Capacitor films with high temperature performance, methods of manufacture, and articles thereof

1. A film, comprising

70 to 99 weight percent of an amorphous, high heat copolycarbonate having a glass transition temperature of at least 170° C., and

1 to 30 weight percent of a cyclic olefin copolymer each based on the total weight of polymers in the film;

wherein the film has

a dielectric breakdown strength of greater than 700 Volts/micrometer at 150° C.

2. The film of claim 1 , wherein the film has a char yield of less than 30 weight percent, as determined using thermogravimetric analysis under nitrogen.

3. The film of claim 1 , wherein the film has one or more of

a glass transition temperature of 170-225° C.,

an average thickness of 1 to 25 micrometers,

a dielectric constant at 1 kHz, 20° C., and 50% relative humidity of at least 2.7,

a dissipation factor at 1 kHz, 20° C., and 50% relative humidity of 1% or less, or an energy density of at least 7 J/cc.

4. The film of claim 1 , wherein the film has a dielectric breakdown strength from 15 to 50 percent greater at 150° C. than the same film not containing a cyclic olefin copolymer.

5. The film of claim 1 , wherein the copolycarbonate comprises

first carbonate units of formula (1)

wherein

R a and R b are each independently C 1-12 alkyl, C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy, p and q are each independently 0 to 4, and

X a is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, a C 1-11 alkylidene of the formula—C(R c )(R d )—wherein R c and R d are each independently hydrogen or C 1-5 alkyl, or a group of the formula —C(═R e )—wherein R e is a divalent C 1-6 hydrocarbon group; and

second carbonate units of formula (4)

wherein

R a and R b are each independently C 1-12 alkenyl, C 3-8 cycloalkyl, or C 1-12 alkoxy,

p and q are each independently integers of 0 to 4, and

X b is

a C 3-8 cycloalkylene,

a fused C 6-18 cycloalkylene,

a group of the formula -J 1 -G-J 2 - wherein J 1 and J 2 are the same or different C 1-6 alkylene group and G is a C 3-12 cycloalkylene, a C 3-12 cycloalkylidene, or a C 6-16 arylene,

a C 12-25 alkylidene of formula —C(R c )(R d )—wherein R c and R d are each independently hydrogen, C 1-24 alkyl, C 4-12 cycloalkyl, C 6-12 aryl, C 7-12 arylalkylene, C 7-12 heteroarylalkylene, C 7-12 alkylarylene, C 1-12 heteroalkyl, C 3-12 heterocycloalkyl, or C 7-12 heteroaryl,

a group of the formula —C(═R e )—wherein R e is a divalent C 7-31 hydrocarbon group,

a C 3-18 cycloalkylidene,

a fused C 7-18 cycloalkylidene, or

a fused C 6-18 heterocycloalkylidene.

6. The film of claim 5 , wherein the first carbonate units are bisphenol A units, and in the second carbonate units X b is a C 3-18 cycloalkylidene, a fused C 7-18 cycloalkylidene, or a fused C 6-18 heterocycloalkylidene.

7. The film of claim 6 , wherein X b is a C 3-18 cycloalkylidene, a fused C 7-18 cycloalkylidene or a fused C 6-18 heterocycloalkylidene of the formula (4a)

wherein R r , R p , R q , and R t are each independently hydrogen, oxygen, or C 1-12 organic groups; Q 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, C 6-42 aryl or C 1-12 acyl; r is 0 to 2, t is 1 or 2, q 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.

8. The film of claim 5 , wherein

the first carbonate unites are derived from bisphenol A, and

the second carbonate units are derived from 1-bis(4-hydroxyphenyl)cyclododecylidene, 1,1-bis(4-hydroxyphenyl)adamantylidene, 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine, 1,1-bis(4-hydroxy-3-methylphenyl)cyclohexane, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane, or a combination comprising at least one of the foregoing.

9. The film of claim 8 , wherein the second carbonate units are derived from 2-phenyl-3,3-bis(4-hydroxyphenyl)phthalimidine.

10. The film of claim 8 , wherein the second carbonate units are derived from 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.

11. The film of claim 1 further comprising a polycarbonate homopolymer.

12. The film of claim 1 , wherein the cyclic olefin copolymer is a copolymer of a cyclic olefin monomer and an acyclic olefin monomer.

13. The film of claim 1 , wherein the cyclic olefin copolymer has at least one of

a heat deflection temperature of 120 to 175° C., measured as per ISO 75, parts 1 and 2 at 0.45 megaPascal; or

a glass transition temperature of 100 to 176° C.

14. The film of claim 1 , comprising

5 to 25 wt % of a copolymer comprising units derived from norbornene and ethylene;

75 to 95 wt % of a copolycarbonate comprising bisphenol A carbonate units and 2-phenyl-3,3′-bis(4-hydroxyphenyl) phthalimidine carbonate units or a copolycarbonate comprising bisphenol A carbonate units and bisphenol 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane units.

15. A method of producing a film of claim 1 , comprising extruding a film-forming composition comprising

the copolycarbonate comprising first repeating bisphenol carbonate units and second repeating carbonate units that are not the same as the first repeating units; and

the cyclic olefin copolymer.

16. An article comprising the film of claim 1 .

17. The article of claim 16 , further comprising a layer of a conductive metal or metal alloy deposited on at least a portion of the film, wherein the conductive metal or metal alloy comprises aluminum, zinc, copper, silver, gold, nickel, titanium, chromium, vanadium, platinum, tantalum, niobium, brass, or a combination comprising at least one of the foregoing.

18. A capacitor comprising the article of claim 16 .

19. An electronic device comprising the capacitor of claim 18 .

20. An inverter comprising the electronic device of claim 19 .