Patent Application
20090023863
The present invention relates to a cross-linked fluorine-containing copolymer moldings, and more particularly to a cross-linked fluorine-containing copolymer moldings, applicable to a plasma irradiation step.
The semiconductor production process or the liquid crystal production process involves a plasma treatment of silicon wafers in various steps such as a CVD production step, an etching step, ashing step, etc., but the plasma treatment involves very severe conditions for organic polymer materials, almost all of which are actually inevitable from occurrence of considerable deterioration owing to the plasma irradiation circumstance.
Particularly, sealing materials used in the semiconductor production apparatuses or the liquid crystal production apparatuses undergo deterioration due to the plasma irradiation, and particles of inorganic compounds, etc. contained in the sealing materials as a filler are generated therefrom and are to foul up the wafer surfaces. Thus, it has been as far required that even the sealing materials for use in the semiconductor and liquid crystal production apparatuses may not generate any denaturated materials from the inorganic compounds, etc. used as a filler leading to defective products.
The fluorine-containing elastomers so far used as a sealing material must contain a reinforcing filler such as carbon black, silica, titanium oxide, etc. to improve normal state physical properties such as mechanical strength, etc. and also compression set value, and also in the case of polyol vulcanization or amine vulcanization it is necessary to add an acid acceptor including such metals as Mg, Pb, Ca, Al, Zn, etc. as a vulcanization promoter to the fluorine-containing elastomers besides the vulcanizing agent.
These inorganic fillers can be a cause for generating particles and a fluorine-containing elastomer free from any inorganic filler is also presumable for the reduction of particle generation, but in that case there will arise such new problems as a difficulty not only in attaining the necessary normal state physical properties or compression set value for the sealing materials, but also in lowering the kneadability at the mixing.
Thus, it has been keenly desired to provide a fluorine-containing molding material capable of attaining desired normal state physical properties and compression set value for the sealing material and also attaining distinguished kneadability at the mixing, while reducing the particle generation rate. In case of without any inorganic fillers, deteriorated sealing materials themselves also may be a cause for generating particles, and therefore it has been desired that even the organic polymer materials themselves used as molding materials for the sealing material have a reduced particle generation quantity, in other words, an increased plasma resistance.
When also used as rollers for conveyance in the semiconductor or liquid crystal production apparatuses, the organic polymer materials have such a problem as particle generation by friction, which is a pollution source.
An object of the present invention is to provide a cross-linked fluorine-containing copolymer moldings having desired normal state physical properties and compression set value while reducing a particle generation quantity of the fluorine-containing copolymers themselves even if used in a plasma irradiation step.
The object of the present invention can be attained by a cross-linked fluorine-containing copolymer moldings applicable to a plasma irradiation step, which is molded as a peroxide cross-linking product of a fluorine-containing copolymer blend comprising a fluorine-containing elastomer copolymer, and a fluorine-containing resin copolymer, which is a vinylidene fluoride-tetrafluoroethylene copolymer, both of the copolymers having reaction sites capable of reacting with a common peroxide-based cross-linking agent, respectively.
The present cross-linked fluorine-containing copolymer moldings can maintain desired normal state physical properties and compression set value, when the moldings are used as a sealing material and are subjected to plasma irradiation treatment, and can reduce the particle generation quantity of the cross-linked fluorine-containing copolymer moldings even if the moldings itself are subjected to plasma irradiation treatment or even if the moldings are used as a sealing material or rolls for conveyance in the semiconductor or liquid crystal production apparatuses, where other parts are subjected to the plasma irradiation treatment in these production processes, and consequently the sealing material or rolls for conveyance are also inevitably subjected to the plasma irradiation treatment, the reduction in the particle generation quantity can be given in terms of reduction in percent weight change or percent volume change. The moldings can also effectively reduce a particle generation quantity by friction at the time of plasma irradiation treatment when used as rollers for conveyance in the semiconductor or liquid crystal production apparatuses.
The cross-linked fluorine-containing copolymer molded as a peroxide cross-linking product of a blend of fluorine-containing resin copolymers comprising a fluorine-containing elastomer copolymer and a fluorine-containing resin copolymer, which is a vinylidene fluorine-tetrafluoroethylene copolymer, both of the copolymers having reaction sites capable of reacting with a common peroxide-based cross-linking agent, respectively, is disclosed in the following Patent Literature 1 proposed by the present Applicant.
Patent Literature 1: JP-A-2002-97329
The fluorine-containing elastomer copolymer for use in the present invention is an elastic polymer having fluorine atoms in the molecule, and all the well-known fluorine-containing elastomer copolymers can be used inclusive of copolymers of at least one monomer selected from the group consisting of vinylidene fluoride [VdF] and tetrafluoroethylene [TFE] with at least one monomer selected from the group consisting of hexafluoropropene [HFP], chlorotrifluoroethylene [CTFE], perfluoro(lower-alkyl vinyl ether) [FAVE], and propylene, the latter monomer group capable of giving an elasticity to the fluorine-containing polymer.
The fluorine-containing elastomer copolymer includes, for example, VDF-HFP copolymer, VDF-TFE-HFP terpolymer, VdF-FAVE copolymer, VdF-TFE-FAVE terpolymer, VdF-CTFE copolymer, VdF-TFE-CTFE terpolymer, TFE-P copolymer, TFE-VdF-P terpolymer, TFE-FAVE copolymer, etc., where perfluoro(ethyl vinyl ether), perfluoro(propyl vinyl ether), etc. can be used as FAVE, and preferably perfluoro(methyl vinyl ether) (FMVE) can be used. These copolymers or terpolymers further copolymerized with ethylene, alkyl vinyl ether, or the like can be also used. Among these fluorine-containing elastomer copolymers, VdF-TFE-FAVE terpolymer can show the best compression set characteristic upon blending with the fluorine-containing resin copolymer, and has a terpolymer composition comprising about 10 to about 80% by mole of VdF, about 10 to about 70% by mole of TFE, and about 10 to about 50% by mole of FAVE, and is further copolymerized with about 0.05 to about 5% by mole of an iodine group- and/or bromine group-containing fluorinated monomer, which will be described below.
Reaction sites capable of reacting with a cross-linking agent, which are to be introduced into the fluorine-containing elastomer copolymers, depend on the selected kind of a cross-linking system. The cross-linking system can be selected from the so far well known cross-linking systems including a peroxide cross-linking system, a polyol cross-linking system, an amine cross-linking system, an isocyanate cross-linking system, an epoxy cross-linking system, etc. Preferably a peroxide cross-linking system can be used.
In the case of selecting a peroxide cross-linking system, it is necessary that the fluorine-containing elastomer copolymer is combined with functional groups such as iodine groups, bromine groups, peroxy groups, unsaturated groups, etc. as reaction sites capable of reacting with the peroxide cross-linking system. From the viewpoint of easy introduction of functional groups, it is preferable to select the iodine groups and/or bromine groups. More preferably, the iodine groups and/or the bromine groups can be derived from unsaturated iodine- and/or bromine-containing compounds, and saturated iodine- and/or bromine-containing compounds.
Introduction of iodine groups and bromine groups can be carried out by the presence of an iodine- and bromine-containing compound represented by the following general formula:
InBrmR
(where R is a fluorohydrocarbon group, a chlorofluorohydrocarbon group, a chlorohydrocarbon group or a hydrocarbon group, each having 1-10 carbon atoms, and n and m each are 1 or 2) in the reaction system for producing a fluorine-containing elastomer copolymer by copolymerization reaction. The iodine- and bromine-containing compound includes saturated or unsaturated aliphatic or aromatic compounds, where preferable n and m each are 1. Unsaturated aliphatic compounds can form iodine- and bromine-containing fluorinated monomers.
Linear iodine-containing bromine compounds include, for example, 1-bromo-2-iodotetrafluoroethane, 1-bromo-3-iodoperfluoropropane, 1-bromo-4-iodoperfluorobutane, 2-bromo-3-iodoperfluorobutane, 1-bromo-2-iodoperfluoro(2-methylpropane), monobromomonoiodoperfluorocyclobutane, monobromomonoiodoperfluoropentane, monobromomonoiodoperfluoro-n-octane, monobromomonoiodoperfluorocyclohexane, 1-bromo-1-iodo-2-chloroperfluoroethane, 1-bromo-2-iodo-2-chloroperfluoroethane, 1-iodo-2-bromo-2-chloroperfluoroethane, 1,1-dibromo-2-iodoperfluoroethane, 1,2-dibromo-2-iodoperfluoroethane, 1,2-diiodo-2-bromoperfluoroethane, 1-bromo-2-iodo-1,2,2-trifluoroethane, 1-iodo-2-bromo-1,2,2-trifluoroethane, 1-bromo-2-iodo-1,1-difluoroethane, 1-iodo-2-bromo-1,1-difluoroethane, 1-bromo-2-iodo-1-fluoroethane, 1-iodo-2-bromo-1-fluoroethane, 1-bromo-2-iodo-1,1,3,3,3-pentafluoropropane, 1-iodo-2-bromo-1,1,3,3,3-pentafluoropropane, 1-bromo-2-iodo-3,3,4,4,4-pentafluorobutane, 1-iodo-2-bromo-3,3,4,4,4-pentafluorobutane, 1,4-dibromo-2-iodoperfluorobutane, 2,4-dibromo-1-iodoperfluorobutane, 1,4-diiodo-2-bromoperfluorobutane, 1,4-dibromo-2-iodo-3,3,4,4-tetrafluorobutane, 1,4-diiodo-2-bromo-3,3,4,4-tetrafluorobutane, 1,1-dibromo-2,4-diiodoperfluorobutane, 1-bromo-2-iodo-1-chloroethane, 1-iodo-2-bromo-1-chloroethane, 1-bromo-2-iodo-2-chloroethane, 1-bromo-2-iodo-1, 1-dichloroethane, 1,3-dibromo-2-iodoperfluoropropane, 2,3-dibromo-2-iodoperfluoropropane, 1,3-diiodo-2-bromoperfluoropropane, 1-bromo-2-iodoethane, 1-bromo-2-iodopropane, 1-iodo-2-bromopropane, 1-bromo-2-iodobutane, 1-iodo-2-bromobutane, 1-bromo-2-iodo-2-trifluoromethyl-3,3,3-trifluoropropane, 1-iodo-2-bromo-2-trifluoromethyl-3,3,3-trifluoroprop ane, 1-bromo-2-iodo-2-phenylperfluoroethane, 1-iodo-2-bromo-2-phenylperfluoroethane, 3-bromo-4-iodoperfluorobutene-1,3-iodo-4-bromoperfluorobutene-1,1-bromo-4-iodoperfluorobutene-1,1-iodo-4-bromoperfluorobutene-1,3-bromo-4-iodo-3,4,4-trifluorobutene-1,4-bromo-3-iodo-3,4,4-trifluorobutene-1,3-bromo-4-iodo-1,1,2-trifluorobutene-1,4-bromo-5-iodoperfluoropentene-1,4-iodo-5-bromoperfluoropentene-1,4-bromo-5-iodo-1,1,2-trifluoropentene-1,4-iodo-5-bromo-1,1,2-trifluoropentene-1,1-bromo-2-iodoperfluoroethyl perfluoromethyl ether, 1-bromo-2-iodoperfluoroethyl perfluoroethyl ether, 1-bromo-2-iodoperfluoroethyl perfluoropropyl ether, 2-bromo-3-iodoperfluoropropyl perfluorovinyl ether, 1-bromo-2-iodo-perfluoroethyl perfluorovinyl ether, 1-bromo-2-iodoperfluoroethyl perfluoroallyl ether, 1-bromo-2-iodoperfluoroethyl methyl ether, 1-iodo-2-bromoperfluoroethyl ethyl ether, 1-iodo-2-bromoethyl ethyl ether, 1-bromo-2-iodoethyl-2′-chloroethyl ether, etc. These iodine- and bromine-containing compounds can be prepared by any well known appropriate method. For example, a monobromomonoiodo fluorine-containing olefin can be obtained by reaction of an fluorine-containing olefin with iodine bromide.
The aromatic iodine-containing bromine compounds include, for example, benzenes substituted with such substituents as 1-iodo-2-bromo, 1-iodo-3-bromo, 1-iodo-4-bromo, 3,5-dibromo-1-iodo, 3,5-diiodo-1-bromo, 1-(2-iodoethyl)-4-(2-bromoethyl), 1-(2-iodoethyl)-3-(2-bromoethyl), 1-(2-iodoethyl)-4-(2-bromoethyl), 3,5-bis(2-bromoethyl)-1-(2-iodoethyl), 3,5-bis(2-iodoethyl)-1-(2-bromoethyl), 1-(3-iodopropyl)-2-(3-bromopropyl), 1-(3-iodopropyl)-3-(3-bromopropyl), 1-(3-iodopropyl)-4-(3-bromopropyl), 3,5-bis-(3-bromopropyl)-1-(3-iodopropyl), 1-(4-iodobutyl)-3-(4-bromobutyl), 1-(4-iodobutyl)-4-(4-bromobutyl), 3,5-bis(4-iodobutyl)-1-(4-bromobutyl), 1-(2-iodoethyl)-3-(3-bromopropyl), 1-(3-iodopropyl)-3-(4-bromobutyl), 3,5-bis(3-bromopropyl)-1-(2-iodoethyl), 1-iodo-3-(2-bromoethyl), 1-iodo-3-(3-bromopropyl), 1,3-diiodo-5-(2-bromoethyl), 1,3-diiodo-5-(3-bromopropyl), 1-bromo-3-(2-iodoethyl), 1-bromo-3-(3-iodopropyl), 1,3-dibromo-5-(2-iodoethyl), 1,3-dibromo-5-(3-iodopropyl), etc., and perfluorobenzenes substituted with such substituents as 1-iodo-2-bromo, 1-iodo-3-bromo, 1-iodo-4-bromo, 3,5-dibromo-1-iodo, 3,5-diiodo-1-bromo, etc.
Introduction of iodine groups can be carried out in the presence of a saturated or unsaturated iodine-containing compound represented by the following general formula:
RIn
(where R is a fluorohydrocarbon group, a chlorofluorohydrocarbon group, a chlorohydrocarbon group or a hydrocarbon group, each having 1-10 carbon atoms, and n is 1 or 2), in the reaction system for producing a fluorine-containing elastomer copolymer by copolymerization reaction. The unsaturated iodine-containing compound can form an iodine-containing fluorinated monomer.
The saturated iodine-containing compound represented by the foregoing general formula includes, for example, 1,2-diiodoperfluoroethane, 1,3-diiodoperfluoropropane, 1,4-diiodoperfluorobutane, 1,6-diiodoperfluorohexane, 1,8-diiodoperfluorooctane, etc. and preferably 1,4-diiodoperfluorobutane is used. The unsaturated iodine-containing compound includes, for example, iodotrifluoroethylene, 1-iodo-2,2-difluoroethylene, perfluoro(2-iodoethyl vinyl ether), etc.
Introduction of bromine groups can be carried out in the presence of a saturated or unsaturated bromine-containing fluorinated compound in the reaction system for producing a fluorine-containing elastomer copolymer by copolymerization reaction. The bromine-containing fluorinated compound can further contain chlorine atoms in the molecule. The unsaturated bromine-containing compound can form a bromine-containing fluorinated monomer.
The bromine-containing fluorinated compound for use herein includes, for example, saturated aliphatic compounds having 2-10 carbon atoms, such as 1,2-dibromo-1-fluoroethane, 1,2-dibromo-1,1-difluoroethane, 1,2-dibromo-1,1,2-trifluoroethane, 1,2-dibromo-1-chlorotrifluoroethane, 2,3-dibromo-1,1,1-trifluoropropane, 1,2-dibromohexafluoropropane, 1,2-dibromoperfluorobutane, 1,4-dibromoperfluorobutane, 1,4-dibromo-2-chloro-1,1,-2-trifluorobutane, 1,6-dibromoperfluorohexane, etc.; unsaturated aliphatic compounds having 2-10 carbon atoms, such as 2-bromotetrafluoroethoxytrifiluoroethylene, 2-bromo-1,1-difluoroethylene, 1,1-dibromodifluoroethylene, bromotrifluoroethylene, 2-bromo-3,3,3-trifluoropropene, 4-bromo-1,1,-2-trifluorobutene-1, 4-bromo-3-chloro-3,4,4-trifluorobutene-1, 4-bromo-3,3,4,4-tetrafluorobutene-1, perfluoro(2-bromoethyl vinyl ether), etc.; or aromatic compounds such as 1,2-dibromo-3,5-difluorobenzene, 1,2-dibromo-4,5-difluorobenzene, 1,4-dibromo-2,5-difluorobenzene, 2,4-dibromo-1-fluorobenzene, 1,3-dibromo-5-fluorobenzene, 1,4-dibromo-2-fluorobenzene, 1,2-dibromoperfluorobenzene, 1,3-dibromoperfluorobenzene, 1,4-dibromoperfluorobenzene, etc.
The iodine group- and/or bromine group-containing compounds can be used alone or in combination thereof, depending on cross-linking conditions for cross-linking molding of a blend of the fluorine-containing elastomer copolymer and the fluorine-containing resin copolymer or on the reactivities of the compounds.
Molecular weight of the fluorine-containing elastomer copolymer for use herein depends on the processability or desired mechanical properties of a blend of fluorine-containing copolymers, but it is desirable that the intrinsic viscosity [η] as an index of molecular weight is about 0.3 to about 1.5 dl/g, preferably about 0.4 to about 1.3 dl/g.
To obtain a fluorine-containing elastomer copolymer having a molecular weight corresponding to an intrinsic viscosity in the aforementioned range, a chain transfer agent such as ethyl malonate, acetone, isopropanol, etc. can be used at the time of polymerization reaction, if required. In the case of the iodine- and bromine-containing compound, the compound itself has a chain transfer action, and thus addition of a chain transfer agent will be unnecessary except for a special case.
Copolymerization reaction for producing a fluorine-containing elastomer copolymer can be carried out by any polymerization method such as emulsion polymerization, suspension polymerization, solution polymerization, bulk polymerization, etc., but from the viewpoints of production cost, heat and yellowing resistances, normal state physical properties, etc. it is desirable to use the polymerization procedure as disclosed in the following Patent Literatures 2 and 3. Furthermore, from the viewpoints of a higher degree of polymerization and economy, an emulsion polymerization method is preferable. Emulsion polymerization reaction can be carried out under pressure of generally about 0 to about 10 MPa·G, preferably about 1 to about 5 MPa·G, at a temperature of about 0 to about 100° C., preferably about 20 to about 80° C., in the presence of a catalyst of a water-soluble inorganic peroxide such as ammonium persulfate, etc. or a redox system thereof with a reducing agent such as sodium hydrogen sulfite, etc., using ammonium perfluorooctanoate, ammonium perfluoroheptanoate, ammonium perfluorononanoate, etc., or a mixture thereof, preferably ammonium perfluorooctanoate as an emulsifying agent. In the emulsion polymerization reaction, it is preferable uniformly and portion-wise addition of a monomer mixture of a predetermined composition ratio to the reaction system. To adjust the pH of the reaction system, an electrolyte substance having a buffering action such as Na2HPO4, NaH2PO4, KH2PO4, etc., or sodium hydroxide, an aqueous ammonia solution, etc. can be added thereto.
Patent Literature 2: JP-A-2003-165802
Patent Literature 3: JP-A-2004-175855
Fluorine-containing resin copolymer to be blended with the fluorine-containing elastomer copolymer is a VdF-TFE copolymer having reaction sites capable of reacting with a cross-linking agent, which is common to the fluorine-containing elastomer copolymer. The copolymers prepared by copolymerizing about 5 to about 90% by mole, preferably about 10 to about 90% by mole, of TFE and about 0.05 to about 5% by mole, of the aforementioned iodine group- and/or bromine group-containing fluorinated monomer can be used. It is preferable that the fluorine-containing resin copolymer has a melting point (softening point) of 100° C. or higher. In the case of using the copolymer having a softening point of lower than 100° C., the improving effect on the normal state physical properties of cross-linked fluorine-containing copolymer moldings is not remarkable and with a poor plasma resistance.
The VdF-TFE copolymer can be further copolymerized with a VdF- and TFE-copolymerizable monomer, such as FAVE, CTFE, HFP, propylene, ethylene, etc. in a proportion in such a range as not to deteriorate the desired properties of the resulting blend of fluorine-containing copolymers, generally not more than about 30% by mole.
Introduction into the VDF-TFE copolymer of peroxide-cross-linkable reaction sites can be carried out in the presence of at least one of the aforementioned iodine- and bromine-containing compound, the aforementioned iodine-containing compound, and the aforementioned bromine-containing compound, preferably unsaturated iodine- and/or bromine-containing compound, and saturated iodine- and/or bromine-containing compound in the reaction system for polymerization reaction to produce the VdF-TFE copolymer.
It is preferable that the polymerization reaction to produce the VdF-TFE copolymer is carried out by emulsion polymerization in the same manner as in the case of the fluorine-containing elastomer copolymer. As to the molecular weight of the resulting VdF-TFE copolymer, an intrinsic viscosity [η] as an index of molecular weight is about 0.5 dl/g or more, preferably about 0.8 dl/g or more. Below about 0.5 dl/g, the improving effect on the strength of cross-linked moldings of a blend of fluorine-containing copolymers is not remarkable.
As will be described below, it is preferable to make a blend of fluorine-containing copolymers by the so called aqueous emulsion blending, i.e. by mixing an aqueous latex of fluorine-containing elastomer with an aqueous emulsion of VdF-TFE copolymer.
The fluorine-containing elastomer copolymer and the VdF-TFE copolymer are blended together in a proportion of the former of about 95 to about 55% by weight, preferably about 90 to about 60% and the latter of about 5 to about 45% by weight, preferably about 10 to about 40% by weight. When the blending proportion of VdF-TFE copolymer is less than about 5% by weight, the improving effect of the fluorine-containing elastomer copolymer on the normal state physical properties is not remarkable, and the improving effect on the plasma resistance is not remarkable, either. A blending proportion of more than 45% by weight, on the other hand, lowers not only the kneadability at the blending, but also the compression set characteristics. Furthermore, it is preferable that the blend of fluorine-containing copolymers has a F content of not more than 72% by weight. When the F content is more than 72% by weight, dispersion of a cocross-linking agent will be poor, so it will be difficult to obtain a uniform blend.
The blend can be made by mixing and kneading the fluorine-containing elastomer copolymer and the VdF-TFE copolymer, each being isolated into a solid state, through mixing rolls, a kneader, a Banbury mixer, etc., but by the afore-mentioned aqueous emulsion blending method, which comprises blending an aqueous latex of fluorine-containing elastomer copolymer with an aqueous emulsion of VdF-TFE copolymer, both of which are obtained by emulsion polymerization, in a blending proportion of desired solid matters to obtain an aqueous emulsion, followed by coagulation, washing, and drying, more advantages can be attained, such as (a) one run each of coagulation, washing, and drying can be satisfactory, (b) kneading time can be shorter, and (c) dispersibility of fluorine-containing elastomer copolymer in VDF-TFE copolymer can be improved. Coagulation of the aqueous emulsion can be carried out by drop wise addion of the aqueous emulsion to an aqueous solution of a salt such as calcium chloride, sodium chloride, potassium alum, etc., or to a water-soluble alcohol-based organic solvent such as methanol, ethanol, etc., or to a ketone-based organic solvent such as acetone, methyl ethyl ketone, methyl isobutyl ketone, etc. To much reduce the amount of impurities contained in the blend of fluorine-containing copolymers, freeze-coagulation, or coagulation using a water-soluble organic solvent, or coagulation using a cationic surfactant is preferable.
Patent Literature 4: JP-A-2004-285264
Cross-linked moldings of the blend of fluorine-containing elastomer copolymer and VdF-TFE copolymer can be carried out by a cross-linking agent corresponding to the kind of reaction sites introduced into the two kinds of fluorine-containing copolymers.
When the fluorine-containing elastomer copolymer and the VDF-TFE copolymer each contain about 0.005 to about 0.050 millimoles/g polymer, preferably about 0.01 to about 0.04 millimoles/g polymer, of iodine groups as introduced therein, or about 0.005 to about 0.050 millimoles/g polymer, preferably about 0.01 to about 0.04 millimoles/g polymer, of the brimine groups as introduced therein together with the above-mentioned proportion of the iodine groups, and organic peroxide can be used as a cross-linking agent. The bromine groups to be cross-linked by an organic peroxide can be introduced into the polymers in a proportion of about 0.015 to about 0.035 millimoles/g polymer, preferably about 0.02 to about 0.03 millimoles/g polymer.
The organic peroxide for use herein includes, for example, 2,5-dimethyl-2,5-bis(t-butylperoxy)hexane, 2,5-dimethyl-2,5-bis(t-butylperoxy)hexine-3, benzoyl peroxide, 2,4-dichlorobenzoyl peroxide, p-chlorobenzoyl peroxide, t-butyl perbenzoate, bis(2,4-dichlorobenzoyl) peroxide, dicumyl peroxide, di-t-butyl peroxide, t-butylcumyl peroxide, t-butylperoxybenzene, 1,1-bis(t-butylperoxy)-3,5,5-trimethylcyclohexane, 2,5-dimethylhexane-2,5-dihydroxyperoxide, α,α′-bis(t-butylperoxy)-p-diisopropylbenzene, 2,5-dimethyl-2,5-di(benzoylperoxy)hexane, and t-butylperoxyisopropyl carbonate, and preferably from the viewpoints of half-life temperature and cross-linking temperature 2,5-dimethyl-2,5-di(t-butylperoxy)hexane is used.
Together with the organic peroxide, a cocross-linking agent of polyfunctional unsaturated compound can be used, if required, and includes, for example, tri(meth)allyl isocyanurate, tri(meth)allyl cyanurate, triallyl trimellitate, N,N′-m-phenylene bismaleimide, diallyl phthalate, tris(diallylamine)-s-triazine, triallyl phosphite, 1,2-polybutadiene, ethyleneglycol di(meth)acrylate, diethyleneglycol di(meth)acrylate, 1,3-butyleneglycol di(meth)acrylate, 1,4-butyleneglycol di(meth)acrylate, 1,6-hexanediol di(meth)acrylate, poiyethyleneglycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, pentaerythritol tri(meth)acrylate, 3-chloro-2-hydroxypropane methacrylate, oligoester (meth)acrylate, diallyl chlorendate, divinyl benzene, etc., and preferably from the viewpoint of compatibility with the blend of fluorine-containing copolymers triallyl isocyanurate, triallyl cyanurate, and triallyl trimellitate are used.
Among the foregoing components used in the peroxide cross-linking system, about 0.01 to about 10 parts by weight, preferably about 0.5 to about 5 parts by weight, of an organic peroxide, and about 0.1 to about 20 parts by weight, preferably about 1 to about 15 parts by weight, of a cocross-linking agent can be used on the basis of 100 parts by weight of the blend of fluorine-containing copolymers.
The foregoing individual components are kneaded through mixing rolls, a kneader, a Banbury mixer, etc. to prepare a cross-linkable composition. It is preferable not to add an inorganic filler in a cross-linkable composition, which is a cause for the particle generation. The cross-linkable composition so prepared is subjected to cross-linking molding in a press molding machine by heating at about 100° to about 250° C. for about 1 to about 60 minutes, and further, if required, to second cross-linking by heating at about 100° to about 250° C. for about 1 to about 50 hours.
The resulting cross-linked fluorine-containing copolymer moldings can be applied to a plasma irradiation step. Plasma irradiation involves such a case that the cross-linked fluorine-containing copolymer moldings itself is a targent of plasma irradiation treatment and also such a case that the moldings are used as a sealing material or rolls for conveyance in the semiconductor or liquid crystal production apparatuses, while other parts are subjected to plasma irradiation treatment in the production process, and consequently the sealing material and rolls for conveyance are inevitably subjected to the plasma irradiation treatment, where the cross-linked fluorine-containing copolymer moldings is plasma treated with, for example, perfluoroalkanes such as CF4, C2F6, etc., an oxygen gas, or an oxygen-containing compound gas such as carbon oxide, nitrogen oxide, etc., a nitrogen-containing compound such as ammonia, volatile amine compound, etc., and unsaturated or saturated chlorinated hydrocarbons such as vinyl chloride, vinylidene chloride, trichloroethylene, tetrachloroethylene, dichloroethane, trichloroethane, etc.
Plasma treatment in the gaseous atmosphere can be carried out by placing a cross-linked fluorine-containing copolymer moldings into a tubular plasma reaction chamber connected to a vacuum pump, a leak valve, and a main valve, and provided with a vacuum gage, adjusting the inside pressure of the reaction chamber to a vacuum of about 0.01 Torr or more, then opening the main valve to introduce a mixed gas into the reaction chamber until the pressure reaches about 0.02 to about 1 Torr, thereby filling the mixed gas in the reaction chamber, and conducting plasma irradiation from an oscillation coil wound around the cylinder in a small diameter provided at the edge of the reaction chamber under such conditions as an effective power of about 10 to about 300 W for a glow discharge time of about 1 to about 60 minutes, using a high-frequency power source comprising a high-frequency generator (13.56 MHz) and a matching unit. As a reaction chamber a bell jar type, etc. can be also used besides the above-mentioned tubular type. As the discharge electrodes, external or internal parallel electrode plates can be also used besides the above-mentioned coil type.
The present invention will be described in detail below, referring to Examples.
The following components were charged into a SUS316 autoclave having a net capacity of 100 L, provided with a stirrer:
The autoclave was thoroughly degassified. Then, the following compound was charged therein:
Then, the autoclave was heated to 80° C., and after maintaining the temperature at 80° C. for 30 minutes, the following monomers were charged therein:
Polymerization reaction of the charged monomers was initiated by setting the inner pressure of the autoclave to 3.0 MPa·G. When the inner pressure of the autoclave was lowered to 2.9 MPa·G as a result of progress of polymerization reaction, a monomer mixture of uniform composition ratio of VdF/TFE/FMVE/FBrVE=68/12/19/1 (mol. %) was portion wise added thereto to continue the operation of adjusting the internal pressure fluctuating between 2.9 and 3.0 MPa·G until total amount of portion wise added monomers reached 24 kg, and then aging was conducted until the inner pressure reached to 0.5 MPa·G, thereby completing the polymerization reaction.
The aqueous latex of fluorine-containing elastomer discharged from the autoclave had a solid matter concentration of 33% by weight, and a portion of the aqueous latex was subjected to coagulation by an aqueous 1 wt. % calcium chloride solution, separation by filtration, and washing with deionized water to recover polymerizate, followed by drying, whereby white, powdery fluorine-containing elastomer copolymer A was obtained.
The fluorine-containing elastomer copolymer A thus obtained was subjected to determination of the following items:
Determination of glass transition point: Glass transition point Tg was determined by Model DSC220C, made by Seiko Instrument Co., according to a temperature program of heating a sample from −100° C. to 100° C. at a temperature elevation rate of 10° C./min., then cooling it to −100° C. at a cooling rate of 10° C./min., and again elevating the temperature to 100° C. at a temperature elevation rate of 10° C./min
Determination of Intrinsic viscosity: By preparing solutions of fluorine-containing elatomer copolymer in acetone (Solvent A) or FC-77 (Solvent B) at concentrations of 2 g/L, 4 g/L, and 10 g/L, respectively, intrinsic viscosity was determined from intercepts of falling time and concentration at 35° C., using an Ube-Rhode viscosimeter
Melt viscosity: The copolymer was placed in a cylinder, 9.5 mm in inner diameter, kept at a predetermined temperature for 5 minutes and extruded through an orifice, 2.095 mm in inner diameter and 8.00 mm in length, under a load of 5 kg to measure the extruded weight, using a melt indexer, made by Toyo Seiki Mfg. Co.
Mooney viscosity: Mooney viscosity of a sample was measured at 121° C., using a Mooney viscosimeter Model SMV-201, made by Shimadzu Corp.
Fluorine-containing elastomer copolymers B-E and fluorine-containing resin copolymers F-H were papared in the same manner as in Reference Example 1, and were subjected to determination of the same items (where as to the fluorine-containing resin copolymers determination of not Tg, but melting point was conducted). Determination of melting point: By Model DSC220C, made by Seiko Instrument Co., according to a temperature program of heating a sample from 30° to 250° C. at a temperature elevation rate of 10° C./min., then cooling it to 30° C. at a cooling rate of 10° C./min., and again elevating the temperature to 250° C. at a temperature elevation rate of 10°/min., where the endothermic peak apex temperature was made as a melting point
The results of determination in the foregoing Reference Examples are shown in the following Table 1.
Aqueous latexes of fluorine-containing elastomer copolymers A-E obtained in Reference Examples 1 to 5, and aqueous emulsions of fluorine-containing resin copolymers F-H obtained in Reference Examples F-H were mixed together with thorough stirring in percent solid matter weight proportions as shown in the following Table 2, and the resulting mixed aqueous emulsions were subjected to coagulation with an aqueous 1 wt. % calcium chloride solution, separation by filtration, and washing with deionized water to recover individual mixed copolymers. By drying, individual blends I-XI of the fluorine-containing copolymers were obtained.
Blends I-XI were subjected to Mooney viscosity determination in the same manner as mentioned before, and then admixed with predetermined amounts of a triallyl isocyanurate cocross-linking agent and a 2,5-dimethyl-2,5-di(t-butylperoxy)hexane cross-linking agent, followed by kneading through rolls. The individual kneaded cross-linkable compositions were subjected to primary vulcanization at 180° C. for 6 minutes and to secondary vulcanization at 175° C. for 15 hours, whereby sheets and O-rings were obtained by cross-linking molding.
The individual cross-linkable compositions were subjected to determination or evaluation of kneadability (roll processability and cross-linking moldability), and the individual cross-linked moldings were also subjected to determination or evaluation of normal state physical properties (hardness test and tensile test), compression set value, and plasma resistance.
Roll processability: Evaluation of roll processability was made by an 8-inch roll mill, where good windability was evaluated as “◯” occurrence of cracks at the edge of wound sheet as “Δ”, and poor windability as “x”
Cross-linking moldability: cross-linked moldings resulting from the primary vulcanization, which showed a good mold releasability and a smooth surface, were evaluated as “◯”, those which had a relatively good mold releasability and a partially uneven surface as “Δ”, and those which completely failed to retain the original shape after the mold releasing as “x”
Hardness test: 2 mm-thick cross-linked sheets prepared according to JIS K6250 were subjected to a hardness test by a Type A durometer hardness tester according to JIS K6253
Tensile test: 2 mm-thick cross-linked sheets prepared according to JIS K6250 were subjected to blanking to obtain dumb-bell type No. 6 test pieces, which were then subjected to determination of tensile strength, elongation at breaking, and 100% tensile stress at a stretching rate of 500 mm/min. according to JIS K6251
Compression set test: Cross-linked O-rings were subjected to 25% compression strain in the height direction to measure a compression set value at 100° C., 175° C. or 200° C. for 70 hours according to JIS K6262
Apparatus: Dry etching apparatus, Model RBH-3030, made by ULVAC Co.
Plasma gas species: CF4 or O2
Chamber pressure: 0.1 Pa
Gas flow rate: 20 sccm
Rf power: 500 W
Electrode height: 120 mm
Irradiation time: Continuous irradiation for 6 hours
Evaluation: Evaluated as percent weight change and percent volume change by an automatic specific gravimeter
Results of the foregoing determination or evaluation are shown in the following Table 3, together with Mooney viscosities of the compositions and blending proportions of the cross-linkable compositions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2004-291031 | Oct 2004 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP05/16587 | 9/9/2005 | WO | 00 | 4/4/2007 |
