Use of thermosetting organopolysiloxane compositions as coatings or adhesives

Abstract: A thermosetting organopolysiloxane composition made from organopolysiloxane gum, reinforcing silica having at least two weight percent methoxy groups, organohydrogenpolysiloxane having at least three silicon-bonded hydrogen atoms per molecule, and a curing catalyst, such as organic peroxide or platinum catalyst, exhibit improve adhesive to a variety of substrates such as glasses, metals, and plastics.

Description: The present invention relates to uses of a thermosetting organopolysiloxane composition which has good adhesive properties, and in particular further relates to a thermosetting organopolysiloxane composition which strongly bonds to various types of materials upon its thermal cure. Thermosetting organopolysiloxane compositions are in fact known in the form of so-called silicone rubbers and silicone varnishes, but unfortunately in general they adhere poorly to other materials. In applications involving bonding silicone rubber to other materials, the general technique has heretofore been to treat the surface of the other material with a primer. However, the generation a bond by the application of a thermosetting organopolysiloxane composition after a primer treatment is economically disadvantageous due to the required two-step operation. The problem also arises of the risk of nonuniform bonding deriving from a nonuniform coating of primer. In addition, the generation of adhesion has been attempted through the addition to thermosetting organopolysiloxane compositions of particular types of components. However, this approach has not been suitable to practical applications because, inter alia, there are limitations on the materials which can be bonded and the adhesive strength and durability of adhesion are unsatisfactory even when a bond is obtained. Document US-A 4 418 165 teaches of an optically clear silicone composition consisting of 100 parts by weight of at least one very specifically defined polydiorganosiloxane and 15 to 120 parts by weight of a hydrophobic reinforcing silica filler of sufficient small particle size to produce optically clear compositions, even when refractive indices of the polydiorganosiloxane and silica filler are not matched. The resultant cured product of this combination are reinforced elastomers which are useful as optically clear articles. The reinforcing silica used may contain less than 3 weight percent of methoxy groups. The present inventors, as a result of investigations directed at solving the above problems, found that an excellent mechanical strength as well as strong bonding to various types of materials were to be had from the composition obtained by the joint addition to a thermosetting organopolysiloxane composition of a specific reinforcing silica and an organohydrogenpolysiloxane containing at least 3 silicon-bonded hydrogen atoms in each molecule. The present invention was achieved based on this finding. That is, the object of the present invention is to provide a thermosetting organopolysiloxane composition which is distinguished by its ability to convert into a silicone rubber which bonds well to various types of materials, such as glasses, metals, plastics, etc., and which also has an excellent mechanical strength. Structure and Function of the Invention The present invention relates to the use of a thermosetting organopolysiloxane composition comprising (A) 100 parts by weight of organopolysiloxane gum having the following average unit formula R n SiO (4 - n)/2 in the formula, R is a substituted or unsubstituted monovalent hydrocarbon group, and n = 1.9 to 2.1, (B) 5 to 100 weight parts reinforcing silica which has a specific surface area of at least 200 m²/g, which contains more than 3.0 weight percent methoxy groups, and which consists of the SiO₂ unit and the organosiloxane units selected from the group comprising the R₃SiO 1/2 unit, R₂SiO unit, RSiO 3/2 unit, and their mixtures, where R is defined as above, with the proviso that the molar ratio of organosiloxane units/SiO₂ unit is from 0.08:1 to 2.0:1, (C) 1 to 10 parts by weight organohydrogenpolysiloxane having at least 3 silicon-bonded hydrogen atoms in each molecule, and (D) a curing catalyst in a quantity sufficient to cure the instant composition for coating various types of materials or for joining various types of materials together without using a primer. To explain this in detail, R in the above formula for the organopolysiloxane gum comprising component (A) used in the present invention comprises substituted and unsubstituted monovalent hydrocarbon groups, and is exemplified by alkyl groups such as methyl, ethyl, propyl, etc.; alkenyl groups such as vinyl, allyl, etc.; cycloalkyl groups such as cyclohexyl, etc.; aralkyl groups such as beta-phenylethyl, etc.; aryl groups such as phenyl, etc.; and halogenated alkyl groups such as chloromethyl, 3-chloropropyl, 3,3,3-trichloropropyl, etc. While n in the above formula is specified at 1.9 to 2.1, substances in which n = 2, that is, a diorganopolysiloxane gum, are preferred. The molecular weight of the diorganopolysiloxane gum is not specifically restricted, and useable molecular weights will fall within the range associated with organopolysiloxane gums in this art. In general, viscosities of at least 10⁷ centistokes at 25 degrees Centigrade and average molecular weights of at least 25 x 10⁴ and preferably at least 40 x 10⁴ will be used. Furthermore, while the organic groups in the organopolysiloxane comprising component (A) are not specifically restricted to within the range for R given above, it will be necessary that component (A) be a diorganopolysiloxane having at least two alkenyl groups in each molecule in the specific case in which the curing catalyst comprising component (D) consists of only a platinum-type compound without the use of organoperoxide. The reinforcing silica comprising the component (B) of the present invention is the essential component which characterizes the present invention. While it functions to improve the mechanical strength of the silicone rubber obtained by the thermal curing of the composition of the present invention, at the same time, through its Joint use with component (C), it functions to promote the bonding performance of the composition of the present invention and to equip the thermally cured silicone rubber with adhesiveness, and particularly with a durable adhesion, for various types of materials. Component (B) is a reinforcing silica which consists of SiO₂ units and organosiloxane units selected from the group comprising the R₃SiO 1/2 unit, R₂SiO unit, RSiO 3/2 unit, and their mixtures. Generally speaking, said organosiloxane units are to be present in a quantity sufficient to render the reinforcing silica filler hydrophobic, and the molar ratio of organosiloxane units/SiO₂ unit will be from 0.08:1 to 2.0:1 and preferably from 0.08:1 to 0.5:1. The adhesiveness drops off when this molar ratio falls below 0.08:1. On the other hand, when the molar ratio of 2.0:1 is exceeded, the decline in reinforcement is so substantial that the main function as a reinforcing silica can longer be fulfilled. In addition, component (B) must contain more than 3.0 weight percent up to 30 weight percent methoxy groups, CH30 groups: at less than 3 weight percent one encounters a substantial reduction in adhesion by the present invention's composition for various types of materials. Furthermore, this component should have a specific surface area of at least 200 m²/g and preferably has a specific surface area of at least 300 m²/g in order to obtain an increased mechanical strength for the silicone rubber product. The addition of component (B) will fall within the range of 5 to 100 parts by weight and preferably within the range of 10 to 30 parts by weight, in each case based on 100 parts by weight of component (A). This component (B) can be obtained according to methods disclosed in, for example, U.S. Pat. No. 4,344,800, issued Aug. 17, 1982 to Lutz; U.S. Pat. No. 4,418,165, issued Nov. 29, 1983, to Polmanteer et al; and U.S. Pat. No. 4,454,288, issued Jun. 12, 1984, to Lee et al to show methods of preparing silicas and the silicas prepared thereby. The organohydrogenpolysiloxane comprising the component (C) used in the present invention, through its joint use with the above component (B), promotes the adhesiveness of the composition of the present invention and functions to equip the thermally cured silicone rubber with adhesiveness, and particularly with a durable adhesion, for various types of materials. With regard to this component (C), its content of at least 3 silicon-bonded hydrogen atoms in each molecule is essential from the standpoint of adhesiveness. These hydrogen atoms may be bonded at the molecular chain terminals, or may be pendant on the chain, or may be present at both positions. The silicon-bonded organic groups comprise monovalent hydrocarbon groups, for example, alkyl groups such as methyl, ethyl, propyl, and octyl; aryl groups such as phenyl; and substituted alkyl groups such as 3,3,3-trifluoropropyl; however, aliphatically unsaturated hydrocarbon groups must not be present. The molecular weight of this component is not specifically restricted, and in general, can be used in the range where the viscosity at 25 degrees Centigrade is from 1 to 1,000 centistokes and preferably 1 to 100 centistokes. Examples of component (C) are trimethylsiloxy-terminated dimethylsiloxane-methylhydrogensiloxane copolymers, dimethylhydrogensiloxy-terminated dimethylpolysiloxanes, and organopolysiloxanes consisting of H(CH₃)₂SiO 1/2 units and SiO₂ units. Component (C) is to be added within the range of 1 to 10 parts by weight for each 100 weight parts component (A). The curing agent comprising component (D) used in the present invention is a catalyst for curing the composition of the present invention, and organoperoxides are generally used in this regard. While it is possible to use a platinum-type compound or to use an organoperoxide and platinum-type compound in combination, the use of only a platinum-type compound necessitates the exercise of some caution due to the restriction on the organic groups in the organopolysiloxane comprising component (A) as above. The organoperoxide is exemplified by dicumyl peroxide, di-t-butyl peroxide, t-buty cumyl peroxide, 2,5-dimethyl-2,5-di-(t-butylperoxy)hexane, 2,5-dimethyl-2,5-di-(t-butylperoxy)hexyne, 1,1-bis(t-butylperoxy)-3,3,5-trimethylcyclohexane, benzoyl peroxide, and 2,4-dichlorobenzoyl peroxide. The platinum-type compounds are exemplified by chloroplatinic acid, alcohol-modified chloroplatinic acid, platinum chelates, chloroplatinic acid-olefin coordination compounds, and microparticulate platinum adsorbed on a particulate carbon support. Component (D) is to be present in a quantity sufficient for the curing of the present invention's composition: for organoperoxides this falls within the range of 0.1 to 10 parts by weight; for platinum-type compounds this falls within the range of 0.1 to 300 parts by weight for each one million parts by weight of the total quantity of components (A) through (C). In order even further to improve the properties, and particularly the adhesiveness, of the present invention's thermosetting organopolysiloxane composition, it is advantageous to add to components (A) through (D) an alkoxysilane having at least one alkenyl group in each molecule, or the partial hydrolysis condensate of such a silane. The instant component is concretely exemplified by gamma-methacryloxypropyltrimethoxysilane, gamma-acryloxypropyltrimethoxysilane, vinyltrimethoxysilane, vinyltri(methoxyethoxy)silane, and allyltrimethoxysilane. This component is preferably added at within the range of 0.1 to 5 parts by weight for each 100 weight parts component (A). In order even further to improve the properties, and particularly the adhesiveness, of the present invention's thermosetting organopolysiloxane composition, it is advantageous to add to components (A) through (D) an organopolysiloxane having a degree of polymerization of 2 through 50 and having in each molecule at least 1 epoxy group, at least 1 alkenyl group, and at least 1 methoxy group. The instant component is exemplified by the organopolysiloxane obtained by the condensation reaction (alcohol-liberating) between gamma-glycidoxypropyltrimethoxy silane and a hydroxyl group-terminated methylvinylsiloxanedimethylsiloxane copolymer. This component is preferably added at 0.1 to 5 parts by weight for each 100 weight parts component (A). The composition of the present invention can be prepared by kneading the specified quantities of the above components (A) through (D) in, for example, a two-roll, kneader, Banbury mixer, etc. With the proviso that the object of the present invention is not adversely impacted, the various additives known in the art can also be added here, for example, heat stabilizers such as titanium oxide, iron oxide red, cerium oxide, barium zirconate; flame retardants such as halogen compounds and antimony oxide; and physical property-improvers such as silanes or polysiloxanes, etc. The composition of the present invention as described above, because it affords a silicone rubber having an excellent mechanical strength as well as excellent adhesion to various types of materials in contact with it, can be used as a coating and as an adhesive for joining various types of materials together. EXAMPLES The present invention is explained in the following illustrative examples and reference examples. In the illustrative examples, parts = parts by weight, and the viscosity was measured at 25 degrees Centigrade. In the reference examples and illustrative examples, the following methods wee used to obtain the surface area and methoxy group content of the reinforcing silica and to carry out adhesion testing. METHOD FOR MEASUIRNG THE SURFACE AREA OF THE REINFORCING SILICA This was measured according to the well-known BET method (continuous flow nitrogen adsorption) using a Model 2200 specific surface area automatic measurement device from Shimadzu Seisakusho Limited. METHOXY GROUP CONTENT IN THE REINFORCING SILICA The synthesized reinforcing silica and acetic anhydride were reacted in 1,2-dichloroethane in the presence of a perchloric acid catalyst (acetylation reaction). After subsequent hydrolysis of the unreacted reagent using a mixture of dimethylformamide/pyridine/water (weight ratio = 6/3/1), the determination was carried out by quantitating the amount of reacted acetic anhydride using a potassium hydroxide solution, and the methoxy group content was calculated as a percentage. ADHESION TESTING According to JIS K-6301, a test specimen was prepared by bonding the silicone rubber on a 25.4 mm wide test panel. The silicone rubber edge of this test specimen was then subjected to a 90 degree tensile peel, and the adhesive strength was calculated from the tensile strength at this time. REFERENCE EXAMPLE 1. PREPARATION OF HYDROPHOBE AGENTS Preparation was carried out accoding to the method disclosed in U.S. Pat. No. 4,454,288. A ring-opened and randomly distributed organopolysiloxane was prepared by reacting the following at 105 degrees Centigrade for approximately 2 hours: 277 g octamethylcyclotetrasiloxane, 4.6 g 1,3,5,7-tetramethyl1,3,5,7-tetravinylcyclotetrasiloxane, 517 g methyltrimethoxysilane, and 0.43 g potassium hydroxide as catalyst. After neutralization of the potassium hydroxide with carbon dioxide, analysis of the obtained organopolysiloxane confirmed it to be a linear organopolysiloxane containing 0.7 mole% methylvinylsiloxy groups (hydrophobe agent A). 282 g octamethylcyclotetrasiloxane, 517 g methyltrimethoxysilane, and 0.4 g potassium hydroxide were also reacted as above to afford a linear organopolysiloxane which did not contain vinyl groups (hydrophobe agent B). REFERENCE EXAMPLE 2. SYNTHESIS OF REINFORCING SILICAS 118 g methanol, 32 g concentrated aqueous ammonia, and 39 g hydrophobe agent A were placed in a glass reactor and mixed to homogeneity using a magnetic stirrer. Then, while vigorously stirring this mixture 96 g methyl orthosilicate was added in one portion The reaction product gelled after 15 seconds and stirring was suspended, and it was then taken directly and aged by standing under seal for one week (solvent dispersion of reinforcing silica A). After pulverization of the obtained gel, it was placed in an evaporator, and a reinforcing silica (reinforcing silica A) was obtained by removing the methanol and ammonia gas present in the gel at 90 degrees Centigrade under reduced pressure. The results of the determination of its BET surface area and methoxy group content are reported in Table 1. A reinforcing silica B was prepared as above, but using hydrophobe agent B in place of hydrophobe agent A, and its properties are also reported in Table 1. COMPARATIVE REFERENCE EXAMPLE 3 255 g methanol, 21 g water, 53.4 g concentrated aqueous ammonia, and 36.4 g hexamethyldisilazane were placed in a glass reactor and mixed to homogeneity using a magnetic stirrer. Then, while vigorously stirring this mixture, 96 g methyl orthosilicate was added in one portion. The reaction product gelled after approximately 50 to 60 seconds. The glass reactor was then sealed and allowed to stand as such for 1 week in order to obtain a gelled reaction product. This gelled reaction product was worked up as in Example 1, and the properties of the obtained reinforcing silica (reinforcing silica C) were measurd and are reported in Table 2. In addition, 264 g methanol, 3.14 g water, 66 g concentrated aqueous ammonia, and 25 g hexamethylcyclotrisiloxane were placed in a reactor as above, and a gelled reaction product was obtained by the addition and reaction as above of 96 g methyl orthosilicate. This gelled reaction product was worked up as above, and the properties of the obtained reinforcing silica (reinforcing silica D) were measured and reported in Table 2. EXAMPLE 1 100 Parts dimethylvinylsiloxy-terminated methylphenylpolysiloxane gum (degree of polymerization = approximately 4,000) composed of 92.4 mole% dimethylsiloxane units, 7.5 mole% methylphenylsiloxane units, and 0.14 mole% methylvinylsiloxane units, and 240 parts of the solvent dispersion of reinforcing silica A (reinforcing silica content = 25 wt%) prepared in Reference Example 2 were placed in a kneader mixer and mixed while removing the solvent with heating at 120 degrees Centigrade. The volatile components were then completely removed by additional mixing for 2 hours at 180 degrees Centigrade under reduced pressure, thus to afford a silicone rubber base (silicone rubber base A). A silicone rubber composition (silicone rubber composition A1) was then prepared by mixing 0.4 parts 2,5-bis(t-butylperoxy)-2,5-dimethylhexane as the vulcanizing agent and 1.0 part trimethylsiloxy-terminated methylhydrogenpolysiloxane (viscosity = 25 centistokes, SiH content = 1.5 wt%) into each 100 parts of this silicone rubber base A. Silicone rubber bases B and C were prepared as above, but respectively using reinforcing silica B or C in place of reinforcing silica A, and silicone rubber compositions B1 and C1 were then also prepared as above. Each silicone rubber composition was applied to the surfaces of iron, stainless steel, brass, and aluminum plates (25.4 x 60.3 x 2.54 mm). Vulcanization was carried out for 10 minutes at 170 degrees Centigrade/25 kg/cm² in a metal mold designed so that the post-vulcanization thickness of the silicone rubber would be 5.4 mm. The products were test specimens in which the silicone rubber and test plate had been bonded into a single unit. The obtained test specimens were then subjected to adhesion testing, and the results are reported in Table 3. Table 4 reports the results of measurements of the physical properties of the silicone rubbers according to JIS K-6301. Silicone rubber cmpositions A1 through C1 were also respectively adhered on glass plates (5.0 x 50 x 50 mm) as above, and test specimens were prepared in which the silicone rubber and test plate were bonded into a single piece. The silicone rubber edge of the test specimen was then subjected to a manual 90 degree tensile pull: in all cases, the fracture surface presented fracture in the silicone rubber. For comparison, a silicone rubber composition D1 was prepared as above using reinforcing silica D in place of reinforcing silica A, and it was subjected, again as above, to adhesion testing and measurement of the physical properties of the silicone rubber. These results are also reported in Tables 3 and 4. EXAMPLE 2 Silicone rubber compositions A2 through D2 were obtained by operating as in example 1, with the exception that a dimethylvinylsiloxy-terminated dimethylsiloxanemethylvinylsiloxane copolymer (99.84 mole% dimethylsiloxane units, 0.16 mole% methylvinylsiloxane units) was used in place of the methylphenylsiloxane gum used in Example 1. Again as in Example 1, these compositions were subjected to adhesion testing against the various types of materials and measurement of the physical properties of the silicone rubbers obtained by vulcanization, and these results are reported in Tables 5 and 6. EXAMPLES 3 and 4 1.0 Part vinyltrimethoxysilane was blended into silicone rubber composition A1 obtained as in Example 1, and Table 7 reports, as Example 3, the results of measurement of the adhesive strength as in Example 1 for the resulting composition against various materials. Table 7 also reports, as Example 4, the results of measurement of the adhesive strength as in Example 1 against various materials for a silicone rubber composition obtained as above using 1.0 part gammamethacryloxypropyltrimethoxysilane in place of the above vinyltrimethoxysilane. MATERIAL EXAMPLE 3 EXAMPLE 4 ADHESIVE STRENGTH (kg/cm) ADHESIVE STRENGTH (kg/cm) Iron 6.8 8.0 Stainless steel 6.5 7.0 Brass 3.9 3.5 Aluminum 2.0 2.2 Polyester resin 3.6 3.5 Melamine resin 4.2 4.8 PBT resin 1.0 1.2 EXAMPLE 5 1.0 Part epoxy group-containing organopolysiloxane having formula (1) was blended into silicone rubber composition A1 obtained as in Example 1. The adhesive strength for various types of materials was measured as in Example 1 using this silicone rubber composition, and these results are reported in Table 8. MATERIAL ADHESIVE STRENGTH (kg/cm) Iron 6.0 Stainless steel 5.2 Brass 3.0 Aluminum 1.8 Polyester resin 3.5 Melamine resin 4.0 Polybutylene terephthalate 10 EXAMPLE 6 The following were blended into 100 parts silicone rubber base A obtained as in Example 1: 1.0 part trimethylsiloxy-terminated methylhydrogensiloxanedimethylsiloxane copolymer (viscosity = 7 centistokes at 25 degrees Centigrade) composed of 15 moles methylhydrogensiloxane units and 3 moles dimethylsiloxane units, chloroplatinic acid-methylvinylsiloxane complex in a quantity sufficient to afford 10 ppm as platinum, and 1 ppm methyltris(methylisobutynoxy)-silane. 1.0 Part vinyltrimethoxysilane was blended into 100 weight parts of the obtained addition-curing silicone rubber composition. This composition was subjected to adhesion testing as in Example 1, and these results are reported in Table 9 as Example 6. In addition, 1.0 part of the epoxy group-containing organopolysiloxane used in Example 5 and 1.0 gamma-methacryloxypropyltrimethoxysilane were each respectively blended into 100 weight parts of the above addition-curing silicone rubber composition. These compositions were subjected to adhesion testing as above, and the results are respectively reported as Example 7 and Example 8 in Table 9. Because the thermosetting organopolysiloxane composition of the present invention prepared from components (A) through (D) comprises a thermosetting organopolysiloxane composition which contains in particular the organohydrogenpolysiloxane comprising component (C) and the specific reinforcing silica comprising component (B), it characteristically converts to a silicone rubber which bonds well to other materials, for example, glasses, metals and plastics, and which also has an excellent mechanical strength. Accordingly, it is useful as an adhesive for bonding different types of materials into a single unit.

Claims: Use of a thermosetting organopolysiloxane composition comprising (A) 100 parts by weight of organopolysiloxane gum having the following average unit formula R n SiO (4 - n)/2 in the formula, R is a substituted or unsubstituted monovalent hydrocarbon group, and n = 1.9 to 2.1, (B) 5 to 100 weight parts reinforcing silica which has a specific surface area of at least 200 m²/g, which contains more than 3.0 weight percent methoxy groups, and which consists of the SiO₂ unit and organosiloxane units selected from the group comprising the R₃SiO 1/2 unit, R₂SiO unit, RSiO 3/2 unit, and their mixtures, where R is defined as above, with the proviso that the molar ratio of organosiloxane units/SiO₂ unit is from 0.08:1 to 2.0:1, (C) 1 to 10 parts by weight organohydrogenpolysiloxane having at least 3 silicon-bonded hydrogen atoms in each molecule, and (D) a curing catalyst in a quantity sufficient to cure the instant composition for coating various types of materials or for joining various types of materials together without using a primer. Use according to claim 1, wherein the thermosetting organopolysiloxane composition comprises an alkoxysilane having at least one alkenyl group and one silicon-bonded alkoxy group in each molecule or the partial hydrolysis condensate thereof. Use according to claim 1, wherein the thermosetting organopolysiloxane composition further comprises an organopolysiloxane having a degree of polymerization of 2 to 50 and having at least one epoxy group, at least one alkenyl group, and at least one silicon-bonded methoxy group in each molecule. Use of a thermosetting organopolysiloxane composition according to claim 1 as an adhesive.

Inventors: HIRAI KAZUO, MATSUSHITA TAKAO, HIRAI, KAZUO, MATSUSHITA, TAKAO
Applicants: TORAY SILICONE CO, TORAY SILICONE COMPANY, LIMITED
Application year: 1988
Main classification: C08L83
IPC codes: C09J183, C08L83, C08K3, C08K9