US5288529A — Liquid crystal polymer film

Claim 1

Independent Claim 113 words

A multiaxially oriented film prepared from high molecular weight liquid crystalline lyotropic or thermotropic polymer, having two substantially parallel and flat main surfaces and having a controlled molecular orientation in substantially any plane of said film, which orientation in each plane is defined by a selected positive or negative angle with respect to a longitudinal axis of said film, said film having planar surfaces regions wherein said angles defined by said molecular orientation generally have values defined as positive, and said film having an inner region with respect to said surface regions wherein said angles generally have negative values, said film having a nearly uniform coefficient of thermal expansion in all planar directions.

Claim 2

Dependent Claim 113 words

A multiaxially oriented film prepared from high molecular weight liquid crystalline lyotropic or thermotropic polymer, having two substantially parallel and flat main surfaces and having a controlled molecular orientation in substantially any plane of said film, which orientation in each plane is defined by a selected positive or negative angle with respect to a longitudinal axis of said film, said film having planar surfaces regions wherein said angles defined by said molecular orientation generally have values defined as positive, and said film having an inner region with respect to said surface regions wherein said angles generally have negative values, said film having a nearly uniform coefficient of thermal expansion in all planar directions.

Claim 3

Dependent Claim 40 words

A film as in claim 1, wherein said regions are constituted by forming two individual intermediate-product films each having a substantially biaxial orientation, and then laminating said intermediate films in a continuous process to form said film having said regions.

Claim 4

Dependent Claim 41 words

A film as in claim 2, wherein said intermediate-product films are biaxial films formed by employing respective two-rotor counter-rotation dies whose rotors have opposite directions of rotation, and wherein the molecular orientation angles of the facing laminated surfaces are substantially equal.

Claim 5

Dependent Claim 24 words

A film as in claim 1, wherein said inner region is a portion of an integral film structure formed by a single die-forming process.

Claim 6

Dependent Claim 70 words

A film as in claim 4, wherein said integral film structure is formed by employing a tubular die having three concentric rotors which form two annular flow channels therebetween; supplying the polymer through said channels; rotating the outer and inner rotors in a first direction while rotating the middle rotor in the opposite direction; and joining the respective polymer films formed in said channels to form said integral film structure.

Claim 7

Dependent Claim 22 words

A film as in claim 5, wherein said polymer is a blend of said lyotropic or thermotropic polymers and a coil polymer.

Claim 8

Dependent Claim 34 words

A film as in claim 1, wherein each said surface region is relatively thin and said surface regions are substantially equal in thickness, while said inner region is thicker than each said surface region.

Claim 9

Dependent Claim 22 words

A film as in claim 7, wherein the maximum positive and negative angles are substantially equal with respect to said longitudinal axis.

Claim 10

Dependent Claim 13 words

A film as in claim 8, wherein said maximum angles are substantially +/-45°.

Claim 11

Dependent Claim 33 words

A film as in claim 1, wherein said molecular orientation on one side of the midplane of the film is substantially a mirror-image of the orientation on the other side of the midplane.

Claim 12

Dependent Claim 11 words

A film as in claim 1, wherein said polymer is lyotropic.

Claim 13

Dependent Claim 24 words

A film as in claim 11, wherein said lyotropic polymer is selected from the group consisting of poly-(p-phenylene benzobisoxazole), poly-(p-phenylene benzobisthiozole), and poly-(p-phenylene benzobisimidazole).

Claim 14

Dependent Claim 11 words

A film as in claim 1, wherein said polymer is thermotropic.

Claim 15

Dependent Claim 14 words

A film as in claim 13, wherein said polymer is a paraoriented aromatic polyester.

Claim 16

Dependent Claim 22 words

A film as in claim 1, wherein said polymer is a blend of said lyotropic or thermotropic polymers and a coil polymer

Claim 17

Independent Claim 106 words

A method of preparing a multiaxially oriented film from high molecular weight liquid crystalline lyotropic or thermotropic polymers comprising the steps of: (a) subjecting axially flowing liquid crystalline polymer material to transverse-directional motions, thereby straining the axial flow; and (b) solidifying the microscale structural orientation formed in step (a), wherein said film is formed by first forming two individual intermediate-product films each having a substantially biaxial orientation, and then laminating said intermediate films in a continuous process to form said film having planar surface regions defined by positive molecular orientation angle and an inner region define negative molecular orientation angle, with respect to the longitudinal axis.

Claim 18

Independent Claim 106 words

A method of preparing a multiaxially oriented film from high molecular weight liquid crystalline lyotropic or thermotropic polymers comprising the steps of: (a) subjecting axially flowing liquid crystalline polymer material to transverse-directional motions, thereby straining the axial flow; and (b) solidifying the microscale structural orientation formed in step (a), wherein said film is formed by first forming two individual intermediate-product films each having a substantially biaxial orientation, and then laminating said intermediate films in a continuous process to form said film having planar surface regions defined by positive molecular orientation angle and an inner region define negative molecular orientation angle, with respect to the longitudinal axis.

Claim 19

Dependent Claim 41 words

A method as in claim 16, wherein said intermediate-product films are biaxial films formed by employing respective two-rotor counter-rotation dies whose rotors have opposite directions of rotation, and wherein the molecular orientation angles of the facing laminated surfaces are substantially equal.

Claim 20

Dependent Claim 23 words

A method as in claim 16, wherein said regions are respective portions of an integral film structure formed by a single die-forming process.

Claim 21

Dependent Claim 70 words

A method as in claim 18, wherein said integral film structure is formed by employing a tubular die having three concentric rotors which form two annular flow channels therebetween; supplying the polymer through said channels; rotating the outer and inner rotors in a first direction while rotating the middle rotor in the opposite direction; and joining the respective polymer films formed in said channels to form said integral film structure.

Claim 22

Dependent Claim 95 words

A method as in claim 16, wherein said film is formed by passing said polymer axially through a die which defines a cross-sectional area of said polymer flow; said die having slits at opposing transverse sides of said die; and passing a continuous belt through said slits and through said polymer flow in only one direction, substantially bisecting said cross-sectional area of said polymer flow, thereby setting up a transverse shear pattern at a middle layer of the flow and oppositely directed transverse shear patterns across the sides of the die not having the slits.

Claim 23

Dependent Claim 39 words

A method as in claim 20, wherein the die defines an elongated rectangular cross-section of the polymer flow, said slits being at short sides of said cross-section, and said continuous belt passing parallel to longer sides of said cross-section.

Claim 24

Dependent Claim 40 words

A method as in claim 16, comprising the step of forming the film such that molecular orientation on one side of the midplane of the film is substantially a mirror-image of the orientation on the other side of the midplane.

Claim 25

Dependent Claim 20 words

A method as in claim 16, wherein said polymer is lyotropic and said material is a dope containing said polymer.

Claim 26

Dependent Claim 20 words

A method as in claim 16, wherein said polymer is thermotropic and said material is a melt of said polymer.

Claim 27

Dependent Claim 24 words

A method as in claim 23, wherein said lytropic polymer is selected from the group consisting of poly-(p-phenylene benzobisoxazole), poly-(p-phenylene benzobisthiozole), and poly-(p-phenylene benzobisimidazole).

Claim 28

Dependent Claim 194 words

A multiaxially oriented liquid crystalline film exhibiting a nearly uniform coefficient of thermal expansion in all planar directions prepared from high molecular weight liquid crystalline lyotropic or thermotropic polymers, having a controlled molecular orientation in substantially any plane of said film, which orientation in each plane is defined by a selected positive or negative angle with respect to a longitudinal axis of said film, said film having two surface layers, one said surface layer having a positive angle defined by said molecular orientation, the orientation of the other surface layer being negative, and said film having a central core layer wherein said orientation is generally along said longitudinal axis, wherein said layers are respective portions of an integral film structure formed by a single die-forming process, and wherein said film is formed by employing a tubular die having at least three concentric mandrels including outer, inner, and middle mandrels which form two annular flow channels therebetween, and a third annular flow channel, within said middle mandrel; supplying the polymer through said channels; rotating at least the outer and inner mandrels; and joining the respective polymer films formed in said channels to form said film.

Claim 29

Dependent Claim 194 words

A multiaxially oriented liquid crystalline film exhibiting a nearly uniform coefficient of thermal expansion in all planar directions prepared from high molecular weight liquid crystalline lyotropic or thermotropic polymers, having a controlled molecular orientation in substantially any plane of said film, which orientation in each plane is defined by a selected positive or negative angle with respect to a longitudinal axis of said film, said film having two surface layers, one said surface layer having a positive angle defined by said molecular orientation, the orientation of the other surface layer being negative, and said film having a central core layer wherein said orientation is generally along said longitudinal axis, wherein said layers are respective portions of an integral film structure formed by a single die-forming process, and wherein said film is formed by employing a tubular die having at least three concentric mandrels including outer, inner, and middle mandrels which form two annular flow channels therebetween, and a third annular flow channel, within said middle mandrel; supplying the polymer through said channels; rotating at least the outer and inner mandrels; and joining the respective polymer films formed in said channels to form said film.

Claim 30

Dependent Claim 22 words

A film as in claim 26, wherein the maximum positive and negative angles are substantially equal with respect to said longitudinal axis.

Claim 31

Dependent Claim 13 words

A film as in claim 27, wherein said maximum angles are substantially +/-45°.

Claim 32

Dependent Claim 33 words

A film as in claim 26, wherein the molecular orientation on one side of the midplane of the film is substantially a mirror-image of the orientation on the other side of the midplane.

Claim 33

Dependent Claim 11 words

A film as in claim 26, wherein said polymer is lyotropic.

Claim 34

Dependent Claim 24 words

A film as in claim 30, wherein said lyotropic polymer is selected from the group consisting of poly-(p-phenylene benzobisoxazole), poly-(p-phenylene benzobisthiozole), and poly-(p-phenylene benzobismidazole).

Claim 35

Dependent Claim 11 words

A film as in claim 26, wherein said polymer is thermotropic.

Claim 36

Dependent Claim 14 words

A film as in claim 32, wherein said polymer is a paraoriented aromatic polyester.

Claim 37

Dependent Claim 21 words

A film as in claim 26, wherein said polymer is a blend of lyotropic or thermotropic polymers and a coil polymer.

Claim 38

Dependent Claim 27 words

A film as in claim 26, wherein said polymer includes a plurality of different selected ordered or coil polymers or blends in respective layers within said film.

Claim 39

Dependent Claim 84 words

A multiaxially oriented liquid crystal polymer film structure from high molecular weight liquid crystalline lyotropic or thermotropic polymers comprising two outer surface layers which are oriented generally in a first controllable direction; two intermediate layers respectively inward of said outer surface layers which are oriented generally in a second controllable direction; and a central core layer sandwiched between said intermediate layers which is oriented generally in a third controllable direction, said film having a nearly uniform coefficient of thermal expansion in all planar directions.

Claim 40

Dependent Claim 84 words

A multiaxially oriented liquid crystal polymer film structure from high molecular weight liquid crystalline lyotropic or thermotropic polymers comprising two outer surface layers which are oriented generally in a first controllable direction; two intermediate layers respectively inward of said outer surface layers which are oriented generally in a second controllable direction; and a central core layer sandwiched between said intermediate layers which is oriented generally in a third controllable direction, said film having a nearly uniform coefficient of thermal expansion in all planar directions.

Claim 41

Dependent Claim 20 words

A film as in claim 36, wherein the central core layer is oriented in or close to the machine direction.

Claim 42

Dependent Claim 23 words

A film as in claim 37, wherein the intermediate layers have an orientation which is complementary to that of the adjacent outer layers.

Claim 43

Dependent Claim 40 words

A film as in claim 38, wherein the respective directions of orientation of each outer surface layer and the adjacent intermediate layer define equal and opposite angles with respect to the machine direction in which the extrusion is carried out.

Claim 44

Dependent Claim 46 words

A film as in claim 37, wherein the direction of orientation of each intermediate layer is between that of the adjacent outer layer and that of the central core layer, thus providing a gradual change of direction from the outer layers to the central core layer.

Claim 45

Dependent Claim 39 words

A film as in claim 37, wherein the respective directions of orientation of the outer surface layers and the intermediate layers define equal and opposite angles with respect to the machine direction in which the extrusion is carried out.

Claim 46

Independent Claim 97 words

A method of preparing a multiaxially oriented film from a high molecular weight liquid crystalline lyotropic or thermotropic polymers and having a controlled molecular orientation in substantially any plane of said film comprising the steps of: employing a tubular die having at least three concentric mandrels including outer, inner, and middle mandrels which form two annular flow channels therebetween, and a third annular flow channel within said middle mandrel; supplying the polymer through said channels; rotating at least the outer and inner mandrels; and joining the respective polymer films formed in said channels to form said film.

Claim 47

Independent Claim 97 words

A method of preparing a multiaxially oriented film from a high molecular weight liquid crystalline lyotropic or thermotropic polymers and having a controlled molecular orientation in substantially any plane of said film comprising the steps of: employing a tubular die having at least three concentric mandrels including outer, inner, and middle mandrels which form two annular flow channels therebetween, and a third annular flow channel within said middle mandrel; supplying the polymer through said channels; rotating at least the outer and inner mandrels; and joining the respective polymer films formed in said channels to form said film.

Claim 48

Dependent Claim 18 words

A method as in claim 42, wherein said outer and inner mandrels are rotated in the same direction.

Claim 49

Dependent Claim 39 words

A method as in claim 43, wherein said middle mandrel is rotated more slowly than said outer and inner mandrels and said middle mandrel is rotated in a direction opposite the rotational direction of said outer and inner mandrels.

Claim 50

Dependent Claim 15 words

as in claim 42, wherein said outer and inner mandrels are rotated in opposite directions.

Claim 51

Dependent Claim 13 words

A method as in claim 45, wherein said middle mandrel is not rotated.

Claim 52

Dependent Claim 23 words

A method as in claim 43 or claim 45, wherein said polymer is lyotropic and said quantity is a dope containing said polymer.

Claim 53

Dependent Claim 22 words

A method as in claim 43 or claim 45, wherein said is thermotropic and said quantity is a melt of said polymer.

Claim 54

Dependent Claim 43 words

A method as in claim 43 or claim 45, comprising the step of forming the film such that molecular orientation on one side of the midplane of the film is substantially a mirror-image of the orientation on the other side of the midplane.

Claim 55

Dependent Claim 23 words

A method as in claim 43 or claim 45, wherein said polymer is a blend of lyotropic orthermotropic polymers and a coil polymer.

Claim 56

Dependent Claim 29 words

A method as in claim 43 or claim 45, wherein said polymer includes a plurality of different selected lyotropic or thermotropic coil polymers in respective layers within said film.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1997-02-21	1997-08-23	1998-02-22	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2001-02-21	2001-08-23	2002-02-22	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2005-02-21	2005-08-23	2006-02-22	$7700.00	Window Closed / Lapsed

Liquid crystal polymer film

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