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Modified Polyester Thermosetting Resin Compositions

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Modified Polyester Thermosetting Resin Compositions Europaisches Patentamt M European Patent Office Office europaen des brevets (n) Publication number: 0 211 903 B1 EUROPEAN PATENT SPECIFICATION @ Date of publication of patent specification : ® int. ci.5: C08G 81/00, C08G 63/91, 11.09.91 Bulletin 91/37 C08L 67/06 Application number : 86901295.5 Date of filing : 11.02.86 (£§) International application number: PCT/AU86/00030 (87) International publication number: WO 86/04908 28.08.86 Gazette 86/19 (54) MODIFIED POLYESTER THERMOSETTING RESIN COMPOSITIONS. @) Priority : 13.02.85 AU 9263/85 (73) Proprietor : BRIDGES CORPORATION PTY. LTD. 503 Grand Junction Road (43) Date of publication of application : Wingfield, S.A. 5013 (AU) 04.03.87 Bulletin 87/10 (72) Inventor : STRUDWICK, Kenneth, Roy (45) Publication of the grant of the patent : 503 Grand Junction Road 11.09.91 Bulletin 91/37 Wingfield, S.A. 5013 (AU) (84) Designated Contracting States : (74) Representative : Jump, Timothy John Simon et AT CH DE FR GB IT LJ NL SE al VENNER, SHIPLEY & CO. 368 City Road London EC1V 2QA (GB) (56) References cited : CHEMICAL ABSTRACTS, vol. 82, no. 18, 5th May 1975, page 39, abstract no. 112736u, Col- umbus, Ohio, US CQ « o CM Note : Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. have been Q. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to LU filed until the opposition fee has been paid (Ait 99(1) European patent convention). Jouve, 18, rue Saint-Denis, 75001 PARIS EP 0 211 903 B1 Description BACKGROUND OF THE INVENTION 5 This invention provides polyester thermosetting resin compositions and products obtained from formu- lations containing such compositions, in which the polyester is chemically modified by reaction with organo- silicone thermosetting compounds, in particular, organo-silicone thermosetting elastomers. More particularly, the invention provides polyester thermosetting resin "dough" moulding compositions wherein a "dough" comprising the chemically modified polyester thermosetting resin composition, catalyst, fil- 10 lers and additives can be formed to shape in hot dies under high pressure, although in other embodiments the chemically modified polyester may include thermosetting resin compositions which are suitable for extruding, pultruding and hand lay-up processes and injection, compression and transfer moulding by appropriate changes therein. In the past it has been suggested to add silicone prepolymers to certain thermoplastic materials and refer- 15 ence may be made to the publication "Plastics Technology", August 1 985, pp 57-61 . This publication describes the interpenetrating polymer networks which develop when a silicone prepolymer is admixed with a thermop- lastic resin. JP-A-74132184 discloses a polyester resin comprising an unsaturated polyester, a copolymerisabie mono- mer and a single organo polysiloxane, exemplified by polydimethyl siloxane. 20 No prior art is known which describes the incorporation of heat-curable thermosetting organo-silicone com- pounds, in particular, organo-silicone thermosetting elastomer materials, into unsaturated polyester resins to form heat-curable cross-linked polyester thermosetting resins. By "thermosetting" is meant a polymeric compo- sition capable of being cured or cross-linked so that it cannot be re-melted without destroying its chemical nat- ure. Thermosets are characterized by the presence of extensive primary covalent bonds between molecules, 25 in distinction to the weak secondary intermolecular forces characteristic of the re-meltable thermoplastic polym- ers. SUMMARY OF THE INVENTION 30 In accordance with the present invention, there are provided new polyester thermosetting resins which can be used in moulding, extruding and pultruding processes, wherein organo-silicone thermosetting compounds, in particular, organo-silicone thermosetting elastomer compounds are reacted with an unsaturated polyester resin, optionally with additives, leading to a new type of cross-linked polyester silicone polymer having many improved properties in the final product. 35 Thus, in contrast to the prior art, in which only interpenetrating networks were considered, which do not involve primary chemical bonds between cross-linked networks of a particular type (ie polymer A cross-links with polymer A and polymer B cross-links with polymer B, but not polymer A with polymer B; polymers A and B cross-link to form an intertwining and inextricable mixture), the present invention provides new polyester/or- gano-silicone thermosetting resins, in particular, organo-silicone thermosetting elastomer resin compositions 40 in which the organo-silicone component actually cross-links by primary chemical bonds both within itself and with the polyester resin, forming a solid polyester/silicone chemically cross-linked network. Formulations comprising a polyester thermosetting resin, in particular, organo-silicone thermosetting elas- tomer compounds, catalyst (generally tertiary butyl perbenzoate), cellulose acetate butyrate or other approp- riate low-profile or low-shrinkage additives, with fillers such as alumina trihydrate and fibre material, as well as 45 mould release agents such as zinc stearate in appropriate proportions, can be cured together under heat and pressure to give products which are superior in quality to that formed in the absence of the silicone elastomer. Variations in the formulation lead to a variety of desirable properties and material that can be injection moulded, transfer moulded, compression moulded, extruded or pultruded. Thus, the heat-cured thermoset polyester resin/thermoset organo-silicone component, with or without the 50 benefit of a low-profile or low-shrinkage additive and/or fillers, provides a complex interpenetrating molecular network containing primary chemical bonds, forming cross-links within the organo-silicone component and be- tween the organo-silicone component and the polyester resin, which achieves physical characteristics in the products fabricated therefrom that are superior to products fabricated from the polyester resin without the pre- sence of the organo-silicone component. The invention has, for instance, important applications in the produc- 55 tion of electrical insulating materials. Moulding formulations in accordance with the invention, used for the production of moulded electrical insulating materials, have been found to provide general improvements in moulding operations and in the moul- ded products, for example: better mould release; improved water resistance; increased ultraviolet light protec- EP 0 211 903 B1 tion; lower moulding, pressures; lowered dust retention; improved chemical resistance; smoother mouldings; better colour distribution of pigment; and improved electrical properties. The invention may also be applied to such things as cookware; roofing materials; building materials; vehicle coachwork, running gear and fittings; and machine components and bodies. 5 GENERAL DISCUSSION Polyester Resin Component 10 Polyester resins which can be used in preparing the resin compositions of the present invention are unsatu- rated thermoset synthetic resins formed by condensation reaction of anhydrides or carfaoxylic acids with alcohols; generally anhydrides ordicarboxylic acids with dihydroxy alcohols are used. The bond resulting from the condensation reaction is an ester bond (RCO2R')- Generally the mixture is dissolved in an unsaturated monomer such as styrene, the unsaturated polyesters usually being cross-linked through their double bonds 15 in the presence of a suitable unsaturated monomer. In the presence of catalysts, and generally of heat, the resins will cure to form a hard thermoset. Polyester resins are formed from a variety of materials including maleic acid or anhydride or fumaric acid, possibly in combination with phthalic acid or anhydride, or isophthalic acid, with alcohols such as ethylene glycol, propylene glycol, diethylene glycol and dipropylene glycol. The most common cross-linking agents are 20 styrene and diallyl phthalate. Peroxide catalysts such as benzoyl peroxide, methyl ethyl ketone peroxide, tertiary butyl perbenzoate and cumene hydroperoxide are usually added to the polyester resin to effect curing. A number of other peroxide catalysts such as cyclohexanone peroxide, 2,4-dichlorobenzoyl peroxide, bis(para-bromobenzoyl)peroxide, and acetyl peroxide, are also used. 25 Polymerization inhibitors are added to polyester resins to prevent polymerization of the polyester resin at room temperature in the absence of catalysts. Some typically used inhibitors include hydroquinone, para-ter- tiary-butyl-catechol, phenolic resins, aromatic amines, pyrogallol, chloranil, picric acid and quinones. General literature references relevant to polyester resins which may be used in preparing resin compo- sitions in accordance with the invention are The Condensed Chemical Dictionary (1 Oth Ed.), G D Hawley (Rev- 30 iser), Van Nostrand Reinhold (NY), 1981 , p 830, and Encyclopaedia of Polymer Science and Technology, H F Mark, N G Gaylord, and N M Bikales (Eds), John Wiley and Sons, NY, 1969, Vol 11, p 62-168. Polyester resins without a "low-profile" or "low shrinkage" additive, referred to hereinafter as being known in the art to alleviate the shrinkage and warping stresses created particularly in a polyester resin during curing, may be used in preparing resin compositions in accordance with the invention,
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