Patent Publication Number: US-2015079407-A1

Title: Silicone-polyester composition

Description:
This invention relates to silicone-polyester compositions. To improve heat and weathering resistance, polyesters are often modified with silicone technology for example at levels ranging from thirty to fifty percent of polyester weight. The silicone and polyester compositions when reacted together are believed to form silicone-polyester copolymers. Silicone-polyester resins typically employs the SiOH or SiOR1 (R1 being a hydrocarbyl moiety) functional groups of silicone reacting with the COH functional group of polyester. Both prepolymers are generally formed having three-dimensional units, typically formed via condensation reactions 
     The terms “silicone-polyester composition” used herein are designed to mean either unreacted silicone-polyester mixture or reacted silicone-polyester resins i.e. silicone-polyester hybrid copolymers. 
     Silicone-polyester compositions are frequently used for cookware coatings or for electrical domestic appliance such as coatings for steam irons. These resins systems are able to form release or non-stick coatings to which extraneous materials will not adhere and residues for example food residues or spray starch can be removed easily as the cookware or appliance is cleaned. Cookware coatings include the external and interior surfaces of the utensils, such as sauté or frying pans, toasters, deep-fat fryers and baking trays. These coatings require, along with thermal stability, resistance to scratches and marring, particularly when heated. Most organic coatings will exhibit some degree of thermo-plasticity that, under normal kitchen conditions, can result in damaged coatings. The polyester component imparts low thermoplasticity, high flexibility and good pigmentability while the silicone part brings heat resistance, weathering resistance and low surface tension. 
     Polyester siloxane backing enamel lacquers are disclosed in GB 1070174. The enamels are produced by heating polyester with an organopolysiloxane obtained by hydrolysis of phenyltrichlorosilane, dimethyldichlorosilane and trimethylchlorosilane. 
     U.S. Pat. No. 4,465,712 describes siloxane-polyester compositions comprising (A) a siloxane-polyester copolymer, (B) a solvent for the siloxane-polyester copolymer, (C) a silane wherein one of the groups attached to silicon contains at least one amino group and (D) a silane having 3 or 4 alkoxy or alkoxyalkoxy groups attached to silicon any remaining group being hydrocarbon or hydrocarbon ether groups. 
     U.S. Pat. No. 6,893,724 describes silicone-polyester-polysilicate hybrid compositions for thermal resistance coating. Alkyl polysilicate is reacted with silicone-polyester resin, thereby creating a composition forming a hybrid structure having good thermal resistance, especially hot-oil resistance and hot hardness, and good adhesion to metals such as carbon steel, stainless steel and aluminum. However adding the alkyl polysilicate part requires an additional step for making the final coating. 
     U.S. Pat. No. 2005/0136267 discloses solid siliconized polyester resins for powder coatings. The organopolysiloxane resin preferably comprises 0-15 mole percent Q units, 30-100 mole percent T units, 0-20 mole percent M units, and 0-20 mole percent D units, based on the total number of moles of the organopolysiloxane resin. More preferably, the organopolysiloxane resin comprises 0-5 mole percent Q units, 75-100 mole percent T units, 0-10 mole percent M units, and 0-10 mole percent D units, based on the total number of moles organopolysiloxane resin, Even more preferably, the organopolysiloxane resin comprises 95 mole percent T units and 5 mole percent D units, based on the total number of moles of the organopolysiloxane resin. Most preferably, the organopolysiloxane resin comprises 57 mole percent T-phenyl units, 39 mole percent T-methyl units and 4 mole percent D-methyl units. 
     Silsesquioxane containing T (RSiO3/2) units silicone resins are known as the standard of the industry for providing an acceptable balance of thermal (film integrity and color stability), and physical properties. 
     While widely utilized, the need exists to reduce the thermo-plasticity and improve the hot hardness of silicone-polyester formulated coatings. Reduced thermoplasticity can be achieved via incorporation of Q (SiO4/2) moieties, but dramatic viscosity increases and the risk of gellation are problematic. Better hot hardness, good heat resistance together with acid resistance are required for the non-stick coating of cookware, therefore better performance is looked for the silicone-polyester hybrid resins. 
     A new material was synthesized by incorporating Q (SiO4/2) units along with Phenyl T (PhSiO3/2) (hereafter referred to as “T Ph  units”) into a silicone intermediate that was subsequently reacted with a hydroxyl functional polyester without gellation or prohibitive viscosity build. The resulting copolymer exhibited the needed boost in hot hardness. 
     Therefore, the invention provides a silicone-polyester composition characterised in that the silicone part contains T Ph  and Q units and is free of D units. 
     The invention further provides a process of forming a silicone-polyester composition characterised in that a polyester precursor or polyester resin and a silicone precursor or silicone resin are mixed and reacted together so as to form a silicone-polyester composition wherein the silicone part contains T Ph  and Q units and optionally (MeSiO3/2) units (hereafter referred to as “T Me  units”). 
     It is believed that the T Ph  units of the silicone part provide good compatibility of the silicone resin intermediate to the polyester resin intermediate. It is believed that the presence of Q units in the silicone part enhances the hot hardness and heat resistance (lower yellowing) of the final silicone-polyester resin. The inclusion of D units like D-methyl units (Me2SiO2/2) is believed to reduce the Tg of the polymer, resulting in a softer coating and reduced mar resistance hence it is preferred that D units are absent in the silicone part. 
     In one preferred embodiment, the silicone part is composed of T Ph  and Q units. The silicone part of the silicone-polyester composition is thus formed of only T Ph  and Q units. Of course the silicone part can contain end units in addition to the T Ph  and Q units. These end units are preferably SiOR moieties where R is preferably H or an alkyl more preferably methyl, ethyl, propyl. These can further react with COH moieties of the polyester resin. 
     We have found that such composition form coatings with hot hardness and heat resistance exceeding that of prior art. 
     In other preferred embodiments, the silicone part of the silicone-polyester composition further contains T Me  units. It is believed the adding of T Me  units balances the hot hardness, heat resistance and further improves film formation and subsequent acid resistance of the final silicone-polyester resin. Furthermore, it has a positive impact on material cost. 
     Preferably, the silicone component of the silicone-polyester composition of the invention is characterised in that it is composed of T Ph , T Me  units and Q units. We have found that such composition permits to form coatings with excellent resistance to acids and hot hardness. Of course the silicone part can contain end units in addition to the T Ph , T Me  units and Q units. These end units are preferably SiOR moieties where R is preferably H or an alkyl more preferably methyl, ethyl, propyl. Such end units can react with COH moieties of the polyester resin. 
     Preferably T Ph  units, T Me  units and Q units are present in molar ratios of 10-80%, 0-70% and 1-60% respectively, calculated on the molar sum of the T Ph , T Me  and Q units. Preferably, if there are no T Me  units, the T Ph  and Q units are present in molar ratios of 60-80%:40-20% for example 70%:30%. When there are T Ph  units, T Me  units and Q units, they are preferably present in amount of 30-50%, 30-50%, 10-30% calculated on the molar sum of the T Ph , T Me  and Q units. In one preferred embodiment, the ratio is 40%:40%:20%. In another preferred embodiment it is 60%:30%:10%. 
     Preferably, the remaining alkoxy function is from 40-200 mol % (calculation based on Si as 100%). The alkoxy refers to C1-C6 alkoxy function, preferably C1-C3 (methoxy, ethoxy and propoxy). 
     The invention extends to a process of forming a silicone-polyester composition characterised in that a polyester precursor and a silicone precursor are mixed and reacted together so as to form a silicone-polyester composition wherein the silicone part contains T Ph  and Q units and optionally T Me  units and is free of D units. 
     In one preferred embodiment, silicone precursor and polyester precursor are first reacted separately to form silicone resin and polyester resin respectively and these resins are subsequently reacted together. 
     The reaction temperature at which the polyester precursor or resin and the silicone precursor or resin are mixed together is preferably in the range of 80 to 150 C, optionally it may be around 100-125 C, more preferably 110-120 C. 
     Preferably, the polyester precursor is formed of isophtalic acid, neopentylglycol and trimethylolpropane or trimethylolethane. 
     Preferably, the silicone precursor is formed of a mixture of phenyltrimethoxysilane or phenyltriethoxysilane, tetraethylorthosilicate and optionally methyltrimethoxysilane or methyltriethoxysilane. Phenyltrimethoxysilane or phenyltriethoxysilane forms T Ph  units in the silicone polymer. Tetraethylorthosilicate forms Q units in the silicone polymer. The optional methyltrimethoxysilane or methyltriethoxysilane forms T Me  units in the silicone polymer. 
     Ingredients other than silicone and polyester components can be added to the composition. For example, the composition may contain organic and/or inorganic pigment like titanium oxide or barium sulfate, binder that adheres to the surface to be treated, a carrier either an organic solvent or water that carries the ingredients but evaporates when the coating is cured, or a reinforcing agent to provide wear protection. It can also contain filler like carbon black or silica, glimmer, matting agent, release additives and curing catalysts. 
     The invention extends to a coating on a substrate characterised in that the coating comprises a silicone-polyester composition as defined above. The coating may be fairly thin for example 20-25 micrometer and more generally from 5 to 500 micrometer, preferably from 15 to 100 micrometer. The coating may be applied in several ways to the substrate for example by spraying, curtain coating or roller coating the composition containing all ingredients. 
     The coating may be applied in several successive layers which may have different compositions. However preferably it is applied as a single coating layer which simplifies the process. 
     The invention extends to a substrate bearing a coating characterised in that the coating comprises a silicone-polyester composition as defined above. 
     The substrate is preferably made of aluminium, stainless steel, iron, plastics or glass. 
     The invention extends to the use of a silicone-polyester composition as defined above to form a coating on a substrate. 
    
    
     EXAMPLES 
     A. Polyester resin synthesis 
     Trimethylolpropane (TMP, 164 g), Neopentyl glycol (NPG, 38 g) and m-Phthalic acid (IPA, 202 g) were added to 3 necked, round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple. The nitrogen sweep, condenser and heating mantle were turned on. The materials were heated to 150° C. prior to turn on the stirrer motor. Then the whole was heated to 180° C. and hold until bulk of reaction water was removed. Periodically drain was trapped, and heated to 220° C. until water evolution stops. The temperature was kept and some samples were taken from the mixture for testing acid value. When the acid value was less than 10 mg KOH/g, heating was turned off and cooled to 140° C., added propylene glycol monomethyl ether acetate (PMA, 439 g) as solvent for diluting. 
     B. Silicone Resin Synthesis 
     A 500 g, three necked, round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple was charged with phenyltrimethoxysilane (238.0 g), methyltrimethoxysilane (81.7 g) and tetraethylorthosilicate (41.7 g) in molar ratio of 6/3/1. A pressure-equalizing addition funnel was charged with deionized water (40.83 g) which solved concentrated hydrochloric acid (0.2 ml). The nitrogen sweep was turned on. Water was added dropwise about 30 minutes with stirring. The mixture was heated slowly to 60° C. and hold for 1 hour. Then the mixture was heated to 140° C. stepwise to remove volatiles and hold for 1 hour as well as vacuum puling for additional 1 hour. Finally, it was cooled down below 80° C., filtered and drummed off. The resulting resin was clear liquid and its viscosity was about 206.9 cp at 24±1° C. 
     A 500 g, three necked, round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple was charged with phenyltrimethoxysilane (277.60 g), tetraethylorthosilicate (125.00 g) in molar ratio of 7/3. The nitrogen sweep was turned on. A pressure-equalizing addition funnel was charged with deionized water (41.73 g) which solved concentrated hydrochloric acid (0.2 ml). The mixture of silanes was heated to 40° C. with stirring. Then water was added dropwise over 30 minutes. The mixture was heated slowly to 170° C. and hold for 3 hours to remove volatiles. Finally, it was cooled down below 60° C., filtered and drummed off. The resulting resin was clear liquid and its viscosity was about 463.5 cp at 24±1° C. 
     A 500 g, three necked, round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple was charged with phenyltrimethoxysilane (237.6 g), methyltriethoxysilane (106.8 g) and tetraethylorthosilicate (41.6 g) in molar ratio of 6/3/1. A pressure-equalizing addition funnel was charged with deionized water (39.93 g) which solved concentrated hydrochloric acid (0.2 ml). Turn on the nitrogen sweep. Water was added dropwise about 30 minutes with stirring. The mixture was heated slowly to 60° C. and hold for 1 hour. Then heat the mixture stepwise to 140° C. to remove volatiles and hold for 1 hour as well as vacuum puling for additional 1 hour. Finally, cool down below 80° C., filtered and drum off. The resulting resin was clear liquid and its viscosity was about 107.7 cp at 24±1° C. C. Silicone-Polyester resin synthesis 
     Example 1  
     
         
         
           
             Polyester (116.3 g) resin was charged into a 500 g, 3 necked round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple. 
             Silicone resin was add (1, 39.25 g), propylene glycol monomethyl ether acetate (PMA, 62.41 g) as solvent and Tetra-n-butyl Titanate (0.015 g) as catalyst into flask under nitrogen surrounding. 
             The mixture was heated slowly up to 120° C. with stirring, trap off produced methanol and ethanol. After 1 h, a transparent silicone-polyester resin was prepared. 
             Samples were picked up and dropped on glass panel regularly to check the appearance at room temperature until clear. 
             Heating was stopped, cooled down below 60° C., filter and drum off. Viscosity of prepared resin was about 1442 cp at 24±1° C. 
           
         
       
    
     Example 2  
     
         
         
           
             Polyester (116.3 g) resin was charged into a 500 g, 3 necked round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple. 
             Silicone resin (11, 39.25 g), propylene glycol monomethyl ether acetate (PMA, 93.7 g) as solvent and Tetra-n-butyl Titanate (0.015 g) as catalyst were added into flask under nitrogen surrounding. 
             The mixture was heated slowly up to 110° C. with stirring, trap off produced methanol and ethanol. After 160 min, a transparent silicone-polyester resin was prepared. 
             Samples were picked up and dropped on glass panel regularly to check the appearance at room temperature until clear. 
             Heating was stopped, cooled down below 60° C., filter and drum off. Viscosity of prepared resin was about 284.8 cp at 24±1° C. 
           
         
       
    
     Example 3  
     
         
         
           
             Polyester (116.3 g) resin was charged into a 500 g, 3 necked round bottom flask fitted with a water cooled condenser, a PTFE stirrer and a thermocouple. 
             Silicone resin (III, 39.25 g), propylene glycol monomethyl ether acetate (PMA, 62.41 g) as solvent and Tetra-n-butyl Titanate (0.015 g) as catalyst were added into flask under nitrogen surrounding. 
             The mixture was heated slowly up to 120° C. with stirring, trap off produced methanol and ethanol. After 1 h, a transparent silicone-polyester resin was prepared. 
             Samples were picked up and dropped on glass panel regularly to check the appearance at room temperature until clear. 
             Heating was stopped, cooled down below 60° C., filter and drummed off. Viscosity of prepared resin was about 1045 cp at 24±1° C. 
           
         
       
    
     Comparative Example 
     A 100% T phenyl silicone resin available commercially was reacted with polyester resin in the same way as described for examples 1 to 3. 
     D. Performance 
     The final resin was applied onto cleaned steel and aluminum panel (60 μm wet film) for Hot Hardness, adhesion and boiled water solution of acetic acid (3%) resistance test. The coat was allowed to air drying for 15 min, and baked in oven at 280° C. for 10 min. Hot Hardness Test Method (ASTM D3363) 
     Coated steel panels are placed on a cool hot plate. A surface thermometer is placed on the coated surface and the hot plate is turned on. As the panel temperature rises. The coatings are rated by attempting to scratch the surface with drafting pencils of increasing lead hardness. Coating hardness is rated as the highest pencil hardness that cannot scratch through the coating (higher numbers in front of the H indicate higher hardnesses). 
     Adhesion Test Method 
     Cross cut the coat to form 100 grids. Apply and remove pressure-sensitive tape over the grids. Count the number of retaining grids. 
     Acetic Acid Solution Resistance 
     Soak the coated aluminum panel into boiling water solution with 3% acetic acid. After 2 h, take the panels out and wash by water. Observe the surface condition of the coat. 
     
       
         
           
               
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 Silicone- 
                   
                   
                 Acetic Acid  
               
               
                 Polyester  
                 Hot  
                   
                 Solution  
               
               
                 Resin 
                 Hardness 
                 Adhesion 
                 Resistance 
               
               
                   
               
             
            
               
                 Example 1 
                 3H/240° C.; 3H/260° C.;  
                 100/100 
                 No bubble and crack 
               
               
                   
                 2H/280° C., 1H/300° C. 
                   
                   
               
               
                 Example 2 
                 3H/240° C.; 3H/260° C.;  
                 100/100 
                 No bubble and crack 
               
               
                   
                 3H/280° C., 2H/300° C. 
                   
                   
               
               
                 Example 3 
                 3H/240° C.; 3H/260° C.;  
                 100/100 
                 No bubble and crack 
               
               
                   
                 2H/280° C., 1H/300° C. 
                   
                   
               
               
                 Comparative 
                 2H/240° C.; 2H/260° C.;  
                 100/100 
                 No bubble and crack 
               
               
                   
                 1H/280° C., 1H/300° C. 
               
               
                   
               
            
           
         
       
     
     Example 3 further showed improved resistance of the coat after acid resistance test and better scratch resistance when compared to examples 1 and 2. 
     TQ synthesis IV—Example 4 
     Loaded trimethoxyphenylsilane (277.2 g), methyltriethoxysilane (71.2 g) and ethylsilicate (41.6 g) into 4 neck flask (500ml) fitted with a water cooled condenser, PTFE stirrer, nitrogen inlet and thermometer, purged Nitrogen for 15 minutes, then stirred the mixture with 300 rpm under Nitrogen surrounding. Then the flask was fitted a pressure-equalizing addition funnel containing deionized water (41.73 g) and HCl (0.5 ml, 37%). Dropped the water dropwise for 15 min at room temperature, then heated the contents to 65° C. step by step. After hydrolyzed for 1.5 h and a Dean-Stark apparatus was charged, the contents were heated to 140° C. and held at that temperature for 1 h to strip the by-product methanol and ethanol, then cooled to 60° C. and loaded 40 g Methanol. The content was heated to 140° C. again to strip methanol, then held at that temperature for 1 h and vacuumed for additional 1 h. Finally, cooled down below 80° C., filtered and drum off. The resulting resin was clear liquid and its viscosity was about 1065 cp at 24±1° C. 
     Silicone-Polyester Synthesis (Example 4) 
     TQ resin (resin IV, 23.55 g) Polyester resin (69.78 g), PMA (37.45 g) and TnBT (tetranbutyltitanate 10% in Xylene, 0.09 g) were loaded into 4 neck vessel (250 ml) fitted with a water cooled condenser, PTFE stirrer, nitrogen inlet and heat controller, purged Nitrogen for 10 minutes, then stirred the mixture with 300 rpm under Nitrogen surrounding. Then the mixture was heated to 120° C. step by step, and held at that temperature for 6.5 hours. Stop heating, cooled down below 60° C., filter and drummed off. Viscosity of prepared resin was 1009 cp at 24±1° C. 
     Performance of Silicone-Polyester Synthesis (Example 4) 
       
     
       
         
           
               
               
               
               
             
               
                   
               
               
                 Silicone- 
                   
                   
                 Acetic Acid  
               
               
                 Polyester  
                 Hot  
                   
                 Solution  
               
               
                 Resin 
                 Hardness 
                 Adhesion 
                 Resistance 
               
               
                   
               
             
            
               
                 Example 4 
                 3H/240° C.; 3H/260° C.;  
                 100/100 
                 No bubble and crack 
               
               
                   
                 2H/280° C., 1H/300° C. 
               
               
                   
               
            
           
         
       
     
     TQ Synthesis (Silicone Resin V) 
     Loaded phenyltriethoxysilane (2016 g), methyltriethoxysilane (427.2 g) and ethylsilicate (249.6 g) into 4 neck vessel (3 L) fitted with a water cooled condenser, PTFE stirrer, nitrogen inlet and thermometer, purged Nitrogen for 15 minutes, then stirred the mixture with 270 rpm under Nitrogen surrounding. Then the flask was fitted a pressure-equalizing addition funnel containing deionized water (250.2 g) and HCl (3.0 ml, 37%). Dropped the water dropwise for 15 min at room temperature, then heated the contents to 75° C. step by step. After hydrolyzed for 2 h and a Dean-Stark apparatus was charged, the contents were heated slowly to 145° C. to strip by-product ethanol, then held at that temperature for 9 h and vacuumed for additional 1 h. Finally, cooled down below 80° C., filtered and drum off. The resulting resin was clear liquid and its viscosity was about 549.2 cp at 24±1° C. 
     Silicone-Polyester Synthesis (Example 5) TQ resin (resin V, 23.55 g) Polyester resin (69.78 g), PMA (37.45 g) and TnBT (10% in Xylene, 0.09 g) were loaded into 4 neck vessel (250 ml) fitted with a water cooled condenser, PTFE stirrer, nitrogen inlet and heat controller, purged Nitrogen for 10 minutes, then stirred the mixture with 300 rpm under Nitrogen surrounding. Then the mixture was heated to 120° C. step by step, and held at that temperature for 13 hours. Stop heating, cool down below 60° C., filter and drum off. Viscosity of prepared resin was 848 cp at 24±1° C. 
     Performance of Silicone-Polyester Synthesis (Resin V) 
       
     
       
         
           
               
               
               
               
             
               
                   
               
               
                 Silicone- 
                   
                   
                 Acetic Acid  
               
               
                 Polyester 
                 Hot  
                   
                 Solution 
               
               
                 Resin 
                 Hardness 
                 Adhesion 
                 Resistance 
               
               
                   
               
             
            
               
                 Example 5 
                 3H/240° C.; 2H/260° C.;  
                 100/100 
                 No bubble and crack 
               
               
                   
                 2H/280° C., 1H/300° C.