Polymer electrodeposition process

Claim 2

An electrodeposition process for forming a free standing belt shaped film comprising providing at least one sleeve electrode coaxially spaced apart from and surrounding at least one other electrode in a bath comprising a dispersion of electrically charged, thermoplastic film forming polymer particles in an organic liquid dispersion medium substantially free of water, said polymer particles having a weight average molecular weight of at least about 35,000 and being substantially insoluble in said organic dispersion liquid medium at electrodeposition temperatures and sufficiently soluble in said organic dispersion liquid medium at elevated drying temperatures to coalesce and form a viscous coating, applying an electric field across the electrodes until a thick, substantially uniform deposit of polymer particles forms on the interior surface of said sleeve electrode, removing said sleeve electrode bearing said deposit of polymer particles and residual liquid dispersion medium clinging to said deposit of polymer particles from said bath, heating said deposit to initially solubilize said polymer particles in said residual organic liquid dispersion medium to form a coalesced, continuous viscous coating of the solublized polymer particles, continuing said heating to evaporate said residual organic liquid dispersion medium and form a continuous, solidified, dry, belt shaped polymer film, cooling said continuous, solidified, dry, belt shaped polymer film, and removing said continuous, solidified, dry, belt shaped polymer film from said interior surface of said sleeve electrode.

Claim 3

An electrodeposition process according to claim 1 wherein said thermoplastic film forming polymer particles in said organic liquid dispersion medium have an average particle size of between about 0.01 micrometer and about 10 micrometers and wherein said dispersion is substantially free of polymer particle agglomerates.

Claim 4

An electrodeposition process according to claim 1 wherein the concentration of said polymer particles in said dispersion is between about 0.5 percent by weight and about 60 percent by weight based on the total weight of said dispersion.

Claim 5

An electrodeposition process according to claim 1 wherein the solubility of said polymer particles in said dispersion medium is greater than about 1 percent by weight based on the weight of said deposit of particles at temperatures employed during said heating.

Claim 6

An electrodeposition process according to claim 1 wherein said coalesced, continuous viscous coating of the solublized polymer particles is a sol.

Claim 7

An electrodeposition process according to claim 1 wherein said interior surface of said sleeve electrode is precoated with a thin coating of release material.

Claim 8

An electrodeposition process according to claim 1 wherein said dispersion also comprises up to about 10 percent by weight surfactant based on the total weight of dispersion solids.

Claim 9

An electrodeposition process according to claim 1 wherein said dispersion also comprises up to about 10 percent by weight release material based on the total weight of dispersion solids.

Claim 10

An electrodeposition process according to claim 1 wherein said dispersion also comprises up to about 10 percent by weight of a charge control agent based on the total weight of dispersion solids.

Claim 11

An electrodeposition process according to claim 1 wherein said polymer particles also contain up to about 50 percent by weight filler particles based on the total weight of the polymer particles and filler particles.

Claim 12

An electrodeposition process according to claim 1 wherein said dispersion medium contains less than about 10 percent water based on the total weight of said liquid dispersion medium.

Claim 13

An electrodeposition process according to claim 1 wherein said dispersion has an electrical conductivity between about 4×10 -8 mho-cm and about 1×10 -3 mho/cm.

Claim 14

An electrodeposition process according to claim 1 wherein said interior surface of said sleeve electrode has a critical surface tension of less than about 31 dynes/cm and an electrical conductivity of at least about 1×10 -5 mho/cm.

Claim 15

An electrodeposition process according to claim 1 wherein said organic liquid has a boiling point higher than the temperature employed for electrodeposition.

Claim 16

An electrodeposition process according to claim 1 wherein said continuous, solidified, dry, belt shaped polymer film contains less than about 5 percent by weight of said organic liquid dispersion medium based on the total weight of said continuous, solidified, dry, belt shaped polymer film.

Claim 17

An electrodeposition process according to claim 1 wherein said continuous, solidified, dry, belt shaped polymer film has a thickness between about 5 micrometers and about 500 micrometers.

Claim 18

An electrodeposition process according to claim 1 wherein said dispersion also comprises a second organic liquid comprising an alcohol containing from 1 to 3 carbon atoms.

Claim 19

An electrodeposition process according to claim 1 wherein said cooling of said continuous, solidified, dry, belt shaped polymer film comprises rapid quenching of the coated electrode by immersion in a liquid bath.

Claim 20

An electrodeposition process for forming a free standing belt shaped film comprising providing at least one sleeve electrode, forming a thin electrically conductive layer on the interior surface of said sleeve electrode, submerging said sleeve electrode and thin electrically conductive layer into a bath with said sleeve electrode being coaxially spaced apart from and surrounding at least one other electrode in said bath, said bath comprising a dispersion of electrically charged, thermoplastic film forming polymer particles in an organic liquid dispersion medium substantially free of water, said polymer particles having a weight average molecular weight of at least about 35,000 and being substantially insoluble in said organic dispersion liquid medium at electrodeposition temperatures and sufficiently soluble in said organic dispersion liquid medium at elevated drying temperatures to coalesce and form a viscous coating, applying an electric field across the electrodes until a thick, substantially uniform deposit of polymer particles forms on said thin electrically conductive layer on said interior surface of said sleeve electrode, removing said sleeve electrode bearing said electrically conductive layer and said deposit of polymer particles and residual liquid dispersion medium clinging to said deposit of polymer particles from said bath, heating said deposit to initially solubilize said polymer particles in said residual organic liquid dispersion medium to form a coalesced, continuous viscous coating of the solubilized polymer particles, continuing said heating to evaporate said residual organic liquid dispersion medium and form a continuous, solidified, dry, belt shaped polymer film on said electrically conductive layer, and removing said electrically conductive layer and continuous, solidified, dry, belt shaped polymer film from said interior surface of said sleeve electrode.

Claim 21

An electrodeposition process for forming a free standing belt shaped film comprising providing at least one sleeve electrode, forming a thin electrically conductive layer on the interior surface of said sleeve electrode, submerging said sleeve electrode and thin electrically conductive layer into a bath with said sleeve electrode being coaxially spaced apart from and surrounding at least one other electrode in said bath, said bath comprising a dispersion of electrically charged, thermoplastic film forming polymer particles in an organic liquid dispersion medium substantially free of water, said polymer particles having a weight average molecular weight of at least about 35,000 and being substantially insoluble in said organic dispersion liquid medium at electrodeposition temperatures and sufficiently soluble in said organic dispersion liquid medium at elevated drying temperatures to coalesce and form a viscous coating, applying an electric field across the electrodes until a thick, substantially uniform deposit of polymer particles forms on said thin electrically conductive layer on said interior surface of said sleeve electrode, removing said sleeve electrode bearing said electrically conductive layer and said deposit of polymer particles and residual liquid dispersion medium clinging to said deposit of polymer particles from said bath, heating said deposit to initially solubilize said polymer particles in said residual organic liquid dispersion medium to form a coalesced, continuous viscous coating of the solubilized polymer particles, continuing said heating to evaporate said residual organic liquid dispersion medium and form a continuous, solidified, dry, belt shaped polymer film on said electrically conductive layer, and removing said electrically conductive layer and continuous, solidified, dry, belt shaped polymer film from said interior surface of said sleeve electrode.

Claim 22

An electrodeposition process for forming a free standing belt shaped film comprising providing at least one sleeve electrode coaxially spaced apart from and surrounding at least one other electrode in a bath comprising a dispersion of electrically charged, thermoplastic film forming polymer particles in an organic liquid dispersion medium substantially free of water, said polymer particles having a weight average molecular weight of at least about 35,000 and being substantially insoluble in said organic dispersion liquid medium at electrodeposition temperatures and sufficiently soluble in said organic dispersion liquid medium at elevated drying temperatures to coalesce and form a viscous coating, applying an electric field across the electrodes until a thick, substantially uniform deposit of polymer particles forms on the interior surface of said sleeve electrode, removing said sleeve electrode bearing said deposit of polymer particles and residual liquid dispersion medium clinging to said deposit of polymer particles from said bath, heating said deposit to initially solubilize said polymer particles in said residual organic liquid dispersion medium to form a coalesced, continuous viscous coating of the solublized polymer particles, continuing said heating to evaporate said residual organic liquid dispersion medium and form a continuous, solidified, dry, belt shaped polymer film, removing said continuous, solidified, dry, belt shaped polymer film from said interior surface of said sleeve electrode, applying an electrically conductive layer on said film, applying a charge generation layer, and applying a charge transport layer.

Claim 23

An electrodeposition process for forming a free standing belt shaped film comprising providing at least one sleeve electrode coaxially spaced apart from and surrounding at least one other electrode in a bath comprising a dispersion of electrically charged, thermoplastic film forming polymer particles in an organic liquid dispersion medium substantially free of water, said polymer particles having a weight average molecular weight of at least about 35,000 and being substantially insoluble in said organic dispersion liquid medium at electrodeposition temperatures and sufficiently soluble in said organic dispersion liquid medium at elevated drying temperatures to coalesce and form a viscous coating, applying an electric field across the electrodes until a thick, substantially uniform deposit of polymer particles forms on the interior surface of said sleeve electrode, removing said sleeve electrode bearing said deposit of polymer particles and residual liquid dispersion medium clinging to said deposit of polymer particles from said bath, heating said deposit to initially solubilize said polymer particles in said residual organic liquid dispersion medium to form a coalesced, continuous viscous coating of the solublized polymer particles, continuing said heating to evaporate said residual organic liquid dispersion medium and form a continuous, solidified, dry, belt shaped polymer film, removing said continuous, solidified, dry, belt shaped polymer film from said interior surface of said sleeve electrode, applying an electrically conductive layer on said film, applying a charge generation layer, and applying a charge transport layer.