US4610762A Expired / Lapsed US ⏱️ 0.0 years remaining

Method for forming polymer films having bubble release surfaces

Assignee: Dow Chemical Co

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Filing: 1985-05-31

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Granted: 1986-09-09

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Expires: 2005-05-31

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Abstract

Abstract The invention is a method for forming polymer films having a roughened surface using removable substrates comprising: (a) providing a removable substrate with a roughened surface; (b) forming a dispersion of a perfluorinated polymer containing sites convertible to ion exchange groups in a dispersant having: a boiling point less than about 110° C.; a density of from about 1.55 to about 2.2; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands; (c) depositing the dispersion onto the roughened, removable substrate; (d) removing the dispersant from the dispersion; and (e) removing the substrate. Particularly preferred as a dispersant is a compound represented by the general formula: XCF.sub.2 --CYZX' wherein: X is selected from the group consisting of F, Cl, Br, and I; X' is selected from the group consisting of Cl, Br, and I; Y and Z are independently selected from the group consisting of H, F, Cl, Br, I and R'; R' is selected from the group of perfluoroalkyl radicals and chloroperfluoroalkyl radicals having from 1 to 6 carbon atoms. The most preferred dispersant is 1,2-dibromotetrafluoroethane.

Inventors

👤 Jeffrey D. Birdwell

Bibliographic Details

Application Number —

Jurisdiction US

Data Source google_patents

Last Synchronized 2026-11-02 02:40

CPC Classifications

C; C08; C08J; C08J5/00; C08J5/18; B; B01; B01D; B01D71/00; B01D71/06; B01D71/30; B01D71/32; C08J3/00; C08J3/02; C08J3/09; C08J3/091; C08J3/093; H; H01; H01M; H01M8/00; H01M8/02; H01M8/0289; B01D2323/00; B01D2323/08; B01D2323/081; B01D2323/10; B01D2323/12; C08J2327/00; C08J2327/02; C08J2327/12; C08J2327/18; H01M8/10; H01M8/1004; Y; Y02; Y02E; Y02E60/00; Y02E60/30; Y02E60/50

Claims Analysis

Total Claims: 57

Claim 1

Independent Claim 98 words

A method for forming polymer films having a roughened surface using removal substrates comprising: (a) providing a removable substrate with a roughened surface; (b) forming a dispersion of a perfluorinated polymer containing sites convertible to ion exchange groups and a dispersant having: a boiling point less than about 110° C.; a density of from about 1.55 to about 2.97 grams per cubic centimeter; and a solubility parameter of from greater than about 7.1 to about 8.2 hildebrands; (c) depositing the dispersion onto the roughened, removable substrate; (d) removing the dispersant from the dispersion; and (e) removing the substrate.

Claim 2

Independent Claim 98 words

Claim 3

Dependent Claim 255 words

The method of claim 1 wherein the perfluorinated polymer is a copolymer of a first type of monomer and a second type of monomer: wherein the first type of monomer is represented by the general formula: CF.sub.2 ═CZZ' (I) where: Z and Z' are independently selected from the group consisting of --H, --Cl, --F, or CF 3 ; second monomer represented by the general formula: Y--(CF.sub.2).sub.a --(CFR.sub.f).sub.b --(CFR'.sub.f).sub.c --O--[CF(CF.sub.2 X)--CF.sub.2 --O].sub.n --CF═CF.sub.2 (II) where: Y is selected from the group consisting of --SO 2 Z, --CN, --COZ and C(R 3 f )(R 4 f )OH; Z is I, Br, Cl, F, OH, or NR 1 R 2 ; R is a branched or linear alkyl radical having from 1 to about 10 carbon atoms or an aryl radical; R 3 f and R 4 f are independently selected from the group consisting of perfluoroalkyl radicals having from 1 to about 10 carbon atoms; R 1 and R 2 are independently selected from the group consisting of H, a branched or linear alkyl radical having from 1 to about 10 carbon atoms or an aryl radical; a is 0-6; b is 0-6; c is 0 or 1; provided a+b+c is not equal to 0; X is Cl, Br, F or mixtures thereof when n>1; n is 0 to 6; and R f and R' f are independently selected from the group consisting of F, Cl, perfluoroalkyl radicals having from 1 to about 10 carbon atoms and fluorochloroalkyl radicals having from 1 to about 10 carbon atoms.

Claim 4

Dependent Claim 120 words

The method of claim 2 wherein the perfluorinated polymer is a copolymer formed from three types of monomers wherein the third type of monomer is one or more monomers represented by the general formula: Y'--(CF.sub.2).sub.a' --(CFR.sub.f).sub.b' --(CFR'.sub.f).sub.c' --O--[CF(CF.sub.2 X')--CF.sub.2 --O].sub.n' --CF═CF.sub.2 (III) where: Y' is F, Cl or Br; a' and b' are independently 0-3; c' is 0 or 1; provided a'+b'+c' is not equal to 0; n' is 0-6; R f and R' f are independently selected from the group consisting of Br, Cl, F, perfluoroalkyl radicals having from about 1 to about 10 carbon atoms, and chloroperfluoroalkyl radicals having from about 1 to about 10 carbon atoms; and X' is F, Cl, Br, or mixtures thereof when n'>1.

Claim 5

Dependent Claim 21 words

The method of claim 1 wherein the boiling point of the dispersant is from about 30° C. to about 110° C.

Claim 6

Dependent Claim 22 words

The method of claim 1 wherein the density of the dispersant is from about 1.55 to about 2.2 grams per cubic centimeter.

Claim 7

Dependent Claim 22 words

The method of claim 1 wherein the solubility parameter of the dispersant is from greater than about 7.1 to about 7.5 hildebrands.

Claim 8

Dependent Claim 29 words

The method of claim 1 wherein the density of the dispersant and the density of the polymer are both from about 1.55 to about 2.2 grams per cubic centimeter.

Claim 9

Independent Claim 130 words

A method for forming polymer films on removable substrates comprising: (a) roughening a surface of a removable substrate; (b) forming a dispersion of a perfluorinated polymer containing sites convertible to ion exchange groups and a dispersant, wherein the dispersant is represented by the general formula: XCF.sub.2 --CYZX' wherein: X is selected from the group consisting of F, Cl, Br, and I; X' is selected from the group consisting of Cl, Br, and I; Y and Z are independently selected from the group consisting of H, F, Cl, Br, I and R'; R' is selected from the group of perfluoroalkyl radicals and chloroperfluoroalkyl radicals having from 1 to 6 carbon atoms; (c) depositing the dispersion onto a removable substrate; (d) removing the dispersant from the dispersion; and (e) removing the substrate.

Claim 10

Independent Claim 130 words

Claim 11

Dependent Claim 11 words

The method of claim 8 wherein X and X' are Br.

Claim 12

Dependent Claim 11 words

The method of claim 8 wherein X and X' are Cl.

Claim 13

Dependent Claim 25 words

The method of claim 8 wherein the polymer is present in the dispersion at a concentration of from about 0.1 to about 50 weight percent.

Claim 14

Dependent Claim 25 words

The method of claim 8 wherein the polymer is present in the dispersion at a concentration of from about 0.3 to about 30 weight percent.

Claim 15

Dependent Claim 256 words

The method of claim 8 wherein the perfluorinated polymer is a copolymer of a first type of monomer and a second type of monomer: wherein the first type of monomer is represented by the general formula: CF.sub.2 ═CZZ' (I) where: Z and Z' are independently selected from the group consisting of --H, --Cl, --F, or CF 3 ; the second monomer is represented by the general formula: Y--(CF.sub.2).sub.a --(CFR.sub.f).sub.b --(CFR'.sub.f).sub.c --O--[CF(CF.sub.2 X)--CF.sub.2 --O].sub.n --CF═CF.sub.2 (II) where: Y is selected from the group consisting of --SO 2 Z, --CN, --COZ and C(R 3 f )(R 4 f )OH; Z is I, Br, Cl, F, OH, or NR 1 R 2 ; R is a branched or linear alkyl radical having from 1 to about 10 carbon atoms or an aryl radical; R 3 f and R 4 f independently selected from the group consisting of perfluoroalkyl radicals having from 1 to about 10 carbon atoms; R 1 and R 2 are independently selected from the group consisting of H, a branched or linear alkyl radical having from 1 to about 10 carbon atoms or an aryl radical; a is 0-6; b is 0-6; c is 0 or 1; provided a+b+c is not equal to 0; X is Cl, Br, F or mixtures thereof when n>1; n is 0 to 6; and R f and R' f are independently selected from the group consisting of F, Cl, perfluoroalkyl radicals having from 1 to about 10 carbon atoms and fluorochloroalkyl radicals having from 1 to about 10 carbon atoms.

Claim 16

Dependent Claim 120 words

The method of claim 13 wherein the perfluorinated polymer is a copolymer formed from three types of monomers wherein the third type of monomer is one or more monomers represented by the general formula: Y'--(CF.sub.2).sub.a' --(CFR.sub.f).sub.b' --(CFR'.sub.f).sub.c' --O--[CF(CF.sub.2 X')--CF.sub.2 --O--].sub.n' --CF═CF.sub.2 (III) where: Y' is F, Cl or Br; a' and b' are independently 0-3; c' is 0 or 1; provided a'+b'+c' is not equal to 0; n' is 0-6; R f and R' f are independently selected from the group consisting of Br, Cl, F, perfluoroalkyl radicals having from about 1 to about 10 carbon atoms, and chloroperfluoroalkyl radicals having from about 1 to about 10 carbon atoms; and X' is F, Cl, Br, or mixtures thereof when n'>1.

Claim 17

Dependent Claim 11 words

The method of claim 1 wherein the removable substrate is aluminum.

Claim 18

Dependent Claim 17 words

The method of claim 1 wherein the substrate is removed by dissolving the substrate with a solvent.

Claim 19

Dependent Claim 18 words

The method of claim 1 wherein the substrate is removed by dissolving the substrate with an alkaline solution.

Claim 20

Dependent Claim 15 words

The method of claim 1 wherein the substrate is roughened by air blasting the substrate.

Claim 21

Dependent Claim 13 words

The method of claim 1 wherein the substrate is roughened by chemical etching.

Claim 22

Dependent Claim 11 words

The method of claim 8 wherein the removable substrate is aluminum.

Claim 23

Dependent Claim 17 words

The method of claim 8 wherein the substrate is removed by dissolving the substrate with a solvent.

Claim 24

Dependent Claim 14 words

The method of claim 8 wherein the substrate is removed by an alkaline solution.

Claim 25

Dependent Claim 15 words

The method of claim 8 wherein the substrate is roughened by air blasting the substrate.

Claim 26

Dependent Claim 13 words

The method of claim 8 wherein the substrate is roughened by chemical etching.

Claim 27

Dependent Claim 10 words

The roughened film produced from the method of claim 1.

Claim 28

Dependent Claim 10 words

The roughened film produced from the method of claim 2.

Claim 29

Dependent Claim 10 words

The roughened film produced from the method of claim 3.

Claim 30

Dependent Claim 10 words

The roughened film produced from the method of claim 4.

Claim 31

Dependent Claim 10 words

The roughened film produced from the method of claim 5.

Claim 32

Dependent Claim 10 words

The roughened film produced from the method of claim 6.

Claim 33

Dependent Claim 10 words

The roughened film produced from the method of claim 7.

Claim 34

Dependent Claim 10 words

The roughened film produced from the method of claim 8.

Claim 35

Dependent Claim 10 words

The roughened film produced from the method of claim 9.

Claim 36

Dependent Claim 10 words

The roughened film produced from the method of claim 10.

Claim 37

Dependent Claim 10 words

The roughened film produced from the method of claim 11.

Claim 38

Dependent Claim 10 words

The roughened film produced from the method of claim 12.

Claim 39

Dependent Claim 10 words

The roughened film produced from the method of claim 13.

Claim 40

Dependent Claim 10 words

The roughened film produced from the method of claim 14.

Claim 41

Dependent Claim 10 words

The roughened film produced from the method of claim 15.

Claim 42

Dependent Claim 10 words

The roughened film produced from the method of claim 16.

Claim 43

Dependent Claim 10 words

The roughened film produced from the method of claim 17.

Claim 44

Dependent Claim 10 words

The roughened film produced from the method of claim 18.

Claim 45

Dependent Claim 10 words

The roughened film produced from the method of claim 19.

Claim 46

Dependent Claim 10 words

The roughened film produced from the method of claim 20.

Claim 47

Dependent Claim 10 words

The roughened film produced from the method of claim 21.

Claim 48

Dependent Claim 10 words

The roughened film produced from the method of claim 22.

Claim 49

Dependent Claim 10 words

The roughened film produced from the method of claim 23.

Claim 50

Dependent Claim 32 words

An electrochemical cell of the type having an anode and a cathode separated by an ion exchange membrane film, wherein the film is the film produced by the method of claim 2.

Claim 51

Dependent Claim 32 words

An electrochemical cell of the type having an anode and a cathode separated by an ion exchange membrane film, wherein the film is the film produced by the method of claim 3.

Claim 52

Dependent Claim 32 words

An electrochemical cell of the type having an anode and a cathode separated by an ion exchange membrane film, wherein the film is the film produced by the method of claim 8.

Claim 53

Dependent Claim 32 words

An electrochemical cell of the type having an anode and a cathode separated by an ion exchange membrane film, wherein the film is the film produced by the method of claim 9.

Claim 54

Dependent Claim 22 words

An electrochemical process comprising passing electrical current through an electrolyte between the anode and the cathode of the cell of claim 48.

Claim 55

Dependent Claim 22 words

An electrochemical process comprising passing electrical current through an electrolyte between the anode and the cathode of the cell of claim 49.

Claim 56

Dependent Claim 22 words

An electrochemical process comprising passing electrical current through an electrolyte between the anode and the cathode of the cell of claim 50.

Claim 57

Dependent Claim 22 words

An electrochemical process comprising passing electrical current through an electrolyte between the anode and the cathode of the cell of claim 51.

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USPTO Annuity & Maintenance Windows

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1989-09-08	1990-03-10	1990-09-09	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1993-09-08	1994-03-10	1994-09-09	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1997-09-08	1998-03-10	1998-09-09	$7700.00	Window Closed / Lapsed

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