Stock material or miscellaneous articles – Composite – Of silicon containing
Reexamination Certificate
2002-01-30
2004-05-18
Dawson, Robert (Department: 1712)
Stock material or miscellaneous articles
Composite
Of silicon containing
C428S145000, C428S147000, C428S220000, C522S031000, C522S059000, C522S071000, C522S148000, C522S172000, C525S477000, C528S038000
Reexamination Certificate
active
06737169
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to a polymer composition which can form a smooth film, a cured product and a laminate thereof, and a method for producing the cured product. More particularly, the present invention relates to a silicon polymer composition.
BACKGROUND OF THE INVENTION
With recent miniaturization and lightening of optical and electronic parts, an extreme decrease in the thickness of coating films has progressed in the coating field. Recent improvement in thin film coating techniques, improvement in smoothness in forming substrates, and improvement in accuracy of techniques for inspecting surface unevenness have increased requirements for thin films.
Although techniques for forming thin films by methods such as spin coating, sputtering, vapor deposition and plating have hitherto been generally applied, these techniques are unsuitable for coating on films. There are some methods for coating films by roll coating. However, particles of lubricants are added to films and coating materials to retain hardness and scratch resistance, which causes poor surface smoothness due to unevenness caused by the lubricants. Further, defects caused by coating unevenness and cissing are liable to develop according to a decrease in the thickness of coating films, resulting in a tendency to deteriorate the smoothness. For improving the smoothness, it is preferred that the coating materials have a viscosity of higher than 10 mPa·s and a high concentration to increase the thickness of the films. Accordingly, there has been the problem that this is incompatible with a decrease in the thickness of the films.
As conventional release films for the production of ceramic condensers, there have been used films in which compositions containing fine particles of lubricants such as silica are applied onto substrate films and cured to form coating films. The above-mentioned lubricants are used for lowering the coefficient of friction of the release films in taking up them to make it difficult to be scratched. However, when a recent increase in the number of layers of the ceramic condensers results in the decreased thickness of the respective layers, the unevenness on surfaces of the coating films due to the fine particles of the lubricants gives a limitation on the smoothness of the surfaces of the layers of the ceramic condensers produced.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a polymer composition which can form a coating film having high hardness, excellent in mechanical strength such as wear resistance, having good taking-up properties and difficult to be scratched even when no lubricants are contained, extremely smooth and having no difference in film thickness.
Further, another object of the present invention is to provide a polymer composition excellent in storage stability without increasing foreign matter in long-term storage.
Still another object of the present invention is to provide a cured product obtained from the above-mentioned polymer composition, and a method for producing the cured product.
According to the present invention, there is provided a polymer composition comprising (A) a polymer having a silicon atom bound to a hydrolytic group and/or a hydroxyl group, in which the maximum size of particles contained therein is 2 &mgr;m or less, and the number of particles having a size of 0.2 &mgr;m to 2 &mgr;m is 1,000 particles/ml or less.
The above-mentioned polymer composition may further contain (B) at least one component selected from the group consisting of an organosilane represented by the following general formula (1), a hydrolyzate of the organosilane and a condensate of the organosilane:
(R
1
)
n
Si(X)
4-n
(1)
wherein, R
1
, which may be the same or different when two or more R
1
groups are present, represents a monovalent organic group having 1 to 8 carbon atoms; X represents a halogen atom or an alkoxyl or acetoxyl group having 1 to 8 carbon atoms; and n is an integer of 0 to 2.
The above-mentioned polymer composition may further contain a compound having a recurring unit represented by the following general formula (2):
wherein m is from 5 to 250, and n′ is from 4 to 40.
The polystyrene-converted weight-average molecular weight of the above-mentioned component (A) is preferably from 1,000 to 100,000.
The above-mentioned polymer composition may further contain (C) a photoacid generating agent.
The above-mentioned polymer composition may further contain (D) a dehydrating agent.
Further, according to the present invention, there is provided a cured product obtained by coating a substrate with the above-mentioned polymer composition and subjecting the composition to heat curing and/or photo-curing.
A surface of the above-mentioned substrate may have an arithmetical mean roughness of 0.5 &mgr;m or less and/or a maximum height of projections thereon of 2 &mgr;m or less.
The above-mentioned substrate may be a film whose surface has an arithmetical mean roughness of 0.5 &mgr;m or less and/or a maximum height of projections thereon of 2 &mgr;m or less.
A surface of the above-mentioned cured product may have an arithmetical mean roughness of 0.2 &mgr;m or less and/or a maximum height of projections thereon of 2 &mgr;m or less.
The surface of the above-mentioned cured product may have a hydroxyl group concentration of 10% or less. The surface of the above-mentioned cured product may have a coefficient of dynamic friction of 0.5 or less.
The above-mentioned cured product may have a release, non-adhesive function, and is useful for a release film for the production of a ceramic condenser.
Still further, according to the present invention, there is provided a laminate having the cured product composed of the above-mentioned polymer composition on a substrate film, in which a surface of the substrate has an arithmetical mean roughness of 0.5 &mgr;m or less and/or a maximum height of projections thereon of 2 &mgr;m or less and 1,000 projections/m
2
or less of projections having a height of 0.2 &mgr;m to 2 &mgr;m, and a surface of the cured product has an arithmetical mean roughness of 0.2 &mgr;m or less and/or a maximum height of projections thereon of 2 &mgr;m or less and 500 projections/m
2
or less of projections having a height of 0.2 &mgr;m to 2 &mgr;m. This laminate is useful for a release film for the production of a ceramic condenser.
Yet still further, according to the present invention, there is provided a method for producing a cured product, which comprises coating a substrate with the above-mentioned polymer composition, and subjecting the composition to heat-curing and/or photo-curing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Respective components constituting the polymer composition of the present invention will be described in turn below.
Component (A)
Component (A) is a polymer in which a silyl group having a silicon atom is bonded to a hydrolytic group and/or a hydroxyl group (hereinafter referred to as a “specific silyl group”), preferably at an end and/or a side chain of a molecular chain of the polymer.
In the polymer composition of the present invention, silyl group-containing polymer (A) is a component that brings about excellent coating film performances by co-condensation of the hydrolytic group and/or the hydroxyl group of the silyl group with itself and with component (B) in curing the coating film.
The content of silicon atoms in component (A) is generally from 0.001% to 20% by weight, and preferably from 0.01% to 15% by weight, based on the whole component (A).
The preferred specific silyl group is a group expressed by the following general formula (3):
wherein, X represents a hydrolytic group such as a halogen atom, an alkoxyl group, an acetoxyl group, a phenoxy group, a thioalkoxyl group or an amino group, or a hydroxyl group; R
3
represents a hydrogen atom, an alkyl group having 1 to 10 carbon atoms or an aralkyl group having 1 to 10 carbon atoms; and i is an integer of 1 to 3.
Component (A) can be produced, for example, by methods described in the following (a)
Hashiguchi Yuichi
Shimada Mibuko
Yoshimura Nakaatsu
Dawson Robert
JSR Corporation
Keehan Christopher
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