Methods of making polysiloxanes

Abstract: Linear or straight-chain trimethylsiloxy endcapped methylhydrogen polysiloxanes are made by contacting hexamethyldisiloxane with a highly pure methylhydrogen cyclic siloxane, in the presence of anhydrous trifluoromethane sulfonic acid catalyst at room temperature. Trimethylsiloxy endcapped alkylmethyl siloxanes are made by reacting the linear or straight-chain trimethylsiloxy endcapped methylhydrogen polysiloxanes with an alpha-olefin, in the presence of a platinum catalyst. Alkylmethyl cyclic siloxanes containing zero parts per million residual ≡SiH, are made by reacting anhydrous alpha-olefins and a highly pure methylhydrogen cyclic siloxane, in the presence of dried platinum catalyst supported on carbon particles.

Description: This invention is directed to methods for preparing linear or straight-chain polysiloxanes. US-A-5,395,956 discloses a process for preparing cyclic organohydrogensiloxanes, in which an organohydrogendichlorosilane is reacted with water. The hydrolyzate is contacted with an acidic rearrangement catalyst. EP-A-0,641,799 discloses a process for the production of pristine alkylsiloxanes in which an SiH containing siloxane polymer and an olefinic compound are reacted in the presence of a supported platinum catalyst and oxygen. US-A-2,491,843 discloses a linear trimethylsiloxy endcapped methylhydrogen polysiloxane having a degree of polymerisation of up to 500. The present invention provides a method of making linear triorganosiloxy endcapped methylhydrogen polysiloxanes comprising (i) forming a reaction mixture containing a silanol-free (1ppm or less residual ≡SiOH or within the detection limits of Fourier Transform Infrared Spectroscopy) hexaorganodisiloxane, one or more silanol-free (1ppm or less residual ≡SiOH or within the detection limits of Fourier Transform Infrared Spectroscopy) methylhydrogen cyclic siloxanes, and less than 100 parts per million water, (ii) contacting the reaction mixture with anhydrous trifluoromethane sulfonic acid catalyst, and (iii) agitating the mixture and the catalyst at below 100°C, to form a linear triorganosiloxy endcapped methylhydrogen polysiloxane having a degree of polymerization of 750-2200 and containing less than 0.2% branch sites. The invention also provides a linear triorganosiloxy endcapped methylhydrogen polysiloxane having a degree of polymerization of 750-2200 and containing less than 0.2% branch sites. The invention further provides a method of making triorganosiloxy endcapped alkylmethyl siloxanes comprising contacting and reacting a linear triorganosiloxy endcapped methylhydrogen polysiloxane as defined above, with an alpha-olefin, in the presence of a platinum catalyst, until a triorganosiloxy endcapped alkylmethyl siloxane containing less than 200 parts per million hydrogen as residual ≡SiH is formed. Acid equilibration (polymerization) of siloxanes such as tetramethylcyclotetrasiloxane (D H 4) and pentamethylcyclopentasiloxane (D H 5) has been performed in the past. Our invention, however, relates in one embodiment to the polymerization of highly pure silanol-free hexamethyldisiloxane and highly pure mixtures of silanol-free D H 4 and D H 5 containing no more than 100 parts per million (ppm) water, with anhydrous trifluoromethane sulfonic acid (triflic acid, CF 3 SO 3 H), at room temperature, to provide linear or straight-chain methylhydrogen siloxanes of molecular weight up to MD H 2200 M. Hydrosilation (≡SiH + CH 2 =CHR → ≡SiCH 2 CH 2 R) of alpha-olefins with methylhydrogen siloxanes has been performed in the past, but the method of our invention relates to hydrosilation of alpha-olefins with high molecular weight methylhydrogen siloxanes (degree of polymerization up to 2200), efficiently performed to provide alkylmethyl polysiloxanes with low ≡SiH content. It is known that methylhydrogen chlorosilanes can be hydrolyzed and condensed to obtain silicone fluids retaining a high proportion of reactive hydrogen, but typically they contain 1% or more of branch sites. The reactions are often difficult to control and the results are erratic (i) sometimes producing useless gels or hard brittle solids instead of fluids, and (ii) hydroxyl substitution on silicon (≡SiOH) which leads to gelation. This limits the usefulness of methylhydrogen siloxanes as starting materials for polymer synthesis. These disadvantages are overcome in our invention by utilizing highly pure essentially anhydrous silanol-free organodisiloxanes, and highly pure essentially anhydrous silanol-free methylhydrogen cyclic siloxanes (D H 4) and (D H 5), as starting materials. Since our starting materials contain no water or residual ≡SiOH, branching and cross-linking do not occur. Therefore, our end products are not branched-chain polysiloxanes or gels, but linear or straight-chain polysiloxanes. The interested reader is referred to US Patent 2,469,890 for illustrations showing the structural differences between linear or straight-chain and branched-chain polysiloxanes. Our invention, therefore, is in sharp contrast to the gel containing cross-linked oily materials taught in US Patent 2,491,843; or the cross-linked high polymers bearing SiOH end groups, described in the European Polymer Journal, Vol. 29, No. 1, Pages 15-22, (1993). Furthermore, our alkylated products are prepared from highly pure essentially anhydrous silanol-free starting materials and contain low or no residual ≡SiH. According to our first embodiment, high molecular weight trimethylsiloxy-endcapped methylhydrogen siloxanes are prepared via an anhydrous triflic acid catalyzed, mild room temperature polymerization, of highly pure essentially anhydrous silanol-free hexamethyldisiloxane (CH 3 ) 3 SiOSi(CH 3 ) 3 , highly pure essentially anhydrous silanol-free tetramethylcyclotetrasiloxane, and highly pure essentially anhydrous silanol-free pentamethylcyclopentasiloxane. By silanol-free is meant that the siloxane starting materials contain no residual ≡SiOH, within the limits of detection by Silicon-29 Nuclear Magnetic Resonance ( 29 Si NMR) and Fourier Transform Infrared Spectroscopy (FTIR), which is one part per million or less. The resulting linear or straight-chain trimethylsiloxy-endcapped methylhydrogen siloxanes are fluids containing less than 0.2% branch sites by 29 Si NMR, that could eventuate in the formation of an undesirable gel. A branch site frequency of 0.2% means that 1 out of 500 silicon atoms contains a branch site. Reaction conditions are mild so that branch sites are not formed during polymerization. Thus, the preferred temperature range is 20-30°C. (68-86°F.), although if desired, temperatures up to 100°C. can be employed, consonant with the desire to avoid the formation of branch sites. The method of preparing these high molecular weight trimethylsiloxy-endcapped methylhydrogen siloxanes is illustrated in the following examples. Example I Preparation of (CH 3 ) 3 Si(CH 3 HSiO) 758 Si(CH 3 ) 3 or MD H 758 M A solution of silanol-free hexamethyldisiloxane (0.05 g, 0.31 mmol), a silanol-free mixture of 50% by weight D H 4 and 50% by weight D H 5 (57.6 g, 0.213 mol), and 0.1% by weight anhydrous triflic acid, containing less than 100 ppm water determined by FTIR, was stirred for one hour at room temperature (20-25°C./68-77°F.), then neutralized with NaHCO 3 (4 g). After neutralization of the reaction mixture, positive-pressure filtration provided a viscous oil. Analysis of the unstripped product by 29 Si NMR showed a degree of polymerization of 758. The room temperature stability of the product without gel formation exceeded two months. The product contained no branch sites. EXAMPLE II Preparation of (CH 3 ) 3 Si(CH 3 HSiO) 2156 Si(CH 3 ) 3 or MD H 2156 M A solution of silanol-free hexamethyldisiloxane (0.06 g, 0.37 mmol), a silanol-free mixture of 50% by weight D H 4 and 50% by weight D H 5 (80 g, 0.296 mol), and 0.05% by weight anhydrous triflic acid, containing less than 100 ppm water, was stirred for 1.5 hours at room temperature, then neutralized with NaHCO 3 (5 g). After neutralization of the reaction mixture, positive-pressure filtration provided a viscous oil. Analysis of the unstripped oil by 29 Si NMR showed a degree of polymerization of 2156. The room temperature stability of the product without gel formation exceeded two months. The product contained 3 branch sites per average molecule which is a branch site frequency rate of 0.139%, i.e. (3/2156)(100). Reaction mixtures may contain 0.001-1.0 mole of organodisiloxane per mole of methylhydrogen cyclic siloxane. The acid catalyst can be used in amounts of 0.05-0.2% by weight, based on the weight of the mixture. It can be neutralized with agents other than sodium bicarbonate, such as ammonia or calcium carbonate. The reaction is preferably conducted at room temperature. Reaction time will vary, depending upon equipment being used and amount of product being produced, but typically a batch reaction requires 1-2 hours for completion. The linear or straight-chain trimethylsiloxy endcapped methylhydrogen polysiloxane products are purified by filtration, although other standard means of separating end products from reaction mixtures can be employed, such as centrifugation. This method can be used to make linear or straight-chain trimethylsiloxy endcapped methylhydrogen polysiloxanes having a degree of polymerization of 1-2200, preferably 750-2200. Silanol-free methylhydrogen cyclic siloxane starting materials containing less than 100 ppm water can be made by processes such as described in US Patent 5,395,956. Briefly, according to that process, an organohydrogen dichlorosilane is contacted with a near stoichiometric equivalent of water to form a hydrolyzate. The hydrolyzate is diluted in an inert solvent and contacted with an acid rearrangement catalyst to effect formation of cyclic organohydrogen siloxanes. The cyclic organohydrogen siloxanes are then separated from the inert solvent and the linear organohydrogen siloxanes. The inert solvent and linear organohydrogen siloxanes are subsequently recycled to the process for further contact with the acid rearrangement catalyst. According to that method, hydroxyl substitution on silicon is minimized. D H 4, D H 5, and mixtures containing D H 4 and D H 5, are preferred methylhydrogen cyclic siloxanes according to our invention. However, other methylhydrogen cyclic siloxanes such as D H 6 can also be used. In addition, the methylhydrogen cyclic siloxanes (RHSiO) n can be used alone or mixed with one another. Further, n can be 3-8, and alkyl groups of R may be other than methyl, such as ethyl, propyl, isopropyl, butyl or hexyl. Silanol-free hexaorganodisiloxanes R 3 Si-O-SiR 3 containing less than 100 ppm water, such as hexamethyldisiloxane are commercially available. Silanol-free disiloxanes where R is an alkyl group other than methyl, can also be employed. Thus, R can be another alkyl group such as ethyl, propyl, isopropyl, butyl or hexyl. In addition, R can be an aryl group such as phenyl, xenyl or naphthyl; an alkaryl group such as tolyl or xylyl; or an aralkyl group such as benzyl, phenylethyl or 2-phenylpropyl. According to our second embodiment, high molecular weight trimethylsiloxy-endcapped alkylmethylsiloxanes are prepared via hydrosilation of alpha-olefins, using the linear high molecular weight methylhydrogen siloxanes from Examples I and II. This scenario provides a route to alkylmethylsiloxanes containing less than 200 ppm hydrogen expressed as residual ≡SiH. Preferably, the alkylmethylsiloxanes contain 25-200 ppm, and most preferably 25-165 ppm hydrogen expressed as residual ≡SiH. This method is illustrated by the following examples. EXAMPLE III Preparation of Trimethylsiloxy-endcapped Polydecylmethylsiloxane MD C10 758 M To a solution of 1-decene (80.9 g, 0.578 mol) and platinum (2.5 ppm, 16 mg, 2% Pt in toluene) was added via an addition funnel, 29 g/0.64 mmol (CH 3 ) 3 Si(CH 3 HSiO) 758 Si(CH 3 ) 3 from Example I, over a period of four hours. After addition, the reaction was stirred at 110°C. for 12 hours. At this point, FTIR analysis showed 440 ppm ≡SiH. An additional 50 mL of 1-decene was added, and the reaction was continued at 110°C. for 6 hours. After excess olefin was stripped 266.7 kPa (2 mm Hg, 50-100°C.) from the polymer, FTIR analysis showed 27 ppm ≡SiH. EXAMPLE IV Preparation of Trimethylsiloxy-endcapped Polydecylmethylsiloxane MD C10 2150 M To a suspension of 1-decene (10.25 g, 0.073 mol, 1.1 eq.) and platinum supported on carbon (50 ppm, 14 mg), was added 4 g/0.03 mmol (CH 3 ) 3 Si(CH 3 HSiO) 2150 Si(CH 3 ) 3 in hexane (25 mL), which provided a slight exotherm (70°C.). MD H 2150 M was prepared according to the method of Example II. After stirring for 20 hours at 75°C., FTIR analysis of the reaction mixture showed 500 ppm ≡SiH. At this point, additional 1-decene (8.4 g, 0.059 mol) was added, and stirring was continued for 4 more hours at 75°C. After excess 1-decene was stripped 266.7 kPa (2 mm Hg, 50-100°C.) from the product, FTIR analysis showed 165 ppm ≡SiH. This method can be used to make linear or straight-chain trimethylsiloxy endcapped alkylmethyl siloxanes having a degree of polymerization of 1-2200, most preferably 750-2200, containing less than 200 ppm residual ≡SiH, most preferably 25-165 ppm residual ≡SiH. Alpha-olefins CH 2 =CHR useable in the methods in Examples III-VII include alkenes with 2-30+ carbon atoms, preferably 6-30 carbon atoms, and most preferably 6-18 carbon atoms. In Examples V-VII, particular care should be taken to insure that the alpha-olefin(s) is anhydrous. Some suitable alpha-olefins are ethene, propene, 1-butene, isobutylene (2-methylpropene), 1-pentene (C 5 ), 2-methyl-1-butene, 3-methyl-1-butene, 1-hexene, 2-methyl-1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-heptene, 2-methyl-1-hexene, 1-octene, 2-methyl-1-heptene, 1-nonene, 1-decene (C 10 ), 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene (C 15 ), 1-hexadecene, 1-octadecene, 1-nonadecene, 1-eicosene (C 20 ), and those alpha-olefin fractions containing varying percentages of C 22-C30+ alpha-olefins sold under the trademarks GULFTENE® 24-28 and GULFTENE® 30+ by Chevron Chemical Company, Houston, Texas. Equivalent amounts of ≡Si-H containing reactants and unsaturated alpha-olefin reactants should be employed in the process, and one ethylenic linkage is the theoretical equivalent of one silicon bonded hydrogen atom. It may be necessary, however, to use an excess of alpha-olefin to totally consume ≡SiH in the siloxane product. The maximum amount of platinum catalyst employed is determined by economical considerations, and the minimum amount by the type and purity of reactants employed. Very low concentrations of platinum catalyst such as 1x10 -10 moles catalyst per equivalent of the alpha-olefin compound, may be used when the reactants are extremely pure. However, it is possible to use 1x10 -8 moles catalyst per equivalent weight of alpha-olefin compound, and even 1x10 -7 to 1x10 -3 moles platinum catalyst, per equivalent weight of alpha-olefin. "Moles" of platinum catalyst are measured in terms of one mole providing one unit atom (e.g. one gram atom) of platinum. An "equivalent weight" of alpha-olefin is the amount of reactant furnishing one unit weight of ethylenic unsaturation (i.e. equivalent to one unit weight of ≡Si-H), regardless of what other reactive or potentially reactive substitutents may be present. Thus, an equivalent weight of ethylene is its molecular weight. The preferred hydrosilation catalyst is platinum supported on active carbon particles having a diameter of 1-2 mm. The amount of platinum supported on the active carbon can vary from 0.1-5% by weight, based on the weight of active carbon. Care should be taken to insure that the platinum on carbon catalyst is dried so that it is anhydrous. The reaction temperature can vary and optimum temperatures depend upon the concentration of platinum catalyst and the nature of the reactants. The reaction can be initiated at a temperature below room temperature (0° to -10°C.) and is exothermic once begun. The temperature should be one at which both reactants are in a liquid or gaseous state. The maximum temperature is determined by the stability of the reactants. Ordinarily, it is best to keep the reaction temperature below 300°C. Best results with most reactants are obtained by initiating the reaction at 80° to 180°C., and maintaining the reaction within reasonable limits of this range. The exothermic nature of the reaction may push the temperature up to 200-250°C. for a short time, however. The optimum reaction time is a variable depending upon the reactants, reaction temperature, and platinum catalyst concentration. Ordinarily, there is no benefit in extending the contact time of the reactants beyond 16 or 17 hours, but likewise there is usually no harm, unless an extremely elevated temperature is employed. With many reactants, a practical quantitative yield of product can be obtained in 30 minutes or less. The reaction can be carried out at atmospheric, sub-atmospheric, or super-atmospheric pressure. Here again, the choice of conditions is largely a matter of logic, based upon the nature of the reactants, and the equipment available. Non-volatile reactants are especially adaptable to being heated at atmospheric pressure, with or without a reflux arrangement. Reactants which are gaseous at ordinary temperatures, are preferably reacted at substantially constant volume under autogenous or induced pressure. The best results are obtained by maintaining all reactants in the liquid phase. The linear trimethylsiloxy endcapped methylhydrogen polysiloxanes in Examples I and II are useful as intermediates for preparing linear trimethylsiloxy endcapped alkylmethyl siloxanes such as in Examples III and IV, which in turn, are useful in the personal care arena for conditioning skin, for instance.

Claims: A method of making linear triorganosiloxy endcapped methylhydrogen polysiloxanes comprising (i) forming a reaction mixture containing a silanol-free (1ppm or less residual ≡SiOH or within the detection limits of Fourier Transform Infrared Spectroscopy) hexaorganodisiloxane, one or more silanol-free (1ppm or less residual ≡SiOH or within the detection limits of Fourier Transform Infrared Spectroscopy) methylhydrogen cyclic siloxanes, and less than 100 parts per million water, (ii) contacting the reaction mixture with anhydrous trifluoromethane sulfonic acid catalyst, and (iii) agitating the mixture and the catalyst at below 100°C. to form a linear triorganosiloxy endcapped methylhydrogen polysiloxane having a degree of polymerization of 750-2200 and containing less than 0.2% branch sites. A method according to claim 1, in which the mixture contains hexamethyldisiloxane, tetramethylcyclotetrasiloxane and pentamethylcyclopentasiloxane. A method according to claim 1 or claim 2, in which the amount of the catalyst used is 0.05-0.2% by weight based on the weight of the mixture, and the reaction mixture and catalyst are agitated at 20-30°C. A method according to any of the preceding claims wherein the linear triorganosiloxy endcapped methylhydrogen polysiloxane is linear trimethylsiloxy endcapped methylhydrogen polysiloxane. A method according to any of the preceding claims in which the catalyst is neutralized after forming the triorganosiloxy endcapped methylhydrogen polysiloxane. A method according to any of the preceding claims in which the linear triorganosiloxy endcapped methylhydrogen polysiloxane is separated from the reaction mixture and purified by filtration. A linear triorganosiloxy endcapped methylhydrogen polysiloxane having a degree of polymerization of 750-2200 and containing less than 0.2% branch sites. A method of making triorganosiloxy endcapped alkylmethyl siloxanes comprising contacting and reacting a linear triorganosiloxy endcapped methylhydrogen polysiloxane as defined in claim 7, with an alpha-olefin, in the presence of a platinum catalyst, until a triorganosiloxy endcapped alkylmethyl siloxane containing less than 200 parts per million hydrogen as residual ≡SiH is formed. A method according to claim 8 in which the alpha-olefin is an alkene selected from the group consisting of ethene, propene, 1-butene, isobutylene (2-methylpropane), 1-pentene (C 5 ), 2-methyl-1-butene, 3-methyl-1-butene, 1-hexene, 2-methyl-1-pentene, 3-methyl-1-pentene, 4-methyl-1-pentene, 1-heptene, 2-methyl-1-hexene, 1-octene, 2-methyl-1-heptene, 1-nonene, 1-decene (C 10 ), 1-undecene, 1-dodecene, 1-tridecene, 1-tetradecene, 1-pentadecene (C 15 ), 1-hexadecene, 1-octadecene, 1-nonadecene, 1-eicosene (C 20 ), and alpha-olefin fractions containing C 22 -C 30+ alpha-olefins. A method according to claim 8 or 9 in which the triorganosiloxy endcapped alkylmethyl siloxane has a degree of polymerization of 750-2200. A method according to any of claims 8 to 10 in which the reaction is continued until the same triorganosiloxy endcapped alkylmethyl siloxane contains 25-200 parts per million hydrogen as residual ≡SiH. A triorganosiloxy endcapped alkylmethyl siloxane obtained by the method of any of claims 8 to 11.

Inventors: BIGGS TIMOTHY NOLEN, LEGROW GARY EDWARD, BIGGS, TIMOTHY NOLEN, LEGROW, GARY EDWARD
Applicants: DOW CORNING, DOW CORNING CORPORATION
Application year: 1996
Main classification: C08G77
IPC codes: C07F7, C08G77