Organosilicon compositions

Abstract: A process for making organosilicon prepolymer compositions by reacting, in the presence of a hydrosilation catalyst, (a) a cyclic polysiloxane or tetrahedral siloxysilane containing at least two ≡SiH groups and (b) a polycyclic polyene having at least two non-aromatic, non-conjugated carbon-carbon double bonds in its rings, one of the compounds (a) and (b) having more than two reactive sites, in which the ratio of the carbon-carbon double bonds to the ≡SiH groups is at least 1.8:1, and the use of the organosilicon prepolymer compositions made by the said process to make thermoset organosilicon polymers by curing them, including blending the organosilicon prepolymer compositions before curing with an additional cyclic polysiloxane or tetrahedral siloxysilane or a linear, short chain ≡SiH - terminated polysiloxane.

Description: This invention relates to a process for making organosilicon prepolymer compositions, the compositions, and their use for making thermoset organosilicon polymers. High molecular weight thermoset or thermoplastic organosilicon polymers comprising alternating polycyclic hydrocarbon residues and cyclic polysiloxanes or tetrahedral siloxysilane residues linked through carbon to silicon bonds are disclosed in EP-A-0 259 711 They have excellent physical, thermal and electrical properties and outstanding resistance to water, and can be used to prepare shaped articles. Copolymer compositions of a linear polysiloxane and a cyclic non-conjugated diene are disclosed in FR-A-2 595 364. There is a need for a process for making prepolymer compositions that can be used to prepare such thermoset organosilicon polymers. According to the invention, a process for making an organosilicon prepolymer composition comprising reacting, in the presence of a hydrosilation catalyst, (a) a cyclic polysiloxane or tetrahedral siloxysilane containing at least two ≡SiH groups and (b) a polycyclic polyene having at least too non-aromatic, non-conjugated carbon-carbon double bonds in its rings, at least one of the compounds (a) and (b) having more than two reactive sites, is characterized in that the ratio of the non-aromatic, non-conjugated carbon-carbon double bonds in the rings of the polycyclic polyene (b) to the ≡SiH groups in the cyclic polysiloxane or tetrahedral siloxysilane (a) is greater than 1.8:1 and the reaction is driven to substantial completion, so that greater than 90% of the ≡SiH groups are consumed. Preferably according to the invention, the said process for making an organosilicon prepolymer composition is further characterized in that the said organosilicon prepolymer composition is blended with (c) an additional cyclic polysiloxane, an additional tetrahedral siloxysilane or a linear, short chain ≡SiH - terminated polysiloxane, the total ratio of the non-aromatic, non-conjugated carbon-carbon double bonds in the rings of the polycyclic polyene (b) to the total number of ≡SiH groups in the cyclic polysiloxane or tetrahedral siloxysilane (a) and in the cyclic polysiloxanes, tetrahedral siloxysilanes and linear, short chain ≡SiH terminated polysiloxanes (c) added to form the blend is in the range of 0.4:1 to 1.7:1. Also according to the invention is the use of the organosilicon prepolymer compositions made by the said process to make thermoset organosilicon polymers by curing the organosilicon prepolymer compositions in the presence of a hydrosilation catalyst, by curing them thermally, or by curing them thermally in the presence of a hydrosilation catalyst. Any cyclic polysiloxane or tetrahedral siloxysilane with two or more hydrogen atoms bound to silicon will enter into the reaction. Cyclic polysiloxanes useful in forming the products of this invention have the general formula: wherein R is hydrogen or a substituted or unsubstituted alkyl, alkoxy, aromatic or aryloxy radical, n is an integer from 3 to 20, and R is hydrogen on at least two of the silicon atoms in the molecule. The tetrahedral siloxysilanes are represented by the general structural formula: wherein R is as defined above and is hydrogen on at least two of the silicon atoms in the molecule. Examples of reactants of Formula (I) include, e.g., tetramethylcyclotetrasiloxyane, pentamethylcyclopentasiloxane, hexamethylcyclohexasiloxane, tetraethylcyclotetrasiloxane, cyclotetrasiloxane, tetraphenylcyclotetrasiloxane, tetraoctylcyclotetrasiloxane and hexamethyltetracyclosiloxane. The most commonly occurring members of this group are the tetra-, penta- and hexamethylcyclotetrasiloxane, with tetramethylcyclotetrasiloxyane being a preferred member. In most cases, however, the material is a mixture of a number of species wherein n can vary widely. Generally, commercial mixtures contain up to about 20% (in purer forms as low as 2%) low molecular weight linear methylhydrosiloxanes, such as heptamethyltrisiloxane, octamethyltetrasiloxane, etc. Examples of reactants of Formula (II) include, e.g., tetrakisdimethylsiloxysilane, tetrakisdiphenylsiloxysilane, and tetrakisdiethylsiloxysilane. The tetrakisdimethylsiloxysilane is the best known and preferred species in this group. Preferably the polycyclic polyenes are compounds selected from the group consisting of cyclopentadiene oligomers (e.g., dicyclopentadiene, tricyclopentadiene and tetracyclopentadiene), bicycloheptadiene and its diels-alder oligomers with cyclopentadiene (e.g., dimethanohexahydronaphthalene), and substituted derivatives of any of these, e.g., methyl dicyclopentadiene. Preferred are bicycloheptadiene, dimethanohexahydronaphthalene, dicyclopentadiene and tricyclopentadiene, with the most preferred being bicycloheptadiene. Two or more polycyclic polyenes can be used in combination. Preferably the linear, short chain ≡SiH terminated polysiloxanes are those having the general formula: wherein n is 0 to 1000 and R is alkyl or aryl, preferably methyl or phenyl. Such polysiloxanes preferably are added with cyclic siloxanes or tetrahedral siloxysilanes. Most preferably they are used in an amount 10 to 50%, by weight of the polysiloxanes and siloxysilanes added to the prepolymer composition. These polysiloxanes impart flexibility to the cured polymers and can be used to produce elastomers. The process for making organosilicon prepolymer compositions according to the invention is carried out by mixing the reactants and the hydrosilation catalyst and bringing the mixture to a temperature at which the reaction is initiated. The basic reaction is exothermic, and either heat removal equipment (cooling coils or a reflux condenser) must be used or the prepolymer must be formed slowly, for instance, over a period of up to twenty-four hours, depending on the reaction mass. In a continuous process with adequate heat removal the reaction can be carried out quickly. When 90% or more of the ≡SiH groups are reacted the prepolymers are stable indefinitely at room temperature. Proper temperature conditions are thereafter maintained to drive the reaction to substantial completion (typically, due to the large ratio of double bonds to ≡SiH groups available for reaction, greater than 90% of the ≡SiH are consumed). The hydrosilation catalysts include metal salts and complexes of Group VIII elements. The preferred hydrosilation catalysts contain platinum, and the most preferred catalyst, in terms of both reactivity and cost, is chloroplatinic acid (H₂PtCl₆.6H₂O). Catalyst concentrations of 0.0005 to 0.05% by weight, based on weight of the reactants, will effect smooth and substantially complete polymerization. Other platinum compounds can also be used to advantage in some instances, such as PtCl₂ and dibenzonitrile platinum dichloride. Platinum on carbon is also effective for carrying out high temperature polymerizations. The catalysis of hydrosilation is well known, for instance from Advances in Organometallic Chemistry , Vol. 17, beginning on page 407. The organosilicon prepolymer compositions are made with a large excess of carbon-carbon double bonds available for reaction with ≡SiH groups, and preferably the proportion of the reactants is such that the ratio of the non-aromatic, non-conjugated carbon-carbon double bonds in the rings of the polycyclic polyene (b) to ≡SiH groups in (a) is from greater than 1.8:1 up to 5:1, and more preferably from 2.2:1 up to 5:1. The prepolymer compositions are generally in the form of a flowable liquid that is stable at room temperature. At a ratio of double bonds to ≡SiH of 2:1 it is assumed that stoichiometrically all ≡SiH bonds are reacted with carbon-carbon double bonds and that the prepolymer is stable against further reaction. Prepolymers having such a stoichiometric ratio are the most stable prepolymers of this invention, and tend to avoid the presence of unreacted polycyclic polyenes which is undesirable because of their odor. (If unreacted polycyclic polyenes are present, they can be stripped, e.g., using a rotoevaporator, to form odorless compositions). The crosslinked polymers are formed by curing a organosilicon prepolymer composition made by the process according to the invention optionally in the presence of an additional amount of a hydrosilation catalyst and/or with the application of heat. The prepolymer composition is the composition made by blending the prepolymer with the additional cyclic polysiloxane, tetrahedral siloxysilane or linear, short chain ≡SiH - terminated polysiloxane in the aforesaid ratio of non-aromatic, non-conjugated carbon-carbon double bonds ratio of 0.4:1 to 1.7:1 to form a low viscosity solution, and more preferably in a ratio of 0.8:1 to 1.3:1, most preferably about 1:1. The components of the process, which have low viscosity and are pumpable, can be premixed in a tank. The reaction can be carried out in an extruder, mold or oven, or the blend can be is applied directly on a substrate or part. For the more reactive compositions, mild complexing agents, such as tetramethylethylenediamine, can be added to control the room temperature reaction. The complex disassociates at temperatures greater than 100°C to let curing proceed. With stronger complexing agents, such as phosphorus compounds, curing temperatures above 150°C are required to disassociate the complex. In the preferred embodiment, the prepolymer composition and polysiloxanes/siloxysilanes are stored separately and the organosilicon prepolymer composition is reacted in a mold with the polysiloxanes and/or tetrahedral siloxysilanes to form the crosslinked polymer, after blending in an in-line mixer directly before entering the mold. The hydrosilation catalyst may be present in either stream or injected directly into the mixer. The reaction is exothermic and proceeds rapidly so that the polymer gels and molded parts can be quickly taken out of the mold, and if necessary, cured further outside the mold. If the reaction upon mixing is too fast and the viscosity increases so rapidly that proper mold filling is prevented, cooling may be applied and/or a cure-rate retardant such as tetramethylethylenediamine can be added. Although a hydrosilation reaction via the carbon-carbon unsaturation of the polycyclic polyene rings and the ≡SiH group is the primary polymerization and crosslinking mechanism, other types of polymerization and crosslinking may also take place as the curing temperature is increased. These may include, e.g., oxidative crosslinking, free radical polymerization (olefin addition reactions) and condensation of ≡SiH with silanols to form siloxane bonds. It is possible, by selection of reactants, reactant concentrations and reaction conditions, to prepare prepolymers and polymers exhibiting a broad range of properties and physical forms. Thus, it has been found possible to prepare elastomeric materials and glassy polymers as well as the prepolymer liquids and conventional thermoset organosilicon polymers. Additives such as carbon black, vermiculite, mica, wollastonite, calcium carbonate, sand, glass spheres, glass beads, ground glass and waste glass and other conventional additives can be incorporated. Fillers in amounts up to about 80% can serve either as reinforcement or as extenders to reduce the cost of the molded product. Glass spheres are especially useful for preparing low density composites. Stabilizers and antioxidants are useful to maintain storage stability of the formulations and thermal oxidative stability of the final product. Coupling agents such as vinyl silane and related compounds may be used to wet the glass and promote adhesion of the resin to the glass. For instance, chopped glass fibers can be slurried in a stabilized liquid blend (prepolymer and added siloxane or siloxysilane) in compounding equipment. It is best to deaerate such a slurry under vacuum before injecting it into a mold. Fibers, e.g., glass fibers, are wetted very well by the liquid blends, making the blends excellent matrix materials for composite structures. Thus, the prepolymer composition can be mixed with cyclic siloxanes, tetrahedral siloxanes and/or linear, short chain ≡SiH terminated polysiloxanes to form a blend, and a mold containing the requisite staple or continuous filament can be charged with the blend before curing to form the desired composite structure. Fiber in fabric form can also be employed. Fiber reinforced composites of the polymers of this invention can contain as much as 80%, preferably 30 to 60%, by weight, of fibrous reinforcement. The thermoset polymers fabricated from the prepolymer compositions and blends described herein are useful in molded electronic parts, electrical connectors, electronic and electrical part encapsulation, and various other applications. They can be molded into intricate shapes having thermal stability, low moisture absorbance and fire resistance (high char yield at 1000°C in air). The thermoset polymers are also useful as structural adhesives, curable in situ, to form strong bonds due to a high affinity of ≡SiH derived silanol groups for polar metal surfaces, especially oxidized metal surfaces. The elastomeric embodiments make excellent potting compounds for electronic applications since they can be cured in situ and have a low equilibrium water content (0.01 - 0.1%) after humid aging (100% relative humidity (RH), 1 week). The glass filled, thermoset products that have been polymerized to the glassy state are characterized by high physical properties, i.e., high modulus and high tensile strength and good flex properties. They are fire resistant, burn very slowly when subjected to a flame, and self-extinguish when the flame is removed. The thermal properties of the thermoset polymers are outstanding. The glass transition temperature (Tg) of a fully cured thermoset polymer is about 200°C or higher. Thermal stability is excellent with usually less than 10% weight loss at 500°C during Thermogravimetric analysis. At 1000°C in air, they leave about 50% of a ceramic residue. The thermoset polymers are also resistant to oxidation at ordinary temperatures. Above 200°C, oxidative cross-linking of silicon portions of the molecule appears to take place, resulting in the formation of a dark siliceous outer layer. This oxidized outer layer appears to impede the oxidative degradation of the bulk polymer. The following examples are presented to demonstrate this invention. All percentages, parts, etc., are by weight, unless otherwise indicated. Example 1 This example shows preparation of an organosilicon prepolymer composition of this invention. With continuous mixing, 0.031 part bisbenzonitrile platinum dichloride, 120.4 parts (2.0 mole, 4.0 equivalents (eq)) bicycloheptadiene, and 120.4 parts (0.05 mole, 2.0 eq) methylhydrocyclosiloxanes (a mixture of tetramethylcyclotetrasiloxane, pentamethylcyclotetrasiloxane, hexamethylcyclotetrasiloxane, available from Huls/Petrarch, Bristol, PA) were added to a reaction chamber and heated gradually to 100°C over a period of seven hours and held at 100°C for ten hours. A yield of 298.5 parts (98%) was obtained. IR analysis was conducted and the product was found not to have a peak at 2140 cm⁻¹ (SiH peak), indicating that the hydrosilation reaction was complete. Proton NMR analysis showed that SiH and bicycloheptadiene double bonds bad reacted and the expected Si-C bonds had formed (5.8-6.0 ppm) giving bicycloheptene substituted methylhydrocyclosiloxane as a pourable fluid. Example 2 This example shows preparation of a thermoset polymer using the prepolymer composition prepared in Example 1. A clear solution was prepared by stirring 110 parts of the prepolymer composition prepared in Example 1 with 48 parts (80 milliequlvalents (meq)) of methylhydrocyclosiloxanes. The resultant low viscosity mixture was poured into a slotted mold (7.6 cm x 1.3 cm x 0.3 cm (3 inch X 1/2 inch X 1/8 inch)) and the mold was put under full vacuum for 5 minutes to remove entrained air. The mold was heated to 100°C for 10 hours and a hard polymer was produced. After further curing (150°C/4 hours, 225°C/2 hours and 285°C/4 hours) the polymer was evaluated using thermogravimetric analysis. It was stable in air and nitrogen to 475°C, and the residue at 1000°C was 60.75% in nitrogen (50.42% in air). Example 3 This example shows preparation of a glass cloth reinforced composite using the prepolymer composition prepared in Example 1. A clear solution was prepared by stirring 110 parts of the prepolymer composition prepared in Example 1 with 48.3 parts (72 meq) of methylhydrocyclosiloxanes. The fluid was injected into two warm ( 100°C) dry molds (12.7 cm x 12.7 cm x 0.3 cm (5 inch X 5 inch X 1/8 inch)) containing 52 parts of unsized fiberglass cloth. An increase in temperature indicated that the resin was polymerizing to a solid in the warm molds after 10 minutes. The above was cured for 10 hours at 100°C and a hard polymer was produced. After further curing at 150°C/4 hrs., 225°C/2 hrs., and, then, 285°C/4 hrs., the composites were analyzed as described below. Example 4 This example shows preparation of a thermoset polymer using the prepolymer composition prepared in Example 1. A clear solution was prepared as in Example 3 and poured into a three slotted, preheated mold (7.6 cm x 1.3 cm x 0.3 cm (3 inch X 1/2 inch X 1/8 inch)). The molds were maintained at 100°C for 10 hours. Then, they were cured at 150°C for 4 hours and 225°C for 2 hours. The following tests were carried out to determine the physical characteristics of the glass reinforced composite materials of Example 3 and the thermoset polymers of Example 4. Dynamic modulus was measured in a Rheometrics Dynamic Spectrometer Model 7700 (Rheometrics, Inc., Piscataway, NJ). A temperature sweep was carried out at a fixed frequency of 10 radians/second. Flexural properties were measured in a standard Instron Universal Tester according to ASTM Method D790. Thermogravimetric analysis was carried out in a Du Pont Thermal Analyzer (E. I. du Pont de Nemours & Company, Inc., Wilmington, DE) at 20°C/minute. Thermal Mechanical Analysis and Thermal Expansion Coefficient were measured using a Du Pont Thermomechanical Analyzer with a 100 mg load, and expansion probe at 10°C/minute. Example 5 This example shows preparation of an organosilicon prepolymer composition. Into a reactor containing methylhydrocyclosiloxanes (mixture primarily comprised of tetramethylcyclotetrasiloxyane, pentamethylcyclotetrasiloxane and hexamethylcyclotetrasiloxane available from Huls/Petrarch) (25 parts), was added a solution of dicyclopentadiene and tricyclopentadiene (63.75 parts, 35.9 weight % tricyclopentadiene), chloroplatinic acid catalyst (in isopropyl alcohol) (35 parts per million (ppm)), and toluene (22.19 parts) over one hour. The exothermic reaction was controlled by the rate of addition and temperatures ranged from 78-106°C. After addition was completed, 80% of the available ≡SiH groups had reacted. The mixture was stirred for 3.5 hours at 70°C and found to have 87% of the ≡SiH groups reacted. Then, 35 ppm catalyst was added and after 3.5 hours of mixing at 70°C the mixture was found to have 92% of the ≡SiH groups reacted. Heating for 15 hours at 70°C brought the total ≡SiH reacted to 95%. Addition of 35 ppm catalyst and 8 hours heating at 70°C brought the reaction to completion. Example 6 This example shows preparation of an organosilicon polymer using the organosilicon prepolymer composition of Example 1. The bicycloheptadiene/methylhydrocyclosiloxanes prepolymer of Example 1 (5.1 parts) was stirred with hexamethyltrisiloxane (≡SiH terminated) (3.5 parts). Then, platinum catalyst (0.01 parts) was added with stirring. The mixture was deaerated under vacuum and poured into a slotted mold (7.6 x 1.3 x 0.3 cm (3 x 1/2 x 1/8 inches)), and cured at 120°C for 2 hours and 150°C for six hours. The cured polymer had a glass transition at 39°C determined by differential scanning calorimetry. Thermogravimetric analysis indicated a 10% loss in weight at 500°C in air and nitrogen, demonstrating the excellent stability of the polymer at high temperatures. Example 7 This example shows preparation of an organosilicon polymer. The bicycloheptadiene/methylhydrocyclosiloxanes prepolymer (5.1 parts) of Example 1 was stirred with ≡SiH terminated polydimethylsiloxane (Huls/Petrarch PS-537) (12.0 parts). Then, platinum catalyst (0.01 parts) was added with stirring. The compatible mixture was deaerated and poured into a slotted mold (7.6 x 1.3 x 0.3 cm (3 x 1/2 x 1/8 inches)) and cured at 120°C for 2 hours and 150°C for six hours. The cured polymer had a glass transition at -34°C determined by differential scanning calorimetry. Thermogravimetric analysis indicated a 10% loss in the cured polymer at 500°C in nitrogen and 490°C in air, demonstrating the excellent stability of the polymer at high temperatures. Example 8 This example shows preparation of an organosilicon prepolymer composition. Methylhydrocyclosiloxanes (0.75 eq SiH) (45.10 parts) and toluene (34.25 parts) were charged to a reaction chamber and stirred while dicyclopentadiene containing chloroplatinic acid complex was added at 45-65°C (74.37 parts) (1.13 eq olefin). The addition was carried out over 109 minutes and a cooling bath was used to control the exotherm. Bicycloheptadiene (17.28 parts (0.38 eq olefin)) was added over a period of one hour. An additional portion of a chloroplatinicacid catalyst complex with dimethanohexahydronaphthalene was added gradually over four days heating at 71-73°C to give 222 ppm pt in the product. Proton NMR analysis showed that the resin contained only 5.7% of the SiH originally charged. Example 9 This example shows preparation of an organosilicon polymer using the prepolymer composition of Example 8. The prepolymer prepared in Example 8 (19.1 parts) was warmed to 50°C and blended with methylhydrocyclosiloxanes (7.0 parts) containing tetramethylethylenediamine (50 ppm). The viscosity of the blend was 620 centistokes. The blend was poured into a finger mold and cured at 150°C for 6 hours. Thermogravimetric analysis determined a 10% weight loss in the cured polymer at 540°C in nitrogen and at 510°C in air (20°C/min). The sample residue at 1000°C was 66.1% in nitrogen and 48.1% in air. Example 10 This example shows preparation of a prepolymer composition. A mixture of dicyclopentadiene (DCPD)/tricyclopentadiene (TCPD) (64.1% DCPD/35.9% TCPD) (63.75 parts) and chloroplatinic acid catalyst in isopropanol (35 ppm pt in resin) (0.12 parts chloroplatinic acid, 1.89 parts isopropanol) were dissolved in toluene (22.2 parts) and heated to 50°C for one hour. This solution was added dropwise to methylhydrocyclosiloxanes (25 parts) stirring in a vessel under nitrogen. The addition was carried out over a period of one hour in a reaction temperature range of 74-106°C. The addition rate was used to control the exotherm of the reaction. After an additional 5.5 hours with stirringat 70°C, 87% of the ≡SiH groups in the methylhydrocyclosiloxanes had reacted. Additional catalyst was added to give a total of 70 ppm pt in the resin prepolymer. After heating at 70°C for 3.5 hours the =SiH groups were 92% reacted. Further heating at 70°C (16 hours) brought the level of ≡SiH groups reacted to 95%. Example 11 This example shows preparation of an organosilicon polymer from the prepolymer composition of Example 10. The prepolymer of Example 10 (17.17 parts) was stirred with methylhydrocyclosiloxanes (4.43 parts) containing 50 ppm tetramethylethylenediamine and toluene (17.34 parts). The resulting solution was coated on glass and cured at 120°C for 1 hour and 150°C for 6 hours. The cured polymer had a 10% weight loss at 500°C in air and 500°C in nitrogen, demonstrating the excellent thermal and thermal oxidative stability of the cured formulation. Example 12 This example shows preparation of an organosilicon polymer from the prepolymer composition of Example 1. The bicycloheptadiene/methylhydrocyclosiloxanes prepolymer composition of Example 1 (15.00 parts) was stirred with tetramethyldisiloxane (6.61 parts). The compatible mixture was a fluid that was degassed under aspirator vacuum and poured into a slotted mold (7.6 x 1.3 x 0.3 cm (3 x 1/2 x 1/8 inches)) and cured at 50°C for 2 hours, 120°C for 2 hours and 150°C for 6 hours. The cured polymer had 10% weight loss at 480°C in nitrogen and 475°C in air, showing excellent thermal and thermal oxidative stability. The polymer was cured further at 200°C for 2 hours and 250°C for 2 hours. The glass transition temperature of the cured polymer was 79°C determined by thermal mechanical analysis. This corresponded closely with the temperature where the complex modulus (G') decreased at the glass transition (80°C) determined by dynamic mechanical analysis. Example 13 This example shows preparation of polymers from the prepolymer composition of Example 8 using various amounts of cyclic polysiloxane. The prepolymer composition of Example 8 was stirred in toluene with various levels of methylhydrocyclosiloxanes to give a total olefin/≡SiH equivalent ratio ranging from 0.50/1.00 to 1.50/1.00. Total olefin includes the dicyclopentadiene and bicycloheptadiene olefin used to prepare the prepolymer before blending with methylhydrocyclosiloxanes (MHCS). Total ≡SiH includes ≡SiH in MHCS used to make the prepolymer (DCPD/BCHD/MHCS) before blending with MHCS and the MHCS added to make the coatings. The prepolymer was dissolved in toluene and MHCS was added before casting the coating on a glass plate with a 30 mil draw blade. Prepolymer/MHCS /Toluene (parts) C=C:≡SiH* Thermogravimetric Analysis 10% Weight Loss Temperature Air Residue at 1000°C N₂ Residue at 1000°C 3.06 / 3.00 / 1.50 0.5:1.0 500 58.0 525 71.5 4.60 / 3.00 / 3.20 0.67:1.0 410 54.8 520 64.0 9.20 / 3.00 / 3.50 1.0:1.0 500 48.2 520 65.7 9.40 / 1.50 / 3.00 1.35:1.0 500 37.9 510 58.1 11.04 / 1.20 1.5:1.0 500 31.9 500 48.8 Excellent thermal and thermal oxidative stability is shown by the high temperatures required to give 10% weight loss. The high residues at 1000°C indicate a high ceramic yield, which decreases as the amount of hydrocarbon in the formulation is increased.

Claims: A process for making an organosilicon prepolymer composition comprising reacting, in the presence of a hydrosilation catalyst, (a) a cyclic polysiloxane with from 4 to 21 SiO units or tetrahedral siloxysilane having the general formula: wherein R is hydrogen or a substituted or unsubstituted alkyl, alkoxy, aromatic or aryloxy radical containing at least two ≡SiH groups and (b) one or more polycyclic polyenes having at least two non-aromatic, non-conjugated carbon-carbon double bonds in its rings selected from the group consisting of a cyclopentadiene oligomer, a dimethanohexahydronaphthalene, or a diels-alder oligomer of bicycloheptadiene with cyclopentadiene, or a substituted derivative thereof, at least one of the compounds (a) and (b) having more than two reactive sites, is characterized in that the ratio of the non-aromatic, non-conjugated carbon-carbon double bonds in the rings of the polycyclic polyene (b) to the ≡SiH groups in the cyclic polysiloxane or tetrahedral siloxysilane (a) is greater than 1.8:1 and the reaction is driven to substantial completion, so that greater than 90% of the ≡SiH groups are consumed. A process for making an organosilicon prepolymer composition as claimed in claim 1, further characterized in that the cyclic polysiloxane or tetrahedral siloxysilane is a cyclic polysiloxane comprising tetramethylcyclotetrasiloxyane, pentamethylcyclopentasiloxane, hexamethylcyclohexasiloxane, tetraethylcyclotetrasiloxane, cyclotetrasiloxane, tetraphenylcyclotetrasiloxane, tetraoctylcyclotetrasiloxane or hexamethyltetracyclosiloxane. A process for making an organosilicon prepolymer composition as claimed in claim 2, further characterized in that the cyclic polysiloxane comprises a tetra-, penta- or hexamethylcyclotetrasiloxane. A process for making an organosilicon prepolymer composition as claimed in claim 2, further characterized in that the the cyclic polysiloxane or tetrahedral siloxysilane is a tetrahedral siloxysilane comprising tetrakisdimethylsiloxysilane, tetrakisdiphenylsiloxysilane, or tetrakisdiethylsiloxysilane. A process for making an organosilicon prepolymer composition as claimed in claim 1, further characterized in that the polycyclic polyene is dicyclopentadiene, tricyclopentadiene, or dimethanohexahydronaphthalene. A process for making an organosilicon prepolymer composition as claimed in any of the preceding claims, further characterized in that the ratio of carbon-carbon double bonds in the rings of the polycyclic polyene (b) to ≡SiH groups in (a) is from greater than 1.8 to 5:1. A process for making an organosilicon prepolymer composition as claimed in claim 6, further characterized in that the ratio of carbon-carbon double bonds to ≡SiH groups is from 2.2:1 to 5:1. A process for making an organosilicon prepolymer composition, characterized in that an organosilicon prepolymer composition prepared by reacting, in the presence of a hydrosilation catalyst, (a) a cyclic polysiloxane with from 4 to 21 SiO units or tetrahedral siloxysilane having the general formula: wherein R is hydrogen or a substituted or unsubstituted alkyl, alkoxy, aromatic or aryloxy radical containing at least two ≡SiH groups and (b) a polycyclic polyene having at least two non-aromatic, non-conjugated carbon-carbon double bonds in its rings, at least one of the compounds (a) and (b) having more than two reactive sites, the ratio of the non-aromatic, non-conjugated carbon-carbon double bonds in the rings of the polycyclic polyene (b) to the ≡SiH groups in the cyclic polysiloxane or tetrahedral siloxysilane (a) is greater than 1.8:1 and the reaction is driven to substantial completion, so that greater than 90% of the ≡SiH groups are consumed, is blended with (c) an additional cyclic polysiloxane, an additional tetrahedral siloxysilane or a linear, short chain ≡SiH - terminated polysiloxane having the general formula: wherein n is 0 to 1000 and R is alkyl or aryl, the total ratio of the non-aromatic, non-conjugated carbon-carbon double bonds in the rings of the polycyclic polyene (b) to the total number of ≡SiH groups in the cyclic polysiloxane or tetrahedral siloxysilane (a) and in the cyclic polysiloxanes, tetrahedral siloxysilanes or linear, short chain ≡SiH terminated polysiloxanes (c) added to form the blend is 0.4:1 to 1.7:1. A process for making an organosilicon prepolymer composition as claimed in claim 8, further characterized in that the cyclic polysiloxane or tetrahedral siloxysilane is a cyclic polysiloxane comprising tetramethylcyclotetrasiloxyane, pentamethylcyclopentasiloxane, hexamethylcyclohexasiloxane, tetraethylcyclotetrasiloxane, cyclotetrasiloxane, tetraphenylcyclotetrasiloxane, tetraoctylcyclotetrasiloxane or hexamethyltetracyclosiloxane. A process for making an organosilicon prepolymer composition as claimed in claim 9, further characterized in that the cyclic polysiloxane comprises a tetra-, penta- or hexamethylcyclotetrasiloxane. A process for making an organosilicon prepolymer composition as claimed in claim 9, further characterized in that the the cyclic polysiloxane or tetrahedral siloxysilane is a tetrahedral siloxysilane comprising tetrakisdimethylsiloxysilane, tetrakisdiphenylsiloxysilane, or tetrakisdiethylsiloxysilane. A process for making an organosilicon prepolymer composition as claimed in any of claims 8 to 11, further characterized in that the polycyclic polyene is, or is a substituted derivative of, a cyclopentadiene oligomer, a dimethanohexahydronaphthalene, bicycloheptadiene, or a diels-alder oligomer of bicycloheptadiene with cyclopentadiene. A process for making an organosilicon prepolymer composition as claimed in claim 12, further characterized in that the polycyclic polyene is dicyclopentadiene, tricyclopentadiene, bicycloheptadiene, or dimethanohexahydronaphthalene. A process for making an organosilicon prepolymer composition as claimed in any of claims 8 to 13, further characterized in that the ratio of carbon-carbon double bonds in the rings of the polycyclic polyene (b) to ≡SiH groups in (a) is from greater than 1.8 to 5:1. A process for making an organosilicon prepolymer composition as claimed in claim 14, further characterized in that the ratio of carbon-carbon double bonds to ≡SiH groups is from 2.2:1 to 5:1. A process for making an organosilicon prepolymer composition as claimed in claims 8-15, further characterized in that the amount of the short chain ≡SiH - terminated polysiloxane blended with the said organosilicon prepolymer composition is 10 to 50% by weight of the polysiloxanes and siloxysilanes added to the prepolymer composition. A process for making an organosilicon prepolymer composition as claimed in claims 8 to 16, further characterized in that the total ratio of the non-aromatic, non-conjugated carbon-carbon double bonds to the total number of ≡SiH groups is 0.8:1 to 1.3:1. Use of the organosilicon prepolymer compositions made by the process as claimed in claims 8 to 17 for forming an organosilicon prepolymer composition, to make thermoset organosilicon polymers by curing the organosilicon prepolymer compositions optionally in the presence of an additional amount of a hydrosilation catalyst. Use as claimed in claim 18 of the organosilicon prepolymer compositions made by the process as claimed in any of claims 8 to 17, for forming an organosilicon prepolymer composition to make thermoset organosilicon polymers, further characterized in that the organosilicon prepolymer composition is cured in a mold in the presence of fibers.

Inventors: LEIBFRIED RAYMOND THOMAS, LEIBFRIED, RAYMOND THOMAS
Applicants: HERCULES INC, HERCULES INCORPORATED
Application year: 1990
Main classification: C08K5
IPC codes: C07F7, C08G77, C08L83, C08K5