U.S. patent number 3,632,443 [Application Number 04/817,348] was granted by the patent office on 1972-01-04 for method of making polypropylene electrets.
This patent grant is currently assigned to Sony Corporation. Invention is credited to Tomosaburo Kitamura, Yoichi Kodera, Etsuro Sawaguchi.
United States Patent |
3,632,443 |
Kodera , et al. |
January 4, 1972 |
METHOD OF MAKING POLYPROPYLENE ELECTRETS
Abstract
An electret which comprises a polypropylene film having a high
volume resistivity and having been permanently electrically
polarized.
Inventors: |
Kodera; Yoichi (Kanagawa-ken,
JA), Kitamura; Tomosaburo (Kanagawa-ken,
JA), Sawaguchi; Etsuro (Kanagawa-ken, JA) |
Assignee: |
Sony Corporation (Tokyo,
JA)
|
Family
ID: |
12246611 |
Appl.
No.: |
04/817,348 |
Filed: |
April 18, 1969 |
Foreign Application Priority Data
|
|
|
|
|
Apr 27, 1968 [JA] |
|
|
43/28366 |
|
Current U.S.
Class: |
427/580; 427/79;
428/335; 307/400; 427/592 |
Current CPC
Class: |
H01G
7/023 (20130101); Y10T 428/264 (20150115) |
Current International
Class: |
H01G
7/02 (20060101); H01G 7/00 (20060101); C23c
013/00 () |
Field of
Search: |
;307/88 ;179/111E
;29/592,25.42 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Miller: Persistent Polarization in Polymers. I; J. Polymer Science:
Part A-2 Vol. 4 685-695 (1966) .
Kresser, Polypropylene, 1960 Reinhold Publ. Corp., Pgs. 60-61,
209.
|
Primary Examiner: Claffy; Kathleen H.
Assistant Examiner: Kundert; Thomas L.
Claims
1. A method of making an electret comprising the steps of
sandwiching a thin polypropylene nonpolar high molecular dielectric
film between two metal electrodes and impressing a voltage of 50 to
600 v. across the metal electrodes in an atmosphere held at a
temperature of 65.degree. C. to
2. A method of making an electret as claimed in claim 1 wherein the
polypropylene nonpolar high molecular dielectric film has a
thickness of 2
3. A method of making an electret as claimed in claim 1 wherein
prior to the sandwiching of said film between said electrodes,
aluminum or palladium is vapor deposited at least on one surface of
the polypropylene
4. A method of making an electret as claimed in claim 1, wherein
said temperature is approximately 85.degree. C.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an electret and a method of making the
same, and more particularly to a polypropylene electret for
electromechanical conversion devices.
2. Description of the Prior Art
It is well known in the art that a permanently polarized dielectric
material, commonly referred to as an electret can be utilized as a
bias power source for condenser microphones, speakers,
electrometers and so on. In the prior art the fabrication of the
electret usually takes place by the following method. This is, a
polar molecule dielectric such as carnauba wax or like natural
organic compound or polymethyl metacrylate, polyethylene
terephthalate, nylonlike synthetic organic compound having a dipole
radical in the molecule is heated up to a temperature exceeding its
melting point or secondary transition temperature so as to
facilitate rotation of the dipole radical and ion migration; a high
DC voltage such as having an electric field intensity of 5 kv./cm.
to 50 kv./cm. is impressed to metal electrodes on both surfaces of
the dielectric to effect dipole radical orientation and ion
polarization; the dielectric is cooled down to room temperature
while being subjected to the voltage; and the electric field is
removed from the dielectric after cooled down to room temperature
to fix the dipole radical orientation and ion polarization, thus
achieving permanent electrification of the dielectric. However, the
carnauba wax is low in volume resistivity and synthetic high
molecular materials such as polymethyl metacrylate, polyethylene
terephthalate, nylon and so on which are composed of polar
molecules are high in hygroscopicity and when they are kept in open
conditions decay of electric charge is great, so that they are not
suitable for industrial use.
SUMMARY OF THE INVENTION
In view of the foregoing, the present invention is to provide a
polarized polypropylene electret for conversion devices which has
stable surface charge lasting for a long period of time unaffected
by humidity and a method of making the polypropylene electret.
One of the features of this invention resides in that the electret
is formed of polypropylene which is a nonpolar high molecule and
has a secondary transition temperature of approximately -35.degree.
C. Polypropylene has no dipole radical, has high volume
resistivity, so that in the electret of this invention decay of the
surface charge resulting from the internal electric field is small
and, in addition, since polypropylene has substantially no
hygroscopicity, decay of the surface charge is small. Accordingly,
the electret of this invention can be expected to have a long
service life.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram showing in cross section one example
of a method of making an electret for conversion devices according
to this invention;
FIGS. 2A and 2B are graphs showing changes of the surface charge
density of the electret with the lapse of time;
FIG. 3 is a graph showing the relationship between voltage and the
surface charge density of the electret; and
FIG. 4 is a graph showing the relationship between temperature and
the surface charge density of the electret.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 there is illustrated a method of making an electret in
accordance with one example of this invention, in which a
relatively thin polypropylene high-molecular dielectric film is
sandwiched between two metal electrodes, the resulting structure is
placed in an atmosphere held at a temperature of 65.degree. C. to
120.degree. C. and a voltage of 50 v. to 600 v. is applied across
the metal electrodes, thus providing an electret for conversion
devices.
A description will be given first in connection with one embodiment
of this invention as applied to a diaphragm of condenser
microphones.
The first step is to prepare a polypropylene film 2, commercially
known under the trademark "TORAYFAN," which is of binary
orientation and has a thickness of 15 microns. The next step is to
coat an aluminum electrode 3 on one surface of the film 2 by means
of vacuum vapor deposition and the resulting assembly is polarized.
In this case the adhesion of the electrode to the polypropylene
film 2 is poor, and hence the material of the electrode is desired
to be excellent in adhesion and not to be deteriorated by gas in
the air. It has been found by experiment that aluminum, palladium,
silver and a gold-silver alloy exhibit excellent adhesion but that
since silver and the gold-silver alloy are chemically affected by
gases in the air such as hydrogen sulfide and so on, aluminum and
palladium are the best for the purpose in practical use.
Subsequent to the polarization of the polypropylene film 2 having
the aluminum electrode 3 deposited thereon, the film 2 is
sandwiched between metal electrode plates 4a and 4b and the
resulting assembly is immersed in a thermostat 5.
The thermostat 5 is held at a temperature of 90.degree. C. and a DC
voltage is impressed between the electrode plates 4a and 4b, under
which conditions the sandwiched film 2 is placed for 2 hours,
thereafter being cooled down to room temperature in 30 minutes
while being exposed to the electric field.
As indicated by a curve 6 in FIG. 2B, the surface charge density of
the electret thus produced undergoes less changes in the air but
stably lasts for a longer period of time, as compared with that of
a conventional electret formed of polyethylene terephthalate
(indicated by a curve 1 in FIG. 2A).
Generally, the charge of the electret consists of heterocharge and
homocharge and the surface charge appears in terms of the
difference between the heterocharge and the homocharge.
Polypropylene used in this invention is a nonpolar high molecule
and its secondary transition temperature is -35.degree. C. and the
motion of the molecular chain is not frozen at room temperature.
Accordingly, in the fabrication of the electret the heterocharge is
not produced due to the orientation of the dipole radical but
instead the homocharge is generated by ions which are yielded by
the voltage impressed the electrodes 4a and 4b or by discharge
between the surface of the film 2 and the electrode 4b which
results from discharge of the charge stored on the film surface
when the electrode 4b is peeled off from the film surface. However,
the hygroscopicity of polypropylene is as low as less than 0.005
percent and its volume resistivity is as high as 6.times.10.sup.18
.OMEGA. cm., so that decay of the surface charge is hard to occur
and this appears to suppress the variations in the surface charge
density with the lapse of time as described previously.
In the conventional polyethylene terephthalate electret great decay
of its surface charge density indicated in FIG. 2A was caused on
damp days. This is considered to be due to the fact that
polyethylene terephthalate has a hygroscopicity of 0.8 percent and
a volume resistivity of 2.times.10.sup.18 .OMEGA. cm. and that
these factors are inferior to those of polypropylene.
In FIG. 3 there is indicated by curve 7 the relationship between
the voltage impressed across the electrode plates 4a and 4b and the
surface charge density of the electret mentioned above. The curve 7
became substantially hump-shaped one such that the surface charge
density reached a maximum value in the vicinity of approximately
400 v., as indicated. It has been found that, with the impressed
voltage being lower than about 50 v. or exceeding about 600 v., the
surface charge density of the electret was too low to be used for
industrial purposes.
Further, there is indicated by a curve 8 in FIG. 4 the relationship
between the surface charge density of the electret and the varying
temperature of the thermostat 5 when the impressed voltage across
the electrodes 4a and 4b was held at a value of 200 v. The curve 8
became substantially hump-shaped one such that the surface charge
density reached a maximum value in the vicinity of approximately
85.degree. C. It has been found that temperatures lower than about
65.degree. C. and exceeding about 120.degree. C. result too low a
surface charge density of the electret and that temperatures
exceeding 120.degree. C. are not preferred from a viewpoint of the
thermal resistance of polypropylene, too.
Where the electret of this invention is applied to a conversion
device such as a condenser microphone, the thickness of the
polypropylene film must be determined in view of the following
points.
Namely, the polypropylene film is desired to be as thin as possible
in order for the film to readily respond as a transducer to the
driving force. However, too small a thickness of the film
introduces lowered mechanical strength of the film and a fatal
defect such that the both surfaces of the film are electrically
short-circuited by a pinhole which might be produced in the
manufacturing processes.
Accordingly, it is preferred from a practical point of view that
the thickness of the film is greater than 2 microns but smaller
than 50 microns.
In the foregoing the metal electrodes 4a and 4b are provided
separately from the polypropylene film 2 and it is also possible to
form electrodes on both surfaces of the polypropylene film 2 by
means of metal vapor deposition or the like.
It will be apparent that many modifications and variations may be
effected without departing from the scope of the novel concepts of
this invention.
* * * * *