U.S. patent application number 11/739333 was filed with the patent office on 2007-12-13 for polymer, processes for producing polymer and composition.
This patent application is currently assigned to KANEKA CORPORATION. Invention is credited to Masayuki Fujita, Kenichi Kitano, Yoshiki Nakagawa.
Application Number | 20070287802 11/739333 |
Document ID | / |
Family ID | 27333621 |
Filed Date | 2007-12-13 |
United States Patent
Application |
20070287802 |
Kind Code |
A1 |
Nakagawa; Yoshiki ; et
al. |
December 13, 2007 |
POLYMER, PROCESSES FOR PRODUCING POLYMER AND COMPOSITION
Abstract
The present invention relates to a vinyl polymer terminated in a
silanol group, a hydrolyzable silyl group or an acrylic functional
group, to a method of producing a vinyl polymer having a
hydrolyzable silyl group at one or more termini thereof which
comprises reacting a vinyl polymer having a silanol group at one or
more termini thereof with a silicon compound having two or more
silicon atom-bound hydrolyzable groups, and a method of producing a
vinyl polymer having an acrylic functional group at one or more
termini thereof which comprises reacting a vinyl polymer having a
silanol group at one or more termini thereof with a silicon
compound represented by the general formula (3):
XSiR.sub.2-G-O--C(O)C(L)=CH.sub.2 (3) wherein X is a hydrolyzable
group.
Inventors: |
Nakagawa; Yoshiki;
(Kobe-shi, JP) ; Kitano; Kenichi; (Kobe-shi,
JP) ; Fujita; Masayuki; (Kobe-shi, JP) |
Correspondence
Address: |
CONNOLLY BOVE LODGE & HUTZ LLP
1875 EYE STREET, N.W.
SUITE 1100
WASHINGTON
DC
20036
US
|
Assignee: |
KANEKA CORPORATION
Osaka
JP
|
Family ID: |
27333621 |
Appl. No.: |
11/739333 |
Filed: |
April 24, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11134354 |
May 23, 2005 |
7223817 |
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11739333 |
Apr 24, 2007 |
|
|
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09786325 |
Jun 11, 2001 |
6930147 |
|
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PCT/JP99/04748 |
Sep 2, 1999 |
|
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11739333 |
Apr 24, 2007 |
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Current U.S.
Class: |
525/104 ;
525/105 |
Current CPC
Class: |
C08F 265/04 20130101;
C08F 290/062 20130101; C08F 290/068 20130101; C08F 290/046
20130101; C08F 283/122 20130101; C08F 290/00 20130101; C08F 283/12
20130101; C08F 290/06 20130101; C08F 283/124 20130101; C08F 293/005
20130101; C08F 8/42 20130101; C08F 2438/01 20130101; C08F 283/00
20130101 |
Class at
Publication: |
525/104 ;
525/105 |
International
Class: |
C08F 8/00 20060101
C08F008/00; C08F 290/00 20060101 C08F290/00; C08F 8/42 20060101
C08F008/42 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 2, 1998 |
JP |
10/247665 |
Sep 14, 1998 |
JP |
10/260193 |
Sep 14, 1998 |
JP |
10/260194 |
Claims
1. A method of producing a vinyl polymer (II) having a hydrolyzable
silyl group at one or more termini thereof which comprises reacting
a vinyl polymer (I) having a silanol group at one or more termini
thereof with a silicon compound having two or more silicon
atom-bound hydrolysable groups.
2. The method of producing according to claim 1, wherein the vinyl
polymer (I) has a main chain obtained by polymerizing at least one
monomer selected from the group consisting of (meth)acrylic
monomers, acrylonitrile monomers, aromatic vinyl monomers,
fluorine-containing vinyl monomers and silicon-containing vinyl
monomers.
3. The method of producing according to claim 1, wherein the
silanol group of the vinyl polymer (I) is represented by the
general formula (1):
--[Si(R.sup.1).sub.2-b(OH).sub.bO].sub.m--Si(R.sup.2).sub.3-a(OH).sub.a
(1) wherein R.sup.1 and R.sup.2 are the same or different and each
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms or an aralkyl group
containing 7 to 20 carbon atoms or a triorganosiloxy group
represented by (R').sub.3SiO--, in which R' is a monovalent
hydrocarbon group containing 1 to 20 carbon atoms and the three R'
groups may be the same or different; when there are two or more
R.sup.1 or R.sup.2 groups, they may be the same or different; a
represents 0, 1, 2 or 3, b represents 0, 1 or 2, and m is an
integer of 0 to 19, provided that the relation a+mb.gtoreq.1 should
be satisfied.
4. The method of producing according to claim 3, wherein, the
general formula (1), m=0.
5. The method of producing according to claim 1, wherein the vinyl
polymer (I) has a ratio (Mw/Mn) of weight average molecular weight
(Mw) to a number average molecular weight (Mn) of less than 1.8 as
determined by gel permeation chromatography.
6. The method of producing according to claim 1, wherein the vinyl
polymer (I) has a main chain obtained by living radical
polymerization.
7. The method of producing according to claim 6, wherein the living
radical polymerization is carried out in the manner of atom
transfer radical polymerization.
8. The method of producing according to claim 7, wherein a metal
complex to be used as a catalyst for the atom transfer radical
polymerization is a copper, nickel, ruthenium or iron complex.
9. The method of producing according to claim 8, wherein the
catalyst for atom transfer radical polymerization is a copper
complex.
10. The method of producing according to claim 1, wherein the vinyl
polymer (1) is obtainable by carrying out the hydrosilylation
reaction of a vinyl polymer having an alkenyl group at one or more
one termini thereof with a silicon compound having both a silicon
atom-bound hydrolyzable group and a hydrosilyl group and then
converting said hydrolyzable group to a silanol group by
hydrolysis.
11. The method of producing according to claim 10, wherein the
silicon compound having both a silicon atom-bound hydrolysable
group and a hydrosilyl group is chlorodimethylsilane.
12. The method of producing according to claim 1, wherein the
silicon compound having two or more silicon atom-bound hydrolyzable
groups is represented by the general formula (2):
Z-[Si(R.sup.3).sub.2-b(Y').sub.bO].sub.m--Si(R.sup.4).sub.3-a(Y').sub.a
(2) wherein R.sup.3 and R.sup.4 are the same or different and each
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms, an aralkyl group containing
7 to 20 carbon atoms or a triorganosiloxy group represented by
(R').sub.3SiO--, in which R' is a monovalent hydrocarbon group
containing 1 to 20 carbon atoms and the three R' groups may be the
same or different and, when there are two or more R.sup.3 or
R.sup.4 groups, they may be the same or different, Y' represents a
hydrolyzable group other than a hydroxyl group, Z represents an
alkyl group containing 1 to 20 carbon atoms, an aryl group
containing 6 to 20 carbon atoms, an aralkyl group containing 7 to
20 carbon atoms, a triorganosiloxy group represented by
(R').sub.3SiO--, in which R' is as defined above, or a hydrolyzable
group other than a hydroxyl group, a represents 0, 1, 2 or 3, b
represents 0, 1 or 2 and m is an integer of 0 to 19 provided that
when Z is a hydrolyzable group, the relation a+mb.gtoreq.1 should
be satisfied and, when Z is other than a hydrolyzable group, the
relation a+mb.gtoreq.2 should be satisfied.
13. The method of producing according to claim 12, wherein the
hydrolyzable groups, namely Y' and Z, in general formula (2) are
each selected from the group consisting of ketoximo, acyloxy,
alkoxy, amido, aminoxy, amino and alkenoxy groups.
14. The method of producing according to claim 12 wherein, in
general formula (2), m=0.
15. A vinyl polymer having a hydrolyzable silyl group at one or
more termini thereof and obtainable by the method of producing
according to claim 1.
16. A curable composition which comprises the vinyl polymer having
a hydrolyzable silyl group at one or more termini thereof according
to claim 15.
17. A method of producing a vinyl polymer (III) having an acrylic
functional group at one or more termini thereof which comprises
reacting a vinyl polymer (I) having a silanol group at one or more
termini thereof with a silicon compound represented by the general
formula (3): XSiR.sub.2-G-O--C(O)C(L)=CH.sub.2 (3) wherein R is a
hydrocarbon group containing 1 to 14 carbon atoms or halogenated
hydrocarbon group containing 1 to 10 carbon atoms and the two R
groups may be the same or different, X is a hydrolyzable group, G
is an alkylene group containing 1 to 4 carbon atoms and L is a
hydrogen atom or a hydrocarbon group containing 1 to 20 carbon
atoms.
18. The method of producing according to claim 17, wherein, in
general formula (3), G is a group represented by --CH.sub.2--,
--CH.sub.2CH.sub.2 or --CH.sub.2CH(CH.sub.3)CH.sub.2-- and L is a
hydrogen atom or methyl group.
19. The method of producing according to claim 17, wherein, the
vinyl polymer (I) has a main chain obtained by polymerizing at
least one monomer selected from the group consisting of (meth)
acrylic monomers, acrylonitrile monomers, aromatic vinyl monomers,
fluorine-containing vinyl monomers and silicon-containing vinyl
monomers.
20. The method of producing according to claim 17, wherein the
silanol group of the vinyl polymer (I) is represented by the
general formula (1):
--[Si(R.sup.1).sub.2-b(OH).sub.bO].sub.m--Si(R.sup.2).sub.3-a(OH).sub.a
(1) wherein R.sup.1 and R.sup.2 are the same or different and each
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms or an aralkyl group
containing 7 to 20 carbon atoms or a triorganosiloxy group
represented by (R').sub.3SiO--, in which R' is a monovalent
hydrocarbon group containing 1 to 20 carbon atoms and the three R'
groups may be the same or different; when there are two or more
R.sup.1 or R.sup.2 groups, they may be the same or different; a
represents 0, 1, 2 or 3, b represents 0, 1 or 2, and m is an
integer of 0 to 19, provided that the relation a+mb.gtoreq.1 should
be satisfied.
21. The method of producing according to claim 20, wherein, in
general formula (1), m=0
22. The method of producing according to claim 17, wherein the
vinyl polymer (I) ha a main chain obtained by living radical
polymerization.
23. The method of producing according to claim 22, wherein the
living radical polymerization is carried out in the manner of atom
transfer radical polymerization.
24. The method of producing according to claim 22, wherein a metal
complex to be used as a catalyst for the atom transfer radical
polymerization is a copper, nickel, ruthenium or iron complex.
25. The method of producing according to claim 24, wherein the
catalyst for atom transfer radical polymerization is a copper
complex.
26. The method of producing according to claim 16, wherein the
vinyl polymer (I) is obtainable by carrying out the hydrosilylation
reaction of a vinyl polymer having an alkenyl group at one or more
one termini thereof with a silicon compound having both a silicon
atom-bound hydrolyzable group and a hydrosilyl group and then
converting said hydrolyzable group to a silanol group by
hydrolysis.
27. The method of producing according to claim 25, wherein the
silicon compound having both a silicon atom-bound hydrolyzable
group and a hydrosilyl group is chlorodimethysilane.
28. A vinyl polymer having an acrylic functional group at one or
more termini thereof and obtainable by the method of producing
according to claim 16.
29. The polymer according to claim 27 which has a ratio (Mw/Mn) of
weight average molecular weight (Mw) to number average molecular
weight (Mn) of less than 1.8 as determined by gel permeation
chromatography.
30. A curable composition which comprises the vinyl polymer having
an acrylic functional group at one or more termini thereof
according to claim 27.
31. The curable composition according to claim 30 which comprises a
photopolymerization initiator so as to be cured by irradiation of
light and/or electron beams.
32. The curable composition according to claim 31. wherein the
photopolymerization initiator is a photo radical initiator.
33. The curable composition according to claim 31. wherein the
photopolymerization initiator is a photo anion initiator.
34. The curable composition according to claim 30, which comprises
a heat polymerization initiator so as to be cured by heating.
35. The curable composition according to claim 30 which comprises a
radical-polymerizable group-containing monomer and/or oligomer.
36. The curable composition according to claim 30 which comprises
an anion-polymerizable group.
37. The curable composition according to claim 35, wherein the
radical- or anion-polymerizable group is an acrylic functional
group.
Description
TECHNICAL FIELD
[0001] The present invention relates to a vinyl polymer terminated
in a silanol group, a hydrolyzable silyl group or an acrylic
functional group, to a method of producing such polymer and to a
curable composition comprising the polymer.
BACKGROUND ART
[0002] Vinyl polymers, in particular (meth)acrylic polymers, having
a crosslinking silyl group(s) within the molecule are used in
highly weathering-resistant coatings utilizing the high weathering
resistance owing to the main chain and crosslinking point(s)
thereof. These (meth) acrylic polymers are generally produced by
copolymerizing a (meth)acrylic monomer having a crosslinking silyl
group(s) with another monomer or other monomers and, therefore,
crosslinking silyl groups occur randomly in the molecular chain. It
is thus difficult to use them in lieu of rubbers. On the other
hands, attempts have been made to produce crosslinking
silyl-terminated (meth)acrylic polymers and use them in sealing or
adhesive compositions. As for the production of crosslinking
silyl-terminated (meth)acrylic polymers, Japanese Kokoku
Publication Hei-03-14068, for instance, discloses a method which
comprises polymerizing a (meth)acrylic monomer(s) in the presence
of a crosslinking silyl-containing mercaptan, a crosslinking
silyl-containing disulfide and a crosslinking silyl-containing
radical polymerization initiator, and Japanese Kokoku Publication
Hei-04-55444 discloses a method which comprises polymerizing an
acrylic monomer(s) in the presence of a crosslinking
silyl-containing hydrosilane compound or a tetrahalosilane.
Further, Japanese Kokai Publication Hei-06-211922 describes a
method of producing crosslinking silyl-terminated (meth)acrylic
polymers which comprises synthesizing a hydroxyl-terminated acrylic
polymer using a hydroxyl-containing polysulfide in excess of an
initiator and further converting the hydroxy group(s).
[0003] As a general method of introducing a crosslinking silyl
group into a polymer terminus or termini, there may be mentioned
the use of the hydrosilylation reaction involving a polymer
terminus alkenyl group(s). However, compounds having both a silanol
group and a hydrosilyl group are unstable and difficult to obtain
and, therefore, it is difficult to introduce a silanol group(s)
into a polymer terminus or termini by this method.
[0004] On the other hand, among crosslinking silyl groups, the
silanol group is highly reactive and frequently used in the field
of silicones, in particular, utilizing its high reactivity.
However, almost no silanol-terminated polymers other than silicones
are known since the production thereof is difficult as discussed
above.
[0005] Further, among crosslinking silyl groups, ketoximo groups,
acyloxy and like groups are highly reactive and are frequently used
in the field of silicones, in particular, utilizing their high
reactivity. However, almost no ketoximo- or acyloxy-terminated
polymers other than silicones are known since the production
thereof is difficult as discussed above.
[0006] Meanwhile, it is known that alkenyl-terminated polymers can
crosslink by themselves or be crosslinked by using a curing agent
such as a hydrosilyl-containing compound to give curing products
excellent in heat resistance and durability. As the main chain
skeletons of such polymers, there may be mentioned polyether
polymers such as polyethylene oxide, polypropylene oxide and
polytetramethylene oxide; hydrocarbon polymers such as
polybutadiene, polyisoprene, polychloroprene, polyisobutylene, and
hydrogenation products derived therefrom; polyester polymers such
as polyethylene terephthalate, polybutylene terephthalate and
polycaprolactone; and polysiloxane polymers such as
polydimethylsiloxane, among others, and these are used in various
fields according to the characteristics of the respective main
chain skeletons.
[0007] (Meth)acrylic polymers have those characteristics which
other polymers such as mentioned above cannot have, for example
high weathering resistance and heat resistance, oil resistance and
transparency, and the use of some having an alkenyl group(s) on a
side chain(s) in highly weathering resistant coatings has been
proposed (e.g. Japanese Kokai Publication Hei-03-277645, Japanese
Kokai Publication Hei-07-70399). However, alkenyl-terminated
(meth)acrylic polymers are difficult to produce, hence have hardly
been put into practical use.
[0008] Japanese Kokai Publication Hei-01-247403 discloses a method
of producing acrylic polymers having an alkenyl group at both
termini which uses an alkenyl-containing dithiocarbamate or diallyl
disulfide as a chain transfer agent.
[0009] Further, Japanese Kokai Publication Hei-06-211922 discloses
a method of producing alkenyl-terminated acrylic polymers which
comprises producing a hydroxyl-terminated acrylic polymer using a
hydroxyl-containing polysulfide or an alcohol compound as a chain
transfer agent and further utilizing the reactivity of the hydroxyl
group.
[0010] On the other hand, curable rubber-like elastomer
compositions are widely used as adhesives, sealants and shock
absorbers. According to the curing means, these are roughly
classifiable into the so-called moisture-curable compositions which
are stable under tightly closed conditions but cured by the action
of moisture at room temperature to give rubber-like elastomers and
compositions undergoing the crosslinking reaction upon heating, for
example through the hydrosililation reaction.
[0011] However, it is difficult by the methods mentioned above to
introduce an alkenyl group terminally into a polymer with
certainty. Further, these methods generally use radical
polymerization and, therefore, the polymers obtained have a broad
molecular weight distribution (ratio of weight average molecular
weight to number average molecular weight), which is generally not
less than 2, and, accordingly, show a high viscosity, which is a
problem. When the viscosity is high, problems arise, for example
handling in application as a sealing agent or adhesive, for
instance, becomes difficult or it is impossible to incorporate a
large amount of a reinforcing filler.
[0012] Furthermore, it is not easy to introduce a
radical-polymerizable acrylic functional group into (meth)acrylic
polymers polymerized by radical polymerization. In particular,
almost no oligomer compounds with an acrylic functional group
introduced terminally thereinto have been synthesized.
[0013] On the other hand, in photocurable compositions,
low-molecular compounds having an acrylic functional group(s) are
used in many instances. In this case, the odor resulting from
evaporation of low-boiling unreacted compounds during and after
curing is a great problem. For avoiding this problem, oligomers
having an acrylic functional group(s) are used. However, mainly
from the synthesis viewpoint, such oligomers are restricted to the
epoxy-acrylate, urethane-acrylate, polyester-acrylate and like
types, and few oligomers having a high molecular weight are
available. As a result, the curing products derived from them tend
to become relatively hard ones. Any products having good rubber
elasticity cannot be obtained.
SUMMARY OF THE INVENTION
[0014] In view of the state of the art mentioned above, it is an
object of the present invention to provide a vinyl polymer having a
silanol group, hydrolyzable silyl group or acrylic functional group
at a molecular terminus or termini with a well controlled
structure, a method of producing the same and, further, a curable
composition comprising the same.
[0015] In a first aspect, the invention provides a vinyl polymer
(I) having a silanol group at one or more termini thereof
[0016] and a curable composition comprising the same.
[0017] In a second aspect, the invention provides a method of
producing a vinyl polymer (II) having a hydrolyzable silyl group at
one or more termini thereof
[0018] which comprises reacting a vinyl polymer (I) having a
silanol group at one or more termini thereof
[0019] with a silicon compound having two or more silicon
atom-bound hydrolyzable groups,
[0020] said vinyl polymer (II) having a hydrolyzable silyl group at
one or more termini thereof and obtainable by the above production
method,
[0021] and a curable composition comprising the same.
[0022] In a third aspect, the invention provides a method of
producing a vinyl polymer (III) having an acrylic functional group
at one or more termini thereof
[0023] which comprises reacting a vinyl polymer (I) having a
silanol group at one or more termini thereof
[0024] with a silicon compound represented by the general formula
(3): XSiR.sub.2-G-O--C(O)C(L)=CH.sub.2 (3) wherein R is a
hydrocarbon group containing 1 to 14 carbon atoms or a halogenated
hydrocarbon group containing 1 to 10 carbon atoms and the two R
groups may be the same or different, X is a hydrolyzable group, G
is an alkylene group containing 1 to 4 carbon atoms and L is a
hydrogen atom or a hydrocarbon group containing 1 to 20 carbon
atoms,
[0025] said vinyl polymer (III) having an acrylic functional group
at one or more termini thereof and obtainable by the above
production method,
[0026] and a curable composition comprising the same.
[0027] In the following, the invention is described in detail.
DETAILED DISCLOSURE OF THE INVENTION
[0028] The invention, in its first aspect, lies in a vinyl polymer
(I) having a silanol group at one or more termini thereof.
[0029] The silanol group is not particularly restricted but
includes, as examples thereof, groups represented by the general
formula (1):
--[Si(R.sup.1).sub.2-b(OH).sub.bO].sub.m--Si(R.sup.2).sub.3-a(OH).sub.a
(1) wherein R.sup.1 and R.sup.2 are the same or different and each
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms or an aralkyl group
containing 7 to 20 carbon atoms or a triorganosiloxy group
represented by (R').sub.3SiO--, in which R' is a monovalent
hydrocarbon group containing 1 to 20 carbon atoms and the three R'
groups may be the same or different, when there are two or more
R.sup.1 or R.sup.2 groups, they may be the same or different, a
represents 0, 1, 2 or 3, b represents 0, 1 or 2, and m is an
integer of 0 to 19, provided that the relation a+mb.gtoreq.1 should
be satisfied. Among them, those silanol groups of the general
formula (1) in which m=0 are preferred, though without any
restrictive meaning.
[0030] As specific examples of R.sup.1 and R.sup.2, there may be
mentioned the following, without any restrictive meaning:
--(CH.sub.2).sub.n--CH.sub.3,
--CH(CH.sub.3)--(CH.sub.2).sub.n--CH.sub.3,
--CH(CH.sub.2CH.sub.3)--(CH.sub.2).sub.n--CH.sub.3,
--CH(CH.sub.2CH.sub.3).sub.2,
--C(CH.sub.3).sub.2--(CH.sub.2).sub.n--CH.sub.3,
--C(CH.sub.3)(CH.sub.2CH.sub.3)--(CH.sub.2).sub.n--CH.sub.3,
--C.sub.6H.sub.5, --C.sub.6H.sub.5 (CH.sub.3), --C.sub.6H.sub.5
(CH.sub.3).sub.2, --(CH.sub.2).sub.n--C.sub.6H.sub.5,
--(CH.sub.2).sub.n--C.sub.6H.sub.5(CH.sub.3),
--(CH.sub.2).sub.n--C.sub.6H.sub.5(CH.sub.3).sub.2
(n being an integer of not less than 0 and the total number of
carbon atoms in each group being not more than 20).
[0031] More specifically, the group --Si (CH.sub.3).sub.2OH is
preferred as the silanol group to be used in the practice of the
invention.
[0032] The monomer constituting the main chain of the vinyl polymer
(I) according to the first aspect of the invention is not
particularly restricted but may be any of various monomers. As
examples, there may be mentioned (meth) acrylic monomers such as
(meth)acrylic acid, methyl (meth)acrylate, ethyl (meth)acrylate,
n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl
(meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate,
n-pentyl (meth)acrylate, n-hexyl (meth)acrylate, cyclohexyl
(meth)acrylate, n-heptyl (meth)acrylate, n-octyl (meth)acrylate,
2-ethylhexyl (meth)acrylate, nonyl (meth)acrylate, decyl
(meth)acrylate, dodecyl (meth)acrylate, phenyl (meth)acrylate,
toluoyl (meth)acrylate, benzyl (meth)acrylate, 2-methoxyethyl
(meth)acrylate, 3-methoxybutyl (meth)acrylate, 2-hydroxyethyl
(meth)acrylate, 2-hydroxypropyl (meth)acrylate, stearyl
(meth)acrylate, glycidyl (meth)acrylate, 2-aminoethyl
(meth)acrylate, .gamma.-(methacryloyloxypropyl)trimethoxysilane,
(meth)acrylic acid-ethylene oxide adducts, trifluoromethylmethyl
(meth)acrylate, 2-trifluoromethylethyl (meth)acrylate,
2-perfluoroethylethyl (meth)acrylate,
2-perfluoroethyl-2-perfluorobutylethyl (meth)acrylate,
2-perfluoroethyl (meth)acrylate, perfluoromethyl (meth)acrylate,
diperfluoromethylmethyl (meth)acrylate,
2-perfluoromethyl-2-perfluoroethylmethyl (meth)acrylate,
2-perfluorohexylethyl (meth)acrylate, 2-perfluorodecylethyl
(meth)acrylate and 2-perfluorohexadecylethyl (meth)acrylate;
styrenic monomers (also referred to as aromatic vinyl monomers in
the present specification) such as styrene, vinyltoluene,
.alpha.-methylstyrene, chlorostyrene, styrenesulfonic acid and
salts thereof; fluorine-containing vinyl monomers such as
perfluoroethylene, perfluoropropylene and vinylidene fluoride;
silicon-containing vinyl monomers such as vinyltrimethoxysilane and
vinyltriethoxysilane; maleic anhydride, maleic acid and monoalkyl
esters and dialkyl esters of maleic acid; fumaric acid and
monoalkyl esters and dialkyl esters of fumaric acid; maleimide
monomers such as maleimide, methylmaleimide, ethylmaleimide,
propylmaleimide, butylmaleimide, hexylmaleimide, octylmaleimide,
dodecylmaleimide, stearylmaleimide, phenylmaleimide and
cyclohexylmaleimide; nitrile-containing vinyl monomers such as
acrylonitrile and methacrylonitrile; amido-containing vinyl
monomers such as acrylamide and methacrylamide; vinyl esters such
as vinyl acetate, vinyl propionate, vinyl pivalate, vinyl benzoate
and vinyl cinnamate; alkenes such as ethylene and propylene;
conjugated dienes such as butadiene and isoprene; vinyl chloride,
vinylidene chloride, allyl chloride, allyl alcohol and so forth.
These may be used singly or a plurality of them may be
copolymerized. In the case of copolymerization, both random
copolymerization and block copolymerization may be employed.
Preferred among these monomers, from the viewpoint of physical
properties of products, among others, are (meth)acrylic monomers,
acrylonitrile monomers, aromatic vinyl monomers,
fluorine-containing vinyl monomers and silicon-containing vinyl
monomers. More preferred are acrylic ester monomers and methacrylic
ester monomers. Butyl acrylate is still more preferred. In the
practice of the present invention, these preferred monomers may be
copolymerized with other monomers and, in such cases, the content
of these preferred monomers is preferably not less than 40% by
weight. The expression "(meth) acrylic acid", for instance, so
referred to hereinabove means "acrylic acid and/or methacrylic
acid".
[0033] The molecular weight distribution, namely the ratio (Mw/Mn)
of weight average molecular weight (Mw) to number average molecular
weight (Mn), of the vinyl polymer (I) according to the first aspect
of the invention is not particularly restricted. For facilitating
the handling by keeping the viscosity of the curable composition,
when this is prepared, at a low level while securing sufficient
curing product physical properties, however, a narrow molecular
weight distribution is preferred. Preferred as the molecular weight
distribution value is a value not more than 1.8, more preferably
not more than 1.7, still more preferably not more than 1.6, still
more preferably not more than 1.5, still more preferably not more
than 1.4, still more preferably not more than 1.3. The molecular
weight distribution is determined most commonly by gel permeation
chromatography (GPC). The number average molecular weight and so on
can be determined on the polystyrene equivalent basis using
chloroform or THF as the mobile phase and polystyrene gel columns
as columns.
[0034] The number average molecular weight of the vinyl polymer (I)
according to the first aspect of the invention is not particularly
restricted but is preferably within the range of 500 to 100,000. At
a molecular weight smaller than 500, the characteristics intrinsic
in the vinyl polymer are hardly manifested and, at above 100,000,
the handling may become difficult in some instances.
<Production of Silanol-Terminated Vinyl Polymer (I)>
[0035] In the following, a method of producing the vinyl polymer
having a silanol group at one or more termini thereof, according to
the first aspect of the invention, is described. The method shown
herein has no limitative meaning, however. As for an appropriate
method of producing silanol-containing polymers, reference may be
made to an article by P. D. Lickiss in Advances in Inorganic
Chemistry, vol. 42, page 142 (1995).
[0036] Basically, the vinyl polymer (I) according to the first
aspect of the invention is produced by polymerizing a vinyl
monomer(s), introducing an alkenyl group thereinto by some or other
method, subjecting the thus-obtained vinyl polymer having the
alkenyl group at one or more termini thereof to hydrosilylation
reaction with a silicon compound having both a silicon atom-bound
hydrolyzable group and a hydrosilyl group, and then converting this
hydrolyzable group to a silanol group by hydrolysis.
[0037] In the following, this process is described in detail.
<Polymerization>
[0038] First, a vinyl polymer having a specific functional group(s)
such as an alkenyl group(s) is synthesized by polymerizing a vinyl
monomer(s). The method of polymerization is not particularly
restricted but radical polymerization is preferred in view of the
wide range of usable monomers and the simple and easy
polymerization procedure. The techniques of radical polymerization
can be classified into techniques of "ordinary radical
polymerization" comprising simply copolymerizing a monomer having a
specific functional group with a vinyl monomer(s) using an azo
compound or peroxide as a polymerization initiator, and techniques
of "controlled radical polymerization" by which a specific
functional group can be introduced into a controlled site(s) such
as a terminus or termini.
[0039] "Ordinary radical polymerization" is easy and simple to
perform but, by this method, the monomer having a specific
functional group(s) is introduced into the polymer according to the
probability. Thus, there arise problems; for obtaining highly
functionalized polymers, it is necessary to use this monomer in
fairly large amounts and, conversely when it is used in a small
amount, the proportion of polymers formed without introduction of
that specific functional group increases. Further, since it
involves free radical polymerization, the rate of polymerization is
high and such a termination reaction as radical-to-radical coupling
is apt to occur, so that it is difficult to control the
polymerization. As a result, there also arises the problem that
only polymers having a broad molecular weight distribution and a
high viscosity are obtained.
[0040] The techniques of "controlled radical polymerization" can
further be classified into "chain transfer agent methods" by which
functional group-terminated vinyl polymers can be obtained by
carrying out the polymerization using a chain transfer agent having
a specific functional group(s), and "living radical polymerization
techniques" by which polymers having a molecular weight
substantially as designed can be obtained owing to the fact that a
growing polymerization terminus grows without causing any
termination reaction.
[0041] The "chain transfer agent methods" can give polymers having
a high rate of functionalization but they require the chain
transfer agent having a specific functional group(s) in fairly
large amounts relative to the initiator. Economical problems thus
arise, involving treatment-related ones. Since they involve free
radical polymerization, like in "ordinary radical polymerization",
other problems arise; the molecular weight distribution becomes
broad and only polymers having a high viscosity are obtained.
[0042] Unlike these polymerization methods, "living radical
polymerization" hardly undergoes termination reactions, gives
polymers with a narrow molecular weight distribution (about 1.1 to
1.5 in terms of Mw/Mn) and, in addition, makes it possible to
freely control the molecular weight by selecting the
monomer/initiator charge ratio. Therefore, "living radical
polymerization" can give polymers with a narrow molecular weight
distribution and a low viscosity and allows introduction of the
monomer having a specific functional group(s) into a substantially
arbitrary site(s), hence, it is preferred as a method of producing
the above vinyl polymer having a specific functional group(s).
[0043] While, in its narrow sense, the term "living polymerization"
means the polymerization in which molecular chains grow while the
terminal activity is always maintained, it generally includes
pseudo-living polymerization in which terminally inactivated
species and terminally active species are in equilibrium. It is the
latter definition that applies in the present invention.
[0044] In recent years, "living radical polymerization" has been
actively studied by a number of groups. As examples, there may be
mentioned, among others, the technique which uses a
cobalt-porphyrin complex as described in J. Am. Chem. Soc, 1994,
vol. 116, page 7943, the technique which uses such a radical
capping agent as a nitroxide compound shown in Macromolecules,
1994, vol. 27, page 7228, and the atom transfer radical
polymerization (ATRP) technique using an organic halide or the like
as an initiator and a transition metal complex as a catalyst.
[0045] Among the "living radical polymerization" techniques, the
"atom transfer radical polymerization" technique, which comprises
polymerizing a vinyl monomer(s) using an organic halide or sulfonyl
halide compound as an initiator and a transition metal complex as a
catalyst, not only has the characteristics of the above-mentioned
"living radical polymerization" but also uses a terminal halogen or
the like, which is relatively advantageous in functional group
conversion reactions, and affords a higher degree of freeness in
initiator and catalyst designing, hence it is more preferred as the
method of producing vinyl polymers having a specific functional
group(s). As specific references to this atom transfer radical
polymerization, there may be mentioned Matyjaszewski et al., J. Am.
Chem. Soc., 1995, vol. 117, page 5614; Macromolecules, 1995, vol.
28, page 7901; Science, 1996, vol. 272, page 866; WO 96/30421; WO
97/18247; and Sawamoto et al., Macromolecules, 1995, vol. 28, page
1721, among others.
[0046] First, the technique which uses a radical capping agent such
as a nitroxide compound is described. In this polymerization, a
nitroxy free radical (.dbd.N--O.), which is generally stable, is
used as the radical capping agent. While such a compound is not
restricted, nitroxy free radicals from cyclic hydroxy amines, such
as the 2,2,6,6-substituted-1-piperidinyloxy radical and
2,2,5,5-substituted-1-pyrrolidinyloxy radical, are preferred.
Appropriate as the substituents are alkyl groups containing not
more than 4 carbon atoms, such as methyl and ethyl groups. Specific
nitroxy free radical compounds include, but are not limited to, the
2,2,6,6-tetramethyl-1-piperidinyloxy radical (TEMPO),
2,2,6,6-tetraethyl-1-piperidinyloxy radical,
2,2,6,6-tetramethyl-4-oxo-1-piperidinyloxy radical,
2,2,5,5-tetramethyl-1-pyrrolidinyloxy radical,
1,1,3,3-tetramethyl-2-isoindolinyloxy radical and
N,N-di-tert-butylamine-oxy radical, among others. Such a stable
free radical as the galvinoxyl free radical may be used in lieu of
the nitroxy free radical.
[0047] The above radical capping agent is used in combination with
a radical generator. It is presumable that the reaction product
from a radical capping agent and a radical generator serve as a
polymerization initiator and the polymerization of an
addition-polymerizable monomer(s) thereby proceed. The mixing ratio
of both is not particularly restricted but the radical initiator is
appropriately used in an amount of 0.1 to 10 moles per mole of the
radical capping agent.
[0048] Although various compounds can be used as the radical
generator, a peroxide capable of generating a radical under
polymerization temperature conditions is preferred. Such peroxide
include, but is not limited to, diacyl peroxides such as benzoyl
peroxide and lauroyl peroxide, dialkyl peroxides such as dicumyl
peroxide and di-tert-butyl peroxide, peroxydicarbonates such as
diisopropyl peroxydicarbonate and
bis(4-tert-butylcyclohexyl)peroxydicarbonate, alkyl peresters such
as tert-butyl peroxyoctoate and tert-butyl peroxybenzoate, and the
like. In particular, benzoyl peroxide is preferred. Further,
another radical generator, for example a radical-generating azo
compound such as azobisisobutyronitrile, may be used in lieu of the
peroxide.
[0049] As reported in Macromolecules, 1995, vol. 28, page 2993,
such alkoxyamine compounds as shown below may be used as the
initiator instead of the combined use of a radical capping agent
and a radical generator. ##STR1##
[0050] When an alkoxyamine compound is used as the initiator and
the compound has a hydroxyl or like functional group, as shown
above, a polymer terminated in the functional group polymer is
obtained.
[0051] The monomer(s) and the polymerization conditions such as
solvent and polymerization temperature which are to be used in the
polymerization using a radical capping agent such as a nitroxide
compound as mentioned above are not restricted but may be the same
as those used in atom transfer radical polymerization to be
mentioned below.
[0052] The technique of atom transfer radical polymerization is
more preferred as the technique of living radical polymerization to
be used in the invention, is now described.
[0053] In this atom transfer radical polymerization, an organic
halide, in particular an organic halide having a highly reactive
carbon-halogen bond (e.g. a carbonyl compound having a halogen at
the .alpha. position, or a compound having a halogen at the benzyl
position), or a sulfonyl halide compound or the like is preferably
used as the initiator.
[0054] For obtaining a vinyl polymer having an alkenyl group at
both termini by this polymerization method, an organic halide or
halogenated sulfonyl compound having two or more initiation sites
is used as the initiator. Specific examples thereof are:
o-, m- or p-XCH.sub.2--C.sub.6H, --CH.sub.2X, o-, m- or
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--C(H)(X)CH.sub.3, o-, m- or
p-(CH.sub.3).sub.2C(X)--C.sub.6H.sub.4--C(X)(CH.sub.3).sub.2
(in the above formulas, C.sub.6H.sub.4 denotes a phenylene group
and X represents a chlorine, bromine or iodine atom),
RO.sub.2C--C(H)(X)--(CH.sub.2).sub.n--C(H)(X)--CO.sub.2R,
RO.sub.2C--C(CH.sub.3)(X)--(CH.sub.2).sub.n--C(CH.sub.3)(X)--CO.sub.2R,
RC(O)--C(H)(X)--(CH.sub.2).sub.n--C(H)(X)--C(O)R,
RC(O)--C(CH.sub.3)(X)--(CH.sub.2).sub.n--C(CH.sub.3)(X)--C(O)R
(in the above formulas, R represents a C.sub.1-C.sub.20 alkyl
group, aryl group or aralkyl group, n represents an integer of 0 to
20 and X represents a chlorine, bromine or iodine atom),
XCH.sub.2--C(O)--CH.sub.2X,
H.sub.3C--C(H)(X)--C(O)--C(H)(X)--CH.sub.3,
(H.sub.3C).sub.2C(X)--C(O)--C(X)(CH.sub.3).sub.2,
C.sub.6H.sub.5C(H)(X)--(CH.sub.2).sub.2--C(H)(X)C.sub.6H.sub.5
(in the above formulas, X represents a chlorine, bromine or iodine
atom and n represents an integer of 0 to 20),
XCH.sub.2CO.sub.2--(CH.sub.2).sub.n--OCOCH.sub.2X,
CH.sub.3C(H)(X)CO.sub.2--(CH.sub.2).sub.n--OCOC(H)(X)CH.sub.3,
(CH.sub.3).sub.2C(X)CO.sub.2--(CH.sub.2).sub.n--OCOC(X)(CH.sub.3).sub.2
(in the above formulas, n represents an integer of 1 to 20),
XCH.sub.2C(O)C(O)CH.sub.2X, CH.sub.3C(H)(X)C(O)C(O)C(H)(X)CH.sub.3,
(CH.sub.3).sub.2C(X)C(O)C(O)C(X)(CH.sub.3).sub.2, o-, m- or
p-XCH.sub.2CO.sub.2--C.sub.6H.sub.4--OCOCH.sub.2X, o-, m- or
p-CH.sub.3C(H)(X)CO.sub.2--C.sub.6H.sub.4--OCOC(H)(X)CH.sub.3, o-,
m- or
p-(CH.sub.3).sub.2C(X)CO.sub.2--C.sub.6H.sub.4--OCOC(X)(CH.sub.3).sub.2,
o-, m- or p-XSO.sub.2--C.sub.6H.sub.4--SO.sub.2X
(in the above formulas, X represents a chlorine, bromine or iodine
atom).
[0055] The transition metal complex to be used as the
polymerization catalyst is not particularly restricted but
includes, as preferred species, transition metal complexes the
central metal of which belongs to the group 7, 8, 9, 10 or 11 of
the periodic table of the elements. As more preferred species,
there may be mentioned complexes of zero-valence copper, monovalent
copper, divalent ruthenium, divalent iron or divalent nickel.
Copper complexes are preferred among others. As specific examples
of the monovalent copper compound, there may be mentioned cuprous
chloride, cuprous bromide, cuprous iodide, cuprous cyanide, cuprous
oxide and cuprous perchlorate. When a copper compound is used, a
ligand, for example 2, 2'-bipyridyl or a derivative thereof,
1,10-phenanthroline or a derivative thereof, or a polyamine such as
tetramethylethylenediamine, pentamethyldiethylenetriamine or
hexamethyltris(2-aminoethyl)amine, is added for increasing the
catalytic activity. The tristriphenylphosphine complex of divalent
ruthenium chloride (RuCl.sub.2(PPh.sub.3).sub.3) is also suited for
use as a catalyst. When a ruthenium compound is used as a catalyst,
an aluminum alkoxide is added as an activator. Further, the
bistriphenylphosphine complex of divalent iron
(FeCl.sub.2(PPh.sub.3).sub.2) the bistriphenylphosphine complex of
divalent nickel (NiCl.sub.2(PPh.sub.3).sub.2) and the
bistributylphosphine complex of divalent nickel
(NiBr.sub.2(PBu.sub.3).sub.2) are also suited as catalysts.
[0056] The vinyl monomer(s) to be used in this polymerization is
(are) not particularly restricted but any of those already
mentioned specifically hereinabove can appropriately be used.
[0057] The above polymerization reaction can be carried out without
using any solvent or in any of various solvents. As the solvents,
there may be mentioned hydrocarbon solvents such as benzene and
toluene; ether solvents such as diethyl ether, tetrahydrofuran,
diphenyl ether, anisole and dimethoxybenzene; halogenated
hydrocarbon solvents such as methylene chloride, chloroform and
chlorobenzene; ketone solvents such as acetone, methyl ethyl ketone
and methyl isobutyl ketone; alcohol solvents such as methanol,
ethanol, propanol, isopropanol, n-butyl alcohol and tert-butyl
alcohol; nitrile solvents such as acetonitrile, propionitrile and
benzonitrile; ester solvents such as ethyl acetate and butyl
acetate; carbonate solvents such as ethylene carbonate and
propylene carbonate; and so on. These may be used singly or two or
more of them may be used in admixture. It is also possible to carry
out the polymerization in an emulsion system or a system in which
the supercritical fluid CO.sub.2 is used as a medium.
[0058] This polymerization can be carried out in the range of 0 to
200.degree. C., preferably within the range of room temperature to
150.degree. C., although such range has no restrictive meaning.
<Alkenyl Group Introduction>
[0059] The method of producing the vinyl polymer having an alkenyl
group at one or more termini thereof specifically includes, but is
not limited to, the methods (A) to (C) mentioned below.
(A) The method comprising directly introducing an alkenyl group
into the polymer main chain on the occasion of synthesizing a vinyl
polymer by radical polymerization.
[0060] (B) The method comprising using a vinyl polymer having at
least one halogen atom and substituting an alkenyl-containing
functional group for this halogen atom. This halogen group is not
restricted but is preferably one represented by the general formula
(4): --C(R.sup.5)(R.sup.6)(X) (4) wherein R.sup.5 and R.sup.6 each
represents a group bound to an ethylenically unsaturated group of
the vinyl monomer and X represents a chlorine, bromine or iodine
atom. (C) The method comprising using a vinyl polymer having at
least one hydroxyl group and substituting an alkenyl-containing
functional group for this hydroxyl group.
[0061] Referring to the above method of synthesis (A), the method
of directly introducing an alkenyl group into the polymer main
chain is not particularly restricted but specifically includes,
among others, the methods (A-a) and (A-b) mentioned below.
[0062] (A-a) The method comprising subjecting a compound having
both a polymerizable alkenyl group and a low-polymerizable alkenyl
group in each molecule as represented by the general formula (5)
shown below to reaction together with a predetermined vinyl
monomer(s) on the occasion of synthesizing a vinyl polymer by
living radical polymerization:
H.sub.2C.dbd.C(R.sup.7)--R.sup.8--R.sup.9--C(R.sup.7).dbd.CH.sub.2
(5) wherein R.sup.7s represent a hydrogen atom or a methyl group
and they may be the same or different, R.sup.8 represents a
--C(O)O-- (ester group) or an o-, m- or p-phenylene group, R.sup.9
represents a direct bond or a divalent organic group containing 1
to 20 carbon atoms, which may optionally contain one or more ether
bonds. When R.sup.8 is an ester group, the compound is a
(meth)acrylate compound and, when R.sup.8 is a phenylene group, the
compound is a styrenic compound. As examples of R.sup.9 in the
above general formula (5) there may be mentioned alkylene groups
such as methylene, ethylene and propylene; o-, m- and p-phenylene;
aralkyl groups such as benzyl; and ether bond-containing alkylene
groups such as --CH.sub.2CH.sub.2--O--CH.sub.2-- and
--O--CH.sub.2--.
[0063] Among the compounds of the general formula (5), the
following are preferred because of ready availability:
H.sub.2C.dbd.C(H)C(O)O(CH.sub.2).sub.n--CH.dbd.CH.sub.2,
H.sub.2C.dbd.C(CH.sub.3)C(O)O(CH.sub.2).sub.n--CH.dbd.CH.sub.2
(in the above formulas, n represents an integer of 0 to 20),
H.sub.2C.dbd.C(H)C(O)O(CH.sub.2).sub.n--O--(CH.sub.2).sub.mCH.dbd.CH.sub-
.2,
H.sub.2C.dbd.C(CH.sub.3)C(O)O(CH.sub.2).sub.n--O--(CH.sub.2).sub.mCH.d-
bd.CH.sub.2
(in the above formulas, n represents an integer of 1 to 20 and m
represents an integer of 0 to 20),
[0064] o-, m-, p-divinylbenzene, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH.dbd.CH.sub.2, o, m,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2--C(CH.sub.3).dbd.CH.sub.2,
o, m,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH.sub.2CH.dbd.CH.sub.2,
o, m, p-H.sub.2C.dbd.CH--C.sub.6H, --OCH.sub.2CH.dbd.CH.sub.2, o,
m,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--OCH.sub.2--C(CH.sub.3).dbd.CH.sub.2,
o, m,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--OCH.sub.2CH.sub.2CH.dbd.CH.sub.2-
, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--(CH.sub.3).dbd.CH.sub.-
2, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--CH.sub.2CH.dbd.CH.sub-
.2, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--CH.sub.2C(CH.sub.3).-
dbd.CH.sub.2, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--CH.sub.2CH.sub.2CH.dbd.CH.sub-
.2, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--OCH.sub.2CH.dbd.CH.s-
ub.2, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--OCH.sub.2--C(CH.sub.3).dbd.CH-
.sub.2, o, m,
p-H.sub.2C.dbd.C(CH.sub.3)--C.sub.6H.sub.4--OCH.sub.2CH.sub.2CH.dbd.CH.su-
b.2
(in the above formulas, C.sub.6H.sub.4 represents a phenylene
group).
[0065] The time when the compound having both a polymerizable
alkenyl compound and a low-polymerizable alkenyl group is not
particularly restricted. Preferably, however, it is subjected to
reaction as a second monomer at the final stage of the
polymerization or after completion of the reaction involving a
predetermined monomer(s) in the living radical polymerization.
[0066] (A-b) The method comprising subjecting a compound having at
least two low-polymerizable alkenyl groups to reaction as a second
monomer at the final stage of the polymerization or after
completion of the reaction involving a predetermined monomer(s) in
synthesizing a vinyl polymer by living radical polymerization.
[0067] Such compound is not particularly restricted but includes,
among others, compounds represented by the general formula (6)
H.sub.2C.dbd.C(R.sup.7)--R.sup.10--C(R.sup.7).dbd.CH.sub.2 (6)
wherein R.sup.7s represents a hydrogen atom or a methyl group and
they may be the same or different, R.sup.10 represents a divalent
organic group containing 1 to 20 carbon atoms, which may optionally
contain one or more ether bonds.
[0068] The compound represented by the above general formula (6) is
not particularly restricted. Preferred are, however, 1,5-hexadiene,
1,7-octadiene and 1,9-decadiene in view of their ready
availability.
[0069] Among the variations of the above synthetic method (A) for
synthesizing a vinyl polymer having an alkenyl group at one or more
termini thereof by directly introducing the alkenyl group into the
polymer main chain, the method (A-b) is preferred since the alkenyl
groups introduced per molecule can be controlled more easily.
[0070] The above method (B) for synthesizing a vinyl polymer
having, at one or more termini thereof, a halogen atom, preferably
halogen atom represented by the general formula (4) is preferably
carried out in the manner of atom transfer living polymerization.
The method of substituting an alkenyl-containing functional group
for the halogen atom of that polymer is not particularly restricted
but specifically includes, among others, the methods (B-a) to (B-d)
mentioned below.
[0071] (B-a) The method comprising reacting a vinyl polymer having,
at one or more termini thereof, a halogen atom, preferably a
halogen atom represented by the general formula (4), with one of
various alkenyl-containing organometallic compounds to thereby
substitute for the halogen.
[0072] As such organometallic compounds, there may be mentioned
organolithium, organosodium, organopotassium, organomagnesium,
organotin, organosilicon, organozinc, organocopper and like
compounds. In particular, roganotin and organocopper compounds are
preferred since they react selectively with the halogen represented
by the general formula (4) and are low in reactivity with a
carbonyl group.
[0073] The alkenyl-containing organotin compound is not
particularly restricted but compounds represented by the general
formula (7):
H.sub.2C.dbd.C(R.sup.7)C(R.sup.11)(R.sup.12)Sn(R.sup.13).sub.3 (7)
wherein R.sup.7 is as defined above, R.sup.11 and R.sup.12 each
represents a hydrogen, an alkyl group containing 1 to 10 carbon
atoms, an aryl group containing 6 to 10 carbon atoms or an aralkyl
group containing 7 to 10 carbon atoms and they may be the same or
different, R.sup.13 represents a C.sub.1-C.sub.10 alkyl group, aryl
group or aralkyl group. As specific examples of the organotin
compound of the general formula (7), there may be mentioned
allyltributyltin, allyltrimethyltin, allyltri(n-octyl)tin and
allyltri(cyclohexyl)tin.
[0074] As the alkenyl-containing copper compound, there may be
mentioned divinylcopper-lithium, diallylcopper-lithium and
diisopropenylcopper-lithium.
[0075] (B-b) The method comprising reacting a vinyl polymer having,
at one or more termini thereof, a halogen atom, preferably a
halogen represented by the general formula (4), with a stabilized
alkenyl-containing carbanion represented by the general formula
(8), for instance, to thereby substitute for the halogen:
M.sup.+C.sup.-(R.sup.15)(R.sup.16)--R.sup.14--C(R.sup.7).dbd.CH.sub.2
(8) wherein R.sup.7 is as defined above, M.sup.+ represents an
alkali metal ion or a quaternary ammonium ion, R.sup.14 represents
a divalent organic group containing 1 to 20 carbon atoms, which may
optionally contain one or more ether bonds, and R.sup.15 and
R.sup.16 each represents an electron-attracting group stabilizing
the carbanion C-- or one of them represents such an
electron-attracting group and the other represents a hydrogen atom,
an alkyl group containing 1 to 10 carbon atoms or a phenyl group.
As the electron-attracting group R.sup.15 and/or R.sup.16, there
may be mentioned --CO.sub.2R (ester group), --C(O)R (keto group),
--CON(R.sub.2) (amide group), --COSR (thioester group), --CN
(nitrile group) and --NO.sub.2 (nitro group), among others. The
substituent R is an alkyl group containing 1 to 20 carbon atoms, an
aryl group containing 6 to 20 carbon atoms or an aralkyl group
containing 7 to 20 carbon atoms and preferably is an alkyl group
containing 1 to 10 carbon atoms or a phenyl group. Particularly
preferred as R.sup.15 and R.sup.16 are --CO.sub.2R, --C(O)R and
--CN.
[0076] As specific examples of the alkali metal ion, there may be
mentioned the lithium ion, sodium ion and potassium ion and, as the
quaternary ammonium ion, there may be mentioned the
tetramethylammonium ion, tetraethylammonium ion,
trimethylbenzylammonium ion, trimethyldodecylammonium ion and
tetrabutylammonium ion.
[0077] The carbanion of the general formula (8) can be obtained by
reacting a precursor thereof with a basic compound to thereby
withdraw the active proton.
[0078] As examples of the precursor of the carbanion of the general
formula (8), there may be mentioned the following compounds:
[0079] H.sub.2C.dbd.CH--CH(CO.sub.2CH.sub.3).sub.2,
H.sub.2C.dbd.CH--CH(CO.sub.2C.sub.2H.sub.5).sub.2,
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(CO.sub.2CH.sub.3).sub.2,
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(CO.sub.2C.sub.2H.sub.5).sub.2,
o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(CO.sub.2CH.sub.3).sub.2, o-,
m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(CO.sub.2C.sub.2H.sub.5).sub.2,
o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(CO.sub.2CH.sub.3).s-
ub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(CO.sub.2C.sub.2H.sub.5).sub-
.2, H.sub.2C.dbd.CH--CH(C(O)CH.sub.3)(CO.sub.2C.sub.2H.sub.5),
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(C(O)CH.sub.3)(CO.sub.2C.sub.2H.sub.5)-
, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(C(O)CH.sub.3)(CO.sub.2C.su-
b.2H.sub.5), o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(C(O)CH.sub.3)(CO.sub.2C.sub-
.2H.sub.5), H.sub.2C.dbd.CH--CH(C(O)CH.sub.3).sub.2,
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(C(O)CH.sub.3).sub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(C(O)CH.sub.3).sub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(C(O)CH.sub.3).sub.2,
H.sub.2C.dbd.CH--CH(CN)(CO.sub.2C.sub.2H.sub.5),
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(CN)(CO.sub.2C.sub.2H.sub.5),
o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(CN)(CO.sub.2C.sub.2H.sub.5),
o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(CN)(CO.sub.2C.sub.2H.su-
b.5), H.sub.2C.dbd.CH--CH(CN).sub.2,
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(CN).sub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(CN).sub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(CN).sub.2,
H.sub.2C.dbd.CH--(CH.sub.2).sub.nNO.sub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2NO.sub.2, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH.sub.2NO.sub.2,
H.sub.2C.dbd.CH--CH(C.sub.6H.sub.5)(CO.sub.2C.sub.2H.sub.5),
H.sub.2C.dbd.CH--(CH.sub.2).sub.nCH(C.sub.6H.sub.5)(CO.sub.2C.sub.2H.sub.-
5), o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH(C.sub.6H.sub.5)(CO.sub.2C.sub.2H.su-
b.5), o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2CH(C.sub.6H.sub.5)(CO.sub.2C.s-
ub.2H.sub.5)
(in the above formulas, n represents an integer of 1 to 10).
[0080] For withdrawing a proton from the above compound to give the
carbanion of the general formula (8), one of various basic
compounds are used. As such basic compounds, there may be mentioned
the following:
[0081] Alkali metals such as sodium, potassium and lithium; metal
alkoxides such as sodium methoxide, potassium methoxide, lithium
methoxide, sodium ethoxide, potassium ethoxide, lithium ethoxide,
sodium tert-butoxide and potassium tert-butoxide; carbonates such
as sodium carbonate, potassium carbonate, lithium carbonate and
sodium hydrogen carbonate; hydroxides such as sodium hydroxide and
potassium hydroxide; hydrides such as sodium hydride, potassium
hydride, methyllithium and ethyllithium; organometals such as
n-butyllithium, tert-butyllithium, lithium diisopropylamide and
lithium hexamethyldisilazide; ammonia; alkylamines such as
trimethylamine, triethylamine and tributylamine; polyamines such as
tetramethylethylenediamine and pentamethyl-diethylenetriamine;
pyridine compounds such as pyridine and picoline, etc.
[0082] The basic compound is used in an equivalent amount or in a
slight excess relative to the precursor substance, preferably in an
amount of 1 to 1.2 equivalents.
[0083] A quaternary ammonium salt may also be used as the above
carbanion. In this case, it can be obtained by preparing an alkali
metal salt of a carboxylic acid compound and reacting this with a
quaternary ammonium halide. As examples of the quaternary ammonium
halide, there may be mentioned tetramethylammonium halides,
tetraethylammonium halides, trimethylbenzylammonium halides,
trimethyldodecylammonium halides and tetrabutylammonium
halides.
[0084] As the solvent to be used in reacting the above precursor
with a basic compound, there may be mentioned hydrocarbon solvents
such as benzene and toluene; ether solvents such as diethyl ether,
tetrahydrofuran, diphenyl ether, anisole and dimethoxybenzene;
halogenated hydrocarbon solvents such as methylene chloride and
chloroform; ketone solvents such as acetone, methyl ethyl ketone
and methyl isobutyl ketone; alcohol solvents such as methanol,
ethanol, propanol, isopropanol, n-butyl alcohol and tert-butyl
alcohol; nitrile solvents such as acetonitrile, propionitrile and
benzonitrile; ester solvents such as ethyl acetate and butyl
acetate; carbonate solvents such as ethylene carbonate and
propylene carbonate; amide solvents such as dimethylformamide and
dimethylacetamide; sulfoxide solvents such as dimethyl sulfoxide;
and so on. These may be used singly or two or more of them may be
used in admixture.
[0085] By reacting the above precursor with a basic compound, a
carbanion represented by the general formula (8) is prepared and,
by reacting the same with a vinyl polymer having a terminal
halogen, preferably a terminal halogen represented by the general
formula (4), the desired alkenyl-terminated vinyl polymer can be
obtained.
[0086] (B-c) The method comprising reacting a vinyl polymer having,
at one or more termini thereof, a halogen atom, preferably a
halogen atom represented by the general formula (4), with a simple
substance metal or an organometallic compound and then reacting the
thus-formed enolate anion with an alkenyl-containing electrophilic
compound.
[0087] Particularly preferred as the simple substance metal is
zinc, since the resulting enolate anion will not attack other ester
groups or hardly undergo such side reactions as rearrangement.
Various species can be used as the alkenyl-containing electrophilic
compound, for example alkenyl-containing compounds having a leaving
group such as a halogen and an acetyl group, alkenyl-containing
carbonyl compounds, alkenyl-containing isocyanate compounds and
alkenyl-containing acid halides. Among these, alkenyl-containing
compounds having a leaving group such as a halogen atom and an
acetyl group are preferred since when they are used, no other atoms
than carbon atoms are introduced into the main chain, hence the
vinyl polymer will not lose its weathering resistance.
[0088] (B-d) The method comprising reacting a vinyl polymer having,
at one or more termini thereof, a halogen atom, preferably a
halogen atom represented by the general formula (4), with an
alkenyl-containing oxyanion represented by the general formula (9)
given below or an alkenyl-containing carboxylate anion represented
by the general formula (10) given below to thereby substitute the
alkenyl group for the halogen atom:
CH.sub.2.dbd.C(R.sup.7)R.sup.14--O.sup.-M.sup.+ (9) wherein
R.sup.7, R.sup.14 and M.sup.+ are as defined above;
CH.sub.2.dbd.C(R.sup.7)--R.sup.14--C(O)O.sup.-M.sup.+ (10) wherein
R.sup.7, R.sup.14 and M.sup.+ are as defined above.
[0089] As the precursor of the oxyanion represented by the general
formula (9) or (10), there may be mentioned the following
compounds:
[0090] Alcoholic hydroxyl-containing compounds such as
H.sub.2C.dbd.CH--CH.sub.2--OH, H.sub.2C.dbd.CH--CH(CH.sub.3)--OH,
H.sub.2C.dbd.C(CH.sub.3)--CH.sub.2--OH,
H.sub.2C.dbd.CH--(CH.sub.2).sub.n--OH (n being an integer of 2 to
20), H.sub.2C.dbd.CH--CH.sub.2--O--(CH.sub.2).sub.2--OH,
H.sub.2C.dbd.CH--C(O)O--(CH.sub.2).sub.2--OH,
H.sub.2C.dbd.C(CH.sub.3)--C(O)O--(CH.sub.2).sub.2--OH, o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--CH.sub.2--OH, o-, m-,
p-H.sub.2C.dbd.CH--CH.sub.2--C.sub.6H.sub.4--CH.sub.2--OH, o-, m-,
p-H.sub.2C.dbd.CH--CH.sub.2--O--C.sub.6H.sub.4--CH.sub.2--OH;
phenolic hydroxyl-containing compounds such as o-, m-,
p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--OH, o-, m-,
p-H.sub.2C.dbd.CH--CH.sub.2--C.sub.6H.sub.4--OH, o-, m-,
p-H.sub.2C.dbd.CH--CH.sub.2--O--C.sub.6H.sub.4--OH;
carboxyl-containing compounds such as H.sub.2C.dbd.CH--C(O)--OH,
H.sub.2C.dbd.C(CH.sub.3)--C(O)--OH,
H.sub.2C.dbd.CH--CH.sub.2--C(O)--OH, H.sub.2C.dbd.CH--
(CH.sub.2).sub.n--C(O)--OH (n being an integer of 2 to 20),
H.sub.2C.dbd.CH--(CH.sub.2)--OC(O)--(CH.sub.2)--C(O)--OH (m and n
being the same or different and each being an integer of 0 to 19),
o-, m-, p-H.sub.2C.dbd.CH--C.sub.6H.sub.4--C(O)--OH, o-, m-,
p-H.sub.2C.dbd.CH--CH.sub.2--C.sub.6H.sub.4--C(O)--OH, o-, m-,
p-H.sub.2C.dbd.CH--CH.sub.2--O--C.sub.6H.sub.4--C(O)--OH, o-, m-,
p-H.sub.2C.dbd.CH--(CH.sub.2).sub.n--OC(O)--C.sub.6H.sub.4--C(O)--OH
(n being an integer of 0 to 13); and the like.
[0091] For withdrawing a proton from the above compound to give an
anion of the general formula (9) or (10), various basic compounds
can be used. As specific examples thereof, those basic compounds
which are mentioned hereinabove for use in preparing the carbanion
of the general formula (8) are all suited for use. As for the
reaction solvent, all the solvents usable in preparing the
carbanion can appropriately be used.
[0092] Among the synthetic method (B), the method (B-d) is
preferred since the alkenyl group introduction can be realized at a
high rate. Thus, a vinyl polymer having, at one or more termini
thereof, a halogen atom, preferably a halogen atom represented by
the general formula (4), as obtained by atom transfer radical
polymerization using an organic halide or halogenated sulfonyl
compound as an initiator and a transition metal complex as a
catalyst is subjected to halogen conversion by the method (B-d).
Among the method (B-d), the method comprising reacting an
alkenyl-containing carboxylate anion represented by the general
formula (10) or the like is more preferred.
[0093] When, in the process for producing a vinyl polymer which is
characterized by using the atom transfer radical polymerization
technique for polymerizing a vinyl monomer(s) with an organic
halide or halogenated sulfonyl compound as an initiator and a
transition metal complex as a catalyst, an alkenyl-containing
organic halide is used as the initiator, a vinyl polymer terminated
in the alkenyl group at one terminus and in the halogen atom,
preferably in a structure of the general formula (4), at the other
terminus can be obtained. When the halogen in a termination
terminus of the thus-obtained polymer is converted to an
alkenyl-containing substituent, a vinyl polymer having the
respective alkenyl groups at the respective termini can be
obtained. As the method of conversion, the methods already
described hereinabove can be used.
[0094] The alkenyl-containing organic halide is not particularly
restricted but includes, among others, compounds having the
structure represented by the general formula (11):
R.sup.17R.sup.18C(X)--R.sup.19--R.sup.9--C(R.sup.7).dbd.CH.sub.2
(11) wherein R.sup.7, R.sup.9 and X are as defined above, R.sup.17
and R.sup.18 each represents a hydrogen atom, an alkyl group
containing 1 to 20 carbon atoms, an aryl group containing 6 to 20
carbon atoms or an aralkyl group containing 7 to 20 carbon atoms or
both are linked together at the respective other termini and
R.sup.19 represents --C(O)O-- (ester group), --C(O)-- (keto group)
or an o-, m- or p-phenylene group.
[0095] As specific examples of the alkenyl-containing organic
halide represented by the general formula (11), there may be
mentioned the following:
XCH.sub.2C(O)O(CH.sub.2).sub.nCH.dbd.CH.sub.2,
H.sub.3CC(H)(X)C(O)O(CH.sub.2).sub.nCH.dbd.CH.sub.2,
(H.sub.3C).sub.2C(X)C(O)O(CH.sub.2).sub.nCH.dbd.CH.sub.2,
CH.sub.3CH.sub.2C(H)(X)C(O)O(CH.sub.2).sub.nCH.dbd.CH.sub.2,
##STR2## (in the above formulas, X represents a chlorine, bromine
or iodine atom and n represents an integer of 0 to 20),
XCH.sub.2C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mCH.dbd.CH.sub.2,
H.sub.3CC(H)(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mCH.dbd.CH.sub.2,
(H.sub.3C).sub.2C(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mCH.dbd.CH.sub.2-
,
CH.sub.3CH.sub.2C(H)(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mCH.dbd.CH.s-
ub.2, ##STR3## (in the above formulas, X represents a chlorine,
bromine or iodine atom, n represents an integer of 1 to 20 and m
represents an integer of 0 to 20), o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2)--CH.dbd.CH.sub.2, o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.n--CH.dbd.CH.sub.2,
o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.n--CH.dbd.C-
H.sub.2 (in the above formulas, X represents a chlorine, bromine or
iodine atom and n represents an integer of 0 to 20), o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2)--O--(CH.sub.2).sub.n--CH.dbd.CH.s-
ub.2, o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.n--O--(CH.sub.2).sub.m--
-CH.dbd.CH.sub.2, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.n--O--(CH.sub.2-
).sub.m--CH.dbd.CH.sub.2 (in the above formulas, X represents a
chlorine, bromine or iodine atom, n represents an integer of 1 to
20 and m represents an integer of 0 to 20), o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--O--(CH.sub.2).sub.n--CH.dbd.CH.sub.2,
o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.n--CH.dbd.CH.sub-
.2, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.n--CH.dbd.CH-
.sub.2 (in the above formulas, X represents a chlorine, bromine or
iodine atom and n represents an integer of 0 to 20), o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--O--(CH.sub.2).sub.n--O--(CH.sub.2).sub.m--CH-
.dbd.CH.sub.2, o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.n--O--(CH.sub.2).sub-
.m--CH.dbd.CH.sub.2, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.n--O--(CH.su-
b.2).sub.mCH.dbd.CH.sub.2 (in the above formulas, X represents a
chlorine, bromine or iodine atom, n represents an integer of 1 to
20 and m represents an integer of 0 to 20).
[0096] As the alkenyl-containing organic halide, there may further
be mentioned compounds represented by the general formula (12):
H.sub.2C.dbd.C(R.sup.7)--R.sup.9--C(R.sup.17)(X)--R.sup.20R.sup.18
(12) wherein R.sup.7, R.sup.9, R.sup.17, R.sup.18 and X are as
defined above and R.sup.20 represents a direct bond, --C(O)O--
(ester group), --C(O)-- (keto group) or an o-, m- or p-phenylene
group.
[0097] R.sup.9 is a direct bond or a divalent organic group
containing 1 to 20 carbon atoms (which may contain one or more
ether bonds) and, when it is a direct bond, the vinyl group is
bound to the carbon to which the halogen is bound, giving an allyl
halide compound. In this case, the carbon-halogen bond is activated
by the neighboring vinyl group and, therefore, R.sup.20 is not
always required to be a C(O)O group, a phenylene group or the like
but may be a direct bond. In cases where R.sup.9 is not a direct
bond, R.sup.17 is preferably a C(O)O, C(O) or phenylene group so
that the carbon-halogen bond can be activated.
[0098] The compound of the above general formula (12) specifically
includes, among others, the following compounds:
[0099] CH.sub.2.dbd.CHCH.sub.2X, CH.sub.2.dbd.C(CH.sub.3)CH.sub.2X,
CH.sub.2.dbd.CHC(H)(X)CH.sub.3,
CH.sub.2.dbd.C(CH.sub.3)C(H)(X)CH.sub.3,
CH.sub.2.dbd.CHC(X)(CH.sub.3).sub.2,
CH.sub.2.dbd.CHC(H)(X)C.sub.2H.sub.5,
CH.sub.2.dbd.CHC(H)(X)CH(CH.sub.3).sub.2,
CH.sub.2.dbd.CHC(H)(X)C.sub.6H.sub.5,
CH.sub.2.dbd.CHC(H)(X)CH.sub.2C.sub.6H.sub.5,
CH.sub.2.dbd.CHCH.sub.2C(H)(X)--CO.sub.2R,
CH.sub.2.dbd.CH(CH.sub.2).sub.2C(H)(X)--CO.sub.2R,
CH.sub.2.dbd.CH(CH.sub.2).sub.3C(H)(X)--CO.sub.2R,
CH.sub.2.dbd.CH(CH.sub.2).sub.8C(H)(X)--CO.sub.2R,
CH.sub.2.dbd.CHCH.sub.2C(H)(X)--C.sub.6H.sub.5,
CH.sub.2.dbd.CH(CH.sub.2).sub.2C(H)(X)--C.sub.6H.sub.5,
CH.sub.2.dbd.CH(CH.sub.2).sub.3C(H)(X)--C.sub.6H.sub.5
(in the above formulas, X represents a chlorine, bromine or iodine
atom and R represents a C.sub.1-C.sub.20 alkyl group, aryl group or
aralkyl group).
[0100] The alkenyl-containing halogenated sulfonyl compound
specifically includes, among others, the following compounds:
o-, m-,
p-CH.sub.2.dbd.CH--(CH.sub.2).sup.n--C.sub.6H.sub.4--SO.sub.2X, o-,
m-,
p-CH.sub.2.dbd.CH--(CH.sub.2).sub.n--O--C.sub.6H.sub.4--SO.sub.2X
(in the above formulas, X represents a chlorine, bromine or iodine
atom and n represents an integer of 0 to 20).
[0101] When an alkenyl-containing organic halide or halogenated
sulfonyl compound or the like is used as the initiator, a polymer
having the alkenyl group at one terminus and a halogen group,
preferably a halogen represented by the general formula (4), at the
other terminus can be obtained. By coupling the terminal halogen in
one of this polymer with the terminal halogen in another using a
compound having a total of at least two functional groups which are
the same or different and can substitute for the halogen atom of
the polymer, it is also possible to obtain a vinyl polymer having
an alkenyl group at both termini.
[0102] The compound having a total of at least two functional
groups which are the same or different and can substitute for the
terminal halogen atom is not particularly restricted but preferably
includes polyols, polyamines, polycarboxylic acids, polythiols, and
salts thereof, and alkali metal sulfides, among others. Specific
examples of these compounds are as follows:
[0103] Polyols such as ethylene glycol, 1,2-propanediol,
1,3-propanediol, 2-methyl-1,3-propanediol,
2,2-dimethyl-1,3-propanediol, 1,4-butanediol, 1,3-butanediol,
1,2-butanediol, 2,3-butanediol, pinacol, 1,5-pentanediol,
1,4-pentanediol, 2,4-pentanediol, 1,6-hexanediol, 1,7-heptanediol,
1,8-octanediol, 1,9-nonanediol, 1,10-decanediol, 1,12-dodecanediol,
1,2-cyclopentanediol, 1,3-cyclopentanediol, 1,2-cyclohexanediol,
1,3-cyclohexanediol, 1,4-cyclohexanediol, glycerol,
1,2,4-butanetriol, catechol, resorcinol, hydroquinone,
1,2-dihydroxynaphthalene, 1,3-dihydroxynaphthalene,
1,5-dihydroxynaphthalene, 2,6-dihydroxynaphthalene, 2,2'-biphenol,
4,4'-biphenol, bis(4-hydroxyphenyl)methane,
4,4'-isopropylidenephenol, 3,3'-(ethylenedioxy)diphenol,
.alpha.,.alpha.'-dihydroxy-p-xylene,
1,1,1-tris(4-hydroxyphenyl)ethane, pyrogallol and
1,2,4-benzenetriol; and alkali metal salts of the polyol compounds
mentioned above;
[0104] Polyamines such as ethylenediamine, 1,3-diaminopropane,
1,2-diaminopropane, 1,4-diaminobutane, 1,2-diamino-2-methylpropane,
1,5-diaminopentane, 2,2-dimethyl-1,3-propanediamine,
1,6-hexanediamine, 1,7-heptanediamine, 1,8-octanediamine,
1,9-diaminononane, 1,10-diaminodecane, 1,12-diaminododecane,
4,4'-methylenebis(cyclohexylamine), 1,2-diaminocyclohexane,
1,3-diaminocyclohexane, 1,4-diaminocyclohexane,
1,2-phenylenediamine, 1,3-phenylenediamine, 1,4-phenylenediamine
and .alpha.,.alpha.'-diamino-p-xylene; and alkali metal salts of
the polyamine compounds mentioned above;
[0105] Polycarboxylic acids such as oxalic acid, malonic acid,
methylmalonic acid, dimethylmalonic acid, succinic acid,
methylsuccinic acid, glutaric acid, adipic acid,
1,7-heptanedicarboxylic acid, 1,8-octanedicarboxylic acid,
1,9-nonanedicarboxylic acid, 1,10-decanedicarboxylic acid,
1,11-undecanedicarboxylic acid, 1,12-dodecanedicarboxylic acid,
1,2-cyclopentanedicarboxylic acid, 1,2-cyclohexane-dicarboxylic
acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic
acid, 1,3,5-cyclohexanetricarboxylic acid, phthalic acid,
isophthalic acid, terephthalic acid, 1,2,3-benzenetricarboxylic
acid and 1,2,4,5-benzenetetracarboxylic acid; and alkali metal
salts of the polycarboxylic acids mentioned above;
[0106] Polythiols such as 1,2-ethanedithiol, 1,3-propanedithiol,
1,4-butanedithiol, 2,3-butanedithiol, 1,5-pentanedithiol,
1,6-hexanedithiol, 1,7-heptanedithiol, 1,8-octanedithiol,
1,9-nonanedithiol, 2-mercaptoethyl ether,
p-xylene-.alpha.,.alpha.'-dithiol, 1,2-benzenedithiol,
1,3-benzenedithiol and 1,4-benzenedithiol; and alkali metal salts
of the polythiol compounds mentioned above;
[0107] Lithium sulfide, sodium sulfide and potassium sulfide.
[0108] When the above polyols, polyamines, polycarboxylic acids or
polythiols are used, a basic compound is combinedly used for
promoting the substitution reaction and, as specific examples,
there may be mentioned those already mentioned hereinabove.
[0109] The synthetic method (C) mentioned above which comprises
using a vinyl polymer having at least one hydroxyl group and
substituting an alkenyl-containing functional group for this
hydroxyl group is not particularly restricted but specifically
includes, among others, the methods (C-a) to (C-d) mentioned below.
The vinyl polymer having at least one hydroxyl group can be
obtained by the methods (D-a) to (D-i) mentioned later herein.
(C-a) The method comprising reacting a vinyl polymer having at
least one hydroxyl group with a base, such as sodium hydroxide and
sodium methoxide, followed by reacting with an alkenyl-containing
halide, such as allyl chloride.
(C-b) The method comprising reacting a vinyl polymer having at
least one hydroxyl group with an alkenyl-containing isocyanate
compound, such as allyl isocyanate.
(C-c) The method comprising reacting a vinyl polymer having at
least one hydroxyl group with an alkenyl-containing acid halide,
such as (meth)acrylic acid chloride, in the presence of a base,
such as pyridine.
(C-d) The method comprising reacting a vinyl polymer having at
least one hydroxyl group with an alkenyl-containing carboxylic
acid, such as acrylic acid, in the presence of an acid
catalyst.
[0110] The method of producing the vinyl polymer having at least
one hydroxyl group which is to be used according to method (C)
includes, but is not limited to, the methods (D-a) to (D-f)
mentioned below.
[0111] (D-a) The method comprising subjecting a compound having
both a polymerizable alkenyl group and a hydroxyl group in each
molecule as represented by the general formula (13) shown below to
reaction as a second monomer in synthesizing the vinyl polymer by
living radical polymerization:
H.sub.2C.dbd.C(R.sup.7)--R.sup.8--R.sup.9--OH (13) wherein R.sup.7,
R.sup.8 and R.sup.9 are as defined above.
[0112] The time when the compound having both a polymerizable
alkenyl group and a hydroxyl group in each molecule is not
particularly restricted but, when rubber-like properties are
expected, the compound is subjected to reaction as a second monomer
preferably at the final stage of the polymerization reaction or
after completion of the reaction of a predetermined monomer.
[0113] (D-d) The method comprising subjecting a compound having a
low-polymerizable alkenyl group and a hydroxyl group in each
molecule to reaction as a second monomer at the final stage of the
polymerization reaction or after completion of the reaction of a
predetermined monomer in synthesizing the vinyl polymer by living
radical polymerization. Such compound is not particularly
restricted but includes, among others, compounds represented by the
general formula (14): H.sub.2C.dbd.C(R.sup.7)--R.sup.10--OH (14)
wherein R.sup.7 and R.sup.10 are as defined above. The compound
represented by the above general formula (14) is not particularly
restricted but alkenyl alcohols such as 10-undecenol, 5-hexenol and
allyl alcohol are preferred from the viewpoint of ready
availability. (D-c) The method as disclosed in Japanese Kokai
Publication Hei-04-132706, for instance, which comprises terminally
introducing a hydroxyl group by hydrolyzing the halogen of a vinyl
polymer having at least one carbon-halogen bond represented by the
general formula (4) as obtained by atom transfer radical
polymerization or reacting the same with a hydroxyl-containing
compound. (D-d) The method comprising reacting a vinyl polymer
having at least one carbon-halogen bond represented by the general
formula (4) as obtained by atom transfer radical polymerization
with a stabilized, hydroxyl-containing carbanion such as one
represented by the general formula (15) to thereby effect
substitution for the halogen:
M.sup.+C.sup.-(R.sup.15)(R.sup.16)--R.sup.14--OH (15) wherein
R.sup.14, R.sup.15 and R.sup.16 are as defined above. (D-e) The
method comprising reacting a vinyl polymer having at least one
carbon-halogen bond represented by the general formula (4) as
obtained by atom transfer radical polymerization with a simple
substance metal, such as zinc, or an organometallic compound and
then reacting the thus-prepared enolate anion with an aldehyde or
ketone. (D-f) The method comprising reacting a vinyl polymer having
at least one terminal halogen, preferably a terminal halogen
represented by the general formula (4), with a hydroxyl-containing
oxyanion represented by the general formula (16) shown below or the
like or a hydroxyl-containing carboxylate anion represented by the
general formula (17) shown below or the like to thereby substitute
a hydroxyl-containing group for the halogen:
HO--R.sup.14--O.sup.-M.sup.+ (16) wherein R.sup.14 and M.sup.+ are
as defined above; HO--R.sup.14--C(O)O.sup.-M.sup.+ (17) wherein
R.sup.14 and M.sup.+ are as defined above.
[0114] In the practice of the invention, when any halogen is not
directly involved in introducing a hydroxyl group, as in the
methods (D-a) and (D-b), the method (D-b) is more preferred since
the control is easier. In cases where the hydroxyl group
introduction is effected by converting the halogen of a vinyl
polymer having at least one carbon-halogen bond, as in the methods
(D-c) to (D-f), the method (D-f) is more preferred since the
control is easier.
<Hydrosilylation Reaction>
[0115] By subjecting the alkenyl-terminated vinyl polymer produced
in the above manner to hydrosilylation reaction using a silicon
compound having both a silicon atom-bound hydrolyzable group and a
hydrosilyl group, the silicon atom-bound hydrolyzable group can be
introduced terminally into the polymer.
[0116] The silicon compound having both a silicon atom-bound
hydrolyzable group and a hydrosilyl group is not particularly
restricted but includes compounds represented by the general
formula (18):
H--[Si(R.sup.1).sub.2-b(Y'').sub.bO].sub.m--Si(R.sup.2).sub.3-a(Y'').sub.-
a (18) wherein R.sup.1 and R.sup.2 are the same or different and
each represents an alkyl group containing 1 to 20 carbon atoms, an
aryl group containing 6 to 20 carbon atoms, an aralkyl group
containing 7 to 20 carbon atoms or a triorganosiloxy group
represented by (R').sub.3SiO-- (in which R' is a hydrocarbon group
containing 1 to 20 carbon atoms and the three R.sup.1 groups may be
the same or different) and, when there are two or more R.sup.1 or
R.sup.2 groups, they may be the same or different, Y'' represents a
hydrolyzable group other than a hydroxyl group, a represents 0, 1,
2 or 3, b represents 0, 1 or 2 and m is an integer of 0 to 19
provided that the relation a+mb.gtoreq.1 should be satisfied. Among
them, those in which m is 0 are preferred.
[0117] Y'' is not particularly restricted but includes, among
others, ketoximo, acyloxy, alkoxy, amido, aminoxy, amino, alkenoxy
and halogen groups and a hydrogen atom. Among them, halogen groups
are preferred.
[0118] As more specific examples of such silicon compound, there
may be mentioned dialkylchlorosilanes, in particular
chlorodimethylsilane.
[0119] The amount of the silicon compound having both a silicon
atom-bound hydrolyzable group and a hydrosilyl group which is to be
reacted with the alkenyl-terminated polymer is not particularly
restricted but, when a compound having only one hydrosilyl group is
used, the amount thereof may be equivalent relative to the alkenyl
group. When a compound having a plurality of hydrosilyl groups is
used, there is the possibility of coupling thereof by the
hydrosilylation reaction and, therefore, the compound is preferably
used in excess.
[0120] For causing the hydrosilylation reaction to proceed rapidly,
a hydrosilylation catalyst is added. As such hydrosilylation
catalyst, there may be mentioned a radical initiator such as an
organic peroxide and an azo compound, and a transition metal
catalyst.
[0121] The radical initiator is not particularly restricted but may
be any of various compounds. As examples, there may be mentioned
dialkyl peroxides such as di-tert-butyl peroxide,
2,5-dimethyl-2,5-di(tert-butylperoxy)hexane,
2,5-dimethyl-2,5-di(tert-butylperoxy)-3-hexyne, dicumyl peroxide,
tert-butylcumyl peroxide and
.alpha.,.alpha.'-bis(tert-butyl-peroxy)isopropylbenzene, diacyl
peroxides such as benzoyl peroxide, p-chlorobenzoyl peroxide,
m-chlorobenzoyl peroxide, 2,4-dichlorobenzoyl peroxide and lauroyl
peroxide, peresters such as tert-butyl perbenzoate,
peroxydicarbonates such as diisopropyl peroxydicarbonate and
di-2-ethylhexyl peroxy-dicarbonate, and peroxyketals such as
1,1-di(tert-butylperoxy)cyclohexane and
1,1-di(tert-butylperoxy)-3,3,5-trimethylcyclohexane, among
others.
[0122] As the transition metal catalyst, there may be mentioned,
for example, simple substance platinum, solid platinum dispersed on
a support such as alumina, silica or carbon black, chloroplatinic
acid, complexes of chloroplatinic acid with alcohols, aldehydes,
ketones and the like, platinum-olefin complexes and
platinum(0)-divinyltetramethyldisiloxane complex. As examples of
the catalyst other than platinum compounds, there may be mentioned
RhCl(PPh.sub.3).sub.3, RhCl.sub.3, RuCl.sub.3, IrCl.sub.3,
FeCl.sub.3, AlCl.sub.3, PdCl.sub.2.H.sub.2O, NiCl.sub.2,
TiCl.sub.4, etc.
[0123] These catalyst may be used singly or two or more of them may
be used combinedly.
[0124] The amount of the catalyst is not particularly restricted
but recommendably is within the range of 10.sup.-1 to 10.sup.-8
mole, preferably within the range of 10.sup.-3 to 10.sup.-6 mole,
per mole of the alkenyl group of the polymer. When it is less than
10.sup.-8 mole, the curing may not proceed to a sufficient extent.
Since the hydrosilylation catalyst is expensive, it is
recommendable that it be not used in an amount exceeding 10.sup.-1
mole.
[0125] The hydrosilylation reaction may be conducted without using
any solvent or in the presence of a solvent. Ordinary organic
solvents, such as hydrocarbon solvents, ether solvents and ester
solvents, can be used as the solvent. However, those capable of
coordinating with transition metals, for example amines and
phosphines may possibly lower the catalytic activity, hence are
undesirable, when a transition metal catalyst is used.
[0126] The hydrosilylation reaction temperature is not particularly
restricted but the reaction is generally carried out at 0 to
250.degree. C., preferably 20 to 150.degree. C., most preferably 40
to 120.degree. C.
<Hydrolysis Reaction>
[0127] The silicon atom-bound hydrolyzable group at a terminus of
the polymer produced in the above manner can be converted to a
silanol group by hydrolysis.
[0128] When the hydrolyzable group is a hydrogen atom, the
hydrolysis can be effected by a method known in the art, which is
not restricted, for example by reacting with a buffer solution in
the presence of a Pd/C catalyst (J. Org. Chem., 31, 885 (1966)) or
by reacting a buffer solution in the presence of a platinum
catalyst.
[0129] When the hydrolyzable group is a halogen atom, in particular
a chlorine atom, the hydrolysis is generally carried out at 0 to
60.degree. C., preferably in the presence of a base, such as sodium
bicarbonate, which is used for neutralizing the byproduct
hydrochloric acid, although the conditions are not limited to those
mentioned above.
<<Curable Composition>>
[0130] The vinyl polymer (I) having a silanol group at one or more
termini thereof according to the first aspect of the invention can
be used in a curable composition utilizing the condensation
reaction of the silanol group.
[0131] When there are two or more silanol groups in each polymer,
the polymer can by itself undergo condensation crosslinking. Even
in such case, and in particular in other cases, it is preferred,
but is not always necessary, that the composition contain a silicon
compound having two or more silicon atom-bound hydrolyzable groups
or a polymer having a silicon atom-bound hydrolyzable group(s)
(other than a hydroxyl group).
[0132] The silicon compound having two or more silicon atom-bound
hydrolyzable groups is not particularly restricted but includes
compounds represented by the general formula (2):
Z-[Si(R.sup.3).sub.2-b(Y').sub.bO].sub.m--Si(R.sup.4).sub.3-a(Y').sub.a
(2) wherein R.sup.3 and R.sup.4 are the same or different and each
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms, an aralkyl group containing
7 to 20 carbon atoms or a triorganosiloxy group represented by
(R').sub.3SiO-- (in which R' is a monovalent hydrocarbon group
containing 1 to 20 carbon atoms and the three R' groups may be the
same or different) and, when there are two or more R.sup.3 or
R.sup.4 groups, they may be the same or different, Y' represents a
hydrolyzable group other than a hydroxyl group, Z represents an
alkyl group containing 1 to 20 carbon atoms, an aryl group
containing 6 to 20 carbon atoms, an aralkyl group containing 7 to
20 carbon atoms, a triorganosiloxy group represented by
(R').sub.3SiO-- (in which R' is as defined above) or a hydrolyzable
group other than a hydroxyl group, a represents 0, 1, 2 or 3, b
represents 0, 1 or 2 and m is an integer of 0 to 19 provided that
when Z is a hydrolyzable group, the relation a+mb.gtoreq.1 should
be satisfied and, when Z is other than a hydrolyzable group, the
relation a+mb.gtoreq.2 should be satisfied.
[0133] Referring to the general formula (2), the hydrolyzable
groups (Y' and Z) are not particularly restricted but are
preferably selected from the group consisting of ketoximo, acyloxy,
alkoxy, amido, aminoxy, amino and alkenoxy groups.
[0134] The silicon compound having two or more hydrolyzable groups
is not particularly restricted but, more specifically, it includes
oximosilanes such as methyltris(methyl ethyl ketoximo)silane and
vinyltris(methyl ethyl ketoximo)silane, acetoxysilanes such as
methyltrisacetoxysilane, ethyltrisacetoxysilane and
vinyltrisacetoxysilane, alkoxysilanes such as
methyltrismethoxysilane, ethyltrismethoxysilane,
vinyltrismethoxysilane, tetraethoxysilane and tetrapropoxysilane,
amidosilanes such as ones represented by the formula shown below,
aminoxysiloxanes such as ones represented by the formula shown
below, aminosilanes such as methyltriscyclohexylaminosilane,
alkenoxysilanes such as methyltrisisopropenoxysilane, and cyclic
aminoxysiloxanes such as ones represented by the formula shown
below, among others: ##STR4## R=methyl, ethyl, vinyl, etc.,
R'=methyl, ethyl, etc., m=0, 1, 2. ##STR5##
[0135] The curable composition according to the first aspect of the
invention may contain a polymer having a silicon atom-bound
hydrolyzable group(s) and no silanol group.
[0136] The skeleton of the polymer having a silicon atom-bound
hydrolyzable group(s) and no silanol group includes, but is not
limited to, polysiloxane polymers, polyether polymers, hydrocarbon
polymers (e.g. polyisobutylene) and vinyl polymers (e.g.
(meth)acrylic polymers, styrenic polymers).
[0137] In curing the curable composition according to the first
aspect of the invention, a condensation catalyst may be used or the
use thereof may be omitted. As the condensation catalyst, use may
be made of one or two of known silanol condensation catalysts, as
necessary, for example tetravalent tin compounds such as dibutyltin
dilaurate, dibutyltin diacetate, dibutyltin diethylhexanolate,
dibutyltin diocotate, dibutyltin di(methyl maleate), dibutyltin
di(ethyl maleate), dibutyltin di(butyl maleate), dibutyltin
di(isooctyl maleate), dibutyltin di(tridecyl maleate), dibutyltin
di(benzyl maleate), dibutyltin maleate, dioctyltin diacetate,
dioctyltin distearate, dioctyltin dilaurate, dioctyltin di(ethyl
maleate) and dioctyltin di(isooctyl maleate); titanic acid esters
such as tetrabutyl titanate and tetrapropyl titanate;
organoaluminum compounds such as aluminum trisacetylacetonate,
aluminum tris(ethyl acetoacetate) and diisopropoxyaluminum ethyl
acetoacetate; chelate compounds such as zirconium
tetraacetylacetonate and titanium tetraacectylacetonate; lead
octylate; amine compounds such as butylamine, octylamine,
laurylamine, dibutylamine, monoethanolamine, diethanolamine,
triethanolamine, diethylenetriamine, triethylenetetramine,
oleylamine, cyclohexylamine, benzylamine, diethylaminopropylamine,
xylylenediamine, triethylenediamine, guanidine, diphenylguanidine,
2,4,6-tris(dimethylaminomethyl)phenol, morpholine,
N-methylmorpholine, 2-ethyl-4-methylimidazole and
1,8-diazabicyclo[5.4.0]undecene-7 (DBU), or salts of these amine
compounds with carboxylic acids; low-molecular-weight polyamide
resins obtained from an excess polyamine and a polybasic acid;
reaction products from an excess polyamine and an epoxy compound;
amino-containing silane coupling agents such as
.gamma.-aminopropyltrimethoxysilane and
N-(.beta.-aminoethyl)-aminopropylmethyldimethoxysilane; and silanol
condensation catalysts, and other silanol condensation catalysts
such as acidic and basic catalysts. They are preferably used in an
amount of 0 to 10% by weight relative to the silanol-terminated
vinyl polymer (I). When an alkoxy group is used as the silicon
atom-bound hydrolyzable group Y, this polymer, if used alone, shows
a slow rate of curing, hence the use of a curing catalyst is
preferred.
[0138] In the curable composition according to the first aspect of
the invention, there may be incorporated various fillers according
to the use thereof. Usable as the filler are reinforcing fillers
such as woodmeal, pulp, cotton chips, asbestos, glass fibers,
carbon fibers, mica, walnut shell flour, rice hull flour, graphite,
diatomaceous earth, clay, fumed silica, precipitated silica,
crystalline silica, fused silica, dolomite, silicic anhydride,
hydrous silicic acid and carbon black; fillers such as calcium
carbonate, magnesium carbonate, diatomaceous earth, calcined clay,
clay, talc, titanium oxide, bentonite, organic bentonite, ferric
oxide, finely divided aluminum, flint powder, zinc oxide, activated
zinc white, zinc dust and shirasu balloons; and fibrous fillers
such as asbestos, glass fibers and filaments. For obtaining high
strength cured products using such fillers, the use of a filler
selected mainly from among fumed silica, precipitated silica,
silicic anhydride, hydrous silicic acid, carbon black,
surface-treated fine calcium carbonate, calcined clay, clay,
activated zinc white and the like in an amount within the range of
1 to 100 parts by weight per 100 parts by weight of the vinyl
polymer (I) gives favorable results. When cured products low in
strength but high in elongation are desired, the use of a filler
selected mainly from among titanium oxide, calcium carbonate, talc,
ferric oxide, zinc oxide, shirasu balloons and the like in an
amount within the range of 5 to 200 parts by weight per 100 parts
by weight of the vinyl polymer (I) gives good results. These
fillers may be used singly or two or more of them may be used in
admixture.
[0139] In the practice of the first aspect of the invention, the
use of a filler in combination with a plasticizer is more effective
in increasing the elongation of cured products or enabling
admixture of the filler in large amounts. The plasticizer is not
particularly restricted but, according to the physical property or
appearance characteristic which is to be adjusted, use may be made
of, for example, the following, either singly or in combination of
two or more: phthalate esters such as dibutyl phthalate, diheptyl
phthalate, di(2-ethylhexyl)phthalate and butyl benzyl phthalate;
nonaromatic dibasic acid esters such as dioctyl adipate, dioctyl
sebacate, dibutyl sebacate and isodecyl succinate; aliphatic esters
such as butyl oleate and methyl acetylricinolate; polyalkylene
glycol esters such as diethylene glycol dibenzoate, triethylene
glycol dibenzoate and pentaerythritol esters; phosphate esters such
as tricresyl phosphate and tributyl phosphate; trimellitic acid
esters; chlorinated paraffins; hydrocarbon oils such as
alkyldiphenyls and partially hydrogenated terphenyl; process oils;
polyethers such as polyethylene glycol and polypropylene glycol, or
polyethers derived therefrom by partially or totally converting the
hydroxyl groups occurring in these molecules to alkoxy groups or
the like; epoxy plasticizers such as epoxidized soybean oil and
benzyl epoxystearate; polyester plasticizers; etc. The addition of
these plasticizers is not always necessary, however. It is also
possible to incorporate these plasticizers in the step of polymer
production. The use of such a plasticizer in an amount within the
range of 0 to 100 parts by weight per 100 parts by weight of the
silanol-terminated vinyl polymer (I) gives good results.
[0140] While a filler, a plasticizer and a condensation catalyst
are mainly used in the curable composition according to the first
aspect of the invention, an adhesiveness providing agent such as a
phenolic resin, sulfur and a silane coupling agent; a modifier such
as a silanol and hydrolyzable group-containing polysiloxane; a tack
and weathering resistance improver such as an ultraviolet-curable
resin, a pigment, an antioxidant, an ultraviolet absorber and other
additives may arbitrarily be added.
[0141] As the antisagging agent, there may be mentioned polyamide
waxes; hydrogenated castor oil derivatives; metal soaps such as
calcium stearate, aluminum stearate and barium stearate, and so on.
The use thereof is unnecessary in some instances, however,
depending on the intended use or as a result of incorporation of a
filler, a reinforcing agent and/or the like.
[0142] Usable as the colorant when necessary are inorganic
pigments, organic pigments and dyes in common use, among
others.
[0143] As the physical property modifier, there may be added, when
necessary, various silane coupling agents, for example
alkylalkoxysilanes such as methyltrimethoxysilane,
dimethyldimethoxysilane, trimethylmethoxysilane and
n-propyltrimethoxysilane; alkylisopropenoxysilanes such as
dimethyldiisopropenoxysilane, methyltriisopropenoxysilane and
.gamma.-glycidoxypropylmethyldiisopropenoxysilane, functional
group-containing alkoxysilanes such as
.gamma.-glycidoxypropylmethyldimethoxysilane,
.gamma.-glycidoxypropyltrimethoxysilane, vinyltrimethoxysilane,
vinyldimethylmethoxysilane, .gamma.-aminopropyltrimethoxysilane,
N-(.beta.-aminoethyl)aminopropylmethyldimethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane and
.gamma.-mercaptopropylmethyldimethoxysilane; silicone varnishes;
polysiloxanes and the like. By using such a physical property
modifier, it is possible to increase or decrease the hardness or
increase the elongation on the occasion of curing of the
composition of the invention.
[0144] Since the polymer of the invention itself has good
adhesiveness to glass, ceramics other than glass, metals and so on
and can be caused to adhere to a wide range of materials also by
using various primers, the use of an adhesion promoter is not
always necessary. It is possible, however, to improve the
adhesiveness to a wider range of adherends as well by using one or
more of epoxy resins, phenol resins, various silane coupling
agents, alkyl titanates, aromatic polyisocyanates and the like.
[0145] The curable composition according to the first aspect of the
invention may be prepared as a one-pack formulation by compounding
all the components beforehand and storing in a tightly closed
vessel. In this case, the composition, after application, is cured
by moisture in the air. It is also possible to prepare the
composition as a two-pack formulation, namely separately preparing
a curing agent composition by compounding a curing catalyst, a
filler, a plasticizer and water, among others. This composition and
the polymer composition are mixed up before application.
[0146] The curable composition according to the first aspect of the
invention may have a wide variety of forms, from rubber-like to
resin-like, according to the molecular weight and main chain
skeleton of the polymer. Therefore, this composition can be
utilized in or as sealing compositions, adhesives, elastic
adhesives, pressure-sensitive adhesives, coatings, powder coatings,
foamed products, potting agents for electric or electronic use,
films, gaskets, various molding materials, etc.
<<Method of Producing Polymer (II)>>
[0147] The second aspect of the present invention is now
described.
[0148] In accordance with the second aspect of the invention, a
vinyl polymer (II) having a hydrolyzable silyl group at one or more
termini thereof is produced by reacting a vinyl polymer (I) having
a silanol group at one or more termini thereof with a silicon
compound having two or more silicon atom-bound hydrolyzable groups.
The "hydrolyzable silyl group" means a group resulting from the
binding of a hydrolyzable group or groups to a silicon atom.
[0149] The vinyl polymer (I) is as described in detail referring to
the first aspect of the present invention.
[0150] The silicon compound having two or more hydrolyzable groups
is not particularly restricted but includes compounds represented
by the general formula (2)
Z-[Si(R.sup.3).sub.2-b(Y').sub.bO].sub.m--Si(R.sup.4).sub.3-a(Y').sub.a
(2) wherein R.sup.3 and R.sup.4 are the same or different and each
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms, an aralkyl group containing
7 to 20 carbon atoms or (R').sub.3SiO-- (in which R' is a
hydrocarbon group containing 1 to 20 carbon atoms and the three R'
groups may be the same or different) and, when there are two or
more R.sup.3 or R.sup.4 groups, they may be the same or different,
Y' represents a hydrolyzable group other than a hydroxyl group, Z
represents an alkyl group containing 1 to 20 carbon atoms, an aryl
group containing 6 to 20 carbon atoms, an aralkyl group containing
7 to 20 carbon atoms, a triorganosiloxy group represented by
(R').sub.3SiO-- (in which R' is as defined above) or a hydrolyzable
group other than a hydroxyl group, a represents 0, 1, 2 or 3, b
represents 0, 1 or 2 and m is an integer of 0 to 19 provided that
when Z is a hydrolyzable group, the relation a+mb.gtoreq.1 should
be satisfied and, when Z is other than a hydrolyzable group, the
relation a+mb.gtoreq.2 should be satisfied. Here, it is preferred
that m=0.
[0151] Referring to the general formula (2), the hydrolyzable
groups (Y' and Z) are not particularly restricted but are
preferably selected from the group consisting of ketoximo, acyloxy,
alkoxy, amido, aminoxy, amino and alkenoxy groups.
[0152] The silicon compound having two or more hydrolyzable groups
is not particularly restricted but, more specifically, it includes
those compounds mentioned hereinabove referring to the first aspect
of the invention.
[0153] The reaction may be carried out under ordinary alcohol
elimination/condensation reaction conditions. The reaction
conditions may depend on the silanol group and on the substituents
of the silicon compound having two or more hydrolyzable groups.
Generally, however, the reaction temperature is preferably 0 to
100.degree. C., more preferably 20 to 80.degree. C. The reaction
time is preferably 1 to 20 hours, more preferably 2 to 8 hours. The
reaction may be carried out under ordinary pressure, increased
pressure or reduced pressure. Ordinary pressure is preferred,
however, since the apparatus can be simplified and the production
procedure becomes easy. The reaction is preferably carried out in
an inert gas atmosphere.
[0154] In the above production method, it is preferred that one
mole silanol group react with one mole of the silicon compound
having two or more silicon atom-bound hydrolyzable groups. For
suppressing side reactions, the reaction is preferably carried out
under conditions such that the silicon compounds having two or more
hydrolyzable groups occur in excess (more preferably in large
excess). Specifically, the reaction is preferably carried out under
conditions such that the mole ratio between the silanol group and
the silicon compound having two or more one-mole hydrolyzable
groups amounts to 1:3 or more (more preferably 1:5 or more).
[0155] Although this reaction is preferably carried out in the
absence of any catalyst, the reaction may be promoted by using a
transesterification catalyst in common use. As this catalyst, there
may be mentioned organometal catalysts such as Ti(OEt).sub.4,
Ti(OBu).sub.4, Ti(OPr).sub.4, SnO, Sn(COO).sub.2, Bu.sub.2SnO,
Bi(OH).sub.3, Zn(CH.sub.3COO).sub.2.2H.sub.2O,
Pb(CH.sub.3COO).sub.2.3H.sub.2O,
Pb(C.sub.6H.sub.5COO).sub.2.H.sub.2O, PbO, Sn.sub.2O.sub.3,
Al(CH.sub.3COO).sub.3, Mn(CH.sub.3COO).sub.2.4H.sub.2O,
Co(CH.sub.3COO).sub.2.4H.sub.2O, Cd(CH.sub.3COO).sub.2,
Cd(COO).sub.2, dibutyltin laurate, dibutyltin dimaleate, dibutyltin
thiocarboxylates, dioctyltinmercaptides and stannous octoate, lead
octenoate, triethylenediamine, tetramethylguanidine,
2-(dimethylaminomethyl)phenol,
N,N,N',N'-tetramethylhexane-1,6-diamine,
1,8-diazabicyclo[5.4.0]undecene-7, p-toluenesulfonic acid and
trifluoroacetic acid, among others. Among them, the use of
p-toluenesulfonic acid or trifluoroacetic acid is preferred. When
these catalysts are used, the amount thereof is preferably 0.1 to
5% by weight based on the total amount of the silanol group and the
silicon compound having two or more hydrolyzable groups.
[0156] While the above reaction is preferably carried out in the
absence of any solvent, an organic solvent may be used for
facilitating the control of the reaction or decreasing the
viscosity of the reaction mixture, for instance. This organic
solvent may be any of the solvents capable of dissolving the
starting materials and reaction product and inert under the
reaction conditions. Thus, for example, diethyl ether,
tetrahydrofuran, acetone, methyl ethyl ketone, benzene, toluene,
xylene, hexane, mineral spirit and the like are adequate.
[0157] The second aspect of the invention is also directed to a
vinyl polymer (II) having a hydrolyzable silyl group at one or more
termini thereof and obtainable by such a production method as
mentioned above. This polymer is not limited to the one produced by
the method described herein.
<<Curable Composition>>
[0158] The vinyl polymer (II) having a hydrolyzable silyl group at
one or more termini thereof, according to the second aspect of the
invention, can be used in formulating a curable composition which
utilizes the condensation reaction of the hydrolyzable silyl group.
In the description which follows, the vinyl polymer having a
hydrolyzable silyl group at one or more termini thereof, according
to the second aspect of the invention, is sometimes referred to as
"polymer (II)".
[0159] In curing the curable composition according to the second
aspect of the invention, a condensation catalyst may be used or the
use thereof may be omitted. As the condensation catalyst, use may
be made of one or two of known silanol condensation catalysts, as
necessary, for example tetravalent tin compounds such as dibutyltin
dilaurate, dibutyltin diacetate, dibutyltin diethylhexanolate,
dibutyltin dioctoate, dibutyltin di(methyl maleate), dibutyltin
di(ethyl maleate), dibutyltin di(butyl maleate), dibutyltin
di(isooctyl maleate), dibutyltin di(tridecyl maleate), dibutyltin
di(benzyl maleate), dibutyltin maleate, dioctyltin diacetate,
dioctyltin distearate, dioctyltin dilaurate, dioctyltin di(ethyl
maleate) and dioctyltin di(isooctyl maleate); titanic acid esters
such as tetrabutyl titanate and tetrapropyl titanate;
organoaluminum compounds such as aluminum trisacetylacetonate,
aluminum tris(ethyl acetoacetate) and diisopropoxyaluminum ethyl
acetoacetate; chelate compounds such as zirconium
tetraacetylacetonate and titanium tetraacetylacetonate; lead
octylate; amine compounds such as butylamine, octylamine,
laurylamine, dibutylamine, monoethanolamine, diethanolamine,
triethanolamine, diethylenetriamine, triethylenetetramine,
oleylamine, cyclohexylamine, benzylamine, diethylaminopropylamine,
xylylenediamine, triethylenediamine, guanidine, diphenylguanidine,
2,4,6-tris(dimethylamino-methyl)phenol, morpholine,
N-methylmorpholine, 2-ethyl-4-methylimidazole and
1,8-diazabicyclo[5.4.0]undecene-7 (DBU) or salts of these amine
compounds with carboxylic acids; low-molecular-weight polyamide
resins obtained from an excess polyamine and a polybasic acid;
reaction products from an excess polyamine and an epoxy compound;
amino-containing silane coupling agents such as
.gamma.-aminopropyltrimethoxysilane and
N-(.beta.-aminoethyl)aminopropylmethyldimethoxysilane; and silanol
condensation catalysts, and other silanol condensation catalysts
such as acidic and basic catalysts. They are preferably used in an
amount of 0 to 10% by weight relative to the vinyl polymer (II).
When an alkoxy group is used as the hydrolyzable group Y, this
polymer, if used alone, shows a slow rate of curing, hence the use
of a curing catalyst is preferred.
[0160] Since the polymer of the invention itself has adhesiveness
to glass, ceramics other than glass, metals and so forth or can be
adhered to a wide range of materials by using various primers, an
adhesion promoter is not always necessary but, for attaining stable
adhesiveness to various substrates, parts, supports and adherends,
the use thereof is preferred.
[0161] As the adhesion promoter, there may be mentioned resol type
or novolak type phenol resins obtained by reacting a phenolic
compound, such as phenol, cresol, xylenol, resorcinol, an
alkylphenol or a modified phenol (e.g. cashew oil-modified phenol,
tall oil-modified phenol), with an aldehyde compound, such as
formalin or paraformaldehyde; sulfur; epoxy resins such as
bisphenol A-based epoxy resins, bisphenol F-based epoxy resins,
novolak-based epoxy resins, bisphenol A-propylene oxide adduct
glycidyl ether type epoxy resins and hydrogenated bisphenol A-based
epoxy resins; alkyl titanates such as tetrabutyl titanate, aromatic
polyisocyanates such as tolylene diisocyanate and
diphenylmethanediisocyanate; compounds having an amino group and a
crosslinking silyl group in each molecule, such as
.gamma.-aminopropyltrimethoxysilane,
.gamma.-aminopropyltriethoxysilane,
.gamma.-aminopropylmethyldimethoxysilane,
N-(.beta.-aminoethyl)-.gamma.-aminopropyltrimethoxysilane,
N-(.beta.-aminoethyl)-.gamma.-aminopropyltriethoxysilane and
N-(.beta.-aminoethyl)-.gamma.-aminopropylmethyldimethoxysilane;
compounds having an epoxy group and a crosslinking silyl group in
each molecule, such as .gamma.-glycidoxypropyltrimethoxysilane,
.gamma.-glycidoxypropyltriethoxysilane and
.gamma.-glycidoxypropylmethyldimethoxysilane; compounds having a
mercapto group and a crosslinking silyl group in each molecule,
such as .gamma.-mercaptopropyltrimethoxysilane,
.gamma.-mercaptopropyltriethoxysilane and
.gamma.-mercaptopropylmethyldimethoxysilane; compounds having an
isocyanato group and a crosslinking silyl group in each molecule,
such as .gamma.-isocyanatopropyltrimethoxysilane,
.gamma.-isocyanatopropyltriethoxysilane and
.gamma.-isocyanatopropylmethyldimethoxysilane; reaction products
from such a compound having an amino group and a crosslinking silyl
group in each molecule as mentioned above and such a compound
having an epoxy group and a crosslinking silyl group in each
molecule or a compound having an isocyanato group and a
crosslinking silyl group in each molecule as mentioned above;
reaction products from a compound having a (meth)acryloxy group and
a crosslinking silyl group in each molecule, such as
.gamma.-(meth)acryloxypropyltrimethoxysilane,
.gamma.-(meth)acryloxypropyltriethoxysilane or
.gamma.-(meth)acryloxypropylmethyldimethoxysilane, and such a
compound having an amino group and a crosslinking silyl group in
each molecule as mentioned above; and so on. These may be used
singly or two or more of them may be used combinedly. Among them,
compounds having an organic group containing at least one atom
selected from among nitrogen, oxygen and sulfur atoms and a
crosslinking silyl group in each molecule, such as compounds having
an amino group and a crosslinking silyl group in each molecule,
compounds having an epoxy group and a crosslinking silyl group in
each molecule, compounds having a mercapto group and a crosslinking
silyl group in each molecule, reaction products from a compound
having an amino group and a crosslinking silyl group in each
molecule and a compound having an epoxy group and a crosslinking
silyl group in each molecule, reaction products from a compound
having a (meth) acryloxy group and a crosslinking silyl group in
each molecule and a compound having an amino group and a
crosslinking silyl group in each molecule, are preferred since,
when these are used, it is relatively easy to control the physical
properties and adhesiveness. More preferred from the high
adhesiveness viewpoint are those compounds having, in each
molecule, a nitrogen-containing organic group and a crosslinking
silyl group in which the above-mentioned organic group containing
at least one atom selected from among nitrogen, oxygen and sulfur
atoms is an amino group, an isocyanato group or a group resulting
from reaction of these.
[0162] The above adhesion promoter is preferably used in an amount
of 0.01 to 20 parts by weight per 100 parts by weight of the vinyl
polymer (II). When the amount is 0.01 part by weight, the
adhesiveness improving effect can hardly be produced. An amount
exceeding 20 parts by weight adversely affects the physical
properties of cured products. The addition amount of the adhesion
promoter is preferably 0.01 to 10 parts by weight, more preferably
0.5 to 5 parts by weight.
[0163] A physical property modifier may be used to increase the
hardness upon curing of the curable composition or decrease the
hardness and increase the elongation instead, or otherwise modify
the physical properties. As the physical property modifier to be
added as necessary, there may be mentioned, for example,
alkylalkoxysilanes such as methyltrimethoxysilane,
dimethyldimethoxysilane, trimethylmethoxysilane and
n-propyltrimethoxysilane; alkylisopropenoxysilanes such as
dimethyldiisopropenoxysilane, methyltriisopropenoxysilane and
.gamma.-glycidoxypropylmethyldiisopropenoxysilane; various silane
coupling agents such as vinyltrimethoxysilane and
vinylmethyldimethoxysilane, silicone varnishes; polysiloxanes; and
the like. Addition in an amount within the range of 0 to 20 parts
by weight per 100 parts by weight of the vinyl polymer (II) gives
good results.
[0164] A curability modifier may be added to increase or decrease
the rate of curing of the curable composition and, further, a
storage stability improver may be added to inhibit the viscosity
from increasing during storage. As the curability modifier or
storage stability improver, there may be mentioned alcohols such as
methanol and ethanol; ortho esters such as methyl orthoformate;
crosslinking silyl-containing compounds such as tetraethoxysilane,
methyltrimethoxysilane and vinyltrimethoxysilane; carboxylic acids
such as 2-ethylhexanoic acid, and so forth. Addition in an amount
within the range of 0 to 20 parts by weight per 100 parts by weight
of the vinyl polymer (II) gives favorable results.
[0165] In the curable composition according to the second aspect of
the invention, there may be incorporated various fillers according
to the use of the composition. Usable as the filler are reinforcing
fillers such as woodmeal, pulp, cotton chips, asbestos, glass
fibers, carbon fibers, mica, walnut shell flour, rice hull flour,
graphite, diatomaceous earth, clay, fumed silica, precipitated
silica, crystalline silica, fused silica, dolomite, silicic
anhydride, hydrous silicic acid and carbon black; fillers such as
calcium carbonate, magnesium carbonate, diatomaceous earth,
calcined clay, clay, talc, titanium oxide, bentonite, organic
bentonite, ferric oxide, finely divided aluminum, flint powder,
zinc oxide, activated zinc white, zinc dust and shirasu balloons;
and fibrous fillers such as asbestos, glass fibers and filaments.
For obtaining high strength cured products using such fillers, the
use of a filler selected mainly from among fumed silica,
precipitated silica, silicic anhydride, hydrous silicic acid,
carbon black, surface-treated fine calcium carbonate, calcined
clay, clay, activated zinc white and the like in an amount within
the range of 1 to 100 parts by weight per 100 parts by weight of
the vinyl polymer (II) gives favorable results. When cured products
low in strength but high in elongation are desired, the use of a
filler selected mainly from among titanium oxide, calcium
carbonate, talc, ferric oxide, zinc oxide, shirasu balloons and the
like in an amount within the range of 5 to 200 parts by weight per
100 parts by weight of the vinyl polymer (II) gives good results.
These fillers may be used singly or two or more of them may be used
in admixture.
[0166] In the practice of the second aspect of the invention, the
use of a filler in combination with a plasticizer is more effective
in increasing the elongation of cured products or enabling
admixture of the filler in large amounts. The plasticizer is not
particularly restricted but, according to the physical property or
appearance characteristic which is to be adjusted, use may be made
of, for example, the following, either singly or in combination of
two or more: phthalate esters such as dibutyl phthalate, diheptyl
phthalate, di(2-ethylhexyl)phthalate and butyl benzyl phthalate;
nonaromatic dibasic acid esters such as dioctyl adipate, dioctyl
sebacate, dibutyl sebacate and isodecyl succinate; aliphatic esters
such as butyl oleate and methyl acetyllicinolate; polyalkylene
glycol esters such as diethylene glycol dibenzoate, triethylene
glycol dibenzoate and pentaerythritol esters; phosphate esters such
as tricresyl phosphate and tributyl phosphate; trimellitic acid
esters; chlorinated paraffins; hydrocarbon oils such as
alkyldiphenyls and partially hydrogenated terphenyl; process oils;
polyethers such as polyethylene glycol and polypropylene glycol, or
polyethers derived therefrom by partially or totally converting the
hydroxyl groups occurring in these molecules to alkoxy groups or
the like; epoxy plasticizers such as epoxidized soybean oil and
benzyl epoxystearate; polyester plasticizers; etc. The addition of
these plasticizers is not always necessary, however. It is also
possible to incorporate these plasticizers in the step of polymer
production. The use of such a plasticizer in an amount within the
range of 0 to 100 parts by weight per 100 parts by weight of the
vinyl polymer (II) gives good results.
[0167] While a filler, a plasticizer and a condensation catalyst
are mainly used in the curable composition according to the second
aspect of the invention, an adhesiveness providing agent such as a
phenolic resin, sulfur or a silane coupling agent; a modifier such
as a silanol or hydrolyzable group-containing polysiloxane; a tack
and weathering resistance improver such as an ultraviolet-curable
resin, a pigment, an antioxidant, an ultraviolet absorber and other
additives may arbitrarily be added.
[0168] As the antisagging agent, there may be mentioned polyamide
waxes; hydrogenated castor oil derivatives; metal soaps such as
calcium stearate, aluminum stearate and barium stearate, and so on.
The use thereof is unnecessary in some instances, however,
depending on the intended use or as a result of incorporation of a
filler, a reinforcing agent and/or the like.
[0169] Usable as the colorant when necessary are inorganic
pigments, organic pigments and dyes in common use, among
others.
[0170] As the physical property modifier, there may be added, when
necessary, various silane coupling agents, for example
alkylalkoxysilanes such as methyltrimethoxysilane,
dimethyldimethoxysilane, trimethylmethoxysilane and
n-propyltrimethoxysilane; alkylisopropenoxysilanes such as
dimethyldiisopropenoxysilane, methyltriisopropenoxysilane and
.gamma.-glycidoxypropylmethyldiisopropenoxysilane, functional
group-containing alkoxysilanes such as
.gamma.-glycidoxypropylmethyldimethoxysilane,
.gamma.-glycidoxypropyltrimethoxysilane, vinyltrimethoxysilane,
vinyl-dimethylmethoxysilane, .gamma.-aminopropyltrimethoxysilane,
N-(.beta.-aminoethyl)aminopropylmethyldimethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane and
.gamma.-mercaptopropylmethyldimethoxysilane; silicone varnishes;
polysiloxanes and the like. By using such a physical property
modifier, it is possible to increase or decrease the hardness or
increase the elongation on the occasion of curing of the
composition of the invention.
[0171] Another hydrolyzable silyl-containing polymer may be added
to the curable composition according to the second aspect of the
invention. The other hydrolyzable silyl-containing polymer is not
particularly restricted in skeletal structure but includes
polysiloxane polymers, polyether polymers, hydrocarbon polymers
(polyisobutylene etc.) and the like.
[0172] The curable composition according to the second aspect of
the invention may be prepared as a one-pack formulation by
compounding all the components beforehand and storing in a tightly
closed vessel. In this case, the composition, after application, is
cured by moisture in the air. It is also possible to prepare the
composition as a two-pack formulation, namely separately preparing
a curing agent composition by compounding a curing catalyst, a
filler, a plasticizer and water, among others. This composition and
the resin composition are mixed up before application.
[0173] The curable composition according to the second aspect of
the invention may have a wide variety of forms, from rubber-like to
resin-like, according to the molecular weight and main chain
skeleton of the polymer. Therefore, this composition can be
utilized in or as sealing compositions, adhesives, elastic
adhesives, pressure-sensitive adhesives, coatings, powder coatings,
foamed products, potting agents for electric or electronic use,
films, gaskets, various molding materials, etc.
[0174] In using the composition containing the polymer (II) as a
sealing composition, the polymer (II) preferably has a molecular
weight (weight average molecular weight) of 1,000 to 1,000,000.
[0175] The filler which can be added to the curable composition
according to the second aspect of the invention for adjusting the
mechanical properties when the composition is to be used as a
sealing composition includes, more specifically, reinforcing
fillers such as fumed silica, precipitated silica, silicic
anhydride, hydrous silicic acid and carbon black; fillers such as
calcium carbonate, magnesium carbonate, diatomaceous earth,
calcined clay, clay, talc, titanium oxide, bentonite, organic
bentonite, ferric oxide, zinc oxide, activated zinc white and
shirasu balloons; and fibrous fillers such as asbestos, glass
fibers and filaments. For obtaining high strength cured products
using such fillers, the use of a filler mainly selected from among
fumed silica, precipitated silica, silicic anhydride, hydrous
silicic acid, carbon black, surface-treated fine calcium carbonate,
calcined clay, clay, activated zinc white and the like at an
addition amount within the range of 1 to 200 parts by weight per
100 parts by weight of the vinyl polymer (II) gives favorable
results. When cured products low in strength but high in elongation
are desired, the use of a filler selected mainly from among
titanium oxide, calcium carbonate, talc, ferric oxide, zinc oxide,
shirasu balloons and the like at an addition amount within the
range of 1 to 200 parts by weight per 100 parts by weight of the
vinyl polymer (II) gives good results. These fillers may be used
singly or two or more of them may be used in admixture.
[0176] More specific examples of the plasticizer which can be added
for adjusting the physical properties and viscosity include
phthalate esters such as dibutyl phthalate, diheptyl phthalate,
di(2-ethylhexyl)phthalate and butyl benzyl phthalate; nonaromatic
dibasic acid esters such as dioctyl adipate, dioctyl sebacate,
dibutyl sebacate and isodecyl succinate; aliphatic esters such as
butyl oleate and methyl acetylricinolate; polyalkylene glycol
esters such as diethylene glycol dibenzoate, triethylene glycol
dibenzoate and pentaerythritol esters; phosphate esters such as
tricresyl phosphate and tributyl phosphate; trimellitic acid
esters; chlorinated paraffins; hydrocarbon oils such as
alkyldiphenyls and partially hydrogenated terphenyl; process oils;
polyethers such as polyethylene glycol and polypropylene glycol, or
polyethers derived therefrom by partially or totally converting the
hydroxyl groups occurring in these molecules to alkoxy groups or
the like; epoxy plasticizers such as epoxidized soybean oil and
benzyl epoxystearate; polyester plasticizers; etc. These may be
used singly or two or more of them may be used in admixture. The
addition of these plasticizers is not always necessary, however. It
is also possible to incorporate these plasticizers in the step of
polymer production. The use of such a plasticizer in an amount
within the range of 0 to 100 parts by weight per 100 parts by
weight of the vinyl polymer (II) gives good results.
[0177] For use as a sealing composition, the curable composition
according to the second aspect of the invention may be prepared as
a one-pack preparation by compounding all components in advance and
storing the whole in a tightly sealed state, which preparation,
after application, is allowed to be cured by absorption of the
moisture in the air, or as a two-pack preparation by separately
preparing a curing agent composition by compounding such components
as a curing catalyst, a filler, a plasticizer and water, which
composition is mixed with a polymer composition prior to use. The
one-pack type is more preferred, since it can be handled with ease
and the possibility of failure in application is slight.
[0178] In cases where the composition comprising the polymer (II)
is used as an composition for use in adhesive compositions, the
polymer (II) preferably has a Tg of not higher than -20.degree. C.
and preferably has a molecular weight (weight average molecular
weight) of 1,000 to 1,000,000. For further improving the
adhesiveness against substrates, an acid group-containing monomer
is preferably copolymerized.
[0179] When the curable composition according to the second aspect
of the invention is used as a pressure-sensitive adhesive
composition, the addition of a tackifier resin is not always
necessary since its main component is the vinyl polymer. When
necessary, however, various tackifiers can be used. Specific
examples are phenol resins, modified phenol resins,
cyclopentadiene-phenol resins, xylene resins, chroman resins,
petroleum resins, terpene resins, terpene-phenol resins, rosin
esters and the like.
[0180] More specific examples of the solvent to be used for
adjusting the workability are, among others, aromatic hydrocarbon
solvents such as toluene and xylene, ester solvents such as ethyl
acetate, butyl acetate, amyl acetate and cellosolve acetate, and
ketone solvents such as methyl ethyl ketone, methyl isobutyl ketone
and diisobutyl ketone. Those solvents may be used also in the step
of polymer production.
[0181] The plasticizer is not particularly restricted but includes,
among others, liquid polybutene, mineral oils, lanolin, liquid
polyisoprene and liquid polyacrylates. The filler is not
particularly restricted but includes, among others, zinc white,
titanium white, calcium carbonate, clay and various pigments. The
antioxidant is not particularly restricted but includes, among
others, rubber antioxidants (phenolic, amine type) and metal
dithiocarbamates. The above-mentioned tackifiers, plasticizers,
fillers and antioxidants may respectively be used singly or two or
more species may respectively be used in combination.
[0182] The above pressure-sensitive adhesive composition can be
applied to a wide variety of targets such as tapes, sheets, labels
and foils. For example, the above pressure-sensitive adhesive
composition may be applied in the form of a solvent base, emulsion
base or hot melt composition to various substrate materials such as
films made of a synthetic resin or modified natural resin, paper,
all kinds of cloth, metal foils, metallized plastic foils, asbestos
or glass fiber cloths and the like and then cured by exposure to
moisture or water at ordinary temperature or with heating.
[0183] When the composition comprising the polymer (II) is used as
a composition for use in coatings where the coatings are required
to have a certain degree of hardness, hence a certain crosslinking
density is required. Therefore, the polymer (II) to be used for
coating purposes preferably has a crosslinking silyl value of about
20 to 200. Thus, when no crosslinking silyl-containing monomer is
copolymerized, the polymer (II) preferably has a number average
molecular weight of about 50 to 5,000. However, even a polymer (II)
having a number average molecular weight higher than 5,000 can also
be used by copolymerizing a crosslinking silyl-containing monomer.
The polymer (II) to be used for coating purposes preferably has a
Tg of -30.degree. C. to 100.degree. C., more preferably -10.degree.
C. to 60.degree. C. A polymer having a desired Tg can be
synthesized by adjusting the species and proportions of the vinyl
monomers to be used. When the composition comprising the polymer
(II) is used as a composition for use in coatings, the composition
may contain, in addition to the polymer (II), any crosslinking
silyl-containing low molecular compound known in the art, any
crosslinking silyl-containing polymer known in the art, any resin
known in the art for use in coatings, and the like.
[0184] When the curable composition according to the second aspect
of the invention is used as a high-solid coating, the method
comprising copolymerizing a compound having both a polymerizable
alkenyl group and a crosslinking silyl group in each molecule with
another vinyl monomer may also be mentioned as a preferred method
of obtaining a vinyl polymer having a high crosslinking silyl
value, since the production process becomes simple. By using such
method, it becomes possible for the coating to have a high solid
content.
[0185] Among the compounds having both a polymerizable alkenyl
group and a crosslinking silyl group in each molecule, those in
which the crosslinking silyl group is an alkoxysilyl group are
preferred from the cost and/or stability viewpoint. Thus, for
example, the following are particularly preferred: [0186]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(OCH.sub.3).sub.3, [0187]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OCH.sub.3).sub.2,
[0188]
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(OCH.sub.3).sub-
.3,
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OCH.sub-
.3).sub.2. These compounds may be used singly or two or more of
them may be used in admixture.
[0189] The copolymerizing ratio between the compound having both a
polymerizable alkenyl group and a crosslinking silyl group and the
other vinyl monomer is not particularly restricted but it is
preferred that that compound account for 1 to 50 mole percent,
preferably 2 to 40 mole percent, more preferably 3 to 30 mole
percent, based on the total polymerization composition. When the
amount of the compound having both a polymerizable alkenyl group
and a crosslinking silyl group is smaller than 1 mole percent, the
curing becomes insufficient and, when it exceeds 50 mole percent,
the storage stability becomes low.
[0190] When necessary, it is possible to add, to that coating
composition, such an additive as a resin, for example a polyester,
epoxy or acrylic, a coloring auxiliary, a spreading agent, an
antifoam and an antistatic agent, in addition to the additives
mentioned hereinabove referring to the curable adhesive
composition. As more specific examples of the colorant to be used
in this coating composition, there may be mentioned inorganic
pigments such as titanium dioxide, carbon black, iron oxide and
chromium oxide, and organic pigments such as phthalocyanine and
quinacridone pigments, among others. The addition amount of these
additives can appropriately be selected according to the
characteristics required. The additives may also be used in
admixture.
[0191] When a curing catalyst and an additive(s) are added to the
vinyl polymer (II) as necessary and the resulting composition is
applied to a substrate to be coated and then cured, a uniform
coating film can be obtained. The hydrolysis and/or condensation of
the crosslinking silyl group proceeds at room temperature, hence
heating is not always necessary in the step of curing. For
promoting the curing, however, heating may be applied. The heating
temperature is 20 to 200.degree. C., preferably 50 to 180.degree.
C.
[0192] This coating composition can be used as a solvent base one
or a water base one. It is also possible to use the composition as
a powder coating by distilling off the volatile matter from the
main component vinyl polymer, adding desired additives and finely
dividing the resulting composition.
[0193] When the curable composition according to the second aspect
of the invention is used as a coating which can have a high solid
content and is excellent in elastic properties, at least one of the
crosslinking silyl groups preferably occur at a molecular chain
terminus. It is also possible, however, to introduce a crosslinking
silyl group into the molecular chain by copolymerizing a small
amount of a compound having both a polymerizable alkenyl group and
a crosslinking silyl group in each molecule to thereby adjust the
molecular weight between crosslinking sites.
[0194] As examples of such compound, there may be mentioned [0195]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(OCH.sub.3).sub.3, [0196]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OCH.sub.3).sub.2,
[0197]
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(OCH.sub.3).sub-
.3, [0198]
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OCH.sub.3).s-
ub.2, [0199]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(OC.sub.2H.sub.5).sub.3,
[0200] CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si
(CH.sub.3)(OC.sub.2H.sub.5).sub.2, [0201]
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(OC.sub.2H.sub.5).sub.3-
, [0202]
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OC-
.sub.2H.sub.5).sub.2, [0203]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(OC.sub.2H.sub.5).sub.3,
[0204]
CH.sub.2.dbd.CHCO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OC.sub.2H.sub.5).sub-
.2, [0205]
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(OC.sub.2H.sub.5).sub.3-
,
CH.sub.2.dbd.C(CH.sub.3)CO.sub.2(CH.sub.2).sub.3Si(CH.sub.3)(OC.sub.2H-
.sub.5).sub.2. These compounds may be used singly or two or more of
them may be used in admixture.
[0206] In this composition for use in coatings, there may be
incorporated, when necessary, one or more additives, for example
resins such as polyester, epoxy and acrylic resins, coloring aids,
spreading agents or antiforming agents, antistatic agents and the
like, in addition to the additives mentioned hereinabove referring
to the curable adhesive composition. The colorant to be used in
that composition for use in coatings more specifically includes
inorganic pigments such as titanium dioxide, carbon black, iron
oxide and chromium oxide and organic pigments such as the
phthalocyanine and quinacridone series, among others. The addition
amounts of these additives can be adequately selected according to
the characteristics required. They may also be used in
admixture.
[0207] When the vinyl polymer (II) with a curing catalyst or an
additive (s) added as necessary is applied to a substrate to be
coated, and then allowed to cure, a uniform coating film can be
obtained. The hydrolysis and/or condensation of the crosslinking
silyl group proceeds at room temperature and, therefore, no heating
is required in the step of curing. For promoting the curing,
however, heating may be made. The heating temperature is 20 to
200.degree. C., preferably 50 to 180.degree. C.
[0208] This composition for use in coatings can be used as a
solvent base or water base coating. It is also possible to use it
as a powder coating by distilling off the volatile matter from the
main component vinyl polymer, adding desired components and then
finely dividing the resulting compound.
[0209] When the composition comprising the polymer (II) as a
composition for use in adhesive compositions, the polymer (II)
preferably has a molecular weight (weight average molecular weight)
of 1,000 to 1,000,000. By combining this polymer (II) with a
condensation curing agent and other components known in the art, it
is possible to use the composition as a one-pack or two-pack
adhesive. When the composition comprising the polymer (II) as a
composition for use in adhesives, this composition may contain,
when necessary, one or more of the additives known in the art, such
as tackifiers, coupling agents, thixotropic agents, inorganic
fillers and stabilizers. The tackifiers are not particularly
restricted but include, among others, terpene resins, phenol
resins, terpene-phenol resins, rosin resins and xylene resins. The
coupling agents are not particularly restricted but include, among
others, silane coupling agents and titanate coupling agents. The
inorganic fillers are not particularly restricted but include,
among others, carbon black, titanium white, calcium carbonate and
clay. The thixotropic agents are not particularly restricted but
include, among others, Aerosil and Disperon. The stabilizers are
not particularly restricted but include, among others, ultraviolet
absorbers, antioxidants, heat stabilizers and stabilizers against
hydrolysis. The above-mentioned tackifiers, coupling agents,
thixotropic agents, inorganic fillers and stabilizers may
respectively be used singly or two or more may be used in
combination.
[0210] The field of application of the above adhesive is not
particularly restricted but includes, among others, the uses
thereof as an adhesive for food packaging, an adhesive for shoes
and footwear, a decorative paper adhesive, a wood adhesive, a
structural adhesive (for cars, septic tanks, houses), a magnetic
tape binder, a binder for textile treatment and a textile
auxiliary. When the composition comprising the polymer (II) is used
as a composition for use in artificial leathers or synthetic
leathers, this composition may contain any of those compounds known
in the art to be useful in making artificial leathers or synthetic
leathers, as necessary. For example, mention may be made of chain
extenders and solvents. In addition, condensation catalysts,
promoters, pigments, dyes, surfactants, textile softening agents,
ultraviolet absorbers, antioxidants, hydrolysis preventing agents,
antifungal agents, inorganic fillers, organic fillers, matting
agents, antiforming agents and the like may also be used where
necessary.
[0211] This composition can be used in making artificial leathers
as well as dry method synthetic leathers and wet method synthetic
leathers. When the composition comprising the polymer (II) is used
as a printing ink composition, any of those compounds known in the
art to be useful in printing inks can be used in that composition,
if necessary. For example, solvents and the like may be mentioned.
The solvents include alcohols such as ethanol and isopropanol,
ketones such as acetone, MEK, MIBK and cyclohexanone, aromatic
hydrocarbons such as toluene and xylene, halogenated hydrocarbons
such as chlorobenzene, trichlene and perchlene, ethers such as THF
and dioxane and esters such as cellosolve acetate, ethyl acetate
and butyl acetate and these may used singly or two more may be used
combinedly. Further, where necessary, condensation catalysts,
promoters, colorants such as pigments, surfactants, ultraviolet
absorbers, antioxidants, hydrolysis preventing agents and so forth
may be used. In producing printing ink compositions,
nitrocellulose, polyvinyl chloride, vinyl chloride-vinyl acetate
copolymers, polyamides, acrylic ester polymers and so on may also
be incorporated.
[0212] When the composition comprising the polymer (II) is used as
a resin composition for use in flooring materials, any of those
compounds known in the art to be useful in flooring resin
compositions can be used. For example, mention may made of
solvents. The solvents include alcohols such as ethanol and
isopropanol, ketones such as acetone, MEK, MIBK and cyclohexanone,
aromatic hydrocarbons such as toluene and xylene, halogenated
hydrocarbons such as chlorobenzene, trichlene and perchlene, ethers
such as THF and dioxane and esters such as cellosolve acetate,
ethyl acetate and butyl acetate and these may used singly or two
more may be used combinedly. Further, where necessary, condensation
catalysts, promoters, plasticizers, tackifiers, colorants such as
pigments, surfactants, ultraviolet absorbers, antioxidants,
hydrolysis preventing agents, fillers, antiforming agents and so
forth may be used.
[0213] The field of application of the above flooring resin
composition is not particularly restricted but includes, among
others, the uses thereof as a ship or building flooring material, a
coating film waterproofing agent, a sheet waterproofing agent, a
spray-on waterproofing agent, a sealing agent, an adhesive for
artificial lawn and so on, a pavement asphalt modifier, an elastic
paving composition for use in tennis courts and athletic fields and
a floor concrete protective coating.
[0214] When the composition containing the polymer (II) is used as
a foaming composition, the polymer (II) preferably has a molecular
weight (weight average molecular weight) of 1,000 to 1,000,000. In
this case, it may contain water, a surfactant (e.g. silicone,
nonionic or ionic), an additive(s) (e.g. flame retardant,
antimicrobial agent, colorant, filler, stabilizer) a forming agent,
etc.
<<Method of Producing the Polymer (III)>>
[0215] The third aspect of the invention is now described.
[0216] According to the third aspect of the invention, a vinyl
polymer (III) having an acrylic functional group at one or more
termini thereof is produced by reacting the vinyl polymer (I)
having a silanol group at one or more termini thereof with a
silicon compound represented by the general formula (3):
XSiR.sub.2-G-O--C(O)C(L)=CH.sub.2 (3) wherein R is a hydrocarbon
group containing 1 to 14 carbon atoms or a halogenated hydrocarbon
group containing 1 to 10 carbon atoms and the two R groups may be
the same or different, X is a hydrolyzable group, G is an alkylene
group containing 1 to 4 carbon atoms and L is a hydrogen atom or a
hydrocarbon group containing 1 to 20 carbon atoms.
[0217] The acrylic functional group so referred to herein means a
group represented by --C(O)C(L)=CH.sub.2 (L being as defined
above).
[0218] The polymer (I) is as mentioned in detail referring to the
first aspect of the invention.
[0219] In the general formula (3), G includes, but is not limited
to, groups represented by --CH.sub.2--, --CH.sub.2CH.sub.2--,
--CH.sub.2CH.sub.2CH.sub.2-- and --CH.sub.2CH(CH.sub.3)CH.sub.2--
and L is a hydrogen atom or a methyl group.
[0220] In that reaction, X is a silicon atom-bound hydrolyzable
group capable of being condensed with the silanol group of the
polymer (I) to form a siloxane (namely Si--O--Si) or capable of
being hydrolyzed to form an SiOH group while the above-mentioned
silicon compound is then condensed with the silanol group of the
polymer (I) to form a siloxane bond. The group X is selected from
among those silicon atom-bound hydrolyzable groups mentioned
hereinabove referring to the silicon compound to be used in
producing the silanol-terminated vinyl polymer (I) and preferably
having both a silicon atom-bound hydrolyzable group and a
hydrosilyl group as represented by the general formula (17). X is
preferably a chlorine atom, and particularly preferred silicon
compound is either 3-acryloxypropyldimethylchlorosilane or
3-methacryloxypropyldimethylchlorosilane.
[0221] Typically, this reaction is carried out in an organic
solvent (e.g. tetrahydrofuran (THF), diethyl ether, chloroform,
toluene, hexane, or a mixture thereof). The reaction temperature to
be used for this condensation will depend on the group X employed,
as will be understood by those skilled in the art. This is because
some X group species readily react at room temperature, while
others need a high temperature or even a condensation catalyst for
the completion of the reaction. Such specific combinations required
are well within the range of ordinary knowledge those skilled in
the art have and the best combination can be readily selected based
on the results of routine experiments. In a certain preferred
embodiment, X is chlorine and the subsequent reaction is generally
carried out in the presence of an acid acceptor, for example
pyridine, triethylamine or dibutylamine, to neutralize the
byproduct hydrochloric acid. In this mode of embodiment, the
reaction temperature is preferably 0 to 100.degree. C.
[0222] The third aspect of the invention is further directed to the
vinyl polymer (III) having an acrylic functional group at one or
more termini thereof and obtainable by such a production method as
mentioned above. This polymer is not limited to the one produced by
the method described herein.
[0223] The vinyl polymer (III) according to the third aspect of the
invention is not particularly restricted in molecular weight
distribution, namely ratio (Mw/Mn) between weight average molecular
weight (Mw) and number average molecular weight (Mn). For
suppressing the viscosity of the curable composition derived
therefrom to a low level and facilitating the handling of the
composition and for attaining sufficient curing product physical
properties, however, the molecular weight distribution should
preferably be narrow. The value of the molecular weight
distribution is preferably less than 1.8, more preferably not more
than 1.7, still more preferably not more than 1.6, still more
preferably not more than 1.5, still more preferably not more than
1.4, still more preferably not more than 1.3. The molecular weight
distribution is most usually measured by gel permeation
chromatography (GPC). Chloroform or THF is used as the mobile phase
and polystyrene gel columns are used as the column, and the number
average molecular weight and other values can be determined on the
polystyrene equivalent basis.
<<Curable Composition>>
[0224] The vinyl polymer having an acrylic functional group at one
or more termini thereof, according to the third aspect of the
invention, can be used as the main component of a curable
composition.
[0225] The curable composition according to the third aspect of the
invention is not particularly restricted but includes one curable
by heating or irradiation with light and/or electron beams.
<Photo- and/or Electron Beam-Curable Composition>
[0226] In the following, the curable composition capable of curing
upon irradiation with light and/or electron beams is described.
[0227] This photo- and/or electron beam-curable composition
preferably contains a photopolymerization initiator.
[0228] The photopolymerization initiator to be used in the practice
of the invention is not particularly restricted but includes, as
preferred species, photo radical initiators and photo anion
initiators, such as acetophenone, propiophenone, benzophenone,
xanthol, fluorein, benzaldehyde, anthraquinone, triphenylamine,
carbazole, 3-methylacetophenone, 4-methylacetophenone,
3-pentylacetophenone, 4-methoxyacetophenone, 3-bromoacetophenone,
4-allylacetophenone, p-diacetylbenzene, 3-methoxybenzophenone,
4-methylbenzophenone, 4-chlorobenzophenone,
4,4'-dimethoxybenzophenone, 4-chloro-4'-benzylbenzophenone,
3-chloroxanthone, 3,9-dichloroxanthone, 3-chloro-8-nonylxanthone,
benzoyl, benzoin methyl ether, benzoin butyl ether,
bis(4-dimethylaminophenyl)ketone, benzyl methoxy ketal and
2-chlorothioxanthone. These initiators may be used singly or in
combination with another compound. Specifically, there may be
mentioned the combination with an amine such as
diethanol/methylamine, dimethylethanolamine and triethanolamine, a
further combination thereof with an iodonium salt such as
diphenyliodonium chloride, and the combination of a dye such as
methylene blue with an amine, for instance.
[0229] A near infrared absorbing cationic dye may also be used as a
near infrared photopolymerization initiator. Preferred for use as
the near infrared absorbing cationic dye are, among others, those
near infrared absorbing cationic dye-borate anion complexes
disclosed, for example, in Japanese Kokai Publication Hei-03-111402
and Japanese Kokai Publication Hei-05-194619, which are excited by
light energy within the range of 650 to 1500 nm. The combined use
of a boron-containing sensitizer is more preferred.
[0230] Since a slight extent of photofunctionalization of the
system is quite sufficient, the addition amount of the
photopolymerization initiator is not particularly restricted but is
preferably 0.001 to 10 parts by weight per 100 parts by weight of
the polymer in that composition.
[0231] The curable composition according to the third aspect of the
invention basically comprises the above components as main
components. Preferably, it is free of any other polymerizable
monomer so that the residual monomer odor problem may be cleared
up. According to the intended purpose, however, a polymerizable
monomer and/or oligomer and various additives may be used
combinedly. Preferred as the polymerizable monomer and/or oligomer
is a monomer and/or oligomer having a radical-polymerizable group
or a monomer and/or oligomer having an anion-polymerizable group.
As the radical-polymerizable group, there may be mentioned acrylic
functional groups such as a (meth) acrylic group, as well as groups
derived from styrene, acrylonitrile, vinyl esters,
N-vinylpyrrolidone, acrylamides, conjugated dienes, vinyl ketones,
vinyl chloride and the like. Preferred among them are those having
a (meth) acrylic group, which are similar to the polymer of the
invention. The anion-polymerizable group includes (meth)acrylic
groups, styrene, acrylonitrile, N-vinylpyrrolidone, acrylamides,
conjugated dienes, vinyl ketones and the like. Among them, those
having an acrylic functional group, which are similar to the
polymer of the invention, are preferred.
[0232] As specific examples of the above monomers, there may be
mentioned (meth)acrylate monomers, cyclic acrylates,
N-vinylpyrrolidone, styrenic monomers, acrylonitrile,
N-vinylpyrrolidone, acrylamide monomers, conjugated diene monomers
and vinyl ketone monomers, among others. As the (meth)acrylate
monomers, there may be mentioned n-butyl (meth)acrylate,
2-ethylhexyl (meth)acrylate, isooctyl (meth)acrylate, isononyl
(meth)acrylate and compounds of the following formulas: ##STR6##
##STR7##
[0233] The styrenic monomers include styrene,
.alpha.-methylstyrene, etc., the acrylamide monomers include
acrylamide, N,N-dimethylacrylamide, etc., the conjugated diene
monomers include butadiene, isoprene, etc., and the vinyl ketone
monomers include methyl vinyl ketone and the like.
[0234] As polyfunctional monomers, there may be mentioned neopentyl
glycol polypropoxy diacrylate, trimethylolpropane polyethoxy
triacrylate, bisphenol F polyethoxy diacrylate, bisphenol A
polyethoxy diacrylate, dipentaerythritol polyhexanolide
hexaacrylate, tris(hydroxyethyl)isocyanurate polyhexanolide
triacrylate, tricyclodecane dimethylol diacrylate
2-(2-acryloyloxy-1,1-dimethyl)-5-ethyl-5-acryloyloxymethyl-1,3-dioxane,
tetrabromobisphenol A diethoxy diacrylate, 4,4-dimercaptodiphenyl
sulfide dimethacrylate, polytetraethylene glycol diacrylate,
1,9-nonanediol diacrylate, ditrimethylolpropane tetraacrylate,
etc.
[0235] As the oligomers, there may be mentioned epoxy acrylate
resins such as bisphenol A-based epoxy acrylate resins, phenol
novolak-based epoxy acrylate resins and cresol novolak-based epoxy
acrylate resins, COOH-modified epoxy acrylate resins, urethane
acrylate resins produced by reacting urethane resins obtained from
a polyol (e.g. polytetramethylene glycol, polyester diol from
ethylene glycol and adipic acid, .epsilon.-caprolactone-modified
polyester diol, polypropylene glycol, polyethylene glycol,
polycarbonate diol, hydroxyl-terminated hydrogenated polyisoprene,
hydroxyl-terminated polybutadiene, hydroxyl-terminated
polyisobutylene) and an organic isocyanate (e.g. tolylene
diisocyanate, isophoronediisocyanate, diphenylmethanediisocyanate,
hexamethylene diisocyanate, xylylene diisocyanate) with a
hydroxyl-containing (meth)acrylate [e.g. hydroxyethyl
(meth)acrylate, hydroxypropyl (meth)acrylate, hydroxybutyl
(meth)acrylate, pentaerythritol triacrylate], resins resulting from
the introduction of a (meth)acrylic group(s) into the above polyols
via an ester bond, polyester acrylate resins, etc.
[0236] From among these monomers and oligomers, appropriate ones
are selected according to the initiator and curing conditions to be
used.
[0237] The monomers and/or oligomers having an acrylic functional
group preferably have a number average molecular weight of not more
than 2,000, more preferably for the reason that the compatibility
is good, not more than 1,000.
[0238] The method of curing such photo- and/or electron
beam-curable composition is not particularly restricted but
includes the irradiation of light and/or electron beams using a
high pressure mercury lamp, low pressure mercury lamp, electron
beam irradiating apparatus, halogen lamp, light emitting diode or
semiconductor laser, for instance, according to the properties of
the photopolymerization initiator employed.
[0239] The vinyl polymer according to the third aspect of the
invention can be utilized not only in the above-mentioned photo-
and/or electron beam-curable composition but also in various
curable compositions and, further, as a macromonomer. The curable
composition of the invention may vary widely in form, from
rubber-like to resin-like, according to the molecular weight and
main chain skeleton of the polymer. Therefore, as specific uses of
the curable composition of the invention, there may be mentioned
sealing compositions, adhesives, pressure-sensitive adhesives,
elastic adhesives, coatings, powder coatings, foamed products,
potting agents for electric and electronic fields, films, gaskets,
resists, various molding materials, artificial marble and so
on.
<Heat-Curable Composition>
[0240] In the following, a curable composition according to the
invention which can be cured upon heating is described.
[0241] The heat-curable composition of the invention preferably
contains a heat polymerization initiator.
[0242] The heat polymerization initiator to be used in the practice
of the invention is not particularly restricted but includes azo
initiators, peroxides, persulfuric acid and redox initiators.
[0243] Suitable azo initiators include, but are not limited to,
2,2'-azobis(4-methoxy-2,4-dimethylvaleronitrile) (VAZO 33),
2,2'-azobis(2-amidinopropane) dihydrochloride (VAZO 50),
2,2'-azobis(2,4-dimethylvaleronitrile) (VAZO 52),
2,2'-azobis(isobutyronitrile) (VAZO 64),
2,2'-azobis-2-methylbutyronitrile (VAZO 67) and
1,1-azobis(1-cyclohexanecarbonitrile) (VAZO 88) (all available from
du Pont Chemical), 2,2'-azobis(2-cyclopropylpropionitrile) and
2,2'-azobis(methyl isobutyrate) (V-601) (available from Wako Pure
Chemical Industries), among others.
[0244] Suitable peroxide initiators include, but are not limited
to, benzoyl peroxide, acetyl peroxide, lauroyl peroxide, decanoyl
peroxide, dicetyl peroxydicarbonate,
di(4-tert-butylcyclohexyl)peroxydicarbonate (Perkadox 16S)
(available from Akzo Nobel), di(2-ethylhexyl)peroxy dicarbonate,
tert-butyl peroxypivalate (Lupersol 11) (available from Elf
Atochem), tert-butyl peroxy-2-ethylhexanoate (Trigonox 21-C50)
(available from Akzo Nobel) and dicumyl peroxide, among others.
[0245] Suitable persulfate initiators include, but are not limited
to, potassium persulfate, sodium persulfate and ammonium
persulfate.
[0246] Suitable redox (oxidation-reduction) initiators include, but
are not limited to, combinations of the above-mentioned persulfate
initiators with a reducing agent such as sodium hydrogen
metasulfite or sodium hydrogen sulfite; systems based on an organic
peroxide and a tertiary amine, for example the system based on
benzoyl peroxide and dimethylaniline; and systems based on an
organic hydroperoxide and a transition metal, for example the
system based on cumene hydroperoxide and cobalt naphthenate, among
others.
[0247] Other initiators include, but are not limited to, pinacols
such as tetraphenyl-1,1,2,2-ethanediol, among others.
[0248] Preferred heat radical initiators are selected from the
group consisting of azo initiators and peroxide initiators. More
preferred are 2,2'-azobis(methyl isobutyrate), tert-butyl
peroxypivalate and di(4-tert-butylcyclohexyl)peroxydicarbonate, and
mixtures of these.
[0249] In the practice of the third aspect of the invention, the
thermal initiators are present in a catalytically effective amount,
and such amount is not restricted but, typically, is about 0.01 to
5 parts by weight, more preferably about 0.025 to 2 parts by
weight, per 100 parts by weight of the total amount of the polymer
having an acrylic functional group at one or more termini thereof,
of the invention, and the other monomer and oligomer mixture added.
In cases where a mixture of initiators is used, the total amount of
the initiator mixture is selected as if only one initiator species
were used.
[0250] The curable composition according to the third aspect of the
invention basically comprises the above components as main
components. Preferably, it is free of any other polymerizable
monomer so that the residual monomer odor problem may be cleared
up. According to the intended purpose, however, a polymerizable
monomer and/or oligomer and/or various additives may be used
combinedly. Preferred as the polymerizable monomer and/or oligomer
are a monomer and/or oligomer having a radical-polymerizable group
or a monomer and/or oligomer having an anion-polymerizable group.
As the radical-polymerizable group, there may be mentioned acrylic
functional groups such as a (meth)acrylic group, as well as
styrene, acrylonitrile, vinyl esters, N-vinylpyrrolidone,
acrylamides, conjugated dienes, vinyl ketones, vinyl chloride and
the like. Preferred among them are those having a (meth)acrylic
group, which are similar to the polymer of the invention. The
anion-polymerizable group includes (meth)acrylic groups, styrene,
acrylonitrile, N-vinylpyrrolidone, acrylamides, conjugated dienes,
vinyl ketones and the like. Among them, those having an acrylic
functional group, which are similar to the polymer of the
invention, are preferred.
[0251] As specific examples of the above monomers, there may be
mentioned, among others, those (meth)acrylatemonomers, cyclic
acrylates, N-vinylpyrrolidone, styrenic monomers, acrylonitrile,
N-vinylpyrrolidone, acrylamide monomers, conjugated diene monomers
and vinyl ketone monomers mentioned hereinabove referring to the
photo- and/or electron beam-curable composition.
[0252] From among these monomers and oligomers, appropriate ones
are selected according to the initiator and curing conditions to be
used.
[0253] The monomer and/or oligomer having an acrylic functional
group preferably has a number average molecular weight of not more
than 2,000, more preferably for the reason that the compatibility
is good, not more than 1,000.
[0254] The method of curing the heat-curable composition is not
particularly restricted but, generally, the temperature is
preferably within the range of 50.degree. C. to 200.degree. C.,
more preferably within the range of 70.degree. C. to 130.degree.
C., although it may vary depending on the thermal initiator, the
species of the polymer of the invention, having an acrylic
functional group at one or more termini thereof, and the
compound(s) added. The curing time may vary according to the
polymerization initiator, monomer, solvent and reaction temperature
used, among others but, generally, is within the range of 1 minute
to 10 hours.
[0255] The polymer according to the third aspect of the invention
can be utilized not only in the above-mentioned heat-curable
composition but also in various curable compositions and, further,
as a macromonomer. The curable composition of the invention may
vary widely in form, from rubber-like to resin-like, according to
the molecular weight and main chain skeleton of the polymer.
Therefore, as specific uses of the curable composition of the
invention, there may be mentioned sealing compositions, adhesives,
pressure-sensitive adhesives, elastic adhesives, coatings, powder
coatings, foamed products, potting agents for electric and
electronic fields, films, gaskets, resists, various molding
materials, artificial marble and so on.
<Another Mode of Curing>
[0256] Further, it is also expected here that the polymer having an
acrylic functional group at one or more termini thereof, of the
invention, can be caused to cure through the addition of an amine
crosslinking agent, namely via the Michael addition reaction.
BEST MODES FOR CARRYING OUT THE INVENTION
[0257] The following examples illustrate the invention. They are,
however, by no means limitative of the scope of the invention.
[0258] In the following examples and comparative examples,
"part(s)" and "%" mean "part(s) by weight" and "% by weight",
respectively.
[0259] In the examples, the "number average molecular weight" and
"molecular weight distribution (ratio between weight average
molecular weight and number average molecular weight)" were
calculated by the standard polystyrene equivalent method using gel
permeation chromatography (GPC). Columns packed with crosslinked
polystyrene gels were used as the GPC columns and chloroform as the
GPC solvent. The .sup.1H NMR measurement was made in CDCl.sub.3
using Varian Gemini 300 MHz.
PRODUCTION EXAMPLE 1
Synthesis of alkenyl-terminated poly(butyl acrylate)
[0260] A 2-liter separable flask equipped with a reflux condenser
and a stirrer was charged with CuBr (3.39 g, 0.059 mol) and the
reaction vessel inside was purged with nitrogen. Acetonitrile
(111.9 mL) was added and the contents were stirred on an oil bath
at 70.degree. C. for 40 minutes. Thereto were added butyl acrylate
(200 g), diethyl 2,5-dibromoadipate (23.4 g, 0.065 mol) and
pentamethyldiethylenetriamine (0.5 mL) (hereinafter referred to as
"triamine") to thereby initiate the reaction. While heating at
70.degree. C. with stirring, butyl acrylate (800 g) was
continuously added dropwise. During adding dropwise butyl acrylate,
the triamine (2.5 mL) was added. After the lapse of 380 minutes
following reaction initiation, 1,7-octadiene (288 mL, 215 g, 1.95
mol) and the triamine (4.0 mL) were added and the resulting mixture
was further heated at 70.degree. C. with stirring for 8 hours.
[0261] The reaction mixture was diluted with toluene and passed
through an activated alumina column and the volatile matter was
then distilled off under reduced pressure to give a polymer
[1].
[0262] A 2-liter separable flask equipped with a reflux condenser
was charged with the above polymer [1] (1000 g), potassium benzoate
(34.8 g) and N,N-dimethylacetamide (1000 mL) and the contents were
heated at 100.degree. C. with stirring under nitrogen for 15 hours.
The N,N-dimethylacetamide was distilled off by heating under
reduced pressure and the residue was diluted with toluene. The
toluene-insoluble matter (KBr and excess potassium benzoate) was
filtered off using an activated alumina column. The volatile matter
in the filtrate was distilled off under reduced pressure to give a
polymer [2].
[0263] A 2-liter round-bottom flask equipped with a reflux
condenser was charged with the polymer [2] (1000 g), aluminum
silicate (200 g, product of Kyowa Chemical, Kyowaad 700 PEL) and
toluene (5.0 L) and the contents were heated at 100.degree. C. with
stirring under nitrogen for 6 hours. After removal of the aluminum
silicate by filtration, the toluene in the filtrate was distilled
off under reduced pressure to give a polymer [3].
EXAMPLE 1
Synthesis of silanol-terminated poly(butyl acrylate)
[0264] A 30-mL pressure reactor was charged with the polymer [3]
(10 g) synthesized in Production Example 1 and then purged with
nitrogen. Chlorodimethylsilane (0.34 mL, 3.1 mmol), zero valence
platinum-1,1,3,3-tetramethyl-1,3-divinyldisiloxane complex
(1.32.times.10.sup.-6 mol/ml; xylene solution) (0.079 mL) and
toluene (2.0 mL) were added and the contents were heated at 100%
with stirring. Three hours later, 0.071 mL of zero valence
platinum-1,1,3,3-tetramethyl-1,3-divinyldisiloxane complex
(1.32.times.10.sup.-6 mol/ml; xylene solution) was added and
heating was continued at 100.degree. C. with stirring for further 6
hours. The volatile matter of the reaction mixture was distilled
off by heating at 80.degree. C. under reduced pressure to give
chloro-dimethyl-terminated poly(butyl acrylate) (polymer [5]).
[0265] The polymer [5] was dissolved in tetrahydrofuran (10 mL) and
the solution was heated at 50.degree. C. with stirring. A 10%
aqueous solution of NaHCO.sub.3 (10 mL) was added dropwise and the
mixture was further heated with stirring for 1 hour. The reaction
mixture was transferred to a seperatory funnel, ethyl acetate (20
mL) was added, and the organic layer was washed with brine. The
organic layer was dried over Na.sub.2SO.sub.4 and filtered and the
solvent was then distilled off by heating under reduced pressure to
give silanol-terminated poly(butyl acrylate) (polymer [6])
EXAMPLE 2
Production of Cured Product
[0266] A composition was prepared by mixing up 100 parts of the
polymer [6] obtained in Example 1, 3 parts of
methyltriisopropenoxysilane and 1 part of a tin catalyst. The
composition was cast into a form and allowed to cure at room
temperature, whereby a cured product having rubber-like elasticity
was obtained.
EXAMPLE 3
Synthesis of methacryloyl-terminated poly(butyl acrylate)
[0267] In a 10-mL flask was weighed 1.00 g of the polymer [6]
obtained in Example 1 and, after nitrogen purging, tetrahydrofuran
(1.5 mL) was added. After addition of triethylamine (0.022 mL, 0.16
mmol), 3-methacryl-oxypropyldimethylchlorosilane (0.023 mL, 0.10
mmol) was added. The mixture became turbid, whereby the formation
of a salt could be confirmed. After several hours of stirring at
room temperature, the mixture was diluted with toluene and the
dilution was purified by filtration to give the desired
methacryloyl (CH.sub.2.dbd.C(CH.sub.3)CO.sub.2--)-terminated
poly(butyl acrylate) (polymer [7]). The structure was confirmed by
.sup.1H NMR.
EXAMPLE 4
Synthesis of diisopropenoxymethylsilyl-terminated poly(butyl
acrylate)
[0268] In a 10-mL flask was weighed 1.00 g of the polymer [6]
obtained in Example 1 and, after nitrogen purging, tetrahydrofuran
(1.5 mL) was added. Methyltriisopropenoxysilane (0.12 mL, 0.47
mmol) was added and the mixture was stirred at 50.degree. C. The
volatile matter was distilled off using an evaporator. No gelation
occurred and the desired diisopropenoxymethylsilyl-terminated
poly(butyl acrylate) (polymer [8]) was obtained as an oil. The
structure was confirmed by .sup.1H NMR.
INDUSTRIAL APPLICABILITY
[0269] The silanol- or hydrolyzable silyl-terminated vinyl polymer
of the invention, which is preferably produced by utilizing the
technique of living radical polymerization, more preferably atom
transfer radical polymerization, is well controlled in structure,
for example it is high in functionalization rate and narrow in
molecular weight distribution. Therefore, it produces a lower
viscosity as compared with those polymers produced by conventional
radical polymerization and comparable in molecular weight, hence it
is expected that when it is used in a curable composition, it will
be easy to handle the composition. Furthermore, this polymer can
give a highly curable composition.
[0270] The vinyl polymer of the invention having an acrylic
functional group at one or more termini thereof, too, is well
controlled in functional group introduction rate and molecular
weight distribution, among others, since it is preferably obtained
by living radical polymerization, more preferably by atom transfer
radical polymerization. Thus, when this polymer is used in various
curable compositions, it is possible to improve and control the
physical properties.
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