 , wherein the film has a thickness of more than 0 and less than 50 micrometers.

3. The film of claim 1 , wherein the film has a thickness that is more than 0 and less than 10 micrometers.

4. The uniaxially-stretched, high yield extruded 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; and

a ratio of viscosity at 100 sec −1 and 5,000 sec −1 of less than 10 at 340° C. as measured by capillary rheometry;

a tensile modulus of greater than or equal to 380,000 psi (2618 MPa) as determined by ASTM D638; and

wherein the film has

a glass transition temperature of greater than 217° C.,

a heat distortion temperature of at least 195° C. as measured at 66 psi (0.45 MPa) according to ASTM D648 on a 0.125 inch (3.2 mm) thick test sample,

a dielectric constant at 1 kHz, 23° C. and 50% RH of at least 3,

a dissipation factor at 1 kHz, 23° C. and 50% RH of 1% or less,

a breakdown strength of at least 300 Volts/micrometer measured according to ASTM D-149,

and

a wrinkle-free region having

a variation of the thickness of the film of +/−10% or less of the thickness of the film, and

a surface roughness average (Ra) of less than +/−3% of the average thickness of the film as measured by optical profilometry.

5. The uniaxially-stretched, high yield extruded 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; and

a ratio of viscosity at 100 sec −1 and 5,000 sec −1 of less than 11 at 340° C. as measured by capillary rheometry;

a tensile modulus of greater than or equal to 380,000 psi (2618 MPa) as determined by ASTM D638; and

wherein the film has

a glass transition temperature of greater than 217° C.,

a heat distortion temperature was measured at measured at 264 psi (1.8 MPa) according to ASTM D648 on a 0.250 inch (6.4 mm),

a dielectric constant at 1 kHz, 23° C. and 50% RH of at least 3,

a dissipation factor at 1 kHz, 23° C. and 50% RH of 1% or less,

a breakdown strength of at least 300 Volts/micrometer measured according to ASTM D-149,

and

a wrinkle-free region having

a variation of the thickness of the film of +/−10% or less of the thickness of the film, and

a surface roughness average (Ra) of less than +/−3% of the average thickness of the film as measured by optical profilometry.

6. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film has a dynamic and static coefficient of friction on steel, on a metallized surface, and on itself of less than 0.75 measured according to ASTM D1894.

7. The film of claim 1 , wherein the film has a surface resistivity greater than 1E13 Ohm per square measured according to ASTM D257.

8. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film dielectric constant at 1 kHz remains essentially unchanged from 0 to 175° C. with a difference of less than 20% of the highest dielectric constant value.

9. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the dissipation factor at 1 kHz remains essentially unchanged from 0 to 175° C., and is less than 1.3%.

10. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the dissipation factor is less than 1.3% from 1 kHz to 100 kHz at 23° C. and 50% RH.

11. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the breakdown strength difference of the film from 0 to 175° C. is less than 40% from the value at 23° C., measured according to ASTM D149.

12. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the difference in capacitance at 1 kHz is less than +/−5% from 0 to 175° C. based on the value at 23° C.

13. The uniaxially-stretched, high yield extruded film of claim 1 , 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 aromatic hydrocarbon group having 6 to 27 carbon atoms, a halogenated derivative thereof, a straight or branched chain alkylene group having 2 to 10 carbon atoms, a halogenated derivative thereof, a cycloalkylene group having 3 to 20 carbon atoms, a halogenated derivative thereof, or —(C 6 H 10 ) z — wherein z is an integer from 1 to 4; and

R is a residue of the diamine selected from the meta-phenylene diamine, para-phenylene diamine, and a combination thereof.

14. The uniaxially-stretched, high yield extruded film of claim 13 , wherein Z is a divalent group having the formula

wherein Q a is a single bond, —O—, —S—, —C(O)—, —SO 2 —, —SO—, and —C y H 2y — and a halogenated derivative thereof wherein y is an integer from 1 to 5.

15. The uniaxially-stretched, high yield extruded film of claim 13 , wherein T is

16. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the polyetherimide comprises 1.0 to 1.4 molar equivalents of anhydride groups per 1.0 amine groups.

17. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the substituted or unsubstituted aromatic primary monoamine is aniline.

18. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises a crosslinked polyetherimide, and wherein the film exhibits a breakdown strength from 5 to 50% more compared to a film comprising an uncrosslinked polyetherimide.

19. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises a branched polyetherimide, and wherein the film exhibits a breakdown strength that is from 5 to 50% more than a film that is the same except comprising an unbranched polyetherimide.

20. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the polyetherimide comprises 0 to 2 weight percent of a phosphorus-containing stabilizer having a molecular weight greater than or equal to 500 grams/mole.

21. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 50 ppm of a hydroxyl group-containing compound.

22. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 10 ppm each of a phthalic anhydride phenylene diamine or a phthalic anhydride phenylene diamine imide.

23. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 10 ppm total of a phthalic anhydride phenylene diamine or a phthalic anhydride phenylene diamine imide.

24. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 5 weight percent of a compound having a molecular weight of less than 500 Daltons based on the total weight of the film.

25. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 1500 ppm of a halogen-containing compound.

26. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 100 ppm of an alkali metal.

27. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 0.1 ppm each of leachable low ionic chlorides and sulfates.

28. The uniaxially-stretched, high yield extruded film of claim 27 , wherein the total amount of the metal contaminants in the film is less than 20 ppm.

29. The uniaxially-stretched, high yield extruded film of claim 27 , wherein the total amount of the metal contaminants in the film is less than 100 ppm.

30. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 1 ppm each of leachable low ionic chlorides and sulfates.

31. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 10 ppm each of metal contaminants selected from Al, Ca, Cr, Fe, K, Mg, Na, Ni, and Ti.

32. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises less than 25 ppm each of metal contaminants selected from Al, Ca, Cr, Fe, K, Mg, Na, Ni, and Ti.

33. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film compress less than 15% of a polyetherimide other than the polyetherimide comprising units derived from polymerization of an amine selected from meta-phenylene diamines, para-phenylene diamines, and combinations thereof.

34. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film comprises fewer than two carbonized inclusions having a diameter greater than 20 micrometers in an area of 100 cm 2 .

35. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film has a single glass transition temperature greater than 150° C.

36. The uniaxially-stretched, high yield extruded 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.

37. An article comprising the uniaxially-stretched, high yield extruded film of claim 1 .

38. The article of claim 37 , further comprising a layer of a conductive metal disposed on at least a portion of the film.

39. The article of claim 38 , wherein the conductive metal comprises aluminum, zinc, copper, tantalum, niobium, brass, or a combination thereof.

40. The article of claim 38 , wherein the conductive metal layer has a thickness of 1 to 3000 Angstroms.

41. The article claim 38 , wherein the conductive metal layer has a thickness of 1 to 2820 Angstroms.

42. The article of claim 38 , 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, atomic layer deposition, or by high temperature vacuum deposition.

44. A capacitor comprising the article of claim 38 .

45. An electronic article comprising the capacitor of claim 44 .

46. A method of manufacture of the uniaxially-stretched, high yield extruded film of claim 1 , comprising extruding a quantity of the polyetherimide, wherein the extruded film comprises at least 90 weight % of the quantity of the polyetherimide before the extruding.

47. The method of claim 46 , further comprising irradiating the extruded film at a wavelength and for a time effective to crosslink the polyetherimide, wherein the film comprising the crosslinked polyetherimide exhibits an increase in breakdown strength of 5 to 50% more than the same film comprising an uncrosslinked polyetherimide.

48. The uniaxially-stretched, high yield extruded film of claim 1 , wherein the film are extruded and not made from a solvent casting processes.

49. The uniaxially-stretched, high yield extruded film of claim 48 , comprising less than 1000 ppm of a solvent.

50. The uniaxially-stretched, high yield extruded film of claim 1 ,

wherein the high yield extruded polyetherimide film is solvent-free and

has a thickness ranging from more than 0 to less than 10 micrometers.

51. A uniaxially-stretched, high yield extruded polyetherimide film comprising:

an extruded polyetherimide comprising units derived from polymerization of an aromatic dianhydride with a diamine selected from a meta-phenylene diamine, a para-phenylene diamine, and a combination thereof, the polyetherimide being endcapped with a substituted or unsubstituted aromatic primary monoamine;

wherein the high yield extruded polyetherimide film comprises at least 90 weight percent of the polyetherimide before extrusion; and

the film further comprises 0.01 to 5.0 weight percent, based on total weight of the composition, of a release agent selected from C 15 to C 30 carboxylic acids, C 15 to C 30 aliphatic carboxylic amides, and mixtures thereof.

52. The uniaxially-stretched, high yield extruded film of claim 51 , wherein the film further comprises less than 5.0 weight percent, based on total weight of the composition, of a release agent selected from C 15 to C 30 carboxylic acids, C 15 to C 30 aliphatic carboxylic amides, and mixtures thereof.

53. A uniaxially-stretched, high yield extruded film comprising:

an extruded polyetherimide comprising units derived from polymerization of an aromatic dianhydride with a diamine selected from a meta-phenylene diamine, a para-phenylene diamine, and a combination thereof, the polyetherimide being endcapped with a substituted or unsubstituted aromatic primary monoamine,

wherein the high yield extruded polyetherimide film comprises at least 90 weight percent of the polyetherimide before extrusion, and

the film further comprises 1 to 50 weight percent, based on total weight of the composition, of a polymer selected from a silicone polyetherimide, a polyetherimide sulfone, a polyester, a polycarbonate, a silicone polycarbonate-polyester copolymer, and a combination thereof.

54. The uniaxially-stretched, high yield extruded film of claim 53 , wherein the film further comprises less than 20 weight percent, based on total weight of the composition, of a polymer selected from a silicone polyetherimide, a polyetherimide sulfone, a polyester, a polycarbonate, a silicone polycarbonate-polyester copolymer and a combination thereof.