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JP2011056955

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DESCRIPTION JP2011056955
A sound transducer, preferably a microphone or loudspeaker membrane, is provided. SOLUTION:
Formula (I) [wherein R, R, R and R are independently hydrogen, C-alkyl, C-alkoxy or halogen, and
R and R are independently C Deep drawn diaphragms made of cast polyarylate films which at
least include polyarylates (PAR) having structural units of alkyl, C-alkoxy, hydrogen, phenyl or
halogen]. 【Selection chart】 None
Diaphragm made of cast polyarylate film
[0001]
The invention relates to diaphragms made of cast polyarylate films (cast PAR films), in particular
thermoformed microphone diaphragms or thermoformed loudspeaker diaphragms, and
corresponding cast PAR films, cast PAR films The present invention relates to a film, a casting
solution for producing a cast PAR film, a method of producing a thermoformed microphone
diagram or a thermoformed loudspeaker diagram, and a method of producing a PAR film.
[0002]
Polymer films, in particular those made of polycarbonate (PC), polyester (PET, PEN),
polyethersulfone (PES) and polyetherimide (PEI), are microphones, mobile phones, laptops,
personal digital assistants (PDAs) For use in acoustic applications (signal transducers) for use in
mobile devices such as, or headphones, or conventionally used to produce small diaphragms up
to about 10 cm in diameter, for example as signal generators in the automotive industry .
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1
It is intended to minimize the thickness of the film in order to reduce the vibrational mass of the
diaphragm and to ensure an exact reproduction of the embossed structure during thermoforming
and to allow further reductions. There is. Films made of the above-mentioned plastic have high
mechanical strength but have the disadvantage of producing a "metal" sound when used as a
loudspeaker diaphragm, or have the ability to replicate a rather complex relief structure due to
deformation Inappropriate. Thus, disadvantageous changes occur when converting music and /
or speech signals into electrical signals and vice versa.
[0003]
Small microphone diaphragms and small loudspeaker diaphragms are generally manufactured in
the application section referred to as the thermoforming method. This method heats the film for
softening prior to thermoforming, for example by irradiation with infrared light (IR). The more
anisotropic the film, the more industrially difficult it is to control necessary to uniformly heat a
particularly thin film prior to thermoforming and consequently soften uniformly. Cast films are
significantly more anisotropic than stretched and / or extruded films. Films made of extruded PC,
polyethylene naphthalate (PEN), or polyethylene terephthalate (PET) are more or less susceptible
to deformation and / or shrinkage. This is because part of the internal stress accumulated in the
extrusion and / or stretching step is released in the heating step. Thin cast films can be
thermoformed with less internal stress and more homogeneity than extruded / stretched films
and are suitable for the above mentioned applications. However, especially in the case of PET and
PEN, the low solubility of these polymers interferes with cast film production.
[0004]
DESCRIPTION OF THE INVENTION The object of the present invention is to provide a film for the
production of a diaphragm for acoustic applications. These diaphragms are intended to enable
good clarity of speech at appropriate volumes and high quality reproduction of music and to
have high mechanical stability at high temperatures.
[0005]
The requirement for high quality means that even very thin films are capable of uniform heating
by IR and thermoforming without problems, especially when applied to small diaphragms for
acoustic applications.
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[0006]
In the past, film-based diaphragms were mainly manufactured from extruded films.
Cast films made of polycarbonate have also been used only in the production of high quality
loudspeaker diaphragms.
[0007]
It has now surprisingly been found that diaphragms made of cast PAR films have significantly
better acoustic properties than diaphragms made of, for example, extruded PC films, extruded
PEN films, or extruded PEI films. There are also significant advantages over cast PC films.
[0008]
Cast PAR films are known to have very good properties of optical isotropy and high heat
resistance and have been used exclusively for optical applications.
[0009]
EP−A−0488221 JP−A−08/122526 JP−A−08/134336
JP−A−08/269214
[0010]
When measuring the strength of many materials, the measurements are derived from defects
present in the material, and a high degree of scattering can be found whose distribution is a
function of the manufacturing process.
A reliable conclusion regarding the strength of the material and thus also the distribution of
defects in this material is not only the average of the measured tensile stresses (maximum tensile
stress, tensile stress at break) but also the statistical distribution of strength values Require
knowledge of
10-05-2019
3
The statistical method proved is W. Based on the extreme-value-distribution method of W.
Weibull (Ing. Vetenskaps Akad. Handl., 151 (1939) 1-45), calculate the probability that a sample
of a given shape fails under tensile stress σ. Two relevant tensile stress values, the maximum
tensile stress, ie the maximum tensile stress at which the sharp drop of tensile stress starts and
thus the sharp drop of strength starts, and the tensile stress at break, ie before the material
completely separates The final tensile stress measured is directly related to the ultimate failure of
the material.
[0011]
The improvement in the properties of maximum tensile stress and ultimate tensile strength of the
cast PAR film material of the present invention is compared to cast PC films (PC-A and PC-B)
consisting of two different grades of polycarbonate, respectively. Of 40 samples could be
examined and shown (see Example 12).
[0012]
It has also been found that cast PAR films have high attenuation, have substantially linear
acoustic properties over a wide range of frequencies and capacities, and thus can be used for
acoustic applications.
Diaphragms made of cast PAR films have excellent properties with regard to vibration initiation
and decay, and uniform vibrational behavior over a wide range of frequencies and volumes,
allowing for good clarity of speech.
[0013]
It has been found that colored cast PAR films can be very uniformly heated and thermoformed
and are therefore particularly well suited for the production of small diaphragms.
[0014]
It has also been found that the addition of certain dyes or nonionic surfactants has a favorable
effect on the undesirable thixotropic properties of PAR casting solutions.
10-05-2019
4
This result considerably simplifies the technical means before and during the casting process and
decisively improves the overall casting process.
[0015]
Finished molded diaphragms made of PAR have increased heat resistance (Tg = 188 ° C.) as
compared to those made of PC (Tg = 135 ° C.). The low tendency to shrinkage and dimensional
stability of the diaphragm made of cast PAR film is superior to the diaphragm made of extruded
PC film, extruded PEI film, extruded PEN film, extruded PES film, extruded PET film. Diaphragms
with more complex shapes can be made from PAR films as compared to extruded and stretched
films, such as PC films, PEI films, or PEN films.
[0016]
Because of its high degree of isotropy, it is preferred to use cast PAR films in the form of
unstretched films for diaphragm manufacture. However, the cast PAR films of the present
invention can be uniaxially or biaxially stretched prior to diaphragm manufacture, where
appropriate.
[0017]
Diaphragms manufactured from PAR have low flammability even without additives that can
affect vibration performance.
[0018]
It has also been found that diaphragms made of PAR fill have increased moisture resistance.
[0019]
The thermoformed diaphragm for acoustic applications according to claim 1 has the formula
<img class = "EMIRef" id = "204429456-00002" />
[0020]
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[Wherein, each of R <1>, R <2>, R <3>, and R <4> is, independently of the others, hydrogen, C1-4alkyl, C1-4-alkoxy, or Each of halogen and R <5> and R <6> is, independently of the others,
hydrogen, C1-4-alkyl, C1-4-alkoxy, phenyl or halogen.
] From a cast PAR film that includes at least one of polyarylates having structural units.
[0021]
In a preferred embodiment, R <1> = R <2> and R <3> = R <4>, each independently with the other
being hydrogen or C1-4-alkyl.
[0022]
In a particularly preferred embodiment, R <1> = R <2> = R <3> = R <4> and each is hydrogen or
C1-4-alkyl.
[0023]
In another preferred embodiment, each of R <5> and R <6>, independently of the other, is C1-4alkyl.
In a particularly preferred embodiment, R <5> = R <6> = methyl.
[0024]
As an example, R <1> = R <2> = R <3> = R <4> = hydrogen, R <5> = R <6> = methyl, and the
molecular weight is 10,000 to 150,000. Polyarylates in the range can be purchased from
UNITIKA CHEMICAL KK, 3-11, Chikkoshin-machi, Sakai-shi, Osaka 592, Japan under the name
"U-Polymer 100".
[0025]
The diaphragm according to the invention can have a thickness of 5 to 200 μm, preferably 5 to
100 μm, particularly preferably 10 to 50 μm.
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[0026]
According to the invention, the excellent damping properties (internal losses) of PAR films make
them particularly suitable for thermoformed diaphragms as acoustic transducers for acoustic
applications, preferably as microphone diaphragms and / or loudspeaker diaphragms. .
Compared to known diaphragms composed of other polymers, they have less "metallic" sound
properties.
[0027]
The mechanical strength of the PAR diaphragm of the present invention is significantly better
than that of the PC diaphragm, and with the same nominal power rating at elevated
temperatures, gives an extended life when electrically driven.
[0028]
The thermoformed PAR diaphragms of the invention are used, for example, as diaphragms for
microphones or loudspeakers, microphone capsules, mobile phones, hands-free systems, radio
sets, radio devices, listening devices, headphones, microradios, when the demand for speech
clarity is high. It is particularly suitable for use in computers and PDAs.
Another application sector is the use as a signal generator.
[0029]
The following% data for the amounts of dye and surfactant are all in% by weight based on the
solids content in the PAR casting solution and / or cast PAR films made therefrom.
[0030]
The following% data for the amount of polyarylate are all% by weight based on the total weight.
[0031]
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In the production, for example by thermoforming, of a diaphragm according to the invention
made of a cast PAR film as claimed in claim 1, the film is irradiated with infrared light to improve
its deformability and thereby heat it.
The addition of dyes has proven to be advantageous here in order to achieve uniform heat
absorption and softening.
The result is that the cast PAR film of the present invention can be more effectively processed,
and the quality of the diaphragm produced therefrom is improved.
[0032]
Amounts as low as 0.01% of commercially available dyes, such as "CI Solvent Yellow 93" or
"Macrolex <TM> Orange R", are sufficient for uniform heating of the inventive cast PAR film.
The amount of dye can be further reduced by using pure pigments free of assistants and / or
fillers.
[0033]
As an example, the dye "CI Solvent Yellow 93" is a product of BAYER AG, Germany, under the
trade name "Transparent Yellow 3G", and is manufactured by KUNSHAN FAR EAST CHEMICAL
COMPANY LTD., South of Bingxi Town, Kunshan, Jiangsu 215334, PR China ) From China
Chemical Company (CHINA CHEMICALS, Luxun Mansion 12 Fl./Suite G, 568 Ou Yang Road,
Shanghai 200081, PR China), and also HONGMENT CHEMICALS LIMITED, Xinzhuhuayuan 32203, Ningxi Road, Zhuhai, Also available from PR China).
[0034]
The dye "BASF Thermoplast Yellow 104", which is equivalent to "CI Solvent Yellow 93", is from
BASF Germany or under the name "Solvent Yellow 202" (ZHUHAI SKYHIGH CHEMICALS Co., Ltd.,
20 / F, Everbright International Trade Center, Zhuhai City, Guangdong Province, PR China).
10-05-2019
8
[0035]
As an example, "Macrolex <TM> Orange R" can be purchased from BAYER in Germany.
[0036]
The currently available commercially available forms of the indicated dyes include, in particular,
nonionic polyol surfactants, the advantageous effects of which on the PAR casting solution of the
invention are described below.
[0037]
The PAR casting solution of the invention and / or the cast PAR film produced therefrom
comprises at least one of the dyes mentioned and / or one nonionic polyol surfactant.
[0038]
Nonionic polyol surfactants generally are such as poly (ethylene oxide) or poly (ethylene glycol)
(PEO), poly (propylene oxide) or poly (propylene glycol) (PPO), or poly (tetramethylene oxide)
Non-ionic water-soluble polyoxyalkylene as a common feature, structural unit-[(CH2) x-CHR-O][wherein (i) R is H, x is 1 (poly (ethylene glycol) (PEO)); (ii) R is CH 3, x is 1 (poly (propylene
glycol), (PPO)); (iii) R is H, x is 3 (poly (tetramethylene oxide), (PTMO))] Have.
Polyol surfactants are not only PEO homopolymers, PPO homopolymers and PTMO
homopolymers, but also their copolymers, in particular block copolymers, and / or their polymer
mixtures, having an average molecular weight of less than 20,000.
[0039]
Examples of commercially available poly (ethylene glycol) -poly (propylene glycol) block
copolymers are: "Pluronic <TM> PE 6800" from BASF or "Synperonic <TM> F 86 pract.
」がある。
[0040]
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9
In the formula (I) [wherein, R <1>, R <2>, R <3>, and R <4> are each independently hydrogen, C
1-4 -alkyl, C 1-4 And each of R <5> and R <6> is, independently of the others, hydrogen, C1-4alkyl, C1-4-alkoxy, phenyl or halogen.
The casting solution in methylene oxide consisting of PAR) is highly thixotropic and can not be
stored in the form of a ready-to-use casting solution.
In order to prevent the casting solution from solidifying in the form of gel in the storage
container, in the transfer system, in the filter or in the casting apparatus, be careful widely to
ensure continuous operation and avoid "dead spots" It is necessary to.
[0041]
Surprisingly, dyes such as "CI Solvent Yellow 93", "Solvent Yellow 202" or "Macrolex <TM>
Orange R" act as agents with anti-thixotropic properties when added to PAR casting solutions I
found out.
[0042]
Further testing has shown that poly (ethylene glycol) -poly (propylene glycol) block copolymers
also produce this effect when used alone.
PAR casting solutions loaded with non-ionic polyol surfactant and / or one of the indicated dyes
lose their thixotropic properties.
This greatly simplifies the casting process, and the ready-to-use PAR casting solution of the
present invention can be stored for several weeks.
In contrast, PAR casting solutions without the addition of surfactants and / or colorants lose their
usefulness completely after only a few hours when stored without movement (see Example 11).
10-05-2019
10
[0043]
The nonionic polyol surfactant and the dyes mentioned can include other additives such as TiO2.
[0044]
The PAR casting solution of the present invention and / or cast PAR films made therefrom
include dyes and / or nonionic polyol surfactants.
[0045]
In one particular aspect, the PAR casting solution and / or cast PAR film produced therefrom of
the present invention is selected from the group consisting of poly (ethylene glycol), poly
(propylene glycol), and poly (tetramethylene oxide) At least one non-ionic surfactant, which may
be used individually or in the form of mixtures, in the form of homopolymers, copolymers or
block copolymers.
[0046]
In one particularly preferred embodiment, the PAR casting solution of the present invention and
/ or cast PAR film made therefrom comprises at least one polyethylene-polypropylene block
copolymer having an average molecular weight of 6,000 to 10,000.
[0047]
In a particularly preferred embodiment of 1, the PAR casting solution of the invention and / or
the cast PAR film produced therefrom are such as "CI Solvent Yellow 93", "Solvent Yellow 202" or
"Macrolex <TM> Orange R" Dyestuff and / or "Pluronic <TM> PE 6800" or "Synperonic <TM> F86
pract.
"Non-ionic polyol surfactants such as".
[0048]
The PAR casting solution according to the invention and / or the cast PAR film produced
therefrom as claimed in claim 1 comprises a dye and / or an amount of 0.001 to 2%, preferably
0.001 to 0.15%. Or non-ionic polyol surfactants are also included.
10-05-2019
11
[0049]
The dyes and / or nonionic polyol surfactants can be dissolved, for example, in acetone, butyl
acetate or methylene chloride, particularly preferably methylene chloride.
[0050]
1
In a preferred embodiment, dyes such as "C.I. Solvent Yellow 93", "Solvent Yellow 202" or
"Macrolex <TM> Orange R" are themselves "Pluronic <TM> PE 6800" or "Synperonic <TM> F86
pract.
"Non-ionic polyol surfactants such as" can be included and dissolved in the form of mixtures
thereof.
[0051]
The form of metering the PAR casting solution until the desired amount of dye and / or nonionic
polyol surfactant is reached is preferably in the form of a methylene chloride solution.
[0052]
In another preferred embodiment, the dye and / or nonionic polyol surfactant is pre-dissolved in
methylene chloride used as a solvent for the preparation of PAR casting solutions.
[0053]
Suitable concentrations of the PAR cast methylene chloride solution of the invention range from
10% to the solubility limit.
It is preferably in the range of 15 to 25%, particularly preferably in the range of 20 to 24%.
[0054]
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12
In one method of manufacturing the diaphragm, the heated and softened PAR film is deformed
by thermoforming in a thermoforming mold.
For example, this may be done by application of pneumatic or vacuum, or by use of a mechanical
ram.
The thermoforming processes can also be used in combination with one another.
[0055]
The preferred method of heating is irradiation with infrared light.
[0056]
The finished molded diaphragm is then cut out of the film using a mechanical method, such as a
knife or stamp, or by a non-contact method, such as using a water jet or a laser.
The molded diaphragm is preferably stamped or laser cut.
[0057]
The outer periphery of the diaphragm is then joined to a coil with a support ring and connecting
contacts made of plastic or metal, as a microphone diaphragm or loudspeaker diaphragm with
permanent magnets in a suitable device acting as a transducer or generator of acoustic signals It
can be installed.
[0058]
In order to produce a cast polyarylate film, the polyarylate casting solution of the present
invention is applied to the substrate by a suitable casting apparatus, stripped from the substrate
after a predrying period, and then completely dried.
[0059]
In a particular embodiment, the cast film is applied on a glass substrate by a suitable casting
apparatus or doctor blade, pre-dried, stripped and finally dried to the desired residual solvent
10-05-2019
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concentration.
[0060]
In another preferred embodiment, the cast film is applied to a continuous substrate by a suitable
casting apparatus, pre-dried, stripped and finally dried to the desired residual solvent
concentration.
[0061]
In another preferred embodiment, the continuous substrate is a single-sided matte or polished
steel belt having a length of 20 to 100 m or a polished or matted stainless steel roll of 5 to 25 m
in circumference.
[0062]
In particular, in the case of very thin films with a film thickness <20 μm, flow to one of the
indicated substrates in order to improve the stability of the inventive cast film and to avoid strain
due to tensile stress during further processing of this film. It is advantageous to apply the
intermediate film made on the actual substrate without direct application of the rolled film.
After the pre-drying period described above, this intermediate film can be peeled off from the
actual substrate together with the cast film and the cast film can be subjected to the abovementioned final drying.
Here it is not very important where and when the inventive cast film is separated from the
intermediate film.
The intermediate film is preferably wound on a roll with the inventive cast film and then further
processed.
[0063]
In one preferred embodiment, the intermediate film used preferably comprises a polymer film,
particularly preferably a PET film.
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[0064]
In one preferred embodiment, the predrying step prior to stripping of the preformed film can be
performed directly by infrared irradiation, or microwave irradiation, or electrical heating, or
indirectly by contact with hot air.
[0065]
In one preferred embodiment, the solvent content of the PAR film after stripping is 5-15%.
In another preferred embodiment, the final drying to the desired solvent concentration takes
place in a drying chamber which can be heated by direct or indirect heating.
Preferably, the material is not supported during final drying.
[0066]
The heating method can be direct by infrared and / or microwave and / or indirect by contact
with air at controlled temperatures.
[0067]
In one preferred embodiment, the PAR film is transported at a rate of 1 to 20 m / min, preferably
2 to 5 m / min.
During this process, final drying can be performed at a temperature in the range of 50-200 ° C.
The average thickness of the inventive PAR film after the final drying step is 5 to 200 μm and its
solvent content is less than 1.5%.
[0068]
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15
The properties of the inventive cast PAR film can be further optimized by coating.
For example, the coating can be applied from solution, or can be in the form of a laminated film
or layer.
In another aspect, this coating can also be done by extrusion coating as the PAR film is high heat
resistant.
For example, the coating can further improve the damping properties.
[0069]
Examples of methods of solution coating are roller application, doctor blade application or spray
application.
An example of a solution suitable for solution coating is a solution of polyurethane (PUs) or
acrylate in a suitable solvent.
Films composed of PE, PP or PU are suitable for lamination-coating.
For lamination, unstretched or uniaxially or biaxially stretched cast films, or extruded films, for
example, by the additional application of an adhesive (adhesive lamination) or between individual
layers by true lamination by application of pressure and heat It can be used by methods that
provide adequate high adhesion that is permanent.
[0070]
After the drying step, and, where appropriate, after the further coating step and, where
appropriate, the prefinishing, for example by roll cutting, the cast film according to the invention
is further processed in the thermoforming apparatus as described above. It can be processed to
obtain a diaphragm.
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[0071]
The practice of the invention will now be described in detail by way of Examples 1-13, but
variations of the parameters can be carried out by way of example.
Examples of implementing these variations in the claims and defined in the description are
considered to be the invention and within the protection of the present invention.
[0072]
Example 1 The production batch size is from the formula IKIA of 600 kg, formula (I) wherein R
<1> = R <2> = R <3> = R <4> = hydrogen, R <5> = R <6 "U-Polymer 100" polyarylate with> =
methyl] was weighed into 2062 kg of methylene chloride and dissolved for a further 3 hours at
39 ° C. with continuous stirring for 3 hours at room temperature. A "CI Solvent Yellow 93" dye
from 300 g of BAYER was added in powder form while stirring the mixture. The solids content of
the lacquer was 22.5%.
[0073]
This lacquer was used to produce a film 100 μm thick and about 110 cm wide.
[0074]
Example 2 The production batch size is from the formula IKIA of 600 kg, formula (I) [wherein R
<1> = R <2> = R <3> = R <4> = hydrogen, R <5> = R <6 "U-Polymer 100" polyarylate with> =
methyl] was weighed into 2062 kg of methylene chloride and dissolved for a further 3 hours at
39 ° C. with continuous stirring for 3 hours at room temperature.
The "Macrolex <TM> Orange R" dye from 300 g of BAYER was added in powder form while
stirring the mixture. The solids content of the lacquer was 22.5%.
[0075]
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This lacquer was used to produce a film 100 μm thick and about 110 cm wide.
[0076]
Example 3 A manufacturing batch size is from the formula IKIA of 300 kg, formula (I) where R
<1> = R <2> = R <3> = R <4> = hydrogen, R <5> = R <6 U-Polymer 100 polyarylate with> =
methyl], which was weighed into 1100 kg of methylene chloride and dissolved at 39 ° C. for a
further 3 hours with continuous stirring for 3 hours at room temperature.
"CI Solvent Yellow 93" dye from 32 g of BAYER was added in powder form while stirring the
mixture. The solids content of the lacquer was 21.5%.
[0077]
This lacquer was used to produce films of 20, 25, 30, 40, 60, 80, and 100 μm in thickness and
about 110-120 cm in width.
[0078]
Example 4 0.3 to 2.0 kg of lacquer having a polymer content of 15 to 24% of the formula (I)
where R <1> = R <2> = R <, for a cast product by manual method 3> = R <4> = Hydrogen, R <5> =
R <6> = Methyl] U-Polymer 100 PAR from UNITIKA in methylene chloride at room
temperature for 3 hours with continuous stirring 39 It was prepared by dissolving at ° C for
another 3 hours.
The hand cast lacquers for cast products included 0.01% content of "CI. Solvent Yellow 93" dye.
This lacquer was used to produce a cast product by hand method with a film thickness of 15 to
100 μm according to DIN A4 format.
[0079]
Example 5 0.3 to 2.0 kg of lacquer having a polymer content of 15 to 24% of the formula (I)
where R <1> = R <2> = R <, for a cast product by manual method 3> = R <4> = Hydrogen, R <5> =
10-05-2019
18
R <6> = Methyl] U-Polymer 100 PAR from UNITIKA in methylene chloride at room
temperature for 3 hours with continuous stirring 39 It was prepared by dissolving at ° C for
another 3 hours. The hand cast lacquer for cast products included a 0.01% content of "Macrolex
<TM> Orange R" dye. This lacquer was used to produce a cast product by hand method with a
film thickness of 15 to 100 μm according to DIN A4 format.
[0080]
Example 6 A 0.3 to 2.0 kg lacquer with a polymer content of 15 to 24% is prepared according to
the formula (I) in which R <1> = R <2> = R <, for a cast product by manual method. 3> = R <4> =
Hydrogen, R <5> = R <6> = Methyl] U-Polymer 100 PAR from UNITIKA in methylene chloride
at room temperature for 3 hours with continuous stirring 39 It was prepared by dissolving at °
C for another 3 hours. The hand cast lacquer for cast products included 0.01% content of
"Pluronic <PE> 6800" surfactant. This lacquer was used to produce a cast product by hand
method with a film thickness of 15 to 100 μm according to DIN A4 format.
[0081]
Example 7 For a manually cast product, 0.3 to 2.0 kg of lacquer having a content of 15 to 24% of
the formula (I), where R <1> = R <2> = R < 3> = R <4> = Hydrogen, R <5> = R <6> = Methyl] UPolymer 100 PAR from UNITIKA in methylene chloride at room temperature for 3 hours with
continuous stirring 39 It was prepared by dissolving at ° C for another 3 hours. The hand cast
product lacquers contained 0.001% content of "CI. Solvent Yellow 93" dye. This lacquer was used
to produce a cast product by hand method with a film thickness of 15 to 100 μm according to
DIN A4 format.
[0082]
Example 8 For a manually cast product, 0.3 to 2.0 kg of a lacquer having a content of 15 to 24%
of the formula (I), where R <1> = R <2> = R < 3> = R <4> = Hydrogen, R <5> = R <6> = Methyl]
U-Polymer 100 PAR from UNITIKA in methylene chloride at room temperature for 3 hours
with continuous stirring 39 It was prepared by dissolving at ° C for another 3 hours. The hand
cast product lacquers included 0.001% content of "Macrolex <TM> Orange R" dye. This lacquer
was used to produce a cast product by hand method with a film thickness of 15 to 100 μm
according to DIN A4 format.
10-05-2019
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[0083]
Example 9 For hand cast products 0.3 to 2.0 kg of lacquer with a content of 15 to 24% of the
formula (I) where R <1> = R <2> = R < 3> = R <4> = Hydrogen, R <5> = R <6> = Methyl] UPolymer 100 PAR from UNITIKA in methylene chloride at room temperature for 3 hours with
continuous stirring 39 It was prepared by dissolving at ° C for another 3 hours. The hand cast
product lacquers included 0.001% content of "Pluronic <PE> 6800" surfactant. This lacquer was
used to produce a cast product by manual method having a thickness of 15 to 100 μm
according to DIN A4 format.
[0084]
Comparative Example 10 0.3 to 2.0 kg of a lacquer with a content of 15 to 24% of the formula (I)
where R <1> = R <2> = R for a cast product by a manual method <3> = R <4> = Hydrogen, R <5> =
R <6> = Methyl] U-Polymer 100 PAR from UNITIKA with continuous stirring in methylene
chloride at room temperature for 3 hours It was prepared by melting at 39 ° C. for additional 3
hours. No dyes and / or surfactants were present in the hand cast lacquer for cast products. This
lacquer was used to produce a cast product by hand method with a film thickness of 15 to 100
μm according to DIN A4 format.
[0085]
Example 11 The thixotropic behavior of the lacquer samples from the lacquers of Examples 1-9
and Comparative Example 10 was observed at a specific time after preparation of the ready-touse solution. For this purpose, each lacquer sample was transferred to 5 different containers.
Films were prepared by a manual casting method, if possible, after 30 minutes, 4 hours, 8 hours,
20 hours, and 1 to 4 weeks. The observation results are shown in Table 1.
[0086]
Example 12 40 films of 30 μm thickness consisting of three materials (PC-B, PAR, PC-A) in each
case using tensile and maximum tensile stress at break using the Weibull method The samples
were evaluated.
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[0087]
The characteristic Weibull statistical parameters are summarized in Table 2.
The sample designated PAR represents the cast PAR film of the present invention. PC-A and PC-B
represent samples of cast polycarbonate film. PC-A is the current standard polycarbonate for
loudspeaker diaphragms made of cast PC film. PC-B consists of comparative PC material tested as
a substitute for PC-A.
[0088]
N: Number of samples σ ± Δσ: Arithmetic mean and standard deviation σc, 0: Characteristic
strength (probability of fracture 63.2%) σm: Median strength (probability of fracture 50%) m:
Waveble modulus Waveble modulus m is Characterizing the homogeneity of the material, having
the following order for maximum tensile stress and tensile stress, an increase in m indicates an
increase in homogeneity and less scattering of measurements.
[0089]
Maximum tensile stress: m (PC-A) <m (PC-B) <m (PAR) Tensile stress at break: m (PC-B) <m (PCA) <m (PAR) Two different flows Compared to rolled PC films, the cast PAR films of the present
invention have the lowest inhomogeneity values as well as the narrowest distribution of
measurements.
[0090]
Example 13 Cast PAR film and cast PC film (PC-A and PC-B, PC-A and PC-B, based on DIN ETS
300019 [Development; Environmental conditions and environmental test for telecommunication
equipment (Gerate-Entwicklung; Umweltbedingungen und Umweltprufungen fur
Telekommunikationsanlagen)]) Comparison of the lifetimes of the standard and highperformance types of loudspeakers configured in Example 12).
PAR represents the inventive cast PAR film.
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Five different loudspeaker types were tested, each using at least 50 loudspeakers per type and
diaphragm diameter. The loudspeakers were subjected to various tests such as repeated passes
through high humidity temperature cycles (-40 to 85 ° C), extended exposure to 85 ° C. Each
loudspeaker was tested for an entire period of 500 hours under electrical load with "pink noise"
at each power rate given in the data sheet for the respective loudspeaker. The results shown are
limited to qualitative assessment as failures occur at various times within the trial. Table 3 shows
the ratings and states whether the number of loudspeakers tested is significantly different from
the number of functional and remaining loudspeakers after the test. Loudspeaker diaphragms
made of the inventive cast PAR film obtained at least the same life test results as current
standard materials.
[0091]
+ = Life test is minimal loss, pass (+) = life test is acceptable residual loss, conditional pass-= life
test fails due to high loss
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