Method for chemically incorporating metal elements into polysiloxanes

This invention relates to methods for preparing polyheterosiloxane materials having at least two different non-Si metal elements. The polyheterosiloxane materials prepared by these methods are solid materials which can be easily dispersed in a solvent of choice.

BACKGROUND OF THE INVENTION

This invention relates to methods for preparing polyheterosiloxanes with chemically bonded non-Si metal elements using both metal salts and metal alkoxides. The metal salts and metal alkoxides can contain the same or different metal elements. The polyheterosiloxanes prepared by these methods are solid materials which can be easily dispersed in a solvent of choice.

Incorporation of metal elements into polysiloxanes has been of great interest for a wide range of applications due to their ability to impart high refractive index, impact resistance, scratch resistance, fire retardance, anti-corrosion, anti-stain, etc. Generally, two synthetic methods have previously been used to prepare the hybrid materials containing metal elements and polysiloxanes. One method involves modification of prefabricated metal oxide particles with organosilanes or polysiloxanes. This particle modification method often confronts challenges on particle aggregation, dispersion, and opacity issues. Further, the inhomogeneity of the metal oxides severely limits their use for optical and electronic applications. The other method is based on sol-gel hydrolysis and condensation chemistries involving a two-component system of metal alkoxides and alkoxysilanes. The type of metal elements incorporated into the polysiloxane resins by this method is limited by the availability of the metal alkoxide precursors since metal elements other than Ti, Zr, Al, Ge, and Sn are either not available or difficult to synthesize.

The inventors have unexpectedly discovered that adding both a metal alkoxide and a hydrolyzable metal salt in a siloxane polymerization reaction provides a convenient method of incorporating various metal elements into an organosiloxane via Metal-O—Si and Metal-O-Metal oxo-linkages. Thus, the present invention relates to methods of making polyheterosiloxanes having at least two non-Si metal elements which utilize both metal salts and metal alkoxides.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a method for preparing a polyheterosiloxane having at least two non-Si metal elements comprising the step of: (1) adding an amount of water to a dispersion comprising (A) at least one metal (M1) alkoxide, (B) at least one silicon-containing material, and (C) at least one hydrolyzable metal (M2) salt so a polyheterosiloxane having at least two non-Si metal elements is formed.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a method for preparing a polyheterosiloxane having at least two non-Si metal elements comprising reacting:

(B) a silicon-containing material having hydrolyzable groups selected from(B1) an organosiloxane, or(B2) a silane, and

with an amount of water that provides between 50 and 200% necessary to hydrolyze and condense the alkoxy groups and other hydrolyzable groups on Components (A), (B), and (C), to form the polyheterosiloxane, with the proviso that at least two non-Si metal elements are provided by Component (A) and/or (C). In one embodiment, (M1) and (M2) are non-Si metal elements and different from each other.

As used herein, the expression “at least one” means one or more and this includes individual components as well as mixtures/combinations.

Component (A) is a metal (M1) alkoxide. In one embodiment of the present invention the metal (M1) alkoxide (A) is selected from metal alkoxides having a general formula (I) R1mM1OnXp(OR2)v1-m-p-2n, where M1 is selected from Ti, Al, Ge, Zr, Sn, Cr, Ca, Ba, Sb, Cu, Ga, Hf, In, Fe, Mg, Mo, Nb, Ce, Er, La, Nd, Pr, Sm, Y, Sr, Ta, Te, W, and V, each X is independently selected from carboxylate ligands, organosulfonate ligands, organophosphate ligands, β-diketonate ligands, and chloride ligands, v1 is the oxidation state of M1, m is a value from 0 to 3, n is a value from 0 to 2, p is a value from 0 to 3, each R1is an alkyl group having from 1 to 18 carbon atoms, each R2is an independently selected monovalent alkyl group having from 1 to 6 carbon atoms, aryl group having from 6 to 8 carbon atoms, or a polyether group having a general formula (VI) —(R3O)qR4, where q is a value from 1 to 4, each R3is an independently selected divalent alkylene group having from 2 to 6 carbon atoms, R4is an independently selected hydrogen atom or monovalent alkyl group having from 1 to 6 carbon atoms,

Component (B) is a silicon-containing material having hydrolyzable groups selected from (B1) an organosiloxane, or (B2) a silane. In one embodiment, component (B) is at least one silicon-containing material selected from (B1) an organosiloxane having an average formula (II) R5b(R6O)aSiO(4−(a+b))/2or (B2) a silane having a general formula (III) R5cSiYd, where Y is Cl or OR6, each R5is an independently selected hydrogen atom, alkyl group having 1 to 18 carbon atoms, alkenyl group having from 2 to 18 carbon atoms, aryl group having from 6 to 12 carbon atoms, epoxy group, amino group, or carbinol group, R6is an independently selected hydrogen atom or alkyl group having from 1 to 6 carbon atoms, aryl group having from 6 to 8 carbon atoms, or a polyether group having a general formula (VI) —(R3O)qR4, where q is a value from 1 to 4, each R3is an independently selected divalent alkylene group having from 2 to 6 carbon atoms, R4is an independently selected hydrogen atom or monovalent alkyl group having from 1 to 6 carbon atoms, a is a value from 0.1 to 3, b is a value from 0.5 to 3, and (a+b) is a value from 0.6 to 3.9, c is a value from 0 to 3, d is a value from 1 to 4 and (c+d) equals 4, and

Component (C) is a hydrolyzable metal (M2) salt. In one embodiment, the hydrolyzable metal (M2) salt is selected from (C1) a non-hydrated metal salt having a general formula (IV) R7eM2(Z)(v2−e)/wor (C2) a hydrated metal salt having a general formula (V) M2(Z)v2/w.xH2O, where M2 is selected from any of the metal elements in the periodic table, v2 is the oxidation state of M2, w is the oxidation state of ligand Z where Z is independently chosen from carboxylates, β-diketonates, fluoride, chloride, bromide, iodide, organic sulfonate, nitrate, nitrite, sulphate, sulfite, cyanide, phosphites, phosphates, organic phosphites, organic phosphates, and oxalate, each R7is an independently selected alkyl group having 1 to 18 carbon atoms, alkenyl group having from 2 to 8 carbon atoms, or aryl group having from 6 to 8 carbon atoms, e is a value from 0 to 3 and x is a value from 0.5-12, so a polyheterosiloxane having at least two non-Si metal elements is formed, where the total amount of water added is between 50 and 200% of the amount theoretically necessary for the hydrolysis and condensation of all alkoxy groups and other hydrolyzable groups on Components (A), (B), and (C).

Component (A) may comprise at least one metal alkoxide selected from metal alkoxides having a general formula (I) R1mM1OnXp(OR2)v1-m-p-2n, where M1 is selected from Ti, Al, Ge, Zr, Sn, Cr, Ca, Ba, Sb, Cu, Ga, Hf, In, Fe, Mg, Mo, Nb, Ce, Er, La, Nd, Pr, Sm, Y, Sr, Ta, Te, W, and V, each X is independently selected from carboxylate ligands, organosulfonate ligands, organophosphate ligands, β-diketonate ligands, and chloride ligands, subscript v1 is the oxidation state of M1, m is a value from 0 to 3, n is a value from 0 to 2, p is a value from 0 to 3, each R1is a monovalent alkyl group having from 1 to 18 carbon atoms, each R2is an independently selected monovalent alkyl group having from 1 to 6 carbon atoms, aryl group having from 6 to 8 carbon atoms, or a polyether group having a general formula (VI) —(R3O)qR4, where q is a value from 1 to 4, each R3is an independently selected divalent alkylene group having from 2 to 6 carbon atoms, R4is an independently selected hydrogen atom or monovalent alkyl group having from 1 to 6 carbon atoms.

In Formula (I), each R2is an independently selected monovalent alkyl group having from 1 to 6 carbon atoms, aryl group having from 6 to 8 carbon atoms, or a polyether group having a general formula (VI) —(R3O)qR4, where q is a value from 1 to 4, each R3is an independently selected divalent alkylene group having from 2 to 6 carbon atoms, R4is an independently selected hydrogen atom or monovalent alkyl group having from 1 to 6 carbon atoms.

Examples of the alkyl groups of R2include methyl, ethyl, propyl, isopropyl, butyl, t-butyl, and hexyl. Examples of the aryl groups of R2include phenyl and benzyl.

Examples of the divalent alkylene group having from 2 to 6 carbon atoms of R3include —CH2CH2— and —CH2CH(CH3)—. Examples of the alkyl groups having from 1 to 6 carbon atoms of R4are as described above for R2. Subscript q in Formula (VI) is a value from 1 to 4, alternatively 1 to 2. Examples of the polyether group of Formula (VI) include methoxyethyl, methoxypropyl, methoxybutyl, ethoxyethyl, ethoxypropyl, ethoxybutyl, methoxyethoxyethyl, and ethoxyethoxyethyl.

In Formula (I), X is selected from carboxylate ligands, organosulfonate ligands, organophosphate ligands, β-diketonate ligands, and chloride ligands, alternatively carboxylate ligands and β-diketonate ligands. The carboxylate ligands useful for X have a formula R15COO— where R15is selected from hydrogen, alkyl groups, alkenyl groups, and aryl groups. Examples of useful alkyl groups for R15include alkyl groups having from 1 to 18 carbon atoms, alternatively 1 to 8 carbon atoms as described above for R1. Examples of useful alkenyl groups for R15include alkenyl groups having from 2 to 18 carbon atoms, alternatively 2 to 8 carbon atoms such as vinyl, 2-propenyl, allyl, hexenyl, and octenyl. Examples of useful aryl groups for R15include aryl groups having from 6 to 18 carbon atoms, alternatively 6 to 8 carbon atoms such as phenyl and benzyl. Alternatively R15is methyl, 2-propenyl, allyl, and phenyl.

The β-diketonate ligands useful for X can have the following structures:

where R16, R18, and R21are selected from monovalent alkyl and aryl groups. Examples of useful alkyl groups for R16, R18, and R21include alkyl groups having from 1 to 12 carbon atoms, alternatively 1 to 4 carbon atoms such as methyl, ethyl, trifluoromethyl, and t-butyl. Examples of useful aryl groups for R16, R18, and R21include aryl groups having from 6 to 18 carbon atoms, alternatively 6 to 8 carbon atoms such as phenyl and tolyl. R19is selected from alkyl groups, alkenyl groups and aryl groups. Examples of useful alkyl groups for R19include C1 to C18 alkyl groups, alternatively C1 to C8 alkyl groups such as methyl, ethyl, propyl, hexyl and octyl. Examples of useful alkenyl groups for R19include alkenyl groups having from 2 to 18 carbon atoms, alternatively C2 to C8 carbon atoms such as allyl, hexenyl, and octenyl. Examples of useful aryl groups for R19include aryl groups having from 6 to 18 carbon atoms, alternatively 6 to 8 carbon atoms such as phenyl and tolyl. R17and R20are hydrogen or alkyl, alkenyl, and aryl groups. Examples of useful alkyl groups for R17and R20include alkyl groups having from 1 to 12 carbon atoms, alternatively 1 to 8 carbon atoms such as methyl and ethyl. Examples of useful alkenyl groups for R17and R20include alkenyl groups having from 2 to 18 carbon atoms, alternatively 2 to 8 carbon atoms such as vinyl, allyl, hexenyl, and octenyl. Examples of useful aryl groups for R17and R20include aryl groups having from 6 to 18 carbon atoms, alternatively 6 to 8 carbon atoms such as phenyl and tolyl. R16, R17, R18, R19, R20, and R21are each independently selected and can be the same or different.

In Formula (I), subscript v1 is the oxidation state of M1, ranging from 1 to 7. Alternatively, v1 ranges from 1 to 5.

In Formula (I), subscript m is a value from 0 to 3, alternatively 0 to 2, alternatively 0.

In Formula (I), subscript n is a value from 0 to 2, alternatively 0 to 1, alternatively 0.

In Formula (I), subscript p is a value from 0 to 3, alternatively 0 to 2, alternatively 0.

The metal alkoxides described by Formula (I) are generally available from Gelest (Morrisville, Pa. USA).

Component (B) is a silicon-containing material having hydrolyzable groups selected from (B1) an organosiloxane, or (B2) a silane. In one embodiment, component (B) is at least one silicon-containing material selected from (B1) an organosiloxane having an average formula (II) R5b(R6O)aSiO(4−(a+b))/2or (B2) a silane having a general formula (III) R5cSiYd, where Y is Cl or OR6, each R5is an independently selected hydrogen atom, alkyl group having 1 to 18 carbon atoms, alkenyl group having from 2 to 18 carbon atoms, aryl group having from 6 to 12 carbon atoms, epoxy group, amino group, or carbinol group, R6is an independently selected hydrogen atom or alkyl group having from 1 to 6 carbon atoms, aryl group having from 6 to 8 carbon atoms, or a polyether group having a general formula (VI) —(R3O)qR4, where q is a value from 1 to 4, each R3is an independently selected divalent alkylene group having from 2 to 6 carbon atoms, R4is an independently selected hydrogen atom or monovalent alkyl group having from 1 to 6 carbon atoms, a is a value from 0.1 to 3, b is a value from 0.5 to 3, and (a+b) is a value from 0.6 to 3.9, c is a value from 0 to 3, d is a value from 1 to 4 and (c+d) equals 4.

Formula (II) are composed of M, D, T, and Q building blocks. By definition, M building block refers to a siloxy unit that contains one silicon atom bonded to one oxygen atom, with the remaining three substituents on the silicon atom being other than oxygen. D building block refers to a siloxy unit that contains one silicon atom bonded to two oxygen atoms, with the remaining two substituents on the silicon atom being other than oxygen. T building block refers to a siloxy unit that contains one silicon atom bonded to three oxygen atoms, with the remaining one substituent on the silicon atom being other than oxygen. Q building block refers to a siloxy unit that contains one silicon atom bonded to four oxygen atoms. Their molecular structures are listed below:

The alkyl groups having 1 to 18 carbon atoms of R5in Formulas (II) and (III) are as described above for R1. Alternatively, the alkyl group comprises 1 to 6 carbon atoms; alternatively, the alkyl group is methyl, ethyl, propyl, butyl, and hexyl.

The alkenyl groups having from 2 to 18 carbon atoms of R5in Formulas (II) and (III) are illustrated by vinyl, propenyl, butenyl, pentenyl, hexenyl, or octenyl. Alternatively, the alkenyl group comprises 2 to 8 carbon atoms. Alternatively, the alkenyl group is vinyl, allyl, and hexenyl.

The epoxy groups of R5in Formulas (II) and (III) are selected from glycidyl ether groups, alkyl epoxy groups and cycloaliphatic epoxy groups. The glycidyl ether group is illustrated by alkyl glycidyl ether groups such as 2-glycidoxyethyl, 3-glycidoxypropyl, 4-glycidoxybutyl, and 2-(3,4-epoxycyclohexyl)ethyl. Examples of the alkyl epoxy groups are 2,3-epoxypropyl, 3,4-epoxybutyl, and 4,5-epoxypentyl, and the cycloaliphatic epoxy group is illustrated by monovalent epoxycycloalkyl groups such as 3,4-epoxycyclohexylmethyl, 3,4-epoxycyclohexylethyl, 3,4-epoxycyclohexylpropyl, 3,4-epoxycyclohexylbutyl, and alkyl cyclohexene oxide groups. Alternatively, the epoxy group is 3-glycidoxypropyl.

The amino groups of R5in Formulas (II) and (III) typically have the formula —R9NHR10or —R9NHR9NHR10wherein each R9is independently a divalent hydrocarbon radical having at least 2 carbon atoms and R10is hydrogen or an alkyl group having from 1 to 18 carbon atoms. Examples of the R9group include an alkylene radical having from 2 to 20 carbon atoms and are illustrated by —CH2CH2—, —CH2CH2CH2—, —CH2CHCH3—, —CH2CH2CH2CH2—, —CH2CH(CH3)CH2—, —CH2CH2CH2CH2CH2—, —CH2CH2CH2CH2CH2CH2—, —CH2CH2CH(CH2CH3)CH2CH2CH2—, —CH2CH2CH2CH2CH2CH2CH2CH2—, and —CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2—. Alternatively, the alkyl groups of R10are methyl, ethyl, propyl, butyl, hexyl, octyl, decyl, dodecyl, hexadecyl, and octadecyl. Alternatively, when R10is an alkyl group it is methyl.

The carbinol groups of R5in Formulas (II) and (III) are selected from carbinol groups free of aryl groups having at least 3 carbon atoms and aryl-containing carbinol groups having at least 6 carbon atoms. Generally a “carbinol” group is any group containing at least one carbon-bonded hydroxyl (COH) group. Thus the carbinol groups may contain more than one COH group such as for example

Carbinol groups free of aryl groups having at least 3 carbon atoms are illustrated by groups having the formula R11OH wherein R11is a divalent hydrocarbon group having at least 3 carbon atoms or a divalent hydrocarbonoxy group having at least 3 carbon atoms. The group R11is illustrated by alkylene groups selected from —(CH2)s— where s has a value of 3 to 10 and —CH2CH(CH3)—, —CH2CH(CH3)CH2—, —CH2CH2CH(CH2CH3)CH2CH2CH2—, and —OCH(CH3)(CH2)t— wherein t has a value of 1 to 10. The carbinol group free of aryl groups having at least 3 carbon atoms is also illustrated by groups having the formula R12(OH) CH2OH where R12is a group having the formula —CH2CH2(CH2)tOCH2CH— wherein t has a value of 1 to 10.

The aryl-containing carbinol group having at least 6 carbon atoms is illustrated by groups having the formula R13OH wherein R13is an arylene group selected from —(CH2)uC6H4—, —CH2CH(CH3)(CH2)uC6H4— wherein u has a value of 0 to 10, and —(CH2)tC6H4(CH2)u— wherein u and t are as described above. Alternatively, the aryl-containing carbinol groups have from 6 to 14 carbon atoms, alternatively 6 to 10 carbon atoms.

Amino and/or carbinol containing silanes or siloxanes are applicable for some metal-containing resins, such as tin, germanium, and aluminium, however, gelation problems may occur during the synthetic process with certain metal elements (such as Zn and Cu) because of the amino and carbinol silanes or siloxanes ability to chelate to certain metals.

Alternatively, each R5in Formulas (II) and (III) is an independently selected hydrogen atom, an alkyl group having from 1 to 6 carbon atoms, an alkenyl group having from 2 to 8 carbon atoms, or an aryl group having from 6 to 12 carbons atoms. Alternatively, each R5in Formulas (II) and (III) is an independently selected alkyl group having from 1 to 6 carbon atoms, an alkenyl group having from 2 to 6 carbon atoms, or an aryl group having from 6 to 8 carbons atoms. Alternatively, each R5is methyl, vinyl, or phenyl.

The R6group of Formula (II) is an independently selected hydrogen atom, alkyl group having from 1 to 6 carbon atoms, aryl group having from 6 to 8 carbon atoms, or a polyether group having a general formula (VI) —(R3O)qR4, where q is a value from 1 to 4, each R3is an independently selected divalent alkylene group having from 2 to 6 carbon atoms, R4is an independently selected hydrogen atom or monovalent alkyl group having from 1 to 6 carbon atoms or alkyl group. Examples of the alkyl group, aryl group and polyether group of R6are as described above for R2. Alternatively, R6is a hydrogen atom or an alkyl group having from 1 to 4 carbon atoms. Alternatively, R6is hydrogen, methyl, or ethyl.

In Formula (II), subscript a is a value from 0.1 to 3, alternatively 1 to 3.

In Formula (II), subscript b is a value from 0.5 to 3, alternatively 1.5 to 2.5.

In Formula (II), subscripts (a+b) have a value from 0.6 to 3.9, alternatively 1.5 to 3.

Examples of the organosiloxanes (B1) described by Formula (II) and useful in the present method include oligomeric and polymeric organosiloxanes, such as silanol-terminated polydimethylsiloxane, polymethylmethoxysiloxane, polysilsesquioxane, alkoxy and/or silanol containing MQ resin, and combinations thereof. They are made by hydrolysis of the corresponding organomethoxysilanes, organoethoxysilanes, organoisopropoxysilanes, and organochlorosilanes.

In Formula (III), each Y is a chloro atom (Cl) or OR6, where R6is as described above. Alternatively, Y is OR6.

In Formula (III), subscript c is a value from 0 to 3, alternatively, c is a value from 1 to 3, alternatively, from 2 to 3.

In Formula (III), subscript d is a value from 1 to 4, alternatively d is a value from 1 to 3, alternatively, from 1 to 2.

Component (C) may comprise at least one metal (M2) salt selected from (C1) a non-hydrated metal salt having a general formula (IV) R7eM2(Z)(v2−e)/wor (C2) a hydrated metal salt having a general formula (V) M2(Z)v2/w.xH2O, where M2 is selected from any of the metal elements in the Periodic Table, v2 is the oxidation state of M2, w is the oxidation state of ligand Z where Z is independently chosen from carboxylates, β-diketonates, fluoride, chloride, bromide, iodide, organic sulfonate, nitrate, nitrite, sulphate, sulfite, cyanide, phosphites, phosphates, organic phosphites, organic phosphates, and oxalate, each R7is an independently selected alkyl group having 1 to 18 carbon atoms, alkenyl group having from 2 to 8 carbon atoms, or aryl group having from 6 to 8 carbon atoms, e is a value from 0 to 3 and x is a value from 0.5 to 12 and describes the average number of H2O molecules associated with each metal salt molecule.

In Formulas (IV) and (V), subscript v2 is the oxidation state of M2 and can range from 1 to 7, alternatively 1 to 4.

In Formulas (IV) and (V), subscript w is the oxidation state of ligand Z and can range from 1 to 3, alternatively 1 to 2.

The Z group in Formulas (IV) and (V) describes the various counter ligands attached to the metal element (M2). Generally, each Z is independently selected from carboxylate ligands, β-diketonate ligands, fluoride ligand, chloride ligand, bromide ligand, iodide ligand, organic sulfonate ligands, nitrate ligand, nitrite ligand, sulphate ligand, sulfite ligand, cyanide ligand, phosphate ligand, phosphite ligand, organic phosphite ligands, organic phosphate ligands, and oxalate ligand.

The carboxylate ligands and β-diketonate ligands useful for Z are as described above for X.

The organic sulfonate ligands useful for Z have a formula R22SO3—, where R22is selected from monovalent alkyl groups, alkenyl groups and aryl groups. Examples of useful alkyl groups, alkenyl groups and aryl groups are as described above for R15. Alternatively R22is tolyl, phenyl, and methyl.

The organic phosphate ligands useful for Z have a formula (R23O)2PO2−or R23O—PO32-, where R23is selected from monovalent alkyl groups, alkenyl groups and aryl groups. Examples of useful alkyl groups, alkenyl groups and aryl groups are as described above for R15. Alternatively R23is phenyl, butyl, and octyl.

The organic phosphite ligands useful for Z have a formula (R24O)2PO31or R24O—PO22−, where R24is selected from monovalent alkyl groups, alkenyl groups and aryl groups. Examples of useful alkyl groups, alkenyl groups and aryl groups are as described above for R15. Alternatively R24is phenyl, butyl, and octyl.

Alternatively, Z in Formulas (IV) and (V) is independently selected from carboxylate ligands, β-diketonate ligands, nitrate ligand, sulphate ligand, and chloride ligand. Alternatively, Z includes carboxylate ligands and β-diketonate ligands.

In Formulas (IV) and (V), subscript e is a value from 0 to 3, alternatively 0 to 2, alternatively 0.

In Formula (IV), R7is an independently selected alkyl group having 1 to 18 carbon atoms, alkenyl group having from 2 to 8 carbon atoms, or aryl group having from 6 to 8 carbon atoms. Examples of R7are as described above for R5.

In Formula (V), x is a value from 0.5 to 12, alternatively 1 to 9.

Examples of hydrated metal salts (C2) described by Formula (VI) useful in the present method include but are not limited to zinc acetate dihydrate, nickel acetate tetrahydrate, magnesium acetate tetrahydrate, zinc nitrate hexahydrate, and copper sulphate pentahydrate.

Both the non-hydrated metal salts and the hydrated metal salts described above are commercially available through the major chemical vendors, such as Sigma-Aldrich, Fisher Scientific, Alfa-Aesar, Gelest, etc.

The present invention relates to methods for preparing polyheterosiloxanes having at least two non-Si metal elements. In one embodiment, Components (A), (B), and (C) are dispersed or dissolved, water is added and a reaction proceeds forming a polyheterosiloxane having at least two non-Si metal elements.

Another embodiment for preparing a polyheterosiloxane having at least two non-Si metal elements comprises: (1) adding an amount of water to a dispersion comprising at least one Component (A) and at least one Component (B1) or (B2) to form a heterosiloxane containing M1-O—Si linkages; and (2) adding at least one Component (C1) or (C2) and if necessary an additional amount of water to the heterosiloxane containing M1-O—Si linkages such that polyheterosiloxanes having at least two non-Si metal elements are formed, where the total amount of water added is between 50 and 200% of the amount theoretically necessary for the hydrolysis and condensation of all alkoxy groups and other hydrolyzable groups on Components (A), (B), and (C).

Another embodiment for preparing a polyheterosiloxane having at least two non-Si metal elements comprises: (1) adding an amount of water to a dispersion comprising at least one Component (A) and at least one Component (C1) or (C2) to form a mixed metal oxides solution containing M1-O-M2 oxo-linkages, and (2) adding at least one Component (B1) or (B2) to the mixed metal oxides solution containing M1-O-M2 oxo-linkages and if necessary adding an additional amount of water such that polyheterosiloxanes having at least two non-Si metal elements are formed, where the total amount of water added is between 50 and 200% of the amount theoretically necessary for the hydrolysis and condensation of all alkoxy groups and other hydrolyzable groups on Components (A), (B), and (C).

Another embodiment for preparing a polyheterosiloxane having at least two non-Si metal elements comprises: (1) adding an amount of water to a dispersion comprising at least one Component (C1) or (C2) and at least one Component (B1) or (B2) to form a heterosiloxane containing M2-O—Si linkages; and (2) adding at least one Component (A) to the heterosiloxane containing M2-O—Si linkages and if necessary an additional amount of water such that polyheterosiloxanes having at least two non-Si metal elements are formed, where the total amount of water added is between 50 and 200% of the amount theoretically necessary for the hydrolysis and condensation of all alkoxy groups and other hydrolyzable groups on Components (A), (B), and (C).

As used herein, the term “dispersion” in each of the methods means that the molecules of the various components are homogenously distributed. Each of the components may be liquid or solids and so it is preferred that they are pre-mixed or dispersed. Stirring one or more of the components in a solvent is an excellent way to get a homogenous dispersion; or a solvent may not be needed if one or more components can be dispersed in another component. When solvents are used, any kind of solvent is useful including polar solvents, non-polar solvent, hydrocarbon solvents including aromatic and saturated hydrocarbons, alcohols, etc. Examples of solvents useful for dispersing Components (A), (B), and (C) includes hydrocarbonethanol, 1-propanol, isopropanol, 1-butanol, 2-butanol, methoxyethanol, methoxyethoxyethanol, butyl acetate, and toluene, alternatively isopropanol, 1-butanol, 2-butanol, and butyl acetate. One type of solvent could be used or a mixture of different solvents would also be useful. The dispersing or mixing may be done by any conventional means such as stirring.

Generally, the reaction between Components (A), (B), and (C) in each of the methods proceeds at room temperature (20° C.) but if desired, elevated temperatures up to about 140° C. may be used. Alternatively, the temperature can range from 20° C. to 120° C. Generally, the reaction can take between 30 minutes to 24 hours, alternatively 10 minutes to 4 hours.

An optional step in all the methods comprises removing the solvent to produce a solid polyheterosiloxane having at least two non-Si metal elements. The solvents can be removed by any conventional manner such as heating to elevated temperatures or using reduced pressure. This solid material can then be redispersed in a solvent of choice such as toluene, THF, butyl acetate, chloroform, dioxane, 1-butanol, and pyridine. Since the Si—O—M linkages made by the present method can be susceptible to hydrolytic cleavage in the presence of H2O, to ensure longer shelf life it is preferred to minimize the polyheterosiloxane having at least two non-Si metal elements' exposure to moisture.

The polyheterosiloxanes having at least two non-Si metal elements formed by each of the methods have molecular weights (weight average) ranging from 1000 to 1000000, alternatively from 2000 to 100000. In preferred embodiments, the non-Si metal elements are uniformly distributed in the materials and have a domain size smaller than 10 nanometers.

Metal oxides have intrinsic spectral absorption bands, thus exhibit different colors when incorporated into the resins. The polyheterosiloxane resins produced by the present method may be characterized by UV transmission spectroscopy. The present polyheterosiloxane resins exhibit excellent absorption capability in the UV range (280-400 nm). In many instances, the present resins absorb visible light which should enable their use as colorants in coatings.

The polyheterosiloxanes having at least two non-Si metal elements formed by the present methods preferably contain from 1% to 25% by weight alkoxy groups, alternatively, from 5% to 15% by weight alkoxy groups. Although there must be at least 2 non-Si metal elements in each polyheterosiloxane molecule, the molar percentage of the non-Si metal element (M1 and M2) content in the polyheterosiloxane materials can also be from 0.5 to 90 mole percent, alternatively from 5 to 60 mole percent, alternatively from 20 to 50 mole percent. No fatty acid is needed in the present methods.

The molar ratio of M2 to M1 useful in each embodiment ranges from 0.001 to 2, alternatively from 0.05 to 1. The molar ratio of Si units to M1 useful in the present methods range from 0.1 to 200, alternatively from 0.6 to 20.

An amount of water must be added in each embodiment so that polyheterosiloxanes having at least two non-Si metal elements are formed. Since water can also be incorporated via the hydrated metal salts (C2), a person skilled in the art would understand that when hydrated metal salts are utilized either smaller amounts or no additional amounts of water may need to be added in order for the needed amount of water to be present. Generally, the amount of water needed for making polyheterosiloxanes having at least two non-Si metal elements ranges from 50% to 200% of the theoretical amount of water necessary for complete hydrolysis and condensation of all the alkoxy and other hydrolyzable groups present on each of the components. A person skilled in the art would understand that 0.5 mole of water is necessary for hydrolysis and condensation of 1 mole of alkoxy and other hydrolyzable groups. Alternatively, the amount of water needed to make polyheterosiloxanes having at least two non-Si metal elements ranges from 70% to 150% of the theoretical amount of H2O necessary for complete hydrolysis and condensation of all the alkoxy and other hydrolyzable groups present on each of the components, alternatively, 80% to 120% on the same basis. It is preferred in each of the embodiments that the water is added slowly to ensure the metal alkoxide doesn't react so quickly with the water that it precipitates from the solution. A preferred method of accomplishing this is by diluting the water with solvents. The solvents useful for diluting the water are the same as used for dispersing the components. Depending on the components used and when they are added the needed water may also be added at one time or during one or more of the steps. Other hydrolyzable groups that may be present and need to be hydrolyzed and condensed are any found on the components used including but not limited to chloro.

As described above, the polyheterosiloxanes having at least two non-Si metal elements are soluble in many solvents and are compatible with many polymers, such as epoxy and polyurethane. These advantages, along with the low cost of the metal precursors will facilitate the practical use of the polyheterosiloxanes having at least two non-Si metal elements. The material properties and applications depend on the properties of the metal elements incorporated into the polyheterosiloxane. Potential applications include, but not limited to, UV protective coatings, thermal conductive materials, conductive/antistatic materials, self-cleaning coating, photocatalytic materials, colorants for coatings or paints, gloss/mechanical property enhancement, reinforcement components, adhesive components, scratch/impact resistant coating, and catalysts.

EXAMPLES

The following examples are included to demonstrate preferred embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples which follow represent techniques discovered by the inventor to function well in the practice of the invention, and thus can be considered to constitute preferred modes for its practice. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention. Room temperature (RT) in the present examples is 20° C.

Solubility of the products were tested by mixing 1 gram of the solid product in 9 grams of solvent, such as THF, toluene, butyl acetate, and chloroform. Soluble means that the solid product dissolves sufficiently in the solvent (without noticeable insoluble solid). As used herein, Me means methyl, Ac means acetate, acac means acetylacetonate, Ph means phenyl.

4.40 g ZnAc2.2H2O, 11.37 g titanium tetraisopropoxide (TPT), 20 g isopropanol (IPA), and 10 g toluene were charged to a 250 ml flask. A slightly cloudy solution was obtained after the mixture was stirred at RT for 1 hour. A silanol-containing organosiloxane was prepared by mixing 5.47 g phenylmethyldimethoxysilane (PhMeSi(OMe)2), 5.95 g phenyltrimethoxysilane (PhSi(OMe)3), and 2.54 g 0.04 M HCl and sonicating the mixture for 40 minutes (Sonicator: Fisher Scientific Instrument (Pittsburgh, Pa.), Model FS60). The silanol-containing organosiloxane solution was added to the 250 ml flask and the solution turned clear after 10 minutes. Stirring was continued at RT for 2 hours. The total amount of H2O in the reaction mixture was 100% of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. Solvents were removed using a rotary evaporator. No signs of unreacted precursors appear in the GPC analysis of the product. The product was a white solid with a theoretic composition of Ti0.33Zn0.17DPhMe0.25TPh0.25(6.8 w % alkoxy based on13C NMR) which was soluble in many organic solvents, such as butyl acetate, toluene, THF, and chloroform.

0.88 g AgNO3was dissolved in 1.00 g H2O and 25 g IPA and the solution was added into a TPT solution containing 13.18 g TPT and 6 g IPA. After stirring at RT for 18 minutes, 30 g toluene was added into the flask. A silanol-containing organosiloxane solution was prepared by mixing 3.65 g phenylmethyldimethoxysilane, 1.99 g phenyltrimethoxysilane, 10 g toluene, and 1.36 g 0.1 M HNO3and sonicating the mixture for 30 minutes. The silanol-containing organosiloxane solution was added into the 250 ml flask and the solution turned dark brown color. Stirring was continued at RT for 3.5 hours. 0.50 g H2O in 5.0 g IPA was added to the solution. The total amount of H2O used was 120%. of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. After stirring at RT for 2 hours the solvents were removed using a rotary evaporator. No signs of unreacted precursors appear in the GPC analysis of the product. The product was a yellow solid with a theoretic composition of Ti0.57Ag0.06DPhMe0.25TPh0.12(5.8 w % alkoxy based on13C NMR) which was soluble in many organic solvents, such as butyl acetate, acetone, THF, and chloroform.

A wide variety of polyheterosiloxane materials were synthesized using the same synthetic procedures described above. The metal elements included Li, Na, Mg, Ca, Ba, Y, Ce, Eu, Er, Yb, Ti, Zr, V, Cr, Mn, Fe, Co, Ni, Cu, Ag, Zn, Cd, Al, and Pb—at least one metal element in each column from column 1 to column 14 in the Periodic Table. The polyheterosiloxane materials were solid materials dissolvable in various organic solvents. See Table 1.

5.32 g Sn(Ac)4, 5.1 g Ti(OnBu)4, 15 g 1-BuOH was charged to a 250 ml flask. Under stirring, a solution containing 0.86 g H2O and 20 g 1-BuOH was slowly added. The solution was clear after 30 minutes. A silanol-containing organosiloxane solution was prepared by mixing 3.12 g Si(OEt)4, 19 g 1-BuOH, and 0.60 g 0.1 M HCl and sonicating the mixture for 30 minutes. The silanol-containing organosiloxane solution was added to the 250 ml flask and the solution was still clear after stirring at RT for 4 hours. The amount of H2O used was 90%. of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. Solvents were removed using a rotary evaporator. No signs of unreacted precursors appear in the GPC analysis of the product. The product was a white solid with a theoretic composition of Ti0.333Sn0.333Q0.333which was soluble in butyl acetate, toluene, THF, and 1-BuOH.

4.39 g Zn(Ac)2.2H2O, 9.60 g zirconium tetra(n-butoxide) (NBZ, 80% in 1-BuOH), 15 g 1-BuOH was charged to a 250 ml flask. The solution was clear after 20 minutes. 3.22 g phenyl trimethoxysilane and 3.03 g phenylmethyldimethoxysilane was added and stirred for 10 minutes. Then 1.12 g 0.1 N HCl (6% in 1-BuOH) was added slowly and then 20 g toluene. The solution was still clear after stirring at RT for 4 hours. The amount of H2O used was 100% of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. Solvents were removed using a rotary evaporator. No signs of unreacted precursors appear in the GPC analysis of the product. The product was a white solid with a theoretic composition of Zr0.275Zn0.275DPhMe0.228TPh0.223(8.4 w % alkoxy based on13C NMR) which was soluble in butyl acetate, toluene, and THF.

9.1 g TPT, 10 g IPA was charged to a 250 ml flask. Under stirring, a silanol-containing organosiloxane solution which was prepared by mixing 1.98 g PhSi(OMe)3, 3.65 g PhMeSi(OMe)2, 4.5 g tolueme, 1.1 g IPA, and 1.26 g 0.1 N HCl and sonicating the mixture for 30 minutes was slowly added. Solution turned milky after 10 minutes. 20 g toluene was then added and the solution turned clear. Then added 1.72 g Mg(Ac)2.4H2O and 0.10 g H2O in 10 g IPA. The amount of H2O used was 100%. of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. The solution was clear after stirring at RT for 4 hours. Solvents were removed using a rotary evaporator. No signs of unreacted precursors appear in the GPC analysis of the product. The product was a white solid with a composition of Ti0.457Mg0.114DPhMe0.286TPh0.143which was soluble in butyl acetate, toluene, and THF.

3.24 g Al(acac)2was dispersed in a silanol-containing organosiloxane solution which was prepared by mixing 1.98 g PhSi(OMe)3, 3.65 g PhMeSi(OMe)2, 4.5 g tolueme, 1.1 g IPA, and 1.26 g 0.1 N HCl and sonicating the mixture for 30 minutes. The dispersion was stirred at RT for 30 minutes. Then 8.53 g TPT and 10 g IPA was added to the dispersion. Under stirring, 1.01 g H2O (6% in IPA) was slowly added. The amount of H2O used was 100%. of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. The solution was clear after stirring at RT for 4 hours. Solvents were removed using a rotary evaporator. No signs of unreacted precursors appear in the GPC analysis of the product. The product was a white solid with a theoretic composition of Ti0.469Al0.156DPhMe0.250TPh0.125(7.4 w % alkoxy based on13C NMR) which was soluble in butyl acetate, toluene, and THF.

2.64 g Zn(Ac)2.2H2O, 13.65 g TPT, 5.47 g PhMeSi(OMe)2, 1.99 g PhSi(OMe)3, 10 g IPA, and 30 g toluene were charged to a 250 ml flask. The dispersion was stirred at RT for 40 minutes. Then 2.12 g 0.1 N HCl (4% in IPA) was slowly added to the flask. The total amount of H2O was 100% of the amount of water theoretically necessary for complete hydrolysis and condensation of all alkoxy groups. The solution was clear after stirring at RT for 3 hours. Solvents were removed using a rotary evaporator. The product was a white solid with a theoretic composition of Ti0.48Zn0.12DPhMe0.30TPh0.10was soluble in butyl acetate, toluene, and THF.

Comparative Example 1

No Metal Salt Used

6.17 g Sn(OtBu)4, 5.10 g Ti(OnBu)4, and 3.12 g Si(OEt)4was mixed in a 250-ml flask. 3 w % H2O/1-BuOH solution was added slowly into the flask under stirring. At 60% stoichiometric amount of H2O, the solution was still clear after refluxing for 30 min. At 80% stoichiometric amount of H2O it gelled and the solid was not soluble in Toluene, IPA, 1-BuOH, and butyl acetate. Calculation of the theoretic alkoxy content in the product at 60% stoichiometric amount of H2O was 55 wt %.

Application Examples

Metal oxides have intrinsic absorption bands, thus exhibit different colors when incorporated into the resins. The UV transmission spectra of various polyheterosiloxane resins of the above examples exhibited excellent absorption capability in the UV range (280-400 nm).

Polyurethane coatings were formulated using Bayer Desmophen A870 and Desmodur N3390. A typical formulation was composed of 0.60 g polyheterosiloxane resin, 2.58 g butyl acetate, 8.00 g Desmophen A870, and 2.96 g Desmodur N3390. The gel time greatly changed from more than 8 hours (uncatalyzed) to less than 2 minutes (catalyzed with Si+Ti+V resins).