U.S. patent application number 12/186772 was filed with the patent office on 2009-01-08 for curable composition and compatibilizing agent.
This patent application is currently assigned to Kaneka Corporation. Invention is credited to Nao Fujita, Nobuhiro Hasegawa, Yoshiki Nakagawa, Yasuo Shimizu.
Application Number | 20090012237 12/186772 |
Document ID | / |
Family ID | 27343497 |
Filed Date | 2009-01-08 |
United States Patent
Application |
20090012237 |
Kind Code |
A1 |
Fujita; Nao ; et
al. |
January 8, 2009 |
CURABLE COMPOSITION AND COMPATIBILIZING AGENT
Abstract
It is an object of the present invention to provide a curable
which has good storage stability and can give cured products
retaining the high elongation characteristic originating from the
polyether polymer and showing a high gel fraction and good
weatherability. Thus, the present invention provides a durable
composition which comprises the following two components: a
polyether polymer having at least one crosslinkable functional
group and a vinyl polymer which is compatible with said polyether
polymer having at least one crosslinkable functional group at a
polymer terminus. Further, the present invention provides a curable
composition which comprises the following three components: a
polyether polymer having at least one crosslinkable functional
group, a vinyl polymer incompatible with said polyether polymer and
having at least one crosslinkable function group, and a
compatibilizing agent capable of compatibilizing said polyether
polymer and said vinyl polymer with each other when added to a
mixture thereof.
Inventors: |
Fujita; Nao; (Hyogo-ku,
JP) ; Shimizu; Yasuo; (Settsu-shi, JP) ;
Hasegawa; Nobuhiro; (Settsu-shi, JP) ; Nakagawa;
Yoshiki; (Settsu-shi, JP) |
Correspondence
Address: |
CONNOLLY BOVE LODGE & HUTZ LLP
1875 EYE STREET, N.W., SUITE 1100
WASHINGTON
DC
20006
US
|
Assignee: |
Kaneka Corporation
Osaka-shi
JP
|
Family ID: |
27343497 |
Appl. No.: |
12/186772 |
Filed: |
August 6, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10965192 |
Oct 15, 2004 |
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12186772 |
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10296541 |
Apr 4, 2003 |
6831130 |
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PCT/JP01/04369 |
May 24, 2001 |
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10965192 |
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Current U.S.
Class: |
525/187 ;
525/185 |
Current CPC
Class: |
C08L 101/10 20130101;
C08L 71/02 20130101; C08L 101/10 20130101; C08L 2666/02 20130101;
C08L 2666/04 20130101; C08F 290/06 20130101; C08L 2666/14 20130101;
C08L 71/02 20130101; C08G 65/336 20130101; C08L 71/02 20130101;
C08F 293/005 20130101 |
Class at
Publication: |
525/187 ;
525/185 |
International
Class: |
C08G 65/02 20060101
C08G065/02 |
Foreign Application Data
Date |
Code |
Application Number |
May 24, 2000 |
JP |
2000-153778 |
May 24, 2000 |
JP |
2000-153779 |
Jan 23, 2001 |
JP |
2001-15074 |
Claims
1. A curable composition which comprises the following three
components: (I) a polyether polymer having at least one
crosslinkable functional group, (II) a vinyl polymer incompatible
with said polyether polymer and having at least one crosslinkable
function group, and (IV) at least one compatibilizing agent capable
of compatibilizing said polyether polymer and said vinyl polymer
with each other when added to a mixture thereof, said
compatibilizing agent being selected from the group consisting of
nonpolymer organic compounds, polymers obtain able by polymerizing
a monomer or monomers other than vinyl monomers, and polymers
obtain able by polymerizing a single vinyl monomer.
2. The curable composition according to 1 wherein the
compatibilizing agent (IV) is a polyoxyalkylene having a molecular
weight of not more than 3,000.
3. The curable composition according to claim 2, wherein the
compatibilizing agent (IV) is polypropylene oxide having a
molecular weight of not more than 3,000.
4. The curable composition according to 4, in which the cured
product derived there from by curing without using any filler and
having a thickness of not more than 100 .mu.m shows a level of
weatherability which is not shorter than 20 hours in sunshine
weathermeter testing.
5. A compatibilizing agent obtain able by copolymerization of a
plurality of vinyl monomers and capable of compatibilizing the two
components: (I) a polyether polymer having at least one
crosslinkable functional group, and (II) a vinyl polymer
incompatible with said polyether polymer and having at least one
crosslinkable function group, with each other, when added to a
mixture thereof.
6. The compatibilizing agent according to claim 5, which is obtain
able by the copolymerization of at least one vinyl monomer selected
from among the monomers usable in polymerizing the vinyl polymer
(II), with another vinyl monomer.
7. The compatibilizing agent according to claim 6, wherein the
other vinyl monomer is a vinyl monomer having a polyether
structure.
8. The compatibilizing agent according to claim 7, wherein the mole
ratio between the at least one monomer selected from among the
monomers usable in polymerizing the vinyl polymer (II) and the
vinyl monomer having a polyether structure is within the range of
1:20 to 20:1.
9. The compatibilizing agent according to 5, which has a number
average molecular weight of 500 to 50,000 as determined by gel
permeation chromatography.
10. The compatibilizing agent according to 7, wherein the polyether
structure is essentially polypropylene oxide.
11. The compatibilizing agent according to 5 wherein the vinyl
monomer is a (meth)acrylic monomer.
12. The compatibilizing agent according to 7, which is produced by
a living radical polymerization technique.
13. The compatibilizing agent according to claim 12, wherein the
living radical polymerization technique consists in atom transfer
radical polymerization.
14. The compatibilizing agent according to 6, which has a number
average molecular weight of 500 to 50,000 as determined by gel
permeation chromatography.
15. The compatibilizing agent according to 7, which has a number
average molecular weight of 500 to 50,000 as determined by gel
permeation chromatography.
16. The compatibilizing agent according to 8, which has a number
average molecular weight of 500 to 50,000 as determined by gel
permeation chromatography.
17. The compatibilizing agent according to 8, wherein the polyether
structure is essentially polypropylene oxide.
18. The compatibilizing agent according to 9, wherein the polyether
structure is essentially polypropylene oxide.
19. The compatibilizing agent according to 6 wherein the vinyl
monomer is a (meth)acrylic monomer.
20. The compatibilizing agent according to 7 wherein the vinyl
monomer is a (meth)acrylic monomer.
Description
TECHNICAL FIELD
[0001] The present invention relates to a curable composition
comprising a crosslinkable functional group-containing vinyl
polymer and a crosslinkable functional group-containing polyether
polymer and to a compatibilizing agent for compatibilizing the
above polymers with each other.
BACKGROUND ART
[0002] Unlike polymers obtainable by ionic polymerization or
polycondensation, functional group-containing vinyl polymers, in
particular functional group-terminated vinyl polymers, obtain able
by radical polymerization have scarcely been put to practical use.
Among vinyl polymers, (meth)acrylic polymers have such
characteristics as high weatherability and transparency that
polyether polymers, hydrocarbon polymers or polyester polymers
cannot have, and (meth)acrylic polymers having an alkenyl or
crosslinking silyl group(s) on a side chain(s) are currently used
in highly weather-resistant coating compositions and the like. On
the other hand, it is not easy to control the polymerization of
acrylic polymers because of side reactions, and it is very
difficult to introduce a functional group into such polymers at one
or both ends.
[0003] If vinyl polymers having an alkenyl group at a molecular
chain terminus or termini can be obtained by a simple and easy
method, it becomes possible to obtain cured products superior in
cured product physical properties to cured products from vinyl
polymers having a crosslinking group(s) on a side chain(s).
Therefore, a number of researchers have so far made investigations
concerning the method for the production thereof. However, it is
not easy to produce them on a commercial scale. In Japanese Kokai
Publication Hei-01-247403 and Japanese Kokai Publication
Hei-05-255415, for instance, there is disclosed a method of
synthesizing alkenyl-terminated (meth)acrylic polymers which uses
an alkenyl group-containing disulfide as a chain transfer
agent.
[0004] Japanese Kokai Publication Hei-05-262808 discloses a method
of synthesizing alkenyl-terminated (meth)acrylic polymers which
comprises synthesizing a vinyl polymer having a hydroxyl group at
each end using a hydroxyl group-containing disulfide and further
utilizing the reactivity of each hydroxyl group.
[0005] Japanese Kokai Publication Hei-05-211922 discloses a method
of synthesizing silyl group-terminated (meth)acrylic polymers which
comprises synthesizing a vinyl polymer having a hydroxyl group at
each end using a hydroxyl group-containing polysulfide and the
reactivity of each hydroxyl group.
[0006] These methods can hardly ensure that a desired functional
group will be introduced at each of both ends. Hence, cured
products having satisfactory characteristics cannot be obtained.
For introducing a functional group at each of both ends without
fail, a chain transfer agent must be used in large amounts, and
this is a problem from the production process viewpoint. In
addition, these methods use an ordinary method of radical
polymerization, so that it is difficult to control the molecular
weight and molecular weight distribution (ratio of weight average
molecular weight to number average molecular weight) of the product
polymer.
[0007] In view of such a state of the art, the present inventors
have so far made a number of inventions relating to various
crosslinkable functional group-terminated vinyl polymers, methods
of producing the same, curable compositions comprising the same,
and uses thereof (cf. Japanese Kokai Publication Hei-11-080249,
Japanese Kokai Publication Hei-11-080250, Japanese Kokai
Publication Hei-11-005815, Japanese Kokai Publication
Hei-11-116617, Japanese Kokai Publication Hei-11-116606, Japanese
Kokai Publication Hei-11-080571, Japanese Kokai Publication
Hei-11-080570, Japanese Kokai Publication Hei-11-130931, Japanese
Kokai Publication Hei-11-100433, Japanese Kokai Publication
Hei-11-116763, Japanese Kokai Publication Hei-09-272714, and
Japanese Kokai Publication Hei-09-272715, among others).
[0008] For example, vinyl polymers having a silicon-containing
group comprising hydroxyl or hydrolyzable group(s) bound to a
silicon atom and capable of crosslinking under siloxane bond
formation (herein after, such silicon-containing group is also
referred to as "crosslinkable silyl group") or cured products
obtain able from compositions comprising the same are excellent in
heat resistance and weatherability and can be used in various
fields of application which include, but are not limited to,
sealing materials, for example sealing materials such as elastic
sealing materials for building and construction and sealing
materials for laminated glass, electric and electronic part
materials such as solar cell back sealers, electric insulating
materials such as wire/cable insulating sheath, pressure sensitive
adhesive materials, adhesives, elastic adhesives, paints, powder
paints, coating compositions, foamed bodies, potting materials for
electric and electronic use, films, gaskets, casting materials,
various molding materials, and rustproof and waterproof sealants
for end faces (cut sections) of net glass or laminated glass.
[0009] On the other hand, polyether polymers having at least one
crosslinking silyl group are disclosed, for example, in Japanese
Kokoku Publication Sho-45-36319, Japanese Kokoku Publication
Sho-46-12154, Japanese Kokoku Publication Sho-46-30741 and Japanese
Kokoku Publication Sho-49-32673, Japanese Kokai Publication
Sho-50-156599, Japanese Kokai Publication Sho-51-73561, Japanese
Kokai Publication Sho-54-6096, Japanese Kokai Publication
Sho-55-13767, Japanese Kokai Publication Sho-55-13768, Japanese
Kokai Publication Sho-55-82123, Japanese Kokai Publication
Sho-55-123620, Japanese Kokai Publication Sho-55-125121, Japanese
Kokai Publication Sho-55-131021, Japanese Kokai Publication
Sho-55-131022, Japanese Kokai Publication Sho-55-135135 and
Japanese Kokai Publication Sho-55-137129, and Japanese Kokai
Publication Hei-03-72527 and Japanese Kokai Publication
Hei-03-97825. When cured, they give high elongation cured products
and therefore are used in elastic sealing materials and the like
mainly intended for use in building and construction.
[0010] However, these polyethers, in particular polyethers having a
main chain comprising a polypropylene oxide, have a problem in that
hydrogen atoms each bound to a tertiary carbon atom are readily
oxidized, hence the weatherability becomes poor, if no antioxidant
is used. To solve this problem, the present inventors have already
proposed, in Japanese Kokoku Publication Hei-02-42367 and Japanese
Kokoku Publication Hei-02-44845, a curable composition improved in
weatherability as a result of blending an acrylic polymer having at
least one crosslinkable silyl group with a polyether polymer having
at least one crosslinkable silyl group. Further, Japanese Kokoku
Publication Hei-04-69667, there is disclosed a sealing material
composition comprising a blend of an acrylic polymer having an
alkoxysilyl group at each of both molecular ends as produced by
using a chain transfer agent with a polyether polymer having an
alkoxysilyl group at each of both molecular ends.
[0011] That vinyl polymer having at least one crosslinkable
functional group which is to be blended with the polyether polymer
having at least one crosslinkable functional group is generally
produced by using a crosslinkable functional group-containing
radical polymerization initiator or chain transfer agent.
Therefore, it is difficult to attain a high percentage of
crosslinkable functional group introduction at both ends. As a
result, there arises a problem, namely the gel fraction of cured
products decreases.
[0012] On the other hand, the combined use of a crosslinkable
functional group-containing monomer is required for obtaining cured
products with a satisfactory gel fraction. In this case, a problem
arises, namely the high elongation characteristics intrinsic in
polyether polymers are impaired. In this case, the elongation at
break, in particular, decreases and, accordingly, the range of
application of the composition in question is drastically
restricted. Therefore, in using the same as a sealing material,
improvements in weatherability can be attained only by sacrificing
some or other physical characteristic(s), for example increase in
modulus, decrease in elongation, worsening of residual tack,
decrease in gel fraction, etc. In addition, the (meth)acrylic
polymer used there is a product synthesized by free radical
polymerization and, therefore, has a broad molecular weight
distribution and a high viscosity, causing a problem that the
mixture thereof with a polyether polymer also shows a high
viscosity.
[0013] Concerning this problem, Japanese Kokai Publication
Hei-11-116763 proposes to obtain a curable composition high in gel
fraction and excellent in weatherability, without impairing the
high elongation characteristic intrinsic in a crosslinkable
functional group-containing polyether polymer, by using a
low-viscosity vinyl polymer having a terminal crosslinkable
functional group introduced thereinto with a high percentage. In
this case, however, the compatibility of the two polymers may be
poor in certain instances according to the molecular weight and
molecular weight distribution of the vinyl polymer and/or polyether
polymer and to the blending ratio of these two polymers. In that
case, the curable composition resulting from blending, when stored
for a long period of time, may undergo phase separation, for
instance, hence the storage stability thereof may deteriorate.
Furthermore, cured products obtainable from a composition with
insufficient compatibility are inferior in homogeneity, so that
good mechanical and physical properties may not be realized.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide a
curable composition which comprises a crosslinkable functional
group-containing vinyl polymer and a crosslinkable functional
group-containing polyether polymer and which has good storage
stability and can give cured products retaining the high elongation
characteristic originating from the polyether polymer and showing a
high gel fraction and good weatherability.
[0015] Thus, the present invention provides a curable
composition
[0016] which comprises the following two components:
(I) a polyether polymer having at least one crosslinkable
functional group and (II) a vinyl polymer
[0017] which is compatible with said polyether polymer, has a
weight average molecular weight (Mw)-to-number average molecular
weight (Mn) ratio (Mw/Mn) of less than 1.8 as determined by gel
permeation chromatography and has at least one crosslinkable
functional group at a polymer terminus.
[0018] The present invention also provides a curable
composition
[0019] which comprises the following two components:
(I) a polyether polymer having at least one crosslinkable
functional group and (II) a vinyl polymer
[0020] which is compatible with said polyether polymer, is a
product of living radical polymerization and has at least one
crosslinkable functional group at a polymer terminus.
[0021] Further, the present invention provides a curable
composition
[0022] which comprises the following three components:
(I) a polyether polymer having at least one crosslinkable
functional group, (II) a vinyl polymer incompatible with said
polyether polymer and having at least one crosslinkable function
group, and (III) a compatibilizing agent produced by
copolymerization of a plurality of vinyl monomers and capable of
compatibilizing said polyether polymer and said vinyl polymer with
each other when added to a mixture thereof.
[0023] Furthermore, the present invention provides a curable
composition
[0024] which comprises the following three components:
(I) a polyether polymer having at least one crosslinkable
functional group, (II) a vinyl polymer incompatible with said
polyether polymer and having at least one crosslinkable function
group, and (IV) at least one compatibilizing agent capable of
compatibilizing said polyether polymer, and said vinyl polymer with
each other when added to a mixture thereof, said compatibilizing
agent being selected from the group consisting of nonpolymer
organic compounds, polymers obtain able by polymerizing a monomer
or monomers other than vinyl monomers, and polymers obtain able by
polymerizing a single vinyl monomer.
[0025] Further, the present invention provides a compatibilizing
agent obtain able by copolymerization of a plurality of vinyl
monomers and capable of compatibilizing the two components:
(I) a polyether polymer having at least one crosslinkable
functional group, and (II) a vinyl polymer incompatible with said
polyether polymer and having at least one crosslinkable function
group, with each other, when added to a mixture thereof.
[0026] In the following, the present invention is described in
detail.
DETAILED DISCLOSURE OF THE INVENTION
<<Re: Polyether Polymer (I)>>
[0027] The component (I) in the present invention, namely the
polyether polymer having at least one crosslinkable functional
group may contain, or may not contain, a urethane bond or urea bond
in the main chain thereof. The main chain of the polyether polymer
is not particularly restricted but includes, among others,
polyethylene oxide, polypropylene oxide, polybutylene oxide, and
polyphenylene oxide. Among these, those which are essentially
polyalkylene oxides are preferred, and the one which is essentially
polypropylene oxide is more preferred. The latter may contain
ethylene oxide, butylene oxide, phenylene oxide or the like, in
addition to propylene oxide. The expression "the main chain is
essentially polypropylene oxide" means that propylene oxide units
account for at least 50%, preferably at least 70%, more preferably
at least 90%, of all the main chain-constituting repeating units.
The polypropylene oxide polymer preferably has a molecular weight
distribution (Mw/Mn) of not more than 1.5, since a lower viscosity
means better handleability.
[0028] The crosslinkable functional group in component (I) is not
particularly restricted but includes, as preferred species,
crosslinkable silyl groups, alkenyl groups, a hydroxyl group, an
amino group, and groups having a polymerizable carbon-carbon double
bond, and an epoxy group, among others. In particular,
crosslinkable silyl groups are preferred. The definitions of these
are the same as mentioned later herein. The crosslinkable
functional group in component (I) may be the same as or different
from the crosslinkable functional group in component (II). From the
curability viewpoint, however, it is preferred that both be not
different in kind. Even when both are of the same kind, they may be
the same or different in structure. The number of crosslinkable
functional groups which the polyether polymer (I) has is at least 1
on average, but from the viewpoint of the curability of the
composition, it is preferably more than 1, more preferably 1.1 to
4.0 on average, still more preferably 1.5 to 2.5 on average. From
the viewpoint of the rubber elasticity of the cured product, the
crosslinkable functional group is preferably located at a polyether
polymer terminus, more preferably at each of the polymer
termini.
[0029] The method of producing the component (I) polyether polymer
is not particularly restricted but may be any of those known in the
art.
[0030] In cases where the component (I) polyether polymer having at
least one crosslinkable functional group, which is to be used in
accordance with the present invention, contains a urethane or urea
bond in the main chain thereof, any polyether polymer obtain able
by any method of production may be used as the component (I)
provided that it is an organic polymer containing one or more
urethane or urea bonds within the molecule and having at least one
crosslinkable functional group. The crosslinkable functional group
is not particularly restricted but includes such various functional
groups as mentioned above. Preferred among them are, however,
silicon-containing groups represented by the formula (1):
--SiY.sub.aR.sup.1.sub.3-a (1)
wherein, R.sup.1 is 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 univalent
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.1 groups, they may be the same or different; Y
represents a hydroxyl group or a hydrolyzable group and, when there
are two or more Y groups, they may be the same or different; a
represents 0, 1, 2 or 3. Further, use may be made of polyether
polymers produced by industrially easy and simple processes, for
example the process comprising reacting the terminal hydroxyl
groups of a hydroxyl group-terminated oxyalkylene polymer (D) with
a polyisocyanate compound (E) in excess to give a polymer having an
isocyanato group-terminated polyurethane main chain (F) and then
reacting the isocyanato groups with the W group of a silicon
compound (G) represented by the formula (2):
W--R.sup.2--SiY.sub.aR.sup.1.sub.3-a (2)
wherein R.sup.1, Y and a are the same as defined above, R.sup.2 is
a substituted or unsubstituted bivalent organic group containing 1
to 20 carbon atoms and W is an active hydrogen atom-containing
group selected from among hydroxyl, carboxyl, mercapto and amino
(primary or secondary), or reacting the terminal hydroxyl group of
(D) simultaneously with excess (E) and the W group of (G), or the
process comprising reacting the hydroxyl group-terminated
oxyalkylene polymer (D) with a hydrolyzable silyl group-containing
isocyanate compound (H) represented by the formula (3):
O.dbd.C.dbd.N--R.sup.2--SiY.sub.aR.sup.1.sub.3-a (3)
wherein R.sup.1, R.sup.2, Y and a are the same as defined
above.
[0031] The oxyalkylene polymer (D) may be any one produced by any
process but preferably is one having at least 0.7 hydroxyl groups
per molecular terminus on the average for all molecules. More
specifically, mention may be made of conventional oxyalkylene
polymers produced by using an alkali metal catalyst and oxyalkylene
polymers produced by reacting such an initiator as a polyhydroxy
compound having at least two hydroxyl groups with an alkylene oxide
in the presence of a double metal cyanide complex (c) or cesium,
among others.
[0032] Preferred among others is the use of a double metal cyanide
complex (c) since oxyalkylene polymers (D) lower in degree of
unsaturation, higher in molecular weight, narrower in Mw/Mn, lower
in viscosity and higher in acid resistance and weatherability can
be obtained as compared with the conventional oxyalkylene polymers
produced by using an alkali metal catalyst.
[0033] Preferred as the double metal cyanide complex (C) are
complexes whose main component is zinc hexacyanocobaltate, and
ethers and/or alcohol complexes thereof are preferred. The
composition thereof may be the one essentially described in
Japanese Kokoku Publication Sho-46-27250. Preferred as the ether
are tetra hydrofuran, glymes, diglymes and other glymes. Among
them, tetra hydrofuran and glymes are preferred since oxyalkylene
polymers (D) narrower in Mw/Mn and lower in degree of unsaturation
can be obtained using them. Preferred as the alcohol is t-butanol,
which is described in Japanese Kokai Publication Hei-04-145123,
since oxyalkylene polymers (D) lower in degree of unsaturation can
be obtained using the same.
[0034] For attaining a high molecular weight by the reaction with
the polyisocyanate compound (E) and for increasing a high rate of
silyl group introduction by the reaction with the hydrolyzable
silyl group-containing isocyanate compound (H), the number of
hydroxyl groups in the oxyalkylene polymer (D) is preferably not
less than 1.6, more preferably 1.8 to 4, per molecule on the
average for all molecules. Most preferably, it is 1.8 to 3 so that
gelation may be avoided in the step of reaction with the
polyisocyanate compound (E). Oxyalkylene polymers (D) having at
least 2 hydroxyl groups can be produced by using a trifunctional or
higher functionality initiator in lieu of a part or the whole of
the bifunctional initiator. It is also possible to obtain an
oxyalkylene polymer (D) having 1.8 to 3 hydroxyl groups per
molecule on the average for all molecules by blending an
oxyalkylene polymer which is at least bifunctional with an
oxyalkylene polymer which is at most bifunctional.
[0035] As specific species, there may be mentioned polyoxyethylene
compounds, polyoxypropylene compounds, polyoxybutylene compounds,
polyoxyhexylene compounds, polyoxytetramethylene compounds and/or
copolymers of these.
[0036] Polyoxypropylene diol, polyoxypropylene triol,
polyoxypropylene tetraol, copolymers of these polymers with
ethylene oxide and, further, mixtures thereof are particularly
preferred as the oxyalkylene polymer (D).
[0037] Oxyalkylene polymers obtain able by copolymerizing ethylene
oxide so that they may terminate at primary hydroxyl groups are
preferred since their reaction with the polyisocyanate compound (E)
or hydrolyzable silyl group-containing isocyanate compound (H) is
facilitated.
[0038] The number average molecular weight of the oxyalkylene
polymer (D) to be used may be not less than 1,000 but preferably is
not less than 4,000, since when it is less than 4,000, the number
of urethane bonds introduced in the polyurethane main chain (F)
becomes increased, so that the viscosity becomes relatively
high.
[0039] The polyisocyanate compound (E) to be used in obtaining the
polyurethane main chain (F) may be any polyisocyanate compound.
[0040] The number of isocyanato groups contained in the
polyisocyanate compound (E) is preferably 2 to 5 per molecule on
average and, from the ready availability viewpoint, it is more
preferably 2 to 3. Most preferably, it is 2 since no gelation is
caused on the occasion of reaction with the oxyalkylene polymer
(D).
[0041] As specific examples, there may be mentioned tolylene
diisocyanate (TDI), methylene diisocyanate (MDI), xylylene
diisocyanate (XDI), isophoronediisocyanate (IPDI), hexamethylene
diisocyanate (HMDI), tetramethylene diisocyanate (TMDI) and the
like. Uretdione derivatives, isocyanurate derivatives, cyanurate
derivatives or carbodiimide derivatives of these may also be
used.
[0042] As specific examples of the silicon compound (G) represented
by the formula (2), which is to be used for introducing the silyl
group represented by the formula (1) into the polyether polymer
molecules, there may be mentioned amino-substituted alkoxysilanes
such as .gamma.-aminopropyltrimethoxysilane,
.gamma.-aminopropyltriethoxysilane,
.gamma.-aminopropylmethyldimethoxysilane,
N-(.beta.-aminoethyl)-.gamma.-aminopropyltrimethoxysilane,
N-(.beta.-aminoethyl)-.gamma.-aminopropyltriethoxysilane,
N-(.beta.-aminoethyl)-.gamma.-aminopropylmethyldimethoxysialne and
1,3-diaminoisopropyltrimethoxysilane,
.gamma.-hydroxypropyltrimethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane, and the like.
[0043] As specific examples of the silyl group-containing
isocyanate compound (H) represented by the formula (3), which is to
be used for introducing the silyl group represented by the formula
(1) into the polyether polymer molecules, there may be mentioned
.gamma.-trimethoxysilylpropyl isocyanate,
.gamma.-triethoxysilylpropyl isocyanate,
.gamma.-methyldimethoxysilylpropyl isocyanate,
.gamma.-methyldiethoxysilylpropyl isocyanate, and the like.
[0044] A catalyst may be used in the reaction of the hydroxyl
groups of the oxyalkylene polymer (D) with the isocyanato group,
and in the reaction of the W group of the silicon compound with the
isocyanato group. In cases where the storage stability of the
resulting polyether polymer is sacrificed, the reactions are
preferably carried out in the absence of any catalyst. When a
catalyst is used, any of the known catalysts-catalyzing the
reaction between a hydroxyl group and an isocyanato group may be
used.
[0045] When, in the practice of the present invention, the
polyether polymer having at least one crosslinkable functional
group, which is the component (I), contains a urethane or urea
bond(s) in the main chain thereof, the polyether polymer preferably
has a number average molecular weight of not less than 7,500. The
use of such an organic polymer having a number average molecular
weight of 7,500 to 25,000 is more preferred. If the number average
molecular weight of the polyether polymer is lower than 7,500, the
cured products will become hard and low in elongation and, when the
number average molecular weight exceeds 25,000, the adhesiveness of
the polymer itself decreases markedly, rendering the polymer less
practicable, although there is no problem about the flexibility or
elongation of the cured products. From the viscosity viewpoint, a
number average molecular weight of 8,000 to 20,000 is particularly
preferred.
[0046] The mixing ration of the component (II) vinyl polymer to the
component (I) polyether polymer is preferably within the range of
100/1 to 1/100, more preferably 100/5 to 5/100, still more
preferably 100/10 to 10/100. When the blending proportion of the
vinyl polymer (II) is smaller, the weatherability, one of the
effects of the present invention, may hardly be expressed in
certain instances.
<<Re: Vinyl Polymer (II)>>
<Main Chain>
[0047] The present inventors have so far made a number of
inventions relating to various crosslinkable functional
group-terminated vinyl polymers, methods of producing the same,
curable compositions comprising the same and uses thereof (see, for
example, Japanese Kokai Publication Hei-11-080249, Japanese Kokai
Publication Hei-11-080250, Japanese Kokai Publication
Hei-11-005815, Japanese Kokai Publication Hei-11-116617, Japanese
Kokai Publication Hei-11-116606, Japanese Kokai Publication
Hei-11-080571, Japanese Kokai Publication Hei-11-80570, Japanese
Kokai Publication Hei-11-130931, Japanese Kokai Publication
Hei-11-100433, Japanese Kokai Publication Hei-11-116763, Japanese
Kokai Publication Hei-09-272714 and Japanese Kokai Publication
Hei-09-272715). The vinyl polymer (II) to be used according to the
present invention is not particularly restricted. Thus, all the
polymers disclosed in the above-cited publications can
appropriately be used. The term "compatible" as used herein refers
to the condition that two or more polymers can be sufficiently
mixed up and, after one week of standing at room temperature, the
mixture will not show any boundary observable by the eye.
[0048] The vinyl monomer constituting the main chain of the vinyl
polymer (II) according to the invention is not particularly
restricted but includes various species. 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, t-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, myristyl (meth)acrylate, palmityl (meth)acrylate,
stearyl (meth)acrylate, eicosyl (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,
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;
aromatic vinyl monomers 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 maleic
acid monoalkyl esters and dialkyl esters; fumaric acid, and fumaric
acid monoalkyl esters and dialkyl esters; maleimide monomers such
as maleimide, methylmaleimide, ethylmaleimide, propylmaleimide,
butylmaleimide, hexylmaleimide, octylmaleimide, dodecylmaleimide,
stearylmaleimide, phenylmaleimide, and cyclohexylmaleimide;
acrylonitrile monomers such as acrylonitrile and methacrylonitrile;
amide group-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 the like. These may be used singly or
a plurality of them may be subjected to copolymerization.
[0049] The main chain of the vinyl polymer (II) is preferably one
produced by polymerizing mainly 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. The term "mainly"
as used herein means that the above-mentioned monomer accounts for
at least 50 mole percent, preferably at least 70 mole percent, of
the monomer units constituting the vinyl polymer.
[0050] From the viewpoint of physical properties of products, among
others, aromatic vinyl monomers and (meth)acrylic monomers are
preferred among others. Acrylic ester monomers and methacrylic
ester monomers are more preferred, and acrylic ester monomers are
particularly preferred. Butyl actylate is still more preferred. In
the practice of the present invention, these preferred monomers may
be copolymerized or, further block-copolymerized with another
monomer and, on that occasion, the content of these preferred
monomers is preferably 40% by weight. In such a sense, the vinyl
polymer (II) is preferably a (meth)acrylic polymer, more preferably
an acrylic polymer, still more preferably an acrylic ester polymer.
In the above form of expression, "(meth)acrylic acid", for
instance, means acrylic acid and/or methacrylic acid.
[0051] From the physical properties viewpoint, in particular, the
vinyl polymer (II) preferably contains (meth)acrylic ester units
(a) having, in the ester moiety, a group selected from the group
consisting of alkyl groups containing 5 to 30 carbon atoms, aryl
group containing 6 to 30 carbon atoms and aralkyl groups containing
7 to 30 carbon atoms. When the number of carbon atoms is 5 or less,
the compatibility with the polyether polymer (I) can hardly be
secured and, when it is greater than 30, the polymer becomes
difficult to handle. More preferred as the ester moiety are alkyl,
aryl or aralkyl groups containing 8 to 30 carbon atoms. Still more
preferred as the ester moiety are alkyl, aryl or aralkyl groups
containing 10 to 25 carbon atoms.
[0052] Especially preferred as the (meth)acrylic ester polymers are
those resulting from copolymerization of two or more (meth)acrylic
ester monomers differing in the number of carbon atoms in the ester
moiety. More specifically, there may be mentioned copolymers
derived from (a) a (meth)acrylic ester unit having, in their ester
moiety, a group selected from the group consisting of the
above-mentioned C.sub.5-30 alkyl groups, C.sub.6-30 aryl groups and
C.sub.7-30 aralkyl groups and (b) a (meth)acrylic ester unit
having, in their ester moiety, an alkyl group containing 1 to 6
carbon atoms (the number of carbon atoms in the ester moiety in
unit (a) being larger than the number of carbon atoms in the ester
moiety in unit (b)). The mole ratio between both units is not
particularly restricted but may be adjusted in various ways
according to the physical properties desired of the curable
composition or cured products. Generally, however, the ratio is
generally 1:100 to 100:1, preferably 1:50 to 10:1, more preferably
1:20 to 1:1.
[0053] The molecular weight distribution, namely the ratio (Mw/Mn)
between the weight average molecular weight (MW) and number average
molecular weight (Mn) as determined by gel permeation
chromatography, of the vinyl polymer (II) according to the
invention is not particularly restricted but preferably is less
than 1.8, preferably not more than 1.7, more preferably not more
than 1.6, still more preferably not more than 1.5, especially
preferably not more than 1.4, most preferably not more than 1.3. In
the practice of the present invention, the GPC measurement is
generally carried out on a polystyrene gel column using chloroform
as a mobile phase, and the number average molecular weight can be
determined on the polystyrene equivalent basis.
[0054] The number average molecular weight of the vinyl polymer
(II) according to the invention is not particularly restricted but
preferably is not less than 3,000, more preferably not less than
5,000, still more preferably not less than 10,000, as determined by
gel permeation chromatography. When the molecular weight is lower,
the high elongation required of the cured products may not be
attained in certain instances. Further, it is preferably not more
than 1,000,000, more preferably not more than 100,000, still more
preferably not more than 50,000, as determined by the same
method.
<Method of Main Chain Synthesis>
[0055] Although the method of synthesizing the vinyl polymer (II)
according to the invention is not restricted, controlled radical
polymerization is preferred, living radical polymerization is more
preferred, and atom transfer radical polymerization is particularly
preferred. These are explained in the following.
Controlled Radical Polymerization
[0056] Radical polymerization methods can be classified into
"ordinary radical polymerization methods" which comprise merely
copolymerizing a monomer having a specific functional group and a
vinyl monomer (s) using an azo compound, a peroxide or the like as
a polymerization initiator, and "controlled radical polymerization
methods" by which a specific functional group can be introduced
into a controlled site (s), for example a terminus or termini.
[0057] "ordinary radical polymerization methods" are simple and
easy to perform but allow the specific functional group-containing
monomer to be introduced into the polymer only at random. For
obtaining polymers with a high percentage of functionalization, it
is necessary to use this monomer in fairly large amounts. When,
conversely, only a small amount of the monomer is used, the problem
arises that the proportion of polymer molecules formed without
introduction of this specific functional group increases. Further,
since they consist in free radical polymerization, there is another
problem, namely only polymers with a wide molecular weight
distribution and a high viscosity can be obtained.
[0058] "Controlled radical polymerization methods" can be further
classified into "chain transfer agent methods" which comprise
carrying out polymerization using a chain transfer agent having a
specific functional group(s) to give functional group-terminated
vinyl polymers and "living radical polymerization methods" by which
growing polymer termini can grow, without undergoing termination
and like reactions, to give polymers with a molecular weight
approximately as designed.
[0059] "Chain transfer agent methods" can give polymers with a high
level of functionalization but require the use of a fairly large
amount of a chain transfer agent having a specific functional
group(s) relative to the initiator, hence have economical problems,
inclusive of treatment-related problems. Like the above-mentioned
"ordinary radical polymerization methods", there is also the
problem that only polymers having a wide molecular weight
distribution and a high viscosity can be obtained because of their
consisting in free radical polymerization.
[0060] Unlike these polymerization methods, "living radical
polymerization methods" hardly undergo termination reactions and
can give polymers with a narrow molecular weight distribution
(Mw/Mn being about 1.1 to 1.5) and make it possible to arbitrarily
control the molecular weight by changing the monomer-to-initiator
charge ratio, in spite of their belonging to the class of radical
polymerization methods regarded as being difficult to control
because of high rates of polymerization and a tendency toward ready
occurrence of termination reactions, such as radical-to-radical
coupling.
[0061] Therefore, such "living radical polymerization methods" are
more preferred as the methods of producing the specific functional
group-containing vinyl polymers mentioned above, since they can
give polymers narrow in molecular weight distribution and low in
viscosity and, in addition, make it possible to introduce specific
functional group-containing monomers into the polymers at almost
arbitrary positions.
[0062] The term "living polymerization", in its narrow sense, means
a mode of polymerization in which molecular chains grow while their
terminus or termini always retain activity. In the ordinary sense,
however, the term also includes the mode of pseudo-living
polymerization in which molecular chains grow while terminally
inactivated ones and terminally activated ones are in equilibrium.
The latter definition applies also in the present invention.
[0063] In recent years, "living radical polymerization methods"
have actively been studied by a number of groups of researchers or
example, there may be mentioned the one using a cobalt porphyrin
complex, as described in the Journal of the American Chemical
Society (J. Am. Chem. Soc.), 1994, vol. 116, page 7943, the one
using a radical capping agent, such as a nitroxide compound, as
described in Macromolecules, 1994, vol. 27, page 7228, and "atom
transfer radical polymerization" (ATRP) using an organic halide or
the like as an initiator and a transition metal complex as a
catalyst.
[0064] Among the "living radical polymerization methods", the "atom
transfer radical polymerization method", by which vinyl monomers
are polymerized using an organic halide or halogenated sulfonyl
compound, for instance, as an initiator and a transition metal
complex as a catalyst, is more preferred for the production of
specific functional group-containing vinyl polymers, for this
method not only has the characteristic features of "living radical
polymerization" but also gives polymers having a terminal halogen
atom(s) relatively convenient for functional group conversion
reactions and, further, the degree of freedom is large in initiator
and catalyst designing. As examples of this atom transfer radical
polymerization, there may be mentioned those described in
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, WO 98/01480, WO 98/40415 and
Sawamoto et al.: Macromolecules, 1995, vol. 28, page 1721, Japanese
Kokai Publication Hei-09-208616 and Japanese Kokai Publication
Hei-08-41117, among others.
[0065] Which of such living radical polymerization methods is to be
used is not critical in the practice of the present invention.
Preferred, however, is the atom transfer radical
polymerization.
[0066] In the following, this living radical polymerization is
described in detail. Prior thereto, one mode of controlled radical
polymerization, namely polymerization using a chain transfer agent,
which can be used in producing the polymer (II) to be described
later herein, is first described. The radical polymerization using
a chain transfer agent (telomer) is not particularly restricted but
includes, for example, the following two methods for producing
vinyl polymers having a terminal structure(s) suited for
utilization in the practice of the present invention.
[0067] One method is to produce halogen-terminated polymers by
using a halogenated hydrocarbon as a chain transfer agent, as
described in Japanese Kokai Publication Hei-04-132706, and the
other is to produce hydroxyl-terminated polymers using a
hydroxyl-containing mercaptan or a hydroxyl-containing polysulfide
or the like as a chain transfer agent, as described in Japanese
Kokai Publication Sho-61-271306, Japanese Patent No. 2594402 or
Japanese Kokai Publication Sho-54-47782.
[0068] The living radical polymerization is now described.
[0069] First, the technique which uses a radical capping agent such
as a nitroxide compound is described. In this polymerization, a
nitroxy free radial (.dbd.N--O.), which is generally stable, is
used as a radical capping agent. Such compound includes, as
preferred species, but is not limited to,
2,2,6,6-tetrasubstituted-1-piperidinyloxy radicals,
2,2,5,5-tetrasubstituted-1-pyrrolidinyloxy radicals and like cyclic
hydroxyamine-derived nitroxy free radicals. Suitable as the
substituent are alkyl groups containing not more than 4 carbon
atoms, such as methyl or ethyl. Specific nitroxy free radical
compounds include, but are not limited to,
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-t-butylamine-oxy radical. It is also possible to use other
stable free radicals, such as galvinoxyl free radical, in lieu of
nitroxy free radicals.
[0070] The above radical capping agent is used in combination with
a radical former or generator. Presumably, a reaction product
formed from the radical capping agent and radical generator serves
as a polymerization initiator to allow the polymerization of an
addition-polymerizable monomer(s) to proceed. Although the ratio
between both is not particularly restricted, the radical initiator
is used appropriately in an amount of 0.1 to 10 moles per mole of
the radical capping agent.
[0071] While various compounds can be used as the radical
generator, a peroxide capable of generating a radical under
polymerization temperature conditions is preferred. Such peroxide
includes, but is not limited to, diacyl peroxides such as benzoyl
peroxide and lauroyl peroxide, dialkyl peroxides such as dicumyl
peroxide and di-t-butyl peroxide, peroxycarbonates such as
diisopropyl peroxydicarbonate and bis(4-t-butylcyclohexyl)
peroxydicarbonate, and alkyl peresters such as t-butyl
peroxyoctoate and t-butyl peroxybenzoate. In particular, benzoyl
peroxide is preferred. Further, other radical generators, for
example radical-generating azo compounds such as
azobisisobutyronitrile can be used in lieu of peroxides.
[0072] Alkoxyamine compounds such as those illustrated below may be
used as initiators in lieu of the combined use of a radical capping
agent and a radical generator, as reported in Macromolecules, 1995,
vol. 28, page 2993.
##STR00001##
[0073] When an alkoxyamine compound is used as an initiator and
that compound is one having a functional group, such as a hydroxyl
group, such as the one illustrated above, functional
group-terminated polymers are obtained. When this is utilized in
the practice of the present invention, functional group-terminated
polymers can be obtained.
[0074] The polymerization conditions, including monomer(s), solvent
and polymerization temperature, to be used in the above-mentioned
polymerization using a radical capping agent, such as a nitroxide
compound are not particularly restricted but may be the same as
those used in the atom transfer radical polymerization mentioned
below.
Atom Transfer Radical Polymerization
[0075] Now, the atom transfer radical polymerization method, which
is more preferred as the living radical polymerization in carrying
out the present invention, is described.
[0076] In this atom transfer radical polymerization, an organic
halide, in particular a highly reactive carbon-halogen
bond-containing organic halide (e.g. a carbonyl compound having a
halogen at an .alpha.-position or a compound having a halogen at a
benzyl position), a halogenated sulfonyl compound or the like is
used as an initiator.
[0077] Specific examples are as follows:
C.sub.6H.sub.5--CH.sub.2X, C.sub.6H.sub.5--C(H)(X)CH.sub.3,
C.sub.6H.sub.5--C(X)(CH.sub.3).sub.2
[0078] (in the above chemical formulas, C.sub.6H.sub.5 is a phenyl
group and X is a chlorine, bromine or iodine atom);
R.sup.3--C(H)(X)--CO.sub.2R.sup.4,
R.sup.3--C(CH.sub.3)(X)--CO.sub.2R.sup.4,
R.sup.3--C(H)(X)--C(O)R.sup.4,
R.sup.3--C(CH.sub.3)(X)--C(O)R.sup.4
[0079] (in the above formulas, R.sup.3 and R.sup.4 each is a
hydrogen atom or an alkyl, aryl or aralkyl group containing 1 to 20
carbon atoms and X is a chlorine, bromine or iodine atom);
R.sup.3--C.sub.6H.sub.4--SO.sub.2X
[0080] (in the above formula, R.sup.3 is a hydrogen atom or an
alkyl, aryl or aralkyl group containing 1 to 20 carbon atoms and X
is a chlorine, bromine or iodine atom); and the like.
[0081] An organic halide or halogenated sulfonyl compound having a
further functional group in addition to the functional group for
initiating the polymerization may also be used as the initiator in
atom transfer radical polymerization. In such case, vinyl polymers
having the further functional group at one main chain terminus and
the structure of the growing terminus in atom transfer radical
polymerization at the other main chain terminus are produced. As
such further functional group, there may be mentioned alkenyl,
crosslinkable silyl, hydroxyl, epoxy, amino and amide groups, among
others.
[0082] The alkenyl group-containing organic halide is not
particularly restricted but includes, among others, those having a
structure represented by the general formula 4:
R.sup.6R.sup.7C(X)--R.sup.8--R.sup.9--C(R.sup.5).dbd.CH.sub.2
(4)
wherein R.sup.5 is a hydrogen atom or a methyl group, R.sup.6 and
R.sup.7 each is a hydrogen atom or a univalent alkyl, aryl or
aralkyl group containing 1 to 20 carbon atoms and such R.sup.6 and
R.sup.7 groups may be bonded together at the respective other ends,
R.sup.8 is --C(O)O-- (ester group), --C(O)-- (keto group) or an o-,
m- or p-phenylene group, R.sup.9 is a direct bond or a bivalent
organic group containing 1 to 20 carbon atoms, which may contain
one or more ether bonds, and X is a chlorine, bromine or iodine
atom.
[0083] As specific examples of the substituent R.sup.6 and R.sup.7,
there may be mentioned a hydrogen atom, and methyl, ethyl,
n-propyl, isopropyl, butyl, pentyl, hexyl and like groups. R.sup.6
and R.sup.7 may be connected to each other at the respective other
ends to form a cyclic skeleton.
[0084] As specific examples of the alkenyl-containing organic
halide represented by the general formula 4, 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,
##STR00002##
(in the above formulas, X is a chlorine, bromine or iodine atom and
n is 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,
##STR00003##
(in the above formulas, X is a chlorine, bromine or iodine atom, n
is an integer of 1 to 20 and m is an integer of 0 to 20); o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2).sub.n--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 is a chlorine, bromine or iodine
atom and n is an integer of 0 to 20); o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2).sub.n--O--(CH.sub.2).sub.m--CH.db-
d.CH.sub.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 is a chlorine,
bromine or iodine atom, n is an integer of 1 to 20 and m is 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 is a chlorine, bromine or iodine
atom and n is an integer of 0 to 20); and 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.m--CH.dbd.CH.sub.2 (in the above formulas, X is a
chlorine, bromine or iodine atom, n is an integer of 1 to 20 and m
is an integer of 0 to 20).
[0085] As the alkenyl-containing organic halide, there may further
be mentioned compounds represented by the general formula 5:
H.sub.2C.dbd.C(R.sup.5)--R.sup.9--C(R.sup.6)(X)--R.sup.10--R.sup.7
(5)
(wherein R.sup.5, R.sup.6, R.sup.7, R.sup.9 and X are the same as
defined above and R.sup.10 represents a direct bond, --C(O)O--
(ester group), --C(O)-- (keto group) or an o-, m- or p-phenylene
group).
[0086] R.sup.8 is a direct bond or a divalent organic group (which
may contain one or more ether bonds) containing 1 to 20 carbon
atoms. When it is a direct bond, a vinyl group is bound to the
carbon atom to which a halogen is bound, whereby an allyl halide
compound is formed. In this case, the carbon-halogen bond is
activated by the neighboring vinyl group, so that R.sup.10 is not
always required to be a C(O)O or phenylene group, for instance, but
may be a direct bond. When R.sup.9 is other than a direct bond,
R.sup.10 should preferably be a C(O)O, C(O) or phenylene group so
that the carbon-halogen bond may be activated.
[0087] Specific examples of the compound of general formula 5 are
as follows:
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,
[0088] 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.sub.2(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
[0089] (in the above formulas, X is a chlorine, bromine or iodine
atom and R is an alkyl, aryl or aralkyl group containing 1 to 20
carbon atoms), etc.
[0090] The following may be mentioned as specific examples of the
alkenyl-containing halogenated sulfonyl compound:
o-, m-,
p-CH.sub.2.dbd.CH--(CH.sub.2).sub.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 is a chlorine, bromine or iodine atom and
n is in integer of 0 to 20); etc.
[0091] The above-mentioned crosslinkable silyl-containing organic
halide is not particularly restricted but includes, among others,
compounds having a structure represented by the general formula
6:
R.sup.6R.sup.7C(X)--R.sup.8--R.sup.9--C(H)(R.sup.5)CH.sub.2--[Si(R.sup.1-
1).sub.2-b(Y).sub.bO].sub.m--Si(R.sup.12).sub.3-a(Y).sub.a (6)
(wherein R.sup.5, R.sup.6, R.sup.7, R.sup.8, R.sup.9 and X are the
same as defined above, R.sup.11 and R.sup.12 each represents an
alkyl, aryl or aralkyl group containing 1 to 20 carbon atoms or a
triorganosiloxy group represented by (R').sub.3SiO-- (in which R'
is a univalent 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.11 or R.sup.12 groups, they may be the
same or different; Y represents a hydroxyl group or a hydrolyzable
group and, when there are two or more Y 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 is satisfied).
[0092] Specific examples of the compound of general formula 6 are
as follows:
XCH.sub.2C(O)O(CH.sub.2).sub.nSi(OCH.sub.3).sub.3,
CH.sub.3C(H)(X)C(O)O(CH.sub.2).sub.nSi(OCH.sub.3).sub.3,
(H.sub.3C).sub.2C(X)C(O)O(CH.sub.2).sub.nSi(OCH.sub.3).sub.3,
XCH.sub.2C(O)O(CH.sub.2).sub.nSi(CH.sub.3)(OCH.sub.3).sub.2,
CH.sub.3C(H)(X)C(O)O(CH.sub.2).sub.nSi(CH.sub.3)(OCH.sub.3).sub.2,
(H.sub.3C).sub.2C(X)C(O)O(CH.sub.2).sub.nSi(CH.sub.3)(OCH.sub.3).sub.2
(in the above formulas, X is a chlorine, bromine or iodine atom and
n is an integer of 0 to 20);
XCH.sub.2C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(OCH.sub.3).sub.3,
H.sub.3CC(H)(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(OCH.sub.3).sub.3,
(H.sub.3C).sub.2C(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(OCH.sub.3).s-
ub.3,
CH.sub.3CH.sub.2C(H)(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(OCH.-
sub.3).sub.3,
XCH.sub.2C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(CH.sub.3)(OCH.sub.3).su-
b.2,
H.sub.3CC(H)(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(CH.sub.3)(OCH-
.sub.3).sub.2,
(H.sub.3C).sub.2C(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(CH.sub.3)(OC-
H.sub.3).sub.2,
CH.sub.3CH.sub.2C(H)(X)C(O)O(CH.sub.2).sub.nO(CH.sub.2).sub.mSi(CH.sub.3)-
(OCH.sub.3).sub.2 (in the above formulas, X is a chlorine, bromine
or iodine atom, n is an integer of 1 to 20 and m is an integer of 0
to 20); o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2).sub.2Si(OCH.sub.3).sub.3,
o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.2Si(OCH.sub.3).-
sub.3, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.2Si(OCH.sub.3).-
sub.3, o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2).sub.3Si(OCH.sub.3).sub.3,
o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.3Si(OCH.sub.3).sub.3,
o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.3Si(OCH-
.sub.3).sub.3, o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--(CH.sub.2).sub.2--O--(CH.sub.2).sub.3Si(OCH.-
sub.3).sub.3, o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.2--O--(CH.sub.2).sub.3S-
i(OCH.sub.3).sub.3, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--(CH.sub.2).sub.2--O--(CH.sub.2-
).sub.3Si(OCH.sub.3).sub.3, o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--O--(CH.sub.2).sub.3Si(OCH.sub.3).sub.3,
o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.3Si(OCH.sub.3).s-
ub.3, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.3--Si(OCH.su-
b.3).sub.3, o-, m-,
p-XCH.sub.2--C.sub.6H.sub.4--O--(CH.sub.2).sub.2--O--(CH.sub.2).sub.3--Si-
(OCH.sub.3).sub.3, o-, m-,
p-CH.sub.3C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.2--O--(CH.sub.2).sub-
.3Si(OCH.sub.3).sub.3, o-, m-,
p-CH.sub.3CH.sub.2C(H)(X)--C.sub.6H.sub.4--O--(CH.sub.2).sub.2--O--(CH.su-
b.2).sub.3Si(OCH.sub.3).sub.3 (in the above formulas, X is a
chlorine, bromine or iodine atom); etc.
[0093] As further examples of the above-mentioned crosslinkable
silyl-containing organic halide, there may be mentioned compounds
having a structure represented by the general formula 7:
(R.sup.12).sub.3-a(Y).sub.aSi--[OSi(R.sup.11).sub.2-b(Y).sub.b].sub.m--C-
H.sub.2--C(H)(R.sup.5)--R.sup.9--C(R.sup.6)(X)--R.sup.10--R.sup.7
(7)
wherein R.sup.5, R.sup.6, R.sup.7, R.sup.9, R.sup.10, R.sup.11,
R.sup.12, a, b, m, X and Y are the same as defined above.
[0094] Specific examples of such compound are as follows:
(CH.sub.3O).sub.3SiCH.sub.2CH.sub.2C(H)(X)C.sub.6H.sub.5,
(CH.sub.3O).sub.2(CH.sub.3)SiCH.sub.2CH.sub.2C(H)(X)C.sub.6H.sub.5,
(CH.sub.3O).sub.3Si(CH.sub.2).sub.2C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.2(CH.sub.3)Si(CH.sub.2).sub.2C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.3Si(CH.sub.2).sub.3C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.2(CH.sub.3)Si(CH.sub.2).sub.3C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.3Si(C.sub.2).sub.4C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.2(CH.sub.3)Si(CH.sub.2).sub.4C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.3Si(CH.sub.2).sub.9C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.2(CH.sub.3)Si(CH.sub.2).sub.9C(H)(X)--CO.sub.2R,
(CH.sub.3O).sub.3Si(CH.sub.2).sub.3C(H)(X)--C.sub.6H.sub.5,
(CH.sub.3O).sub.2(CH.sub.3)Si(CH.sub.2).sub.3C(H)(X)--C.sub.6H.sub.5,
(CH.sub.3O).sub.3Si(CH.sub.2).sub.4C(H)(X)--C.sub.6H.sub.5,
(CH.sub.3O).sub.2(CH.sub.3)Si(CH.sub.2).sub.4C(H)(X)--C.sub.6H.sub.5
[0095] (in the above formulas, X is a chlorine, bromine or iodine
atom and R is an alkyl, aryl or aralkyl group containing 1 to 20
carbon atoms); etc.
[0096] The above-mentioned hydroxyl-containing organic halide or
halogenated sulfonyl compound is not particularly restricted but
includes, for example, the following:
HO--(CH.sub.2).sub.n--OC(O)C(H)(R)(X) wherein X is a chlorine,
bromine or iodine atom, R is a hydrogen atom or an alkyl, aryl or
aralkyl group containing 1 to 20 carbon atoms and n is an integer
of 1 to 20.
[0097] The above-mentioned amino-containing organic halide or
halogenated sulfonyl compound is not particularly restricted but
includes, for example, the following:
H.sub.2N--(CH.sub.2).sub.n--OC(O)C(H)(R)(X) wherein X is a
chlorine, bromine or iodine atom, R is a hydrogen atom or an alkyl,
aryl or aralkyl group containing 1 to 20 carbon atoms and n is an
integer of 1 to 20.
[0098] The above-mentioned epoxy-containing organic halide or
halogenated sulfonyl compound is not particularly restricted but
includes, for example, the following:
##STR00004##
(wherein X is a chlorine, bromine or iodine atom, R is a hydrogen
atom or an alkyl, aryl or aralkyl group containing 1 to 20 carbon
atoms and n is an integer of 1 to 20).
[0099] For obtaining polymers having two or more growing terminal
structures specified by the present invention in each molecule, an
organic halide or halogenated sulfonyl compound having two or more
initiation sites is preferably used as the initiator. As specific
examples, there may be mentioned the following:
##STR00005##
(in the above formulas, C.sub.6H.sub.4 is a phenylene group and X
is a chlorine, bromine or iodine atom);
##STR00006##
(in the above formulas, R is an alkyl, aryl or aralkyl group
containing 1 to 20 carbon atoms, n is an integer of 0 to 20 and X
is a chlorine, bromine or iodine atom);
##STR00007##
[0100] (in the above formulas, X is a chlorine, bromine or iodine
atom and n is an integer of 0 to 20);
##STR00008##
(in the above formulas, n is an integer of 1 to 20 and X is a
chlorine, bromine or iodine atom);
##STR00009##
(in the above formulas, X is a chlorine, bromine or iodine atom);
etc.
[0101] The vinyl monomers to be used in this polymerization are not
particularly restricted but all those monomers mentioned herein
above as examples can appropriately be used.
[0102] The transition metal complex to be used as the catalyst is
not particularly restricted but preferably is a metal complex
containing, as the central atom, an element of the group 7, 8, 9,
10 or 11 of the periodic table. More preferred are complexes of
zero-valent copper, univalent copper, bivalent ruthenium, bivalent
iron or bivalent nickel. Copper complexes are preferred among
others. Specific examples of the univalent copper compound are
cuprous chloride, cuprous bromide, cuprous iodide, cuprous cyanide,
cuprous oxide and cuprous perchlorate. When such a copper compound
is used, a ligand such as 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. Preferred ligands are nitrogen-containing
compounds, more preferred ligands are chelate type
nitrogen-containing compound, and still more preferred ligands are
N,N,N',N'',N''-pentamethyldiethylenetriamine. The
tristriphenylphosphine complex of divalent ruthenium chloride
(RuCl.sub.2(PPh.sub.3).sub.3) is also suited for use as the
catalyst. When such a ruthenium compound is used as the catalyst,
an aluminum alkoxide is added as an activator. Furthermore, the
divalent iron-bistriphenylphosphine complex
(FeCl.sub.2(PPh.sub.3).sub.2), the divalent
nickel-bistriphenylphosphine complex (NiCl.sub.2(PPh.sub.3).sub.2),
and the divalent nickel-bistributylphosphine complex
(NiBr.sub.2(PBu.sub.3).sub.2) are also suited for use as the
catalyst.
[0103] The polymerization can be carried out without using any
solvent or in the presence of various solvents. As the solvent
species, there may be mentioned hydrocarbon solvents such as
benzene and toluene, ether solvents such as diethyl ether and tetra
hydrofuran, 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, and the like. These may be used
singly or two or more of them may be used in admixture.
[0104] The polymerization can be carried out within the temperature
range of 0.degree. C. to 200.degree. C., preferably 50 to
150.degree. C., although the temperature range is not limited to
such range.
[0105] In the practice of the present invention, the atom transfer
radical polymerization also includes the so-called reverse atom
transfer radical polymerization. The reverse atom transfer radical
polymerization is a method comprising reacting an ordinary atom
transfer radical polymerization catalyst in its high oxidation
state resulting from radical generation, for example Cu(II) when
Cu(I) is used as the catalyst, with an ordinary radical initiator,
such as a peroxide, to thereby bring about an equilibrium state
like in atom transfer radical polymerization (cf. Macromolecules,
1999, 32, 2872).
<Functional Groups>
[0106] The crosslinkable functional group in the vinyl polymer (II)
is not restricted. Preferred as such are, however, crosslinkable
silyl groups, alkenyl groups, a hydroxyl group, an amino group,
polymerizable carbon-carbon double bond-containing groups, epoxy
groups and like groups.
[0107] These crosslinkable functional groups all can be used so as
to adapt to or answer the intended use/purpose.
Positions of Crosslinkable Functional Groups
[0108] When the cured products derived from the curable composition
of the present invention are required to have rubber-like
properties, it is essential that at least one of the crosslinkable
functional groups consist in at a molecular chain terminus in order
that the molecular weight between crosslinking sites, which greatly
influences on the rubber elasticity, may be designed to be high.
More preferably, all crosslinkable functional groups should be
located at molecular chain termini.
[0109] Methods of producing such vinyl polymers, in particular
(meth)acrylic polymers, having at least one crosslinkable
functional group are disclosed in Japanese Kokoku Publication
Hei-03-14068, Japanese Kokoku Publication Hei-04-55444 and Japanese
Kokai Publication Hei-06-211922, among others. However, these
methods consist in the above-mentioned free radical polymerization
using a "chain transfer agent", so that the polymers obtained
generally have a value of molecular weight distribution represented
by Mw/Mn as high as 2 or more, hence have a problem in that their
viscosity becomes high, although they have a crosslinkable
functional group or groups at a molecular terminus or termini with
a relatively high percentage. Therefore, for obtaining a vinyl
polymer narrow in molecular weight distribution, low in viscosity
and high in percentage of crosslinkable functional groups at
molecular chain termini, the use of the above-mentioned "living
radical polymerization technique" is preferred.
Number of Crosslinkable Functional Groups
[0110] The vinyl polymer (II) has at least one crosslinkable
function group on average. From the composition curability
viewpoint, the number of such groups is preferably more than 1,
more preferably 1.1 to 4.0 on average, still more preferably 1.5 to
2.5.
[0111] In the following, an explanation is made of these functional
groups.
Crosslinkable Silyl Groups
[0112] As the crosslinkable silyl groups to be used in the practice
of the present invention, there may be mentioned those groups
represented by the general formula 8:
--[Si(R.sup.11).sub.2-b(Y).sub.bO].sub.m--Si(R.sup.12).sub.3-a(Y).sub.a
(8)
wherein, R.sup.11 and R.sup.12 each is 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 univalent 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.11 or R.sup.12 groups, they may be the
same or different; Y represents a hydroxyl group or a hydrolyzable
group and, when there are two or more Y 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.
[0113] As the hydrolyzable group, there may be mentioned, among
others, a hydrogen atom and those groups which are in general use,
for example alkoxy, acyloxy, ketoximate, amino, amido, aminoxy,
mercapto and alkenyloxy groups. Among them, alkoxy, amido and
aminoxy groups are preferred. In view of mild hydrolyzability and
ease of handling, alkoxy groups are particularly preferred.
[0114] One to three hydroxyl groups and/or hydrolyzable groups can
be bound to each silicon atom and, in the practice of the present
invention, it is preferred that (a+.SIGMA.b) be within the range of
1 to 5. When there are two or more hydrolyzable groups or hydroxyl
groups in one crosslinkable silyl group, they may be the same or
different. The number of silicon atoms forming the crosslinkable
silyl group is not less than 1 and, in the case of silicon atoms
connected by siloxane or like bonding, it is preferably not more
than 20. Particularly preferred are crosslinkable silyl groups
represented by the general formula 9:
--Si(R.sup.12).sub.3-a(Y).sub.a (9)
wherein R.sup.12, Y and a are the same as defined above, because of
ready availability.
[0115] Those in which a is 3 (e.g. trimethoxy functional groups)
are more rapid in curability than those in which a is 2 (e.g.
dimethoxy functional groups) but may have problems with their
storage stability or mechanical properties (elongation etc. in some
instances. For attaining a balance between curability and physical
properties, one in which a is 2 (e.g. dimethoxy functional groups)
and one in which a is 3 (e.g. trimethoxy functional groups) may be
used in combination.
Alkenyl Groups
[0116] The alkenyl group to be used in the practice of the
invention is not particularly restricted but preferably is one
represented by the general formula 10:
H.sub.2C.dbd.C(R.sup.13)-- (10)
wherein R.sup.13 is a hydrogen atom or a hydrocarbon group
containing 1 to 20 carbon atoms.
[0117] In the general formula 10, R.sup.13 is a hydrogen atom or a
hydrocarbon group containing 1 to 20 carbon atoms, typical examples
of which are the following:
--(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).
[0118] Among these, a hydrogen atom is preferred.
[0119] It is preferred, though not obligatory, that the alkenyl
group(s) in the polymer (II) be not activated by a carbonyl or
alkenyl group or an aromatic ring, which is conjugated with the
carbon-carbon double bond of the alkenyl group.
[0120] The mode of bonding of the alkenyl group to the polymer main
chain is not particularly restricted but preferably involves a
carbon-carbon bond, ester bond, ether bond, carbonate bond, amide
bond, or urethane bond, for instance.
Amino Groups
[0121] In the practice of the invention, the amino group is not
particularly restricted but includes groups represented by
--NR.sup.14.sub.2
[0122] wherein R.sup.14 is a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and the two R.sup.14 groups may be
the same or different or may be bonded together at the respective
other ends to form a ring structure. It may be an ammonium salt
represented by
--(NR.sup.14.sub.3).sup.+X.sup.-
[0123] wherein R.sup.14 is as defined above and X.sup.- is a
counter anion, without any problem.
[0124] In the above formulas, R.sup.14 is a hydrogen atom or a
univalent organic group containing 1 to 20 carbon atoms and
includes, among others, a hydrogen atom, alkyl groups containing 1
to 20 carbon atoms, aryl groups containing 6 to 20 carbon atoms,
and aralkyl groups containing 7 to 20 carbon atoms. The two
R.sup.14 groups may be the same or different, or may be bonded
together at the respective other ends to form a ring structure.
Groups Having a Polymerizable Carbon-Carbon Double Bond
[0125] The polymerizable carbon-carbon double bond-containing group
is preferably a group represented by the general formula 11:
--OC(O)C(R.sup.15).dbd.CH.sub.2 (11)
wherein R.sup.15 represents a hydrogen atom or a univalent organic
group containing 1 to 20 carbon atoms, more preferably a group of
formula (11) in which R.sup.15 is a hydrogen atom or a methyl
group.
[0126] Specific examples of R.sup.15 in general formula 11 include,
but are not particularly limited to, --H, --CH.sub.3,
--CH.sub.2CH.sub.3, --(CH.sub.2).sub.nCH.sub.3 (n being an integer
of 2 to 19), --C.sub.6H.sub.5, --CH.sub.2OH, --CN and the like.
Preferred are --H and --CH.sub.3, however.
<Functional Group Introduction Method>
[0127] In the following, several methods of functional group
introduction into the vinyl polymer (II) of the present invention
are described, without any purpose of restriction, however.
[0128] First, methods of crosslinkable silyl, alkenyl or hydroxyl
group introduction by terminal functional group conversion are
described. These functional groups each can serve as a precursor of
another and, therefore, mention is made in the order from
crosslinkable silyl groups to respective precursors.
[0129] As methods of synthesizing vinyl polymers having at least
one crosslinkable silyl group, there may be mentioned, among
others, the following.
(A) Method which comprises causing a crosslinkable silyl
group-containing hydrosilane compound to add to a vinyl polymer
having at least one alkenyl group in the presence of a
hydrosilylation catalyst; (B) Method which comprises reacting a
vinyl polymer having at least one hydroxyl group with a compound
having, in each molecule, a crosslinkable silyl group and a group
capable of reacting with the hydroxyl group, such as an isocyanato
group; (C) Method which comprises subjecting a compound having, in
each molecule, a polymerizable alkenyl group and a crosslinkable
silyl group to reaction in synthesizing a vinyl polymer by radical
polymerization; (D) Method which comprises using a crosslinkable
silyl group-containing chain transfer agent in synthesizing a vinyl
polymer by radical polymerization; and (E) Method which comprises
reacting a vinyl polymer having at least one highly reactive
carbon-halogen bond with a compound having, in each molecule, a
crosslinkable silyl group and a stable carbanion.
[0130] The vinyl polymer having at least one alkenyl group, which
is to be used in the above method (A), can be obtained by various
methods. Several methods of synthesis are mentioned below, without
any purpose of restriction, however.
[0131] (A-a) Method comprising subjecting to reaction a compound
having, in each molecule, a polymerizable alkenyl group together
with a low polymerizability alkenyl group, such as one represented
by the general formula 12 shown below, as a second monomer in
synthesizing a vinyl polymer by radical polymerization:
--H.sub.2C.dbd.C(R.sup.16)--R.sup.17--R.sup.18--C(R.sup.19).dbd.CH.sub.2
(12)
wherein R.sup.16 represents a hydrogen atom or a methyl group,
R.sup.17 represents --C(O)O-- or an o-, m- or p-phenylene group,
R.sup.18 represents a direct bond or a bivalent organic group
containing 1 to 20 carbon atoms, which may contain one or more
ether bonds, and R.sup.19 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.
[0132] The time when the compound having, in each molecule, a
polymerizable alkenyl group and a low polymerizability alkenyl
group is subjected to reaction is not particularly restricted but,
in particular in living radical polymerization and when rubber-like
properties are expected, the compound is preferably subjected to
reaction as a second monomer at the final stage of the
polymerization reaction or after completion of the reaction of the
monomer(s) employed.
[0133] (A-b) Method comprising subjecting to reaction a compound
having at least two low polymerizability alkenyl groups, for
example 1,5-hexadiene, 1,7-octadiene or 1,9-decadiene, at the final
stage of the polymerization or after completion of the reaction of
the monomer(s) employed in vinyl polymer synthesis by living
radical polymerization.
[0134] (A-c) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond with one of various
alkenyl-containing organometallic compounds, for example an
organotin such as allyltributyltin or allyltrioctyltin, for
substitution for the halogen.
[0135] (A-d) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond with a stabilized,
alkenyl-containing carbanion, such as one represented by the
general formula 13, for substitution for the halogen:
M.sup.+C.sup.-(R.sup.20)(R.sup.21)--R.sup.22--C(R.sup.19).dbd.CH.sub.2
(13)
wherein R.sup.19 is as defined above, R.sup.20 and R.sup.21 each is
an electron-withdrawing group capable of stabilizing the carbanion
C.sup.- or one of them is such an electron-withdrawing group and
the other represents a hydrogen atom, an alkyl group containing 1
to 10 carbon atoms or a phenyl group, R.sup.22 represents a direct
bond or a bivalent organic group containing 1 to 10 carbon atoms,
which may contain one or more ether bonds, and M.sup.+ represents
an alkali metal ion or a quaternary ammonium ion.
[0136] Particularly preferred as the electron-withdrawing group
R.sup.20 and/or R.sup.21 are those which have a structure of
--CO.sub.2R, --C(O)R or --CN.
[0137] (A-e) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond with a simple
substance metal, such as zinc, or an organometallic compound and
then reacting the thus-prepared enolate anion with an
alkenyl-containing, electrophilic compound, such as an
alkenyl-containing compound having a leaving group such as a
halogen atom or an acetyl group, an alkenyl-containing carbonyl
compound, an alkenyl-containing isocyanate compound or an
alkenyl-containing acid halide.
[0138] (A-f) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond with an
alkenyl-containing oxy anion or carboxylate anion, such as one
represented by the general formula (14) or (15), for substitution
for the halogen:
H.sub.2C.dbd.C(R.sup.19)--R.sup.23--O.sup.-M.sup.+ (14)
wherein R.sup.19 and M.sup.+ are the same as defined above and
R.sup.23 is a bivalent organic group containing 1 to 20 carbon
atoms, which may contain one or more ether bonds;
H.sub.2C.dbd.C(R.sup.19)--R.sup.24--C(O)O.sup.-M.sup.+ (15)
wherein R.sup.19 and M.sup.+ are the same as defined above and
R.sup.24 is a direct bond or a divalent organic group containing 1
to 20 carbon atoms, which may contain one or more ether bonds.
[0139] The method of synthesizing the above-mentioned vinyl polymer
having at least one highly reactive carbon-halogen bond includes,
but is not limited to, atom transfer radical polymerization
techniques using an organic halide or the like as initiator and a
transition metal complex as catalyst, as mentioned above.
[0140] It is also possible to obtain the vinyl polymer having at
least one alkenyl group from a vinyl polymer having at least one
hydroxyl group. As utilizable methods, there may be mentioned, for
example, the following, without any purpose of restriction.
[0141] (A-g) Method comprising reacting the hydroxyl group(s) of a
vinyl polymer having at least one hydroxyl group with a base, such
as sodium methoxide, followed by reaction with an
alkenyl-containing halide, such as allyl chloride.
[0142] (A-h) Method comprising reacting such hydroxyl group (s)
with an alkenyl-containing isocyanate compound, such as allyl
isocyanate.
[0143] (A-i) Method comprising reacting such hydroxyl group(s) with
an alkenyl-containing acid halide, such as (meth)acrylic acid
chloride, in the presence of a base, such as pyridine.
[0144] (A-j) Method comprising reacting such hydroxyl group(s) with
an alkenyl-containing carboxylic acid, such as acrylic acid, in the
presence of an acid catalyst.
[0145] In the practice of the present invention, when no halogen is
directly associated in the alkenyl group introduction, as in the
method (A-a) or (A-b), the vinyl polymer is preferably synthesized
by living radical polymerization. From the viewpoint of ready
controllability, the method (A-b) is more preferred.
[0146] In cases where alkenyl group introduction is effected by
conversion of the halogen atom(s) of a vinyl polymer having at
least one highly reactive carbon-halogen atom, use is preferably
made of a vinyl polymer having at least one terminal carbon-halogen
bond, which is highly reactive, obtainable by subjecting a vinyl
monomer(s) to radical polymerization (atom transfer radical
polymerization) using, as an initiator, an organic halide or
halogenated sulfonyl compound having at least one highly reactive
carbon-halogen bond and, as a catalyst, a transition metal complex.
In view of more ready controllability, the method (A-f) is more
preferred.
[0147] The crosslinkable silyl group-containing hydrosilane
compound is not particularly restricted but includes, as typical
examples, compounds represented by the general formula 16:
H--[Si(R.sup.11).sub.2-b(Y).sub.bO].sub.m--Si(R.sup.12).sub.3-a(Y).sub.a
(16)
wherein R.sup.11 and R.sup.12 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 univalent 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.11 or R.sup.12 groups, they may be the
same or different; Y represents a hydroxyl group or a hydrolyzable
group and, when there are two or more Y 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.
[0148] Particularly preferred among those hydrosilane compounds in
view of ready availability are crosslinkable group-containing
compounds represented by the general formula 17:
H--Si(R.sup.12).sub.3-a(Y).sub.a (17)
wherein R.sup.12, Y and a are the same as defined above.
[0149] In causing the above crosslinkable silyl-containing
hydrosilane compound to add to the alkenyl group, a transition
metal catalyst is generally used. The transition metal catalyst
includes, among others, simple substance platinum, solid platinum
dispersed in/on a carrier such as alumina, silica or carbon black,
chloroplatinic acid, chloroplatinic acid complexes with alcohols,
aldehydes, ketones or the like, platinum-olefin complexes, and
platinum(0)-divinyltetramethyldisiloxane complex. As other
catalysts 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 and
TiCl.sub.4, for instance.
[0150] The method of producing the Vinyl polymer having at least
one hydroxyl group, which polymer is to be used in the methods (B)
and (A-g) to (A-j), includes, but is not limited to, the following,
among others.
[0151] (B-a) Method comprising subjecting to reaction, as a second
monomer, a compound having both a polymerizable alkenyl group and a
hydroxyl group in each molecule, for example one represented by the
general formula 18 given below, in synthesizing the vinyl polymer
by radical polymerization:
H.sub.2C.dbd.C(R.sup.16)--R.sup.17--R.sup.18--OH (18)
wherein R.sup.16, R.sup.17 and R.sup.18 are the same as defined
above.
[0152] The time for subjecting to reaction the compound having both
a polymerizable alkenyl group and a hydroxyl group in each molecule
is not critical but, in particular in living radical
polymerization, when rubber-like properties are demanded, the
compound is preferably subjected to reaction as a second monomer at
the final stage of the polymerization reaction or after completion
of the reaction of the main monomer(s).
[0153] (B-b) Method comprising subjecting an alkenyl alcohol, such
as 10-undecenol, 5-hexenol or allyl alcohol, to reaction at the
final stage of polymerization reaction or after completion of the
reaction of the main monomer(s) in synthesizing the vinyl polymer
by living radical polymerization.
[0154] (B-c) Method comprising radical-polymerizing a vinyl
monomer(s) using a hydroxyl-containing chain transfer agent, such
as a hydroxyl-containing polysulfide, in large amounts, as
described in Japanese. Kokai Publication Hei-05-262808, for
instance.
[0155] (B-d) Method comprising subjecting a vinyl monomer(s) to
radical polymerization using hydrogen peroxide or a
hydroxyl-containing initiator, as described in/Japanese Kokai
Publication Hei-06-239912 or Japanese Kokai Publication
Hei-08-283310, for instance.
[0156] (B-e) Method comprising subjecting a vinyl monomer(s) to
radical polymerization using an alcohol in excess, as described in
Japanese Kokai Publication Hei-06-116312, for instance.
[0157] (B-f) Method comprising introducing a terminal hydroxyl
group(s) by hydrolyzing the halogen atom(s) of a vinyl polymer
having at least one highly reactive carbon-halogen bond or reacting
such halogen atom(s) with a hydroxyl-containing compound, according
to the method described in Japanese. Kokai Publication
Hei-04-132706, for instance.
[0158] (B-g) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond with a
hydroxyl-containing stabilized carbanion, such as one represented
by the general formula 19, for substitution for the halogen
atom:
M.sup.+C.sup.-(R.sup.20)(R.sup.21)--R.sup.22--OH (19)
wherein R.sup.20, R.sup.21 and R.sup.22 are the same as defined
above.
[0159] Particularly preferred as the electron-withdrawing groups
R.sup.20 and R.sup.21 are those having a structure of --CO.sub.2R,
--C(O)R or --CN.
[0160] (B-h) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond 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.
[0161] (B-i) Method comprising reacting a vinyl polymer having at
least one highly reactive carbon-halogen bond with a
hydroxyl-containing oxy anion or carboxylate anion, such as one
represented by the general formula 20 or 21 given below, for
substitution for the halogen atom:
HO--R.sup.23--O.sup.-M.sup.+ (20)
wherein R.sup.23 and M.sup.+ are the same as defined above;
HO--R.sup.24--C(O)O.sup.-M.sup.+ (21)
wherein R.sup.24 and M.sup.+ are the same as defined above.
[0162] (B-j) Method comprising subjecting, as a second monomer, a
compound having a low polymerizability alkenyl group and a hydroxyl
group in each molecule to reaction at the final stage of the
polymerization reaction or after completion of the reaction of the
main monomer(s) in synthesizing the vinyl polymer by living radical
polymerization.
[0163] Such compound is not particularly restricted but may be a
compound represented by the general formula 22, for instance:
H.sub.2C.dbd.C(R.sup.16)--(R.sup.23)--OH (22)
wherein R.sup.16 and R.sup.23 are the same as defined above.
[0164] The compound represented by the above general formula 22 is
not particularly restricted but, in view of ready availability,
alkenyl alcohols such as 10-undecenol, 5-hexenol and allyl alcohol
are preferred.
[0165] In the practice of the present invention, when no halogen is
directly associated in hydroxyl group introduction, as in the
methods (B-a) to (B-e) and (B-j), the vinyl polymer is preferably
synthesized by living radical polymerization. The method (B-b) is
more preferred because of ready controllability.
[0166] In cases where hydroxyl group introduction is effected by
conversion of the halogen atom(s) of a vinyl polymer having at
least one highly reactive carbon-halogen bond, use is preferably
made of a vinyl polymer having at least one terminal carbon-halogen
bond, which is highly reactive, as obtained by subjecting a vinyl
monomer(s) to radical polymerization (atom transfer radical
polymerization) using an organic halide or halogenated sulfonyl
compound as an initiator and, as a catalyst, a transition metal
complex. From the ready controllability viewpoint, the method (B-i)
is more preferred.
[0167] As the compound having a crosslinkable silyl group and a
group capable of reacting with a hydroxyl group, such as an
isocyanato group, in each molecule, there may be mentioned, for
example, .gamma.-isocyanatopropyltrimethoxysilane,
.gamma.-isocyanatopropylmethyldimethoxysialne,
.gamma.-isocyanatopropyltriethoxysilane and the like. If necessary,
any of urethane formation reaction catalysts generally known in the
art can be used.
[0168] The compound having both a polymerizable alkenyl group and a
crosslinkable silyl group in each molecule, which is to be used in
the method (C), includes, among others, trimethoxysilylpropyl
(meth)acrylate, methyldimethoxysilylpropyl (meth)acrylate and like
compounds represented by the general formula 23:
H.sub.2C.dbd.C(R.sup.16)--R.sup.17--R.sup.25--[Si(R.sup.11)].sub.2-b(Y).-
sub.bO].sub.m--Si(R.sup.12).sub.3-a(Y).sub.a (23)
wherein R.sup.11, R.sup.12, R.sup.16, R.sup.17, Y, a, b and m are
the same as defined above and R.sup.25 is a direct bond or a
bivalent organic group containing 1 to 20 carbon atoms, which may
contain one or more ether bonds.
[0169] The time for subjecting the compound having both a
polymerizable alkenyl group and a crosslinkable silyl group in each
molecule is not critical but, in living radical polymerizationm in
particular, and when rubber-like properties are demanded, the
compound is preferably subjected to reaction as a second monomer at
the final stage of the polymerization reaction or after completion
of the reaction of the main monomer(s).
[0170] As the crosslinkable silyl-containing chain transfer agent
to be used in the chain transfer agent method (D), there may be
mentioned crosslinkable silyl-containing mercaptans and
crosslinkable silyl-containing hydrosilanes, as described in
Japanese Kokoku Publication Hei-03-14068 and Japanese Kokoku
Publication Hei-04-55444, among others.
[0171] The method of synthesizing the vinyl polymer having at least
one highly reactive carbon-halogen bond, which is to be used in the
method (E), includes, but is not limited to, the atom transfer
radical polymerization method which uses an organic halide or the
like as an initiator and a transition metal complex as a catalyst.
As the compound having both a crosslinkable silyl group and a
stabilized carbanion in each molecule, there may be mentioned
compounds represented by the general formula 24:
M.sup.+C.sup.-(R.sup.20)(R.sup.21)--R.sup.26--C(H)(R.sup.27)--CH.sub.2---
[Si(R.sup.11).sub.2-b(Y).sub.bO].sub.m--Si(R.sup.12).sub.3-a(Y).sub.a
(24)
wherein R.sup.11, R.sup.12, R.sup.20, R.sup.21, Y, a, b and m are
the same as defined above, R.sup.26 is a direct bond or a bivalent
organic group containing 1 to 10 carbon atoms, which may contain
one or more ether bonds, and R.sup.27 represents a hydrogen atom,
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.
[0172] Particularly preferred as the electron-withdrawing groups
R.sup.20 and R.sup.21 are those having a structure of --CO.sub.2R,
--C(O)R or --CN.
Epoxy Group
[0173] In the practice of the present invention, the vinyl polymer
having a terminal reactive functional group(s) is produced by the
following steps, though mentioning thereof has no restrictive
meaning:
(1) producing a vinyl polymer by polymerizing a vinyl monomer(s) by
living radical polymerization; and then (2) reacting the polymer
with a compound having a reactive functional group and an
ethylenically unsaturated group.
[0174] Mention may also be made of the method comprising subjecting
allyl alcohol to reaction at the final stage of atom transfer
radical polymerization and then causing epoxy ring formation from
the hydroxyl and halogen groups.
Amino Group
[0175] The method of producing the vinyl polymer having at least
one main chain terminal amino group may comprise the following
steps:
(1) producing a vinyl polymer having at least one main chain
terminal halogen group; and (2) converting the terminal halogen
group to an amino-containing substituent using an amino-containing
compound.
[0176] The amino-containing substituent is not particularly
restricted but includes, for example, groups represented by the
general formula 25:
--O--R.sup.28--NR.sup.14.sub.2 (25)
wherein R.sup.28 represents a bivalent organic group containing 1
to 20 carbon atoms, which may contain one or more ether or ester
bonds; R.sup.14 represents a hydrogen atom or a univalent organic
group containing 1 to 20 carbon atoms and the two R.sup.14 groups
may be the same or different or may be bonded together at the
respective other ends to form a ring structure.
[0177] In the above general formula 25, R.sup.28 is a bivalent
organic group containing 1 to 20 carbon atoms, which may contain
one or more ether or ester bonds, and includes, among others,
alkylene groups containing 1 to 20 carbon atoms, arylene groups
containing 6 to 20 carbon atoms and aralkylene groups containing 7
to 20 carbons atoms and, preferably, groups represented by:
--C.sub.6H.sub.4--R.sup.29--
[0178] wherein C.sub.6H.sub.4 represents a phenylene group and
R.sup.29 represents a direct bond or a bivalent organic group
containing 1 to 14 carbon atoms, which may contain one or more
ether or ester bonds, or
--C(O)--R.sup.30--
[0179] wherein R.sup.30 represents a direct bond or a bivalent
organic group containing 1 to 19 carbon atoms, which may contain
one or more ether or ester bonds.
[0180] An amino group can be introduced into a polymer terminus by
converting a terminal halogen of the vinyl polymer. The method of
substitution is not particularly restricted but, from the ready
reaction controllability viewpoint, a nucleophilic substitution
reaction using an amino-containing compound as a nucleophile agent
is preferred. As such nucleophile agent, there may be mentioned
compounds having both a hydroxyl group and an amino group as
represented by the general formula 26:
HO--R.sup.28--NR.sup.14.sub.2 (26)
wherein R.sup.28 represents ambivalent organic group containing 1
to 20 carbon atoms, which may contain one or more ether or ester
bonds; R.sup.14 represents a hydrogen atom or a univalent organic
group containing 1 to 20 carbon atoms and the two R.sup.14 groups
may be the same or different or may be bonded together at the
respective other ends to form a ring structure.
[0181] In the above general formula 26, R.sup.28 is a bivalent
organic group containing 1 to 20 carbon atoms, which may contain
one or more ether or ester bonds, and includes, for example,
alkylene groups containing 1 to 20 carbon atoms, arylene groups
containing 6 to 20 carbons and aralkylene groups containing 7 to 20
carbon atoms. Among these compounds having both a hydroxyl group
and an amino group, aminophenols of the above general formula in
which R.sup.28 is represented by
--C.sub.6H.sub.4--R.sup.29--
[0182] wherein C.sub.6H.sub.4 represents a phenylene group and
R.sup.29 represents a direct bond or a bivalent organic group
containing 1 to 14 carbon atoms, which may contain one or more
ether or ester bonds; and amino acids of the above formula in which
R.sup.28 is represented by
--C(O)--R.sup.30--
[0183] wherein R.sup.30 represents a direct bond or a bivalent
organic group containing 1 to 19 carbon atoms, which may contain
one or more ether or ester bonds, are preferred.
[0184] As specific compounds, there may be mentioned, among others,
ethanolamine; o-, m- or p-aminophenol; o-, m- or
p-NH.sub.2--C.sub.6H.sub.4--CO.sub.2H; glycine, alanine and
aminobutanoic acid.
[0185] A compound having both an amino group and an oxy anion can
be used as the nucleophilic reagent. Such compound is not
particularly restricted but includes, for example, compounds
represented by the general formula 27:
M.sup.+O.sup.---R.sup.28--NR.sup.14.sub.2 (27)
wherein R.sup.28 represents a bivalent organic group containing 1
to 20 carbon atoms, which may contain one or more ether or ester
bonds; R.sup.14 represents a hydrogen atom or a univalent organic
group containing 1 to 20 carbon atoms and the two R.sup.14 groups
may be the same or different or may be bonded together at the
respective other ends to form a ring structure; and M.sup.+
represents an alkali metal ion or a quaternary ammonium ion.
[0186] In the above general formula 27, M.sup.+ is a counter cation
to the oxy anion and represents an alkali metal ion or a quaternary
ammonium ion. The alkali metal ion includes the lithium ion, sodium
ion, potassium ion, etc., and preferably is the sodium ion or
potassium ion. The quaternary ammonium ion includes the
tetramethylammonium ion, tetraethylammonium ion,
trimethylbenzylammonium ion, trimethyldodecylammonium ion,
tetrabutylammonium ion, dimethylpiperidinium ion, etc.
[0187] Among the above-mentioned compounds having both an amino
group and an oxy anion, salts of aminophenols represented by the
general formula 28 given below or salts of amino acids represented
by the general formula 29 given below are preferred in view of
ready controllability of the substitution reaction or their ready
availability:
M.sup.+O.sup.---C.sub.6H.sub.4--R.sup.29--NR.sup.14.sub.2 (28)
M.sup.+O.sup.---C(O)--R.sup.30--NR.sup.14.sub.2 (29)
wherein C.sub.6H.sub.4 represents a phenylene group, R.sup.29
represents a direct bond or a bivalent organic group containing 1
to 14 carbon atoms, which may contain one or more ether or ester
bonds; R.sup.30 represents a direct bond or a bivalent organic
group containing 1 to 19 carbon atoms, which may contain one or
more ether or ester bonds; R.sup.14 represents a hydrogen atom or a
univalent organic group containing 1 to 20 carbon atoms and the two
R.sup.14 groups may be the same or different or may be bonded
together at the respective other ends to form a ring structure; and
M.sup.+ is as defined above.
[0188] The oxy anion-containing compound represented by the general
formula 27, 28 or 29 can be obtained with ease by reacting a
compound represented by the general formula 26 with a basic
compound.
[0189] Various compounds can be used as the basic compound.
Examples are sodium methoxide, potassium methoxide, lithium
methoxide, sodium ethoxide, potassium ethoxide, lithium ethoxide,
sodium tert-butoxide, potassium tert-butoxide, sodium carbonate,
potassium carbonate, lithium carbonate, sodium hydrogen carbonate,
sodium hydroxide, potassium hydroxide, sodium hydride, potassium
hydride, methyllithium, ethyllithium, n-butyllithium,
tert-butyllithium, lithiumdiisopropylamide,
lithiumhexamethyldisilazide, and the like. The amount of the above
base is not particularly restricted but generally is 0.5 to 5
equivalents, preferably 0.8 to 1.2 equivalents, relative to the
above precursor.
[0190] As the solvent to be used in reacting the above precursor
with the above base, there may be mentioned, among others,
hydrocarbon solvents such as benzene and toluene; ether solvents
such as diethyl ether and tetra hydrofuran; 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; and sulfoxide solvents
such as dimethyl sulfoxide. These may be used singly or two or more
of them may be used in admixture.
[0191] The oxy anion-containing compound in which M.sup.+ is a
quaternary ammonium ion can be obtained by preparing the
corresponding compound in which M.sup.+ is an alkali metal ion and
reacting the same with a quaternary ammonium halide. As example of
the quaternary ammonium halide; there may be mentioned
tetramethylammonium halides, tetraethylammonium halides,
trimethylbenzylammonium halides, trimethyldodecylammonium halides,
and tetrabutylammonium halides.
[0192] Various solvents may be used for the substitution reaction
of the polymer terminal halogen. As examples, there may be
mentioned hydrocarbon solvents such as benzene and toluene; ether
solvents such as diethyl ether and tetra hydrofuran; 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; and sulfoxide solvents such as dimethyl
sulfoxide. These may be used singly or in the form of a mixture of
two or more.
[0193] The reaction can be carried out at a temperature of 0 to
150.degree. C. The amount of the amino-containing compound is not
particularly restricted but generally is 1 to 5 equivalents,
preferably 1 to 1.2 equivalents, relative to the polymer terminal
halogen.
[0194] A basic compound may be added to the reaction mixture for
promoting the nucleophilic substitution reaction. As such basic
compound, there may be mentioned those already mentioned herein
above as well as alkylamines such as trimethylamine; triethylamine
and tributylamine; polyamines such as tetramethylethylenediamine
and pentamethyldiethylenetriamine; pyridine compounds such as
pyridine and picoline, and so on.
[0195] In cases where the amino group in the amino-containing
compound used in the nucleophilic substitution reaction affects the
nucleophilic substitution reaction, the amino group is preferably
protected with an appropriate substituent. Such substituent
includes, among others, benzyloxycarbonyl, t-butoxycarbonyl and
9-fluorenylmethoxycarbonyl group.
[0196] Mention may further be made of the method comprising
substituting a halogen terminus of a vinyl polymer with an azido
anion and then reducing the same with LAH or the like.
Polymerizable Carbon-Carbon Double Bond-Containing Groups
[0197] The method of introducing a polymerizable carbon-carbon
double bond-containing group into a polymer to give the polymer
(II) according to the invention is not particularly restricted but
may be any of the following:
(i) Method comprising substituting a compound having a
radical-polymerizable carbon-carbon double bond for a halogen group
of a vinyl polymer. A specific method comprises reacting a vinyl
polymer having a structure represented by the general formula
30:
--CR.sup.31R.sup.32X (30)
wherein R.sup.31 and R.sup.32 each represents a group bonded to an
ethylenically unsaturated group of the vinyl monomer and X
represents a chlorine, bromine or iodine atom, with a compound
represented by the general formula 31:
M.sup.+--OC(O)C(R.sup.15).dbd.CH.sub.2 (31)
wherein R.sup.15 represents a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and M.sup.+ represents an alkali
metal ion or a quaternary ammonium ion. (ii) Method comprising
reacting a hydroxyl-containing vinyl polymer with a compound
represented by the general formula 32:
XC(O)C(R.sup.15).dbd.CH.sub.2 (32)
wherein R.sup.15 represents a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and X represents a chlorine or
bromine atom or a hydroxyl group. (iii) Method comprising reacting
a hydroxyl-containing vinyl polymer with a diisocyanate compound
and then reacting the residual isocyanato group with a compound
represented by the general formula 33:
HO--R.sup.33--OC(O)C(R.sup.15).dbd.CH.sub.2 (33)
wherein R.sup.15 represents a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and R.sup.33 represents a bivalent
organic group containing 2 to 20 carbon atoms.
[0198] In the following, these methods are described in detail.
[0199] The above method (i) is described.
(i) The method comprising reacting a vinyl polymer having a
terminal structure represented by the general formula 30:
--CR.sup.31R.sup.32X (30)
wherein R.sup.31 and R.sup.32 each represents a group bonded to an
ethylenically unsaturated group of the vinyl monomer and X
represents a chlorine, bromine or iodine atom, with a compound
represented by the general formula 31:
M.sup.+-OC(O)C(R.sup.15).dbd.CH.sub.2 (31)
wherein R.sup.15 represents a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and M.sup.+ represents an alkali
metal ion or a quaternary ammonium ion.
[0200] The vinyl polymer having a terminal structure represented by
the general formula 30 is produced by the method comprising
polymerizing a vinyl monomer(s) using the above-described organic
halide or halogenated sulfonyl compound as an initiator and the
transition metal complex as a catalyst, or by the method comprising
polymerizing a vinyl monomer(s) using a halogen compound as a chain
transfer agent, preferably by the former method.
[0201] The compound represented by the general formula 31 is not
particularly restricted but, as specific examples of R.sup.15,
there may be mentioned --H, --CH.sub.3, --CH.sub.2CH.sub.3,
--(CH.sub.2).sub.nCH.sub.3 (n being an integer of 2 to 19),
--C.sub.6H.sub.5, --CH.sub.2OH, --CN and the like. Among them, --H
and --CH.sub.3 are preferred. M.sup.+ is the counter cation to the
oxy anion and M.sup.+ includes, as species thereof, alkali metal
ions, specifically the lithium ion, sodium ion and potassium ion,
and quaternary ammonium ions. As the quaternary ammonium ions,
there may be mentioned the tetramethylammonium ion,
tetraethylammonium ion, tetrabenzylammonium ion,
trimethyldodecylammonium ion, tetrabutylammonium ion and
dimethylpiperidinium ion, etc. The sodium ion and potassium ion are
preferred, however. The oxy anion of general formula 31 is used
preferably in an amount of 1 to 5 equivalents, more preferably 1.0
to 1.2 equivalents, relative to the halogen group of general
formula 30. The solvent to be used in carrying out this reaction is
not particularly restricted but preferably is a polar solvent since
the reaction is a nucleophilic substitution reaction. Thus usable
are tetra hydrofuran, dioxane, diethyl ether, acetone, dimethyl
sulfoxide, dimethylformamide, dimethylacetamide,
hexamethylphosphoric triamide, acetonitrile and the like. The
temperature for carrying out the reaction is not particularly
restricted but, generally, the reaction is carried out at 0 to
150.degree. C., preferably at room temperature to 100.degree. C. so
that the polymerizable terminal group may be retained.
[0202] The above-mentioned method (ii) is described.
(ii) The method comprising reacting a hydroxyl-containing vinyl
polymer with a compound represented by the general formula 32:
XC(O)C(R.sup.15).dbd.CH.sub.Z (32)
wherein R.sup.15 represents a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and X represents a chlorine or
bromine atom or a hydroxyl group.
[0203] The compound represented by the general formula 32 is not
particularly restricted but, as specific examples of R.sup.15,
there may be mentioned --H, --CH.sub.3, --CH.sub.2CH.sub.3,
--(CH.sub.2).sub.nCH.sub.3 (n being an integer of 2 to 19),
--C.sub.6H.sub.5, --CH.sub.2OH, --CN and the like. Among them, --H
and --CH.sub.3 are preferred.
[0204] The vinyl polymer having a hydroxyl group(s), preferably at
a terminus or termini, is produced by the method comprising
polymerizing a vinyl monomer(s) using the above-mentioned organic
halide or halogenated sulfonyl compound as an initiator and the
transition metal complex as a catalyst, or by the method comprising
polymerizing a vinyl monomer(s) using a hydroxyl-containing
compound as a chain transfer agent, preferably by the former
method. Such method of producing hydroxyl-containing vinyl polymers
includes; but is not limited to, the following:
[0205] (a) Method comprising subjecting a compound having both a
polymerizable alkenyl group and a hydroxyl group in each molecule,
which is represented by the general formula 34, for instance:
H.sub.2C.dbd.C(R.sup.34)--R.sup.35--R.sup.36--OH (34)
(wherein R.sup.34 is an organic group containing 1 to 20 carbon
atoms but preferably is a hydrogen atom or a methyl group, and may
be the same or different; R.sup.35 represents --C(O)O-- (ester
group) or an o-, m- or p-phenylene group; R.sup.36 represents a
direct bond or a bivalent organic group containing 1 to 20 carbon
atoms, which may contain one or more ether bonds; the compound
being a (meth)acrylate compound when R.sup.35 is an ester group, or
a styrenic compound when R.sup.35 is a phenylene group), to
reaction as a second monomer in synthesizing a vinyl polymer by
living radical polymerization.
[0206] The time for subjecting the compound having both a
polymerizable alkenyl group and a hydroxyl group in each molecule
to reaction is not critical but, in particular when rubber-like
properties are demanded, the compound is preferably subjected to
reaction as a second monomer at the final stage of the
polymerization reaction or after completion of the reaction of the
main monomer(s).
[0207] (b) Method comprising subjecting a compound having a
low-polymerizability alkenyl group and a hydroxyl group in each
molecular to reaction as a second monomer in synthesizing a vinyl
polymer by living radical polymerization at the final stage of the
polymerization reaction or after completion of the reaction of the
main monomer(s).
[0208] Such compound is not particularly restricted but includes,
among others, compounds represented by the general formula 35:
H.sub.2C.dbd.C(R.sup.34)--R.sup.37--OH (35)
wherein R.sup.34 is as defined above; and R.sup.37 represents a
bivalent organic group containing 1 to 20 carbon atoms, which may
contain one or more ether bonds.
[0209] The compound represented by the general formula 35 is not
particularly restricted but preferably includes alkenyl alcohols
such as 10-undecenol, 5-hexenol and ally alcohol because of their
ready availability.
[0210] (c) Method comprising introducing a terminal hydroxyl
group(s) by hydrolyzing the halogen atom(s) of a vinyl polymer
having at least one highly reactive carbon-halogen bond or reacting
such halogen atom(s) with a hydroxyl-containing compound, according
to the method described in Japanese Kokai Publication
Hei-04-132706, for instance.
[0211] (d) Method involving halogen substitution which comprises
reacting a vinyl polymer having at least one carbon-halogen bond
such as one represented by the general formula 30, as obtained by
atom transfer radical polymerization, with a hydroxyl-containing
stabilized carbanion such as one represented by the general formula
36:
M.sup.+C.sup.-(R.sup.38)(R.sup.39)--R.sup.37--OH (36)
wherein R.sup.37 is as defined above; and R.sup.38 and R.sup.39
each represents an electron-withdrawing group capable of
stabilizing the carbanion C.sup.- or one of them represents such an
electron-withdrawing group and the other represents a hydrogen
atom, an alkyl group containing 1 to 10 carbon atoms or a phenyl
group. As the electron-withdrawing groups R.sup.38 and R.sup.39,
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), --NO.sub.2 (nitro group), etc. 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, preferably an alkyl group
containing 1 to 10 carbon atoms or a phenyl group. Particularly
preferred as R.sup.38 and R.sup.39 are --CO.sub.2R, --C(O)R and
--CN.
[0212] (e) Method comprising reacting a vinyl polymer obtain able
by atom transfer radical polymerization and having at least one
carbon-halogen bond such as one represented by the general formula
30 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.
[0213] (f) Method comprising reacting a vinyl polymer having at
least one polymer terminal halogen, preferably a halogen group
represented by the general formula 30, with a hydroxyl-containing
oxy anion represented by the general formula 37 shown below, for
instance, or a hydroxyl-containing carboxylate anion represented by
the general formula 38, for instance, for substituting a
hydroxyl-containing group for the halogen:
HO--R.sup.37--O.sup.-M.sup.+ (37)
wherein R.sup.37 and M.sup.+ are the same as defined above;
HO--R.sup.37--C(O)O.sup.-M.sup.+ (38)
wherein R.sup.37 and M.sup.+ are the same as defined above.
[0214] In the practice of the invention, when no halogen is
directly associated in the hydroxyl group introduction as in the
methods (a) and (b), the method (b) is more preferred because of
more ready controllability.
[0215] In cases where the hydroxyl group introduction is effected
by conversion of the halogen of a vinyl polymer having at least one
carbon-halogen bond, such as in the methods (c) to (f), the method
(f) is more preferred because of easier controllability.
[0216] The above method (iii) is now described.
(iii) The method comprising reacting a hydroxyl-containing vinyl
polymer with a diisocyanate compound and then reacting the residual
isocyanato group with a compound represented by the general formula
39:
HO--R.sup.33--OC(O)C(R.sup.15).dbd.CH.sub.2 (39)
wherein R.sup.15 represents a hydrogen atom or an organic group
containing 1 to 20 carbon atoms and R.sup.33 represents a bivalent
organic group containing 2 to 20 carbon atoms.
[0217] The compound represented by the general formula 39 is not
particularly restricted but, as specific examples of R.sup.15,
there may be mentioned --H, --CH.sub.3, --CH.sub.2CH.sub.3,
--(CH.sub.2).sub.nCH.sub.3 (n being an integer of 2 to 19),
--C.sub.6H.sub.5, --CH.sub.2OH, --CN and the like. Among them, --H
and --CH.sub.3 are preferred. As a typical compound, there may be
mentioned 2-hydroxypropyl methacrylate.
[0218] The terminal hydroxyl-containing vinyl polymer is the same
as mentioned herein above.
[0219] The diisocyanate compound is not particularly restricted but
may be any of those known in the art, for example toluoylene
diisocyanate, 4,4'-diphenylmethanediisocyanate, hexamethyl
diisocyanate, xylylene diisocyanate, metaxylylene diisocyanate,
1,5-naphthalenediisocyanate, hydrogenated
diphenylmethanediisocyanate, hydrogenated toluoylene diisocyanate,
hydrogenated xylylene diisocyanate, isophoronediisocyanate, and
like isocyanate compounds. These may be used singly or two or more
of them may be used in combination. These may also be used in the
form of blocked isocyanates.
[0220] For making better use of the excellent weatherability, the
use of aromatic ring-free diisocyanate compounds such as
hexamethylene diisocyanate and hydrogenated
diphenylmethanediisocyanate is preferred.
<<Re: Compatibilizing Agent (III)>>
[0221] The compatibilizing agent, namely component (III), to be
used according to the present invention is a component to be added
to compatibilize the polyether polymer (I) with the vinyl polymer
(II) and is a copolymer produced by copolymerization of a plurality
of vinyl monomers.
[0222] Preferred as the compatibilizing agent (III) according to
the present invention are vinyl copolymers obtain able by
copolymerizing at least one vinyl monomer among the monomers used
in polymerizing the vinyl polymer (II) and another vinyl monomer.
Such vinyl copolymers may be random copolymers or block
copolymers.
[0223] The vinyl monomer to be used in the polymerization of the
vinyl polymer (II) is not particularly restricted but includes
those mentioned herein above. For example, when the vinyl polymer
(II) is a (meth)acrylic polymer, (meth)acrylic monomers are
preferred, acrylic monomers are more preferred, and acrylic ester
monomers having a hydrocarbon group in the ester moiety are still
more preferred.
[0224] On the other hand, the other vinyl monomer is not
particularly restricted but includes vinyl monomers other than the
monomer(s) used in the polymerization of the vinyl polymer (II),
and vinyl monomers having a polyether structure. In particular,
vinyl monomers having a polyether structure are preferred.
[0225] The above polyether structure is not particularly restricted
but preferably is one comprising the same repeating unit as the
repeating unit in the polyether polymer (I) so that the
compatibility with the polyether polymer (I) may be improved. For
example, when the main chain of the polyether polymer (I) is
essentially polypropylene oxide, it is preferred that the above
polyether structure be essentially polypropylene oxide. The number
of oxyalkylene units in each polyether structure may greatly vary
depending on the average number of polyether structures contained
in each molecule but, generally, it is 2 to 20 and, preferably, 2
to 10 in view of ease of synthesis. Furthermore, the terminus of
the polyether structure may be a hydroxyl group itself or may be
blocked with a lower alkyl group. From the compatibility viewpoint,
one blocked with a lower alkyl group is preferred.
[0226] The vinyl monomer having a polyether structure is not
particularly restricted but includes various species, among which a
monomer of the same kind as the monomer constituting the vinyl
polymer (II). For example, when the vinyl polymer (II) is a
(meth)acrylic polymer, a (meth)acrylic monomer having a polyether
structure is preferred. Preferred as such (meth)acrylic monomer
having a polyether structure is (meth)acrylic esters having a
polyether structure in the ester moiety thereof. More preferred are
acrylic acid esters having a polyether structure in the ester
moiety thereof. For example, mention may be made of acrylic
acid-ethylene oxide adducts, acrylic acid-propylene oxide adducts,
and the like.
[0227] The proportions, in the compatibilizing agent (III), of the
same vinyl monomer as used in the polymerization of the vinyl
polymer (II) and the vinyl monomer having a polyether structure may
vary greatly depending on the mixing ratio between the polyether
polymer (I) and vinyl polymer (II) and/or to the polyether
structure. Generally, either monomer preferably accounts for 1 to
99%, more preferably 5% to 95%, of the total number of moles of the
monomers constituting the compatibilizing agent (III). In the
compatibilizing agent (III), the mole ratio of the same monomer as
used in the polymerization of the vinyl polymer (II) to the vinyl
monomer having a polyether structure is not particularly restricted
but, generally, it is 1:100 to 100:1, preferably 1:20 to 20:1, more
preferably 1:10 to 10:1. When the content of the polyether polymer
(I) is high, the mole ratio of the vinyl monomer having a polyether
structure is preferably increased.
[0228] The number average molecular weight of the compatibilizing
agent (III) according to the present invention is not particularly
restricted but preferably is within the range of 500 to 50,000,
more preferably within the range of 1,000 to 10,000, which is
determined by gel permeation chromatography. If the molecular
weight is lower, the effect as a compatibilizing agent may not be
expressed. When the molecular weight is higher, the viscosity may
become high, possibly causing handling difficulties.
[0229] The method of synthesizing the compatibilizing agent (III)
according to the present invention is not particularly restricted
but may involve free radical polymerization or controlled radical
polymerization. From the viewpoint of various characteristics of
curable compositions obtain able, controlled radical polymerization
is preferred, living radical polymerization is more preferred, and
atom transfer radical polymerization is still more preferred.
<<Compatibilizing Agent (IV)>>
[0230] The component (IV) compatibilizing agent to be used
according to the invention is a component to be added for
compatibilizing the polyether polymer (I) with the vinyl polymer
(II) and comprises at least one compound selected from the group
consisting of nonpolymer organic compounds, polymers obtain able by
polymerizing a monomer(s) other than vinyl monomers, and polymers
obtain able by polymerizing a single vinyl monomer.
[0231] The nonpolymer organic compounds are not particularly
restricted but include, among others, phthalates, 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
acetylricirinoleate; polyalkylene glycol esters such as diethylene
glycol dibenzoate, triethylene glycol dibenzoate and
pentaerythritol esters; phosphates such as tricresyl phosphate and
tributyl phosphate; and trimellitates.
[0232] The polymers obtain able by polymerizing a monomer(s) other
than vinyl monomers are not particularly restricted but include,
among others, chlorinated paraffins; hydrocarbon oils such as
alkyldiphenyls and partially hydrogenated terphenyl; process oils;
polyether polyols such, as polyethylene glycol, polypropylene
glycol and polytetramethylene glycol, derivatives of these
polyether polyols by conversion of the hydroxyl groups to ester or
ether groups, and like polyethers; epoxy plasticizers such as
epoxidized soybean oil and benzyl epoxystearate; and polyester
plasticizers obtain able from dibasic acids such as sebacic acid,
adipic acid, azelaic acid and phthalic acid and dihydric alcohols
such as ethylene glycol, diethylene glycol, triethylene glycol,
propylene glycol and dipropylene glycol.
[0233] The polymers obtain able by polymerizing a single vinyl
monomer are not particularly restricted but include, among others,
polystyrenes such as polystyrene and poly-.alpha.-methylstyrene;
polybutadiene, polybutene, polyisobutylene, butadiene-acrylonitrile
copolymers, polychloroprene; acrylic plasticizers, and like vinyl
polymers obtain able by polymerizing vinyl monomers by various
methods.
[0234] The above-mentioned acrylic plasticizers are not
particularly restricted but include, among others, conventional
ones obtain able by solution polymerization and solventless acrylic
polymers. The latter acrylic plasticizers are more suited for the
purpose of the present invention since they are produced by
high-temperature continuous polymerization techniques (U. S. Pat.
No. 4,414,370, Japanese Kokai Publication Sho-59-6207, Japanese
Kokoku Publication Hei-05-58005, Japanese Kokai Publication
Hei-01-313522, U. S. Pat. No. 5,010,166), without using any solvent
or chain transfer agent. Examples thereof are not particularly
restricted but include, among others, UP series products (Toagosei
Co., Ltd.) (cf. Kogyo Zairyo (Magazine for Engineering Materials),
October 1999 issue).
[0235] When the polymer obtain able by polymerizing a single vinyl
monomer is used as the compatibilizing agent, the molecular weight
thereof is not particularly restricted but preferably is not more
than 3,000 from the compatibility viewpoint. The main chain thereof
is not particularly restricted but preferably is a polyolefin. A
polyoxyalkylene is also preferred, and polypropylene oxide is more
preferred.
[0236] The content of the compatibilizing agent (IV) is preferably
1 to 200 parts by weight, more preferably 5 to 150 parts by weight,
most preferably 10 to 100 parts by weight, relative to 100 parts by
weight of the sum of the polyether polymer (I), and vinyl polymer
(II).
<<Curable Composition>>
[0237] In the curable composition of the present invention, a
curing catalyst and/or a curing agent may be required according to
the curable functional group species. Any of various compounding
additives or ingredients may be added thereto according to the
physical properties required.
<Curing Catalyst, Curing Agent>
In the Case of Crosslinkable Silyl Groups
[0238] The crosslinkable silyl group-containing polymer is
crosslinked and cured under siloxane bond formation in the presence
or absence of various condensing catalysts known in the art. The
properties of the cured products can widely range from rubber-like
to resinous ones according to the molecular weight and main chain
skeleton of the polymer.
[0239] As examples of such condensing catalyst, there may be
mentioned, among others, tetravalent tin compounds such as
dibutyltin dilaurate, dibutyltin phthalate, dibutyltin
bisacetylacetonate, 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), dioctyltin di(isooctyl maleate),
dibutyltin dimethoxide, dibutyltin bisnonylphenoxide and
dibutenyltin oxide; divalent tin compounds such as stannous
octylate, stannous naphthenate and stannous stearate; titanate
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 tetraacetylacetoante; 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; amine compound-organotin compound
reaction products and mixtures, for example laurylamine-stannous
octylate reaction products or mixtures; low-molecular-weight
polyamide resins obtain able from a polyamine in excess and a
polybasic acid; reaction products from a polyamine in excess and an
epoxy compound; amino group-containing silane coupling agents such
as .gamma.-aminopropyltrimethoxysilane and
N-(.beta.-aminoethyl)aminopropylmethyldimethoxysilane; and like
silanol condensation catalysts and, further, other known silanol
condensation catalysts such as acidic catalysts and basic
catalysts.
[0240] These catalysts may be used singly or two or more of them
may be used in combination. The level of addition of such
condensation catalyst is preferably about 0.1 to 20 parts (by
weight; herein after the same shall apply), more preferably 1 to 10
parts, per 100 parts of the vinyl polymer (II) having at least one
crosslinkable silyl group. When the addition level of the silanol
condensing catalyst is below the above range, the rate of curing
may fall and the curing can hardly proceed to a satisfactory extent
in certain cases. Conversely, when the level of addition of the
silanol condensation catalyst exceeds the above range, local heat
generation and/or foaming may occur in the step of curing, making
it difficult to obtain good cured products; in addition, the pot
life becomes excessively short and this is unfavorable from the
workability viewpoint as well.
[0241] For further increasing the activity of the condensation
catalyst in the curable composition of the present invention, a
silanol group-free silicon compound represented by the general
formula 40:
(R.sup.49).sub.aSi(OR.sup.50).sub.4-a (40)
wherein R.sup.49 and R.sup.50 each independently is a substituted
or unsubstituted hydrocarbon group containing 1 to 20 carbon atoms
and a is 0, 1, 2 or 3, may be added to the composition.
[0242] The above silicon compound is not restricted but those
compounds of the general formula (40) in which R.sup.49 is an aryl
group containing 6 to 20 carbon atoms, such as
phenyltrimethoxysilane, phenylmethyldimethoxysilane,
phenyldimethylmethoxysilane, diphenyldimethoxysilane,
diphenyldiethoxysilane and triphenylmethoxysilane, are preferred
since their accelerating effect on the curing reaction of the
composition is significant. In particular, diphenyldimethoxysilane
and diphenyldiethoxysilane are low in cost and readily available,
hence are most preferred.
[0243] The level of addition of this silicon compound is preferably
about 0.01 to 20 parts, more preferably 0.1 to 10 parts, per 100
parts of the vinyl polymer (II) having at least one crosslinkable
silyl group. When the level of addition of the silicon compound is
below this range, the curing reaction-accelerating effect may
decrease in certain cases. When, conversely, the level of addition
of the silicon compound exceeds this range, the hardness and/or
tensile strength of the cured products may fall.
In the Case of Alkenyl Groups
[0244] When alkenyl groups are associated in the crosslinking, it
is preferred though not obligatory, that the crosslinking be
effected in the manner of hydrosilylation using a hydrosilyl
group-containing compound as a curing agent, together with a
hydrosilylation catalyst.
[0245] The hydrosilyl group-containing compound is not particularly
restricted but may be any of various hydrosilyl group-containing
compounds which can cure with the alkenyl-containing polymer by
crosslinking. For example, use may be made of linear polysiloxanes
represented by the general formula 41 or 42:
R.sup.51.sub.3SiO--[Si(R.sup.51).sub.2O].sub.a--[Si(H)(R.sup.52)O].sub.b-
--[Si(R.sup.52)(R.sup.53)O].sub.c--SiR.sup.51.sub.3 (41)
HR.sup.51.sub.2SiO--[Si(R.sup.51).sub.2O].sub.a--[Si(H)(R.sup.52)O].sub.-
b--[Si(R.sup.52)(R.sup.53)O].sub.c--SiR.sup.51.sub.2H (42)
wherein R.sup.51 and R.sup.52 each represents an alkyl group
containing 1 to 6 carbon atoms or a phenyl group, R.sup.53
represents an alkyl group or aralkyl group containing 1 to 10
carbon atoms, and a, b and c each represents an integer satisfying
the relations 0.ltoreq.a.ltoreq.100, 2.ltoreq.b.ltoreq.100 or
0.ltoreq.c.ltoreq.100); cyclic siloxanes represented by the general
formula 43:
##STR00010##
wherein R.sup.54 and R.sup.55 each represents an alkyl group
containing 1 to 6 carbon atoms or a phenyl group, R.sup.56
represents an alkyl group or aralkyl group containing 1 to 10
carbon atoms, and d, e and f each represents an integer satisfying
the relations 0.ltoreq.d.ltoreq.8, 2.ltoreq.e.ltoreq.10 or
0.ltoreq.f.ltoreq.8 provided that the relation
3.ltoreq.d+e+f.ltoreq.10 should be satisfied; and like
compounds.
[0246] These may be used singly or two or more of them may be used
in admixture. Among these siloxanes, phenyl-containing: linear
siloxanes represented by the general formula 44 or 45 shown below
and cyclic siloxanes represented by the general formula 46 or 47
shown below are preferred from the viewpoint of compatibility with
the (meth)acrylic polymers.
(CH.sub.3).sub.3SiO--[Si(H)(CH.sub.3)O].sub.g--[Si(C.sub.6H.sub.5).sub.2-
O].sub.h--Si(CH.sub.3).sub.3 (44)
(CH.sub.3).sub.3SiO--[Si(H)(CH.sub.3)O].sub.g--[Si(CH.sub.3{CH.sub.2C(H)-
(R.sup.57)C.sub.6H.sub.5}O).sub.h--Si(CH.sub.3).sub.3 (45)
(In the above formulas, R.sup.57 represents a hydrogen atom or a
methyl group, g and h each represents an integer satisfying the
relation 2.ltoreq.g.ltoreq.100 or 0.ltoreq.h.ltoreq.100, and
C.sub.6H.sub.5 represents a phenyl group.)
##STR00011##
(In the above formulas, R.sup.57 represents a hydrogen atom or a
methyl group, i and j each represents an integer satisfying the
relation 2.ltoreq.i.ltoreq.10 or 0.ltoreq.j.ltoreq.8 provided that
the relation 3.ltoreq.i+j.ltoreq.10 should be satisfied; and
C.sub.6H.sub.5 represents a phenyl group.)
[0247] Further usable as the hydrosilyl-containing compound are
compounds obtain able by subjecting a low-molecular-weight compound
having two or more alkenyl groups in each molecule and a
hydrosilyl-containing compound represented by any of the general
formulas 41 to 47 to addition reaction in a manner such that the
hydrosilyl group partially remains even after reaction. Usable as
the compound having two or more alkenyl groups in the molecule are
various compounds, for example hydrocarbon compounds such as
1,4-pentadiene, 1,5-hexadiene, 1,6-heptadiene, 1,7-octadiene,
1,8-nonadiene and 1,9-decadiene, ether compounds such as
O,O'-diallylbisphenol A and 3,3'-diallylbisphenol A, ester
compounds such as diallyl phthalate, diallyl isophthalate, triallyl
trimellitate and tetraallyl pyromellitate, and carbonate compounds
such as diethylene glycol diallyl carbonate.
[0248] The above compounds can be obtained by slowly adding
dropwise the alkenyl-containing compound to an excess of the
hydrosilyl-containing compound represented by one of the general
formulas 41 to 47 shown above in the presence of a hydrosilylation
catalyst. Among such compounds, the following ones are preferred in
view of the readily availability of raw materials, the ease of
removal of the siloxane used in excess and, further, the
compatibility with the (I) component polymer:
##STR00012##
(n being an integer of 2 to 4 and m being an integer of 0.5 to
10).
[0249] The polymer and curing agent may be mixed together in an
arbitrary ratio but, from the curability viewpoint, the mole ratio
between the alkenyl and hydrosilyl groups is preferably within the
range of 5 to 0.2, more preferably within the range of 2.5 to 0.4.
When the mole ratio is above 5, the curing becomes insufficient and
only cured products having surface tack and low strength can be
obtained. When it is lower than 0.2, the active hydrosilyl group
remains in large amounts in the cured products even after curing,
so that cracks and voids appear and no uniform and strong cured
products can be obtained.
[0250] The curing reaction between the polymer and curing agent
proceeds when the two components are mixed up and heated. For
causing the reaction to proceed more rapidly, a hydrosilylation
catalyst may be added. Such hydrosilylation catalyst is not
particularly restricted but may be, for example, a radical
initiator such as an organic peroxide or azo compound, or a
transition metal catalyst.
[0251] The radical initiator is not particularly restricted but
includes, among others, dialkyl peroxides such as di-t-butyl
peroxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane,
2,5-dimethyl-2,5-di(t-butylperoxy)-3-hexyne, dicumyl peroxide,
t-butyl cumyl peroxide and .alpha.,
.alpha.'-bis(t-butylperoxy)isopropylbenzene, diacyl peroxides such
as benzoyl peroxide, p-chlorobenzoyl peroxide, m-chlorobenzoyl
peroxide, 2,4-dichlorobenzoyl peroxide and lauroyl peroxide, peroxy
esters such as t-butyl perbenzoate, peroxydicarbonates such as
diisopropyl peroxydicarbonate and di-2-ethylhexyl
peroxydicarbonate, peroxy ketals such as
1,1-di(t-butylperoxy)cyclohexane and
1,1-di(t-butylperoxy)-3,3,5-trimethylcyclohexane, and the like.
[0252] The transition metal catalyst is not particularly
restricted, either, but includes, among others, simple substance
platinum, solid platinum dispersed on/in a carrier such as alumina,
silica or carbon black, chloroplatinic acid, chloroplatinic acid
complexes with alcohols, aldehydes, ketones or the like,
platinum-olefin complexes, and
platinum(0)-divinyltetramethyldisiloxane complex. As other
catalysts 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 and
TiCl.sub.4, for instance. These catalysts may be used singly or two
or more of them may be used in combination. 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 10.sup.-3 to
10.sup.-6 mole, per mole of the alkenyl group in the vinyl polymer
(II). When it is less than 10.sup.-8 mole, the curing will not
proceed to a sufficient extent. Since the hydrosilylation catalyst
is expensive, it is preferred that it be not used in an amount
exceeding 10.sup.-1 mole.
[0253] The curing temperature is not particularly restricted but,
recommendably, the curing is carried out generally at 0.degree. C.
to 200.degree. C., preferably at 30.degree. C. to 150.degree. C.,
more preferably at 80.degree. C. to 150.degree. C.
In the Case of Hydroxyl Group
[0254] The hydroxyl-containing polymer according to the invention
can be cured uniformly by using, as a curing agent, a compound
having two or more functional groups capable of reacting with the
hydroxyl group. As specific examples of the curing agent, there may
be mentioned, among others, polyvalent isocyanate compounds having
two or more isocyanato groups in each molecule, aminoplast resins
such as methylolated melamine and alkyl-etherification derivatives
thereof or low condensation products thereof, and polufunctional
carboxylic acids and halogenation derivatives thereof. When cured
products are to be produced by using these curing agents,
appropriate curing catalysts can be used for the respective curing
agents.
In the Case of Amino Groups
[0255] The amino group-containing polymer according to the present
invention can be cured uniformly by using, as a curing agent, a
compound having two or more functional groups capable of reacting
with the amino group(s). As specific examples of the curing agent,
there may be mentioned, among others, polyvalent isocyanate
compounds having two or more isocyanato groups in each molecule,
aminoplast resins such as methylolated melamine and
alkyl-etherification derivatives thereof or low condensation
products thereof, and polyfunctional carboxylic acids and
halogenation derivatives thereof. When cured products are to be
produced by using these curing agents, appropriate curing catalysts
can be used for the respective curing agents.
In the Case of Epoxy Group
[0256] The curing agent to be used for the epoxy-containing polymer
according to the invention is not particularly restricted. Usable
as such are, for example, aliphatic amines, alicyclic amines,
aromatic amines; acid anhydrides; polyamides; imidazoles;
amineimides; urea; melamine and derivatives thereof; polyamine
salts; phenol resins: polymercaptans, polysulfides; and
photocuring/ultra violet curing agents such as aromatic diazonium
salts, diallyliodonium salts, triallylsulfonium salts and
triallylselenium salts.
In the Case of Polymerizable Carbon-Carbon Double Bonds
[0257] The polymerizable carbon-carbon double bond-containing
polymer can be crosslinked through the polymerization reaction of
its polymerizable carbon-carbon double bond(s).
[0258] The method of crosslinking includes curing with activating
energy rays, and curing by means of heat. In the activating energy
ray-curable composition, the photopolymerization initiator is
preferably a photoradical initiator or a photoanion initiator. In
thermocurable compositions, the heat polymerization initiator is
preferably selected from the group consisting of azo initiators,
peroxides, persulfates, and redox initiator systems.
[0259] In the following, these crosslinking reactions are described
in detail.
[0260] When the polymerizable carbon-carbon double bond-containing
polymer is to be crosslinked, a polymerizable monomer and/or
oligomer and/or various additives may be combinedly used according
to the intended purpose. Preferred as the polymerizable monomer
and/or oligomer are monomers and/or oligomers having a
radical-polymerizable group or an anionically polymerizable group.
The radical-polymerizable group includes acrylic functional groups
such as a (meth)acrylic group, styrene group, acrylonitrile group,
vinyl ester group, N-vinylpyrrolidone group, acrylamide group,
conjugated diene group, vinyl ketone group, vinyl chloride group,
etc. Among them, those having a (meth)acrylic group similar to the
polymer of the invention are preferred. The anionically
polymerizable group includes a (meth)acrylic group, styrene group,
acrylonitrile group, N-vinylpyrrolidone group, acrylamide group,
conjugated diene group, vinyl ketone group, etc. Among them, those
having an acrylic functional group are preferred.
[0261] As specific examples of the above monomer, there may be
mentioned (meth)acrylate monomers, cyclic acrylates,
N-vinylpyrrolidone, styrenic monomers, acrylonitrile,
N-vinylpyrrolidone, acrylamide monomers, conjugated diene monomers,
vinyl ketone monomers, etc. 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:
##STR00013## ##STR00014##
[0262] The styrenic monomers include styrene,
.alpha.-methylstyrene, and the like, the acrylamide monomers
include acrylamide, N,N-dimethylacrylamide, and the like, the
conjugated diene monomers include butadiene, isoprene, and the
like, and the vinyl ketone monomers include methyl vinyl ketone and
the like.
[0263] As the 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, tricyclodecanedimethylol 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-nonandiol diacrylate, ditrimethylolpropane tetraacrylate,
etc.
[0264] As the oligomers, there may be mentioned bisphenol A-based
epoxy acrylate resins, phenol novolak-based epoxy acrylate resins,
cresol novolak-based epoxy acrylate resins and like epoxy acrylate
resins, COOH-modified epoxy acrylate resins, urethane acrylate
resins obtain able by reacting urethane resins prepared from a
polyol (e.g. polytetramethylene glycol, polyester diol derived 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, etc.) 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 derived from
the above-mentioned polyol by introduction of a (meth)acrylic group
via ester bonding, polyester acrylate resins, and so forth.
[0265] An appropriate one is to be selected from among these
monomers and oligomers according to the initiator and curing
conditions employed.
[0266] It is preferred for good compatibility reasons that the
acrylic functional group-containing monomer and/or oligomer have a
number average molecular weight of not higher than 2,000, more
preferably not higher than 1,000.
[0267] As for the method of crosslinking the polymerizable
carbon-carbon double bond-containing polymer, the use of UV or
electron beams or like activating energy rays is preferred.
[0268] When crosslinking is to be accomplished by means of
activating energy rays, it is preferred that the composition
contain a photopolymerization initiator.
[0269] The photopolymerization initiator to be used in the practice
of the invention is not particularly restricted but preferably is a
photoradical initiator or photoanion initiator, in particular a
photoradical initiator. As examples, there may be mentioned
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, benzoil, benzoin
methyl ether, benzoin butyl ether, bis(4-dimethylaminophenyl)
ketone, benzyl methoxy ketal, 2-chlorothioxanthone, and the like.
These initiators may be used singly or in combination with another
compound. More specifically, mention may be made of combinations
with amines such as diethanol/methylamine, dimethylethanolamine and
triethanolamine, optionally further combined with an iodonium salt
such as diphenyliodonium chloride, and combinations with a dye,
such as Methylene Blue, and an amine.
[0270] Further, a near infrared-absorbing cationic dye may also be
used as a neat infrared photopolymerization initiator. The near
infrared-absorbing cationic dye to be used is preferably a near
infrared-absorbing cationic dye-borate anion complex capable of
being excited by light energy in the region of 650 to 1,500 nm,
such as one disclosed in Japanese Kokai Publication Hei-03-111402
or Japanese Kokai Publication Hei-05-194619, for instance. The
combined use of a boron-containing sensitizer is more
preferred.
[0271] The level of addition of the photopolymerization initiator
is such that the system can be photofunctionalized only slightly;
hence it is not particularly restricted. Preferably, however, the
level is 0.001 to 10 parts by weight per 100 parts of the polymer
in the composition.
[0272] The method of curing the activating energy ray-curable
composition of the present invention is not particularly restricted
but may involve irradiation with light rays or electron beams using
a high-pressure mercury lamp, low-pressure mercury lamp, electron
beam irradiation equipment, halogen lamp, light emitting diode,
semiconductor laser, etc. according to the characteristics of the
photopolymerization initiator.
[0273] As for the method of crosslinking the polymerizable
carbon-carbon double bond-containing polymer, the use of heat is
preferred.
[0274] In effecting the crosslinking by means of activating energy
rays, it is preferred that the composition contain a heat
polymerization initiator.
[0275] The heat polymerization initiator to be used in the practice
of the present invention is not particularly restricted but
includes azo initiators, peroxides, persulfate salts, and redox
initiator systems.
[0276] 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),
1,1-azobis(1-cyclohexanecarbonitrile) (VAZO 88) (all available from
DuPont Chemical), 2,2'-azobis(2-cyclopropylpropionitrile), and
2,2'-azobis(methyl isobutyrate) (V-601) (available from Wako Pure
Chemical Industries), among others.
[0277] Appropriate peroxide initiators include, but are not limited
to, benzoyl peroxide, acetyl peroxide, lauroyl peroxide, decanoyl
peroxide, dicetyl peroxydicarbonate, di(4-t-butylcyclohexyl)
peroxydicarbonate (Perkadox 16S) (available from Akzo Nobel),
di(2-ethylhexyl) peroxydicarbonate, t-butyl peroxypivalate
(Lupersol 11) (available from Elf Atochem), t-butyl
peroxy-2-ethylhexanoate (Trigonox 21-C50) (available from Akzo
Nobel) and dicumyl peroxide, among others.
[0278] Appropriate persulfate initiators include, but are not
limited to, potassium persulfate, sodium persulfate and ammonium
persulfate, among others.
[0279] Suitable redox (oxidation/reduction) initiators include, but
are not limited to, combinations of the above-mentioned persulfate
initiators and a reducing agent such as sodium hydrogen meta
sulfite or sodium hydrogen sulfite; systems based on an organic
peroxide and a tertiary amine, such as the system based on benzoyl
peroxide and dimethylaniline; and systems based on an organic
hydroperoxide and a transition metal, such as the system based on
cumene hydroperoxide and cobalt naphthenate.
[0280] Other initiators include, but are not limited to, pinacols,
such as tetraphenyl-1,1,2,2-ethanediol.
[0281] Preferred heat radical initiators are selected from the
group consisting of azo initiators and peroxide initiators. More
preferred ones are 2,2'-azobis(methyl isobutyrate), t-butyl
peroxypivalate and di(4-t-butylcyclohexyl) peroxydicarbonate, and
mixtures of these.
[0282] When used in the present invention, the heat initiator is
present in a catalytically effective amount, and such amount is not
restricted but, typically, is about 0.01 to 5 parts by weight,
preferably about 0.025 to 2 parts by weight, per 100 parts by
weight of the total amount of the polymer according to the
invention, which has at least one terminal acrylic functional
group, and the additional monomer and oligomer mixture. When a
mixture of initiators is used, the total amount of the initiator
mixture is selected as if only one initiator were used.
[0283] The method of curing the heat-curable composition of the
invention is not particularly restricted. However, the temperature
depends on the heat initiator used, the polymer (II), and the
compound(s) added, among others. Generally, it is preferably within
the range of 50.degree. C. to 250.degree. C., more preferably
within the range of 70.degree. C. to 200.degree. C. The curing time
depends, among others, on the polymerization initiator, monomer(s),
solvent and reaction temperature employed but, generally, it is
within the range of about 1 minute to 10 hours.
<Adhesive Property Providing Agent>
[0284] In the composition of the present invention, there may be
incorporated a silane coupling agent and/or an adhesive property
providing agent other than the silane coupling agent. By adding
such an adhesive property providing agent, it becomes possible to
reduce the risk of the sealing material peeling off from adherends
such as siding boards due to changes in joint width as caused by an
eternal force. Further, it becomes no more necessary in certain
cases to use a primer for improving the adhesiveness, whereby the
laying operation can be expected to be simplified. As specific
examples of the silane coupling agent, there may be mentioned
isocyanato group-containing silanes such as
.gamma.-isocyanatopropyltrimethoxysilane,
.gamma.-isocyanatopropyltriethoxysilane,
.gamma.-isocyanatopropylmethyldiethoxysilane and
.gamma.-isocyanatopropylmethyldimethoxysilane; amino
group-containing silanes such as
.gamma.-aminopropyltrimethoxysilane,
.gamma.-aminopropyltriethoxysilane,
.gamma.-aminopropylmethyldimethoxysilane,
.gamma.-aminopropylmethyldiethoxysilane,
.gamma.-(2-aminoethyl)aminopropyltrimethoxysilane,
.gamma.-(2-aminoethyl)aminopropylmethyldimethoxysilane,
.gamma.-(2-aminoethyl)aminopropyltriethoxysilane,
.gamma.-(2-aminoethyl)aminopropylmethyldiethoxysilane,
.gamma.-ureidopropyltrimethoxysilane,
N-phenyl-.gamma.-aminopropyltrimethoxysilane,
N-benzyl-.gamma.-aminopropyltrimethoxysilane and
N-vinylbenzyl-.gamma.-aminopropyltriethoxysilane; mercapto
group-containing silanes such as
.gamma.-mercaptopropyltrimethoxysilane,
.gamma.-mercaptopropyltriethoxysilane,
.gamma.-mercaptopropylmethyldimethoxysilane and
.gamma.-mercaptopropylmethyldiethoxysilane; epoxy group-containing
silanes such as .gamma.-glycidoxypropyltrimethoxysilane,
.gamma.-glycidoxypropyltriethoxysilane,
.gamma.-glycidoxypropylmethyldimethoxysilane,
.beta.-(3,4-epoxycyclohexyl)ethyltrimethoxysilane and
.beta.-(3,4-epoxycyclohexyl)ethyltriethoxysilane; carboxysilanes
such as .beta.-carboxyethyltriethoxysilane,
.beta.-carboxyethylphenylbis(2-methoxyethoxy)silane and
N-.beta.-(carboxymethyl)
aminoethyl-.gamma.-aminopropyltrimethoxysilane; vinyl type
unsaturated group-containing silanes such as vinyltrimethoxysilane,
vinyltriethoxysilane,
.gamma.-methacryloyloxypropylmethyldimethoxysilane and
.gamma.-acryloxyloxypropylmethyltriethoxysilane; halogen-containing
silanes such as .gamma.-chloropropyltrimethoxysilane; and
isocyanurate silanes such as tris(trimethoxysilyl) isocyanurate.
Also usable as the silane coupling agent are modified derivatives
of these, for example amino-modified silyl polymers, silylated
amino polymers, unsaturated amino silane complexes,
phenylamino-long chain alkylsilanes, aminosilylated silicones and
silylated polyesters.
[0285] In the practice of the invention, the silane coupling agent
is used generally in an amount within the range of 0.1 to 20 parts
per 100 parts of the polyether polymer (I) plus vinyl polymer (II).
In particular, the use thereof within the range of 0.5 to 10 parts
is preferred. If the addition level is excessively high, the cured
products obtain able by curing the resulting curable composition
may not have the desired rubber elasticity any longer, hence they
can no longer function as a sealing material in certain instances.
When it is added to a two-component system, as mentioned later
herein, it is preferred that the sum of the amounts added to both
components be within the range mentioned above. As for the effect
of the silane coupling agent added to the curable composition of
the present invention, it produces marked adhesive property
improving effects under non-primer or primer-treated conditions
when the composition is applied to various adherend materials,
namely inorganic materials such as glass, aluminum, stainless
steel, zinc, copper and mortar, or organic materials such as
polyvinyl chloride, acrylics, polyesters, polyethylene,
polypropylene and polycarbonates. When it is used under non-primer
conditions, the improving effects on the adhesion to various
adherends are particularly remarkable.
[0286] Specific examples of the agent other than the silane
coupling agent include, but are not particularly limited to, epoxy
resins, phenol resins, sulfur, alkyl titanates and aromatic
polyisocyanates, among others.
[0287] The adhesive property providing agents-specifically
mentioned above may be used singly or two or more of them may be
used in admixture. By adding these adhesive property providing
agents, it is possible to improve the adhesion to adherends.
<Plasticizers>
[0288] If necessary, any of various plasticizers may be used in the
curable composition of the present invention. Such plasticizer is
not particularly restricted but, according to the purpose of
addition, for example adjustment of physical properties and/or
modification of other properties, use can be made of one or a
mixture of two or more of phthalate esters such as dibutyl
phthalate, diheptyl phthalate, di(2-ethylhexyl) phthalate and butyl
benzyl phthalate; nonaromatic dibasic carboxylic acid esters such
as dioctyl adipate, dioctyl sebacate, dibutyl sebacate and isodecyl
succinate; aliphatic esters such as butyl oleate and methyl
acetylricirinolate; polyalkylene glycol esters such as diethylene
glycol dibenzoate, triethylene glycol dibenzoate and
pentaerythritol esters; phosphate esters such as tricresyl
phosphate and tributyl phosphate; trimellitates; polystyrenes such
as polystyrene and poly-.alpha.-methylstyrene; polybutadiene,
polybutene, polyisobutylene, butadiene-acrylonitrile copolymers,
polychloroprene; chlorinated paraffins; hydrocarbon oils such as
alkyldiphenyls and partially hydrogenated terphenyl; process oils;
polyethers such as polyethylene glycol, polypropylene glycol,
polytetramethylene glycol and like polyether polyols and
derivatives of these polyether polyols as resulting from conversion
of hydroxyl groups thereof to ester, ether and/or like groups;
epoxy plasticizers such as epoxidized soybean oil and benzyl
epoxystearate; polyester plasticizers obtain able from a dibasic
acid, such as sebacic acid, adipic acid, azelaic acid or phthalic
acid, and a dihydric alcohol, such as ethylene glycol, diethylene
glycol, triethylene glycol, propylene glycol or dipropylene glycol;
and vinyl polymers obtain able by polymerizing a vinyl monomer(s)
by various methods, typically acrylic plasticizers, among others,
although these are not always necessary. It is also possible to
incorporate these plasticizers in the process of polymer
production.
[0289] The above-mentioned acrylic plasticizers are not
particularly restricted but include, among others, conventional
ones obtain able by solution polymerization and solventless acrylic
polymers. The latter acrylic plasticizers are more suited for the
purpose of the present invention since they are produced by
high-temperature continuous polymerization techniques (U.S. Pat.
No. 4,414,370, Japanese Kokai Publication Sho-59-6207, Japanese
Kokoku Publication Hei-05-58005, Japanese Kokai Publication
Hei-01-313522, U. S. Pat. No. 5,010,166), without using any solvent
or chain transfer agent. Examples thereof are not particularly
restricted but include, among others, UP series products (Toagosei
Co., Ltd.) (cf. Kogyo Zairyo (Magazine for Engineering Materials),
October 1999 issue).
[0290] The level of addition of the plasticizer, when this is used,
is not particularly restricted but generally is 5 to 150 parts by
weight, preferably 10 to 120 parts by weight, more preferably 20 to
100 parts by weight, per 100 parts by weight of the sum of the
polyether polymer (I) and vinyl polymer (II). At levels below 5
parts by weight, the effects as the plasticizer are no more
produced and, at levels above 150 parts by weight, the mechanical
strength of the cured products becomes insufficient.
<Fillers>
[0291] If necessary, any of various fillers may be used in the
curable composition of the present invention. The filler is not
particularly restricted but includes, among others, reinforcing
fillers such as wood flour, pulp, cotton chips, asbestos, glass
fibers, carbon fibers, mica, walnut shell flour, rice hull flour,
graphite, diatomaceous earth, terra alba, fumed silica,
precipitated silica, crystalline silica, fused silica, dolomite,
silicic anhydride, hydrous silicic acid and carbon black; fillers
such as heavy calcium carbonate, colloidal calcium carbonate,
magnesium carbonate, diatomaceous earth, calcined clay, clay, talc,
titanium oxide, bentonite, organic bentonite, ferric oxide,
aluminum fine particle, flint powder, zinc oxide, activated zinc
white, powdered zinc and Shirasu balloons; and fibrous fillers such
as asbestos, and glass fibers or filaments. Preferred among these
fillers are precipitated silica, fumed silica, crystalline silica,
fused silica, dolomite, carbon black, calcium carbonate, titanium
oxide, talc and the like. In particular when high strength cured
products are to be obtained using these fillers, a filler selected
from among fumed silica, precipitated silica, silicic anhydride,
hydrous silicic acid, carbon black, surface-treated fine calcium
carbonate, crystalline silica, fused silica, calcined clay, clay
and activated zinc white, among others, may be mainly added.
[0292] When low-strength high-elongation cured products are
desired, a filler selected from among titanium oxide, calcium
carbonate, talc, ferric oxide, zinc oxide and Shirasu balloons may
be mainly added. Generally, when its specific surface area is
small, calcium carbonate may fail to produce sufficient improving
effects on the breaking strength, elongation at break, adhesiveness
and weather-resistant adhesion of cured products. With the
increasing specific surface area, its improving effects on the
breaking strength, elongation at break, adhesiveness and
weather-resistant adhesion of cured products increase.
[0293] Further, those species of calcium carbonate which have been
surface-treated with a surface-finishing agent are more preferred.
When surface-treated calcium carbonate is used, the workability of
the curable composition of the present invention and the improving
effects on the adhesiveness and weather-resistant adhesion of the
curable composition are expected to be improved as compared with
the use of non-surface-treated calcium carbonate. Usable as the
above surface-treating agent are organic materials or various
surfactants, such as fatty acids, fatty acid soaps and fatty acid
esters, and various coupling agents, such as silane coupling agents
and titanate coupling agents. Specific examples include, but are
not limited to, fatty acids such as caproic acid, caprylic acid,
pelargonic acid, capric acid, undecanoic acid, lauric acid,
myristic acid, palmitic acid, stearic acid, behenic acid and oleic
acid, the sodium, potassium or like salts of such fatty acids, and
alkyl esters of such fatty acids. Typical examples of the
surfactants are sulfate ester type anionic surfactants such as
polyoxyethylene alkyl ether sulfate esters and long-chain alcohol
sulfates and the sodium, potassium or like salts thereof, and
sulfonic acid type anionic surfactants such as alkylbenzenesulfonic
acids, alkylnapthalenesulfonic acids, paraffinsulfonic acids,
.alpha.-olefinsulfonic acids, alkylsulfosuccinic acids and the like
and the sodium, potassium or like salts thereof. This
surface-finishing agent is used in the treatment preferably in an
amount within the range of 0.1 to 20% by weight, more preferably
within the range of 1 to 5% by weight, relative to calcium
carbonate. When the amount used for the treatment is less than 0.1%
by weight, the workability, adhesiveness and weather-resistant
adhesion may not be improved to a sufficient extent. When it
exceeds 20% by weight, the storage stability of the curable
composition may decrease.
<Addition Level>
[0294] When a filler is used, the level of addition thereof is
preferably within the range of 5 to 1,000 parts by weight, more
preferably within the range of 20 to 500 parts by Weight, most
preferably within the range of 40 to 300 parts by weight, per 100
parts by weight of the sum of the polyether polymer (I) and vinyl
polymer (II). When the addition level is below 5 parts by weight,
the improving effects on the breaking strength, elongation at
break, adhesiveness and weather-resistant adhesion may be
insufficient and, when it exceeds 1,000 parts by weight, the
workability of the curable composition may decrease in certain
instances. A single filler may be used alone or two or more fillers
may be used in combination.
<Physical Property Modifiers>
[0295] One or more physical property modifiers may be added to the
curable composition of the present invention according to need for
adjusting the tensile characteristics of the resulting cured
products.
[0296] The physical property modifier is not particularly
restricted but includes, among others, alkylalkoxysilanes such as
methyltrimethoxysilane, dimethyldimethoxysilane,
trimethylmethoxysilane and n-propyltrimethoxysilane; functional
group-containing alkoxysilanes, for example
alkylisopropenoxysilanes such as dimethyldiisopropenoxysilane,
methyltriisopropenoxysilane and
.gamma.-glycidoxypropylmethyldiisopropenoxysilane,
.gamma.-glycidoxypropylmethyldimethoxysilane,
.gamma.-glycidoxypropyltrimethoxysilane, vinyltrimethoxysilane,
vinyldimethylmethoxysilane, .gamma.-aminopropyltrimethoxysilane,
N-(.beta.-aminoethyl)aminopropylmethyldimethoxysilane,
.gamma.-mercaptopropyltrimethoxysilane and
.gamma.-mercaptopropylmethyldimethoxysilane; silicone varnishes;
and polysiloxanes. By using such physical property modifier(s) it
becomes possible to increase or decrease the hardness and/or attain
elongation properties at the time of curing of the composition of
the present invention. The physical property modifies such as
mentioned above may be used singly or two or more of them may be
used in combination.
<Thixotropy Providing Agent (Antisagging Agent)>
[0297] A thixotropy providing agent (antisagging agent) may be
added to the curable composition of the present invention according
to need for sagging prevention and workability improvement.
[0298] The antisagging agent is not particularly restricted but
includes, among others, polyamide waxes; hydrogenated castor oil
and derivatives thereof; and metal soaps such as calcium stearate,
aluminum stearate and barium stearate. These thixotropy providing
agents (antisagging agents) may be used singly or two or more of
them may be used in combination.
Other Additives
[0299] Where necessary, one or more of various additives may be
added to the curable composition of the present invention for the
purpose of adjusting various physical properties of the curable
composition and/or cured products. As examples of such additives,
there may be mentioned, among others, flame retardants, curability
adjusting agents, antioxidants, radical inhibitors, ultra violet
absorbers, metal deactivators, antiozonants, light stabilizers,
phosphorus-containing peroxide decomposers, lubricants, pigments,
foaming or blowing agents, antifungal agents, rust preventives, and
photocurable resins. These various additives may be used singly or
two or more species may be used in combination.
[0300] Specific examples of these additives are described, for
example, in Japanese Kokoku Publication Hei-04-69659, Japanese
Kokoku Publication Hei-07-108928, Japanese Kokai Publication
Sho-63-254149 and Japanese Kokai Publication Sho-64-22904.
[0301] The curable composition of the present invention may be
prepared as a one-pack formulation by compounding all the
ingredients in advance and storing the resulting compound in a
tightly closed container, which formulation, when applied,
undergoes curing by atmospheric moisture, or as a two-pack
formulation by separately compounding a curing catalyst, filler,
plasticizer, water and other ingredients in advance. In the latter
case, the compound is admixed with the polymer composition prior to
use. In the case of such two-pack formulation, a colorant can be
added in the step of mixing the two components and thus it becomes
possible to prepare a rich assortment of colors with limited stocks
in providing sealing materials matched in color to the color of
siding boards, for instance. Thus, two-pack formulations make it
easy to cope with the market demand for multicolor systems, hence
are more preferred for use in low-rise buildings or the like. The
colorant, when prepared, for example in the form of a paste by
blending a pigment and plasticizer, optionally together with a
filler, facilitates the application work. Further, by adding a
retarder in blending the two components together, it is possible to
exactly adjust the curing rate at the site of application.
<<Cured Products>>
[0302] It is preferred that cured products not thicker than 100
.mu.m as obtained by curing, without adding any filler or like
additive, the curable composition according to the invention which
comprises the polyether polymer (I), vinyl polymer (II) and
compatibilizing agent (IV) show a level of weatherability not
shorter than 20 hours in sunshine weatherometer testing.
[0303] In the practice of the present invention, the weatherability
of each cured product not thicker than 100 .mu.m is evaluated by
visual observation of the cured product surface. That the
weatherability is not shorter than 20 hours, for instance, means
that the initial good surface condition is maintained for not
shorter than 20 hours without showing surface waviness or flatting
out due to polymer elution, cracking, discoloration (in the case of
colored products), chalking or other changes.
[0304] In the practice of the present invention, the weatherability
testing refers to the WS type test according to JIS A 1415.
<Uses>
[0305] The curing composition of the present invention can be used
in various fields of application which include, but are not limited
to, sealing materials, for example sealing materials such as
elastic sealing materials for building and construction and sealing
materials for laminated glass, electric and electronic part
materials such as solar cell back sealers, electric insulating
materials such as wire/cable insulating sheath, pressure sensitive
adhesive materials, adhesives, elastic adhesives, paints, powder
paints, coating compositions, foamed bodies, potting materials for
electric and electronic use, films, gaskets, casting materials,
various molding materials, and rustproof and waterproof sealants
for end faces (cut sections) of net glass or laminated glass.
BEST MODES FOR CARRYING OUT THE INVENTION
[0306] In the following, specific examples according to the present
invention and comparative examples are given to illustrate the
present invention. The following examples are, however, by no means
limitative of the scope of the present invention.
[0307] In the following examples and comparative examples,
"part(s)" and "%" mean "part(s) by weight" and "% by weight",
respectively.
[0308] In the following examples, the "number average molecular
weigh" and "molecular weight distribution (ratio of weight average
molecular weight to number average molecular weight)" were
calculated by the standard polystyrene equivalent method using gel
permeation chromatography (GPC). The GPC column used was one packed
with crosslinked polystyrene in a gel form (Shodex GPC K-804;
product of Showa Denko) and the GPC solvent used was
chloroform.
Synthesis Example 1
Synthesis of a Crosslinkable silyl Group-Terminated poly(n-butyl
acrylate/stearyl acrylate) copolymer
[0309] A 2-liter flask was charged with 8.39 g (58.5 mmol) of
cuprous bromide and 112 mL of acetonitrile, and the contents were
heated at 70.degree. C. with stirring under a nitrogen stream for
20 minutes. Thereto were added 17.6 g (48.8 mmol) of diethyl
2,5-dibromoadipate, 996 mL (6.94 mol) of butyl acrylate and 279 g
(0.858 mol) stearyl acrylate, and the mixture was further heated at
70.degree. C. for 40 minutes with stirring. Thereto was added 0.41
mL (1.95 mmol) of pentamethyldiethylenetriamine (herein after
referred to as "triamine") to thereby initiate the reaction. Then,
heating at 70.degree. C. was continued with stirring, and 2.05 mL
(9.75 mmol) of triamine was added. At 330 minutes after the start
of the reaction, 288 mL (1.95 mol) of 1,7-octadiene and 4.1 mL
(19.5 mmol) of triamine were added, and heating at 70.degree. C.
was continued with stirring. At 570 minutes after the start of the
reaction, the heating was stopped. The reaction mixture was diluted
with toluene and then filtered, and the filtrate was treated by
heating under reduced pressure to give a polymer (polymer [1]). The
polymer [1] obtained had a number average molecular weight of
28,800 as determined by GPC (mobile phase: chloroform; calculated
on the polystyrene equivalent basis) with a molecular weight
distribution of 1.33. The number of alkenyl groups per polymer
molecule as determined by .sup.1H-NMR spectrometry was 2.9.
[0310] In a nitrogen atmosphere, a 2-liter flask was charged with
the polymer obtained in the above manner, 17.2 g (0.175 mol) of
potassium acetate and 700 mL of DMAc, and the contents were heated
at 100.degree. C. with stirring for 10 hours. The DMAc was removed
from the reaction mixture by heating under reduced pressure,
toluene was added, and the mixture was filtered. The filtrate was
deprived of the volatile matter by heating under reduced pressure
and then charged into a 2-liter flask, an adsorbent (100 g, 1:1
mixture of Kyowaad 500SN and Kyowaad 700SN, products of Kyowa
Chemical) was added, and the mixture was heated at 130.degree. C.
with stirring under a nitrogen stream for 9 hours. After dilution
with toluene and removal of the adsorbent by filtration, the
toluene was distilled off from the filtrate under reduced pressure
to give a polymer (polymer [2]).
[0311] A one-liter pressure reaction vessel was charged with the
polymer [2] (700 g), dimethoxymethylhydrosilane (26.1 mL, 0.212
mol), methyl orthoformate (7.71 mL, 0.0705 mol) and
platinum(0)-1,1,3,3-tetramethyl-1,3-divinyldisiloxane complex. The
amount of the platinum catalyst used was such that the mole ratio
thereof to the alkenyl group in the polymer amounted to
9.times.10.sup.-3 equivalents. The mixture was heated at
100.degree. C. for 195 minutes with stirring. The volatile matter
was then distilled off from the mixture under reduced pressure,
whereby a silyl group-terminated polymer (polymer [3]) was
obtained. The polymer obtained had a number average molecular
weight of 35,900 as determined by GPC (on the polystyrene
equivalent basis) with a molecular weight distribution of 1.9. The
average number of the silyl groups introduced per polymer molecule
as determined by .sup.1H-NMR spectrometry was 2.1.
Synthesis Example 2
Synthesis of a Crosslinkable silyl Group-Terminated poly(n-butyl
acrylate)
[0312] A 2-liter flask was charged with 8.39 g (58.5 mmol) of
cuprous bromide and 112 mL of acetonitrile, and the contents were
heated at 70.degree. C. with stirring under a nitrogen stream for
30 minutes. Thereto were added 17.6 g (48.8 mmol) of diethyl
2,5-dibromoadipate and 224 mL (1.56 mol) of butyl acrylate, and the
mixture was further heated at 70.degree. C. with stirring for 45
minutes. Thereto was added 0.41 mL (1.95 mmol) of
pentamethyldiethylenetriamine (herein after referred to as
"triamine"), and the reaction was thereby started. While continued
heating at 70.degree. C. with stirring, 895 mL (6.24 mol) of butyl
acrylate was added dropwise intermittently over 160 minutes
beginning at 80 minutes after start of the reaction. During this
dropping, 1.84 mL (8.81 mmol) of triamine was added. After the
lapse of 375 minutes after start of the reaction, 288 mL (1.95 mol)
of 1,7-octadiene and 4.1 mL (19.5 mmol) of triamine were added, and
the heating at 70.degree. C. with stirring was further continued.
At 615 minutes after start of the reaction, the heating was
stopped. The reaction mixture was diluted with toluene and
filtered, and the filtrate was heated under reduced pressure to
give a polymer (polymer [4]). The polymer [4] had a number average
molecular weight of 24,100 as determined by GPC (mobile phase:
chloroform; on the polystyrene equivalent basis) with a molecular
weight distribution of 1.27. The number of alkenyl groups as
determined by .sup.1H-NMR spectrometry was 2.6 per polymer
molecule.
[0313] In a nitrogen atmosphere, a 2-liter flask was charged with
the thus-obtained polymer, 11.9 g (0.121 mol) of potassium acetate
and 900 mL of DMAc, and the mixture was heated at 100.degree. C.
with stirring for 11 hours. The DMAc was removed by heating the
reaction mixture under reduced pressure, toluene was added, and the
mixture was filtered. An adsorbent (200 g, Kyowaad 700PEL, product
of Kyowa Chemical) was added to the filtrate, and the mixture was
heated at 100.degree. C. with stirring under a nitrogen stream for
3 hours. The adsorbent was filtered off, and the toluene was
distilled off from the filtrate under reduced pressure to give a
polymer (polymer [5]).
[0314] A one-liter pressure reaction vessel was charged with the
polymer [5] (648 g), dimethoxymethylhydrosilane (25.5 mL, 0.207
mol), methyl orthoformate (7.54 mL, 0.0689 mol) and
platinum(0)-1,1,3,3-tetramethyl-1,3-divinyldisiloxane complex. The
amount of the platinum catalyst used was such that the mole ratio
thereof to the alkenyl group in the polymer amounted to
3.times.10.sup.-3 equivalents. The mixture was heated at
100.degree. C. with stirring for 2 hours. The volatile matter was
then distilled off from the mixture under reduced pressure, whereby
a silyl group-terminated vinyl polymer (polymer [6]) was obtained.
The polymer obtained had a number average molecular weight of
29,600 as determined by GPC (on the polystyrene equivalent basis)
with a molecular weight distribution of 1.9. The average number of
the silyl groups introduced per polymer molecule as determined by
.sup.1H-NMR spectrometry was 1.9.
Examples 1 to 5
[0315] The crosslinkable silyl group-containing vinyl polymer of
Synthesis Example 1 was blended with a commercially available,
crosslinkable silyl group-terminated polyether polymer (S203,
product of Kaneka Corporation) in various mixing ratios shown in
Table 1, and the mixtures were evaluated for compatibility by
visual observation. Each mixture (100 parts by weight) was blended
under stirring with 1 part by weight of water and 1 part by weight
of dibutyltin dimethoxide, the whole mixture was defoamed at room
temperature using a vacuum drier, and then curing was allowed to
proceed at 50.degree. C. for 3 days to give a rubber-like cured
product. The results thus obtained are shown in Table 1.
Comparative Examples 1 to 5
[0316] Compatibility observations were made and cured products were
obtained in the same manner as in Examples 1 to 5 except that the
polymer obtained in Synthesis Example 2 was used in lieu of the
polymer obtained in Synthesis Example 1. The results are also shown
in Table 1.
TABLE-US-00001 TABLE 1 Example Comparative Example 1 2 3 4 5 1 2 3
4 5 Vinyl polymer of 10 30 50 70 90 -- -- -- -- -- Synthesis
Example 1 Vinyl polymer of -- -- -- -- -- 10 30 50 70 90 Synthesis
Example 2 Polyether polymer 90 70 50 30 10 90 70 50 30 10
Compatibility .largecircle. .largecircle. .largecircle.
.largecircle. .largecircle. x x x x x Curing product .largecircle.
.largecircle. .largecircle. .largecircle. .largecircle. x x x x x
homogeneity
[0317] Blending of the polymer of Synthesis Example 1 with the
polyether polymer gave homogeneous mixtures, and the mixtures gave
homogeneous cured products. On the contrary, blending of the
polymer of Synthesis Example 2 with the polyether polymer gave
nonhomogeneous mixtures, and the mixtures gave only nonhomogenous
cured products.
Example 6
[0318] A commercially available, crosslinkable silyl
group-containing polyether polymer (S303; Kaneka Corporation; 70
parts) was mixed, under stirring, with 30 parts of the
crosslinkable silyl group-containing vinyl polymer of Synthesis
Example 1. This polymer mixture (100 parts) was mixed, under
stirring, with 120 parts of calcium carbonate (Hakuenka CCR;
product of Shiraishi Calcium), 20 parts of titanium oxide (TIPAQUE
R-820; Ishihara Sangyo), 55 parts of a plasticizer (DIDP; Daihachi
Chemical Industry), 2 parts of an antisagging agent (DISPARLON
#6500; Kusumoto Chemicals), 1 part of an ultra violet absorber
(TINUVIN 327; Ciba Specialty Chemicals), 1 part of a light
stabilizer (LS-770; Sankyo Organic Chemicals), 2 parts of a
dehydrating agent (A-171 (VTMO); Nippon Unicar), 3 parts of an
adhesiveness providing agent (A-1120 (DAMO); Nippon Unicar) and 2
parts of a curing catalyst (U-220; Nitto Kasei), and the same test
specimens as those for H tensile bond strength testing according to
JIS A 5758 were prepared and subjected to 2 days of indoor curing
and 3 days of curing at 50.degree. C. to give cured products.
Comparative Example 6
[0319] Cured products were produced in the same manner as in
Example 6 except that 100 parts of a commercially available,
crosslinkable silyl group-containing polyether polymer (S303;
Kaneka Corporation) was used in lieu of 100 parts of the polymer
mixture used in Example 6.
[0320] No. 2 (1/3) dumbbell test specimens (JIS K 7113) were
punched out from the cured products obtained in Example 6 and
Comparative Example 6 and measured for breaking strength (Tb) and
elongation at break(Eb) using a Shimadzu autograph (measurement
environment: 23.degree. C., rate of pulling: 200 mm/min). The
results are shown in Table 2.
TABLE-US-00002 TABLE 2 Formulation Comparative Name Particulars
Example 6 Example 6 Polyether polymer S-303 70 100 Vinyl polymer
Synthesis 30 -- Example 1 Calcium carbonate CCR 120 120 Titanium
oxide TIPAQUE R-820 20 20 Plasticizer DIDP 55 55 Antisagging agent
DISPARLON #6500 2 2 Ultraviolet absorber TINUVIN 327 1 1 Light
stabilizer LS-770 1 1 Dehydrating agent A-171(VTMO) 2 2
Adhessiveness A-1120(DAMO) 3 3 providing agent Curing catalyst
U-220 2 2 Total 306 306 Mechanical property test results Tb(MPa)
1.47 1.77 Eb(%) 440 430
[0321] Even when the vinyl polymer of Synthesis Example 1 was
blended with the polyether polymer, cured products comparable in
mechanical properties could be obtained.
Synthesis Example 3
Synthesis of Compatibilizing Agent [1]
[0322] A 50-mL flask was charged with 0.300 g (2.09 mmol) of
cuprous bromide and 3.00 mL of acetonitrile, and the contents were
heated at 70.degree. C. with stirring under a nitrogen stream for
40 minutes. Thereto were added 0.778 mL (6.98 mmol) of methyl
2-propionate, 10.0 mL (69.6 mmol) of butyl acrylate and 14.1 mL
(69.6 mmol) of methoxydipropylene glycol acrylate, and the mixture
was further heated at 70.degree. C. with stirring for 30 minutes.
Thereto was added 0.07 mL (0.35 mmol) of
pentamethyldiethylenetriamine (herein after referred to as
"triamine"), and the reaction was thereby started. While continued
heating at 70.degree. C. with stirring, 0.35 mL (1.75 mmol) of
triamine was added. After the lapse of 290 minutes after start of
the reaction, the temperature was raised to 90.degree. C. and the
heating with stirring was further continued for 70 minutes. The
reaction mixture was diluted with toluene and filtered, and the
filtrate was heated under reduced pressure to give a
compatibilizing agent (compatibilizing agent. [1]). The
compatibilizing agent [1] obtained had a number average molecular
weight of 3,870 as determined by GPC (mobile phase: chloroform; on
the polystyrene equivalent basis) with a molecular weight
distribution of 1.17.
Synthesis Example 4
Synthesis of Compatibilizing Agent [2]
[0323] A compatibilizing agent (compatibilizing agent [2]) was
obtained in the same manner as in Synthesis Example 3 except that
the amount of butyl acrylate was 6.00 mL (41.9 mmol) and the amount
of methoxydipropylene glycol acrylate was 19.7 mL (97.7 mmol). The
compatibilizing agent [2] obtained had a number average molecular
weight of 3,790 as determined by GPC (mobile phase: chloroform; on
the polystyrene equivalent basis) with a molecular weight
distribution of 1.18.
Synthesis Example 5
Synthesis of Compatibilizing Agent [3]
[0324] A compatibilizing agent (compatibilizing agent [3]) was
obtained in the same manner as in Synthesis Example 3 except that
the amount of butyl acrylate was 2.00 mL (14.0 mmol) and the amount
of methoxydipropylene glycol acrylate was 25.3 mL (126 mmol). The
compatibilizing agent [3] obtained had a number average molecular
weight of 3,620 as determined by GPC (mobile phase: chloroform; on
the polystyrene equivalent basis) with a molecular weight
distribution of 1.17.
Examples 7 to 9
[0325] The crosslinkable silyl group-containing vinyl polymer of
Synthesis Example 2 was blended with a commercially available,
crosslinkable silyl group-containing polyether polymer (S203HE,
product of Kaneka Corporation) and one of the compatibilizing
agents [1] to [3] in the mixing ratio shown in Table 3, and the
mixtures were evaluated for compatibility by visual observation.
Each mixture (100 parts by weight) was blended under stirring with
1 part by weight of water and 1 part by weight of dibutyltin
dimethoxide, the whole mixture was degassed at room temperature
using a vacuum drier, and then curing was allowed to proceed at
50.degree. C. for 3 days to give a rubber-like cured product. The
results thus obtained are shown in Table 3.
Comparative Example 7
[0326] A compatibility observation was made and a cured product was
obtained in the same manner as in Examples 7 to 9 except that the
compatibilizing agent was not used. The results are also shown in
Table 3.
TABLE-US-00003 TABLE 3 Comparative Example 7 Example 8 Example 9
Example 3 Vinyl polymer of 30 30 30 30 Synthesis Example 2
Polyether polymer 70 70 70 70 (S203HE) Compatibilizer[1] 10 -- --
-- Compatibilizer[2] -- 10 -- -- Compatibilizer[3] -- -- 10 --
Compatibility .largecircle. .largecircle. .largecircle. X Curing
product .largecircle. .largecircle. .largecircle. X homogeneity
[0327] Blending of the mixture of the polyether polymer and the
vinyl polymer of Synthesis Example 2 with the compatibilizing
agents gave homogeneous mixtures, and the mixtures gave homogeneous
cured products. On the contrary, nonhomogeneous mixtures were
obtained without using any compatibilizing agent, and the mixtures
gave only nonhomogenous cured products.
Synthesis Example 6
[0328] A 50-L reaction vessel equipped with a reflux column and a
stirrer was charged with a suspension of CuBr (251.82 g, 1.76 mol)
in acetonitrile (2,640 g), the reactor inside was sealed with
nitrogen, and the contents were then stirred at 65.degree. C. for
30 minutes. Thereto were added butyl acrylate (6.0 kg), diethyl
2,5-dibromoadipate (526.70 g, 1.46 mol), acetonitrile (695 g) and
pentamethyldiethylenetriamine (herein after referred to as
"triamine") (12.0 mL, 58.5 mmol) to thereby initiate the reaction.
While heating at 80.degree. C. with stirring, butyl acrylate (24.0
kg) was continuously added dropwise. During the dropping of butyl
acrylate, triamine (36.0 mL, 176 mmol) was added. Then, while
continued heating at 80.degree. C. with stirring, 1,7-octadiene
(6.448 kg) and triamine (120.0 mL, 585 mmol) were added. The
resulting mixture was further heated at 80.degree. C. with stirring
for 4 hours. Then, the heating with stirring was once discontinued,
triamine (80.0 mL, 390 mmol) was added, and the mixture was heated
at 90.degree. C. with stirring for 4 hours to give a reaction
mixture containing a polymer (polymer [1]) (polymerization reaction
mixture [1']).
[0329] The polymer [1] had a number average molecular weight of
23,600 as determined by GPC (on the polystyrene equivalent basis)
with a molecular weight distribution of 1.21. The average number of
alkenyl groups introduced per polymer molecule was 2.9 as
determined by .sup.1H NMR analysis.
Example 10
[0330] A curable composition was prepared by thoroughly blending 50
parts of the polymer [1] obtained in Synthesis Example 6 and 50
parts of a commercially available, crosslinkable silyl
group-containing polyether polymer (S203, product of Kaneka
Corporation) with a compatibilizing agent (DIDP (diisodecyl
phthalate), product of Kyowa Hakko).
Comparative Example 8
[0331] A curable composition was prepared in the same manner as in
Example 10 except that the compatibilizing agent was not added.
Evaluation 1
[0332] The curable compositions obtained in Example 10 and
Comparative Example 8 were respectively placed in glass bottles
and, after sealing, allowed to stand at room temperature (15 to
23.degree. C.) for 1 day and, then, observed for their conditions.
The curable composition of Example 10 showed compatibility without
any boundary face being confirmed upon visual observation whereas a
boundary line was confirmed by visual observation with the curable
composition of Comparative Example 8.
Example 11
[0333] One part of a tetravalent tin catalyst (dibutyltin
diacetylacetonate) was thoroughly admixed with 100 parts of the
curable composition of Example 10, and the blend was poured into an
aluminum mold (about 80 mm.times.about 60 mm.times.about 2 mm) and
allowed to stand at room temperature for 2 days and then at
50.degree. C. for 3 days to give a sheet-like cured product.
Comparative Example 9
[0334] One part of a tetravalent tin catalyst (dibutyltin
diacetylacetonate) was thoroughly admixed with 100 parts of the
curable composition of Comparative Example 8, and the blend was
poured into an aluminum mold (about 80 mm.times.about 60
mm.times.about 2 mm) and allowed to stand at room temperature for 2
days and then at 50.degree. C. for 3 days to give a sheet-like
cured product.
Evaluation 2
[0335] No. 2 (1/3) dumbbell test specimens (JIS K 7113) were
punched out from the cured products obtained in Example 11 and
Comparative Example 9 and measured for elongation at break (Eb)
using a Shimadzu autograph (measurement environment: 23.degree. C.,
rate of pulling: 200 mm/min). The results are shown in Table 4. A
higher elongation was obtained in Example 11 as compared with
Comparative Example 9.
TABLE-US-00004 TABLE 4 Eb(%) Example 11 390 Comparative 330 Example
9
Example 12
[0336] One part of a tetravalent tin catalyst (dibutyltin
diacetylacetonate) was thoroughly admixed with 100 parts of the
curable composition of Example 10, and the blend was applied to an
about 100-.mu.m-thick aluminum sheet and allowed to stand at room
temperature for 2 days and then at 50.degree. C. for 3 days to give
a cured product.
Comparative Example 10
[0337] One part of a tetravalent tin catalyst (dibutyltin
diacetylacetonate) was thoroughly admixed with 100 parts of the
curable composition of Comparative Example 8, and the blend was
applied to an about 100-.mu.m-thick aluminum sheet and allowed to
stand at room temperature for 2 days and then at 50.degree. C. for
3 days to give a cured product.
Evaluation 3
[0338] The cured products obtained in Example 12 and Comparative
Example 10 were tested for weatherability using a sunshine
weatherometer (Suga Test Instruments model WEL-SUN-DC, black panel
temperature 63.degree. C., 18 minutes of raining per 2 hours of
irradiation). After the predetermined period of weatherability
testing, the surface condition of each product was observed. The
cured product of Example 12 was observed for surface condition
after 20 hours and 48 hours of irradiation in the sunshine
weatherometer. The results are shown in Table 5.
TABLE-US-00005 TABLE 5 After 20 hours of After 48 hours of
weathering testing weathering testing Example 12 .largecircle.
.DELTA. Comparative X -- Example 10 .largecircle.: No change.
.DELTA.: Slight change in form. X: Dissolution occurred and the
original form was lost.
INDUSTRIAL APPLICABILITY
[0339] The curable composition of the present invention, which has
the above-mentioned constitution, is excellent in storage
stability, gives cured products high in gel fraction and
elongation, excellent in weatherability, among others, and uniform
in appearance.
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