JP2001316472A - Method for synthesizing silicone resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a silicone resin having high resistance to environmentally induced stress cracking. SOLUTION: There is provided a method for synthesizing a silicone resin, which comprises adding at least one member selected from hydridotrichlorosilane, tetrachlorosilane, and an organotrichlorosilane to a two- phase mixture containing a nonpolar organic solvent and an aqueous phase containing 0-43 wt.% hydrochloric acid and at least either a surface-active compound represented by the formula: R2SO4H (wherein R2 is a 4-16C alkyl or a 7-22C alkylphenyl) or an alkali metal salt thereof.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention provides an improved process for hydrolyzing chlorosilanes having at least three chlorine atoms bonded to each silicon atom to form a silicone resin. The method comprises the steps of converting at least one of hydridochlorosilane, tetrachlorosilane or organochlorosilane into a non-polar organic solvent and from 0 to 43% by weight of a surface-active compound selected from hydrochloric acid, organosulfate and alkali metal salts thereof. Aqueous phase, which is added to the two-phase mixture.

[0002]

It is well known in the art that halosilanes readily hydrolyze in the presence of water to form silanols, which condense to form polysiloxanes. Further, it is well known that these two steps occur almost simultaneously if the halosilane contains three or more halogen atoms. The result of this rapid hydrolysis and condensation is an insoluble gel of little practical value (see, for example, US Pat. No. 2,901,460).

[0003] A number of solutions to the above problems have been suggested. U.S. Pat. No. 2,901,460 described the use of a hydrolysis medium comprising, for example, tetrahydrofuran and water to reduce gelation. U.S. Patent No. 3,615,
No. 272 is a method for producing a hydrogen silsesquioxane resin, comprising reacting a silane in a hydrocarbon solvent with sulfuric acid and an aromatic hydrocarbon, washing the reaction mixture with water and sulfuric acid until neutral, and A process comprising recovering the product by evaporation of the solvent is described.

US Pat. No. 5,010,159 is a process for hydrolyzing hydridosilanes with two or more hydrolyzable groups, which produces an aryl sulfonic acid hydrate containing a reaction medium and converts the silane to a reaction medium. To promote hydrolysis of the silane to form a polyester and recovery of the polymer. The aryl sulfonic acid hydrate containing the reaction medium can be produced by dissolving the aryl sulfonic acid hydrate in a solvent such as an alcohol, or by a preferred method of reacting an aromatic hydrocarbon with concentrated sulfuric acid. It is taught that it can be generated.

[0005] Ezerets et al. (SU (11) 1147723) describe a method for hydrolyzing methylchlorosilane alone or 2.9 to 3 in a mixture of an aromatic hydrocarbon solvent and a water-miscible solvent.
The method is taught as co-hydrolysis with diorganodichlorosilane or organotrichlorosilane having a functionality of This method is characterized by the presence of a water-miscible solvent, including acetic acid and concentrated hydrochloric acid, and a water-soluble cationic surfactant. Water-soluble cationic surfactants are described as amine hydrochlorides having 6 to 20 carbon atoms, quaternary ammonium salts and salts of protonated carboxylic acids.

[0006] Hacker et al. (WO 98/47941) describe a process for preparing hydride siloxane and organo hydride siloxane resins. The method involves contacting a silane monomer with a phase transfer catalyst in the presence of a reaction mixture comprising a non-polar solvent and a polar solvent. Hacker et al. State that the phase transfer catalyst is a quaternary ammonium salt.

[0007] Shkolnik et al. (SU (11) 1666469) describes a process for the preparation of oligoorganohydride siloxanes which comprises phenyltrichlorosilane or vinyltrichlorosilane, dimethyldichlorosilane and hexane in the presence of a sulfonated copolymer of divinylbenzene and styrene. A method for carrying out the acid hydrolysis of a mixture of methyldisiloxanes is described.

It is also known that nonionic surfactants can effect the hydrolysis of diorganochlorosilanes. For example, U.S. Pat. No. 4,412,080, the positive C ₆ -C
It teaches that cyclic dimethylpolysiloxanes can be prepared by hydrolyzing dimethyldichlorosilane and aqueous hydrochloric acid in the presence of ₁₆ alkylsulfonic acids to produce good production of cyclic polysiloxanes.

[0009]

SUMMARY OF THE INVENTION The present invention is a method for producing a silicone resin which is easily dissolved in a non-polar solvent in a high yield. Our method does not require the use of (1) sulfuric acid and (2) does not have a solvent that is a reactant in a system such as when the solvent is reacted with sulfuric acid to produce an aryl sulfonic acid hydride. (3) Hydrogen chloride by hydrolysis of chlorosilane, alone from the mixture, in a form which can be recycled or otherwise used as an anhydrous gas and thus in the process And (4) the aqueous phase containing hydrochloric acid and surfactant can be recycled directly back to the process.

The resins prepared by our method have, for a given monomer distribution at a similar percentage of solids, they tend to prefer a high degree of intermolecular cyclization over resins prepared by other techniques. Is unique. Further, thin coatings of the cured resin prepared by the method of the present invention can be highly resistant to environmentally induced stress cracking.

The polymers produced by our method are:
When cured to their ceramic or ceramic-like state, they have excellent coating and sealing properties. Such polymers have utility, for example, in coating electronic devices to create protective barriers.

[0012]

SUMMARY OF THE INVENTION Our method for hydrolyzing chlorosilanes having at least three chlorine atoms bonded to each silicon atom to form a silicone resin comprises hydridotrichlorosilane, tetrachlorosilane or organotrichlorosilane. At least one of the chlorosilanes as a non-polar organic solvent, and 0-43% by weight hydrochloric acid;
R ² is added to a two-phase mixture containing a surface active compound represented by R ² SO ₄ H and an aqueous phase containing an alkali metal salt thereof (wherein R ² is an alkyl group having 4 to 16 carbon atoms or 7 carbon atoms). To 22 alkylphenyl groups).

Our method for the preparation of silicone resins
Is the formula R¹ _XSiCl_4-XAt least one represented by (1)
Two chlorosilanes, a non-polar organic solvent, and 0-4
3% by weight hydrochloric acid, R^TwoSO_FourSurfactant compound represented by H
And an aqueous phase containing the alkali metal salt thereof.
To the two-phase mixture, wherein R ¹
Is hydrogen and a monovalent hydrocarbon group, R^TwoHas 4 to 16 carbon atoms
Alkyl group or alkyl phenyl having 7 to 22 carbon atoms
Group, and X = 0 or 1).

[0014]

DETAILED DESCRIPTION OF THE INVENTION The chlorosilane added to the process of the present invention can be hydridotrichlorosilane, organotrichlorosilane, tetrachlorosilane or a mixture thereof. In formula (1), R ¹ is hydrogen or a monovalent hydrocarbon group, for example alkyl, for example methyl, ethyl,
Propyl, octyl, dodecyl, and octadecyl;
Cycloalkyl, such as cyclopentyl or cyclohexyl; cycloalkenyl, such as cyclopentenyl or cyclohexenyl; aryl, such as phenyl, tolyl and naphthyl; alkenyl, such as vinyl, allyl and pentenyl; aralkyl, such as benzyl and gamma-tolylpropyl; For example, it may be chloromethyl, 3,3,3-trifluoropropyl and perfluoropropyl. Preferred is R ¹
Is selected from hydrogen and a hydrocarbon group having 1 to 20 carbon atoms. Preferred chlorosilanes for use in the method of the present invention are trichlorosilane and methyltrichlorosilane.

[0015] chlorosilane of formula (1) is hydrolyzed alone, or two or more thereof, further, in the formula R ¹ ₂ SiCl ₂ (wherein, R ¹ is the same as defined above) It can be co-hydrolyzed with the represented diorganodichlorosilane.

The chlorosilane is used in liquid form. The liquid may contain essentially chlorosilane in its liquid state, or it may contain chlorosilane mixed with a non-polar organic solvent to form a solution. If a solvent is used, the solvent can be any suitable non-polar hydrocarbon or water-insoluble chlorocarbon that is a solvent for the chlorosilane. Examples of such solvents are saturated aliphatics such as dodecane, n-pentane, n-hexane, n-heptane and isooctane; aromatics such as benzene, toluene and xylene; cycloaliphatic aliphatics such as cyclohexane A halogenated aliphatic substance,
For example, trichloroethylene, perchloroethylene and 3-chloropropane; and halogenated aromatics,
For example, bromobenzene and chlorobenzene. Furthermore, combinations of the above-mentioned solvents can be used together as co-solvents for the chlorosilane. Preferred non-polar organic solvents are aromatic compounds, of which toluene is most preferred.

To obtain good product yields in the process of the present invention, the chlorosilane is diluted in a non-polar organic solvent using toluene as the preferred solvent. Dilution of the chlorosilane in the non-polar organic solvent prior to addition in this step provides better dispersion of the chlorosilane in the two-phase mixture, thereby reducing gel formation and improving yield. The chlorosilane may include from 10 to 80% by weight of the chlorosilane and the non-polar organic solvent mixture. Preferably, the chlorosilane comprises from 20 to 60% by weight of the chlorosilane and a non-polar organic solvent mixture.

The chlorosilanes can be added to the process of the present invention by any standard method known in the art for hydrolyzing such chlorosilanes. However, in order to maximize the yield, it is preferred that the chlorosilane be added in a manner that ensures a fast dispersion of the chlorosilane in the two-phase mixture. Such a method may involve gradually adding chlorosilane to the liquid mixture stream with vigorous stirring.

In a preferred method, the chlorosilane in the non-polar organic solvent is added to a rapidly stirring two-phase mixture containing the non-polar organic solvent, aqueous hydrochloric acid and a surface active compound.
By "two-phase" mixture is meant a mixture containing an organic phase and an aqueous phase. The non-polar organic solvent phase of the biphasic mixture can be any of the non-polar organic solvents described above for diluting the chlorosilane, and is used to dilute the chlorosilane prior to addition to the method. It can be the same or different from any non-polar organic solvent used. The non-polar organic solvent component of the two-phase mixture is preferably the same as any solvent used to dilute the chlorosilane, with toluene being the preferred solvent.

The aqueous phase containing from 0 to 43% by weight of hydrochloric acid is the second phase of the two-phase mixture and has at least a stoichiometric amount, preferably a stoichiometric excess, relative to the silicon-bonded chlorine atoms. Should have an amount of water. An excess of water in the range of 30-1000 mol% is preferred, with an excess of 250-800 mol% being most preferred. The aqueous phase is from 0 to
It contains 43% by weight of hydrochloric acid, preferably the aqueous phase is from 15 to
Contains 37% hydrochloric acid.

An advantage of our method is that the hydrogen chloride produced as a result of the hydrolysis reaction can be generated as anhydrous hydrogen chloride if the aqueous phase is saturated with hydrogen chloride. Thus, the aqueous phase preferably contains at least about 35% by weight of hydrogen chloride. The evolved hydrogen chloride is then recovered as a gas and recycled to the process or used for other uses. Hydrogen chloride present in the aqueous phase can be added to the process alone, as an aqueous solution, or can be generated in situ by hydrolysis of the chlorosilane.

The process of the present invention requires the presence of a surface active compound represented by R ² SO ₄ H and a surface active compound selected from alkali metal salts thereof, wherein R ¹ is hydrogen and a monovalent hydrocarbon group. Is an alkyl group having 4 to 16 carbon atoms or an alkylphenyl group having 7 to 22 carbon atoms). Preferably, the alkyl group of R ² has 6 to 12 carbon atoms,
The alkylaryl group of R ² has 9 to 18 carbon atoms. The surfactant compound is, for example, a compound of the formula C _n H _{(2n + 1)} SO ₄ H (wherein
n = 4 to 16). Alkyl sulfates include, for example, C ₄ H ₉ SO ₄ H,
C ₆ H ₁₃ SO ₄ H, C ₈ H ₁₇ SO ₄ H, C ₁₀ H ₂₁ SO
₄ H, C ₁₂ H ₂₁ SO ₄ H and C ₁₆ H ₃₃ SO ₄ H. The surfactant compound may be the corresponding metal salt of an alkyl sulfate where the alkali metal may be, for example, potassium or sodium. Alkali metal salts of alkyl sulfates include, for example, C ₆ H ₁₁ SO ₄ ⁻ Na ⁺ , C ₈ H _{17
^{SO 4 - Na +, C 10}} H 21 SO 4 - Na +, C 12 H 25 SO 4 - N
_{^{a +, C 16 H 33 SO}} 4 - Na + and C ₈ H ₁₇ SO ₄ ^- may be K ^+. The surfactant compound has the formula C _n H _{(2n + 1)} -C ₆ H ₄
Can be a -SO ₄ H alkylphenyl sulfates and the corresponding alkali metal salt (here, n represents 7 to 22
Carbon number). Alkylphenyl sulfate is, for example,
Methylphenyl sulfate, propylphenyl sulfate and their corresponding sodium and potassium salts

The concentration of the surfactant compound in the aqueous phase of the two-phase mixture is based on the weight of water added to the process.
It can be in the range of 0.1-60% by weight. Preferably,
Preferably, the concentration of the surfactant compound constitutes 0.5 to 10% by weight of the water added to the method. Even more preferred is when the concentration of the surfactant compound comprises 0.5 to 2% by weight of the water added to the process.

[0024] The temperature at which the method of the present invention can be carried out can be, but is not limited to, in the range of 0 ° C to 100 ° C. 10
Temperatures in the range of 30C to 30C are preferred.

In the process of the present invention, if desired, the residual hydroxyl groups on the silicon atoms of the resin may have the formula R ₃ SiCl
(Wherein R is a monovalent hydrocarbon group as described above). Preferred is when the endblocker is a trialkylchlorosilane. Even more preferred is when the endblocker is trimethylchlorosilane.

The hydrolysis reaction of the method of the present invention is completed,
After the silicone resin is formed, the two-phase mixture can be phase separated by a method such as standing. This process can be accomplished, for example, by simply stopping stirring the hydrolysis mixture and allowing it to spontaneously separate into immiscible layers in the reaction vessel. The resulting layers are an organic layer containing a silicone resin and a solvent, and an aqueous layer containing hydrogen chloride and a surface active compound.

Before, during or after this separation, the organic layer is allowed to settle for a period of time to allow further condensation of the residual silicon bonded hydroxyl and chlorine atoms present on the silicon atoms of the silicone resin. It is desirable to provide an increase in the structuring and / or molecular weight of the silicone resin. Preferably, if thickening is effected, this thickening step is preferably effected before the separation of the two phases. To provide stability of the silicone resin produced by the method of the present invention,
A washing step that may involve neutralization may be useful. If the organic layer is washed, water can be used alone, but preferably the washing solution is an aqueous sulfuric acid solution. Wash solutions containing more than 5% by weight sulfuric acid are useful. The washed or unwashed organic layer can be contacted with a neutralizing agent, preferably in the presence of water to promote hydrolysis of the remaining chlorine atoms. Neutralizing agents are used to neutralize any remaining acid species, such as sulfuric acid, hydrogen chloride, and organic acids without causing significant catalytic rearrangement of the silicone resin or reaction of the hydrogen-bonded silicon with water. Must be sufficiently basic. Suitable bases may include, for example, calcium carbonate, sodium carbonate, sodium bicarbonate, ammonium carbonate, ammonia, calcium oxide and calcium hydroxide. Preferably, the neutralizing agent is a solid to facilitate easy separation of the neutralizing agent from the organic phase. Further, preferably, the organic phase should be dried after washing and / or neutralization, and if necessary, filtered to remove any water-insoluble salts or other water-insoluble salts which may affect the silicone resin properties. Remove insoluble particles. Any suitable desiccant,
For example, magnesium sulfate, sodium sulfate or molecular sieves can be used. In addition, water can be removed by azeotropic distillation.

The silicone resin produced by our method can be maintained as a solution in the reaction solvent or, if desired, a simple solvent exchange can be performed by adding a secondary solvent and distilling out the primary solvent. Can be implemented. Alternatively, the silicone resin in solid form can be recovered by removing the solvent by standard steps such as azeotropic distillation.

Silicon which can be produced by the method of the present invention
The resin varies depending on the chlorosilane used.
The following, complete, of possible and co-hydrolysates
The following is a list of condensation and near perfect condensation resins:
(HSiO_3/2)_m, (R¹SiO_3/2)_m, (HSi
O_3/2)_x(R¹SiO_3/2)_y, (HSiO_3/2)_x(R¹ _Two
SiO)_yAnd (R¹SiO_3/2)_x(R¹ _TwoSiO)_yso
The completely condensed resin represented by the formula (HSiO_3/2)_x(H (H
O) SiO)_y, (R¹SiO_3/2)_x(R¹(HO) Si
O)_y, (HSiO_3/2)_w(H (HO) SiO)_x(R¹
SiO_3/2)_y(R¹(HO) SiO)_z, (HSi
O_3/2)_w(H (HO) SiO)_x(R¹ _TwoSiO)_y(R¹ _Two
(HO) SiO_1/2)_z, (R¹SiO_3/2)_w(R¹(H
O) SiO)_x(R¹ _TwoSiO)_y(R¹ _Two(HO) SiO
_1/2)_z And (R¹ _ThreeSiO_1/2)_x(SiO_Two)_y((H
O) SiO_3/2)_zPart containing silanol represented by
Condensed resin, and formula: (R¹ _ThreeSiO_1/2)_x(HSiO
_3/2)_y, (R¹ _ThreeSiO_1/2)_x(R¹SiO_3/2) _y, (R¹
_ThreeSiO_1/2)_x(HSiO_3/2)_y(R¹SiO_3/2)_z,
(R¹ _ThreeSiO_1/2)_x(HSiO_3/2)_y(R¹ _TwoSi
O)_z, (^R1 _ThreeSiO_1/2)_x(R¹SiO_3/2)_y(R¹ _TwoS
iO)_z, (R¹ _ThreeSiO_1/2)_x(SiO_Two)_y, (R¹ _ThreeS
iO_1/2)_w(HSiO_3/2)_x(R¹ _TwoSiO)_y(Si
O_Two)_zAnd (R¹ _ThreeSiO_1/2)_w(R¹SiO _3/2)
_x(R¹ _TwoSiO)_y(SiO_Two)_zTriorgano represented by
Silyl end-capping resin (wherein, R¹Is as described above.
And may be the same or different, and m is 8 or less.
And the sum of the mole fractions of w, x, y and z
Is 1.

[0030]

The following examples are provided to illustrate the invention. These examples do not limit the scope of the claims herein.

Examples 1-16 For Example 1, 151.5 g of 35% by weight HCl, 51.5 g were placed in a 1 L flask equipped with a stirrer and addition funnel.
0.5 g toluene sulfonic acid monohydrate and 334 g
Of toluene was added. 4 in 55.6 g of toluene
A solution consisting of 8.3 g of trichlorosilane was placed in the addition funnel. The trichlorosilane solution was added to the flask with stirring over 45 minutes. After the addition was complete, the contents of the flask were stirred for an additional 2 hours, the stirring was stopped, and the contents of the flask were separated into an aqueous phase and an organic phase. 47% organic phase
Washed twice with 100 ml portions of sulfuric acid, neutralized with 25 g of solid calcium carbonate, dried with 50 g of magnesium sulfate and filtered. Removal of the toluene from the organic phase yielded 17.5 g of a white powder, which provided a 92 mol% yield based on the trichlorosilane added to the flask. Examples 2 to 16 were carried out in the same manner as in Example 1 using the amounts of the reagents shown in Table 1.

[0032]

[Table 1]

Examples 17-33 For Example 17, a 1 L flask equipped with a stirrer and addition funnel was charged with 199 g of 35 wt.
0 g of sodium octyl sulfonate and 333 g
Of toluene was added. 47.3 in 55 g of toluene
A solution containing g of trichlorosilane was placed in the addition funnel. The trichlorosilane solution was added to the flask with stirring over 50 minutes. After the addition was complete, the contents of the flask were stirred for an additional 2 hours, the stirring was stopped, and the contents of the flask were separated into an aqueous phase and an organic phase. The organic phase was washed with water, dried using magnesium sulfate and filtered. Removal of the toluene from the organic phase yielded 16.3 g of a white powder, which provided a yield of 87.9 mol%, based on the trichlorosilane added to the flask. Example 1
8-36 were performed in a similar manner using the amounts of reagents shown in Table 2.

[0034]

[Table 2]

A = 35% by weight aqueous HCl b = benzenesulfonic acid hydrate c = toluene d = 2-chloropropane

Examples 37-39 For Example 37, a 1 L flask equipped with a stirrer and addition funnel was charged with 50.0 g of benzenesulfonic acid hydrate, 150 g of 35 wt% HCl and 333.6 g.
Of toluene was added. While stirring at 600 rpm, a solution consisting of 50.0 g of methyltrichlorosilane in 55.5 g of toluene was added dropwise to the mixture over 65 minutes. After the addition was complete, the contents of the flask were stirred for an additional 2 hours, the stirring was stopped, and the contents of the flask were separated into an aqueous phase and an organic phase. The organic phase is extracted with 100 ml of 47% sulfuric acid.
Washed twice, neutralized with 25 g of solid calcium carbonate,
Dry with 0 g of solid magnesium sulfate and filter. Removal of the toluene from the organic phase yielded 16.5 g of a white powder, which provided a yield of 73.5 mol% based on the trichlorosilane added to the flask.
Examples 38 and 39 were performed in a similar manner using the amounts of reagents shown in Table 3.

[0037]

[Table 3]

Examples 40 to 47 A toluene solution of methyltrichlorosilane was placed in a flask containing concentrated hydrochloric acid (36% by weight in an aqueous solution), toluene and sodium octylsulfonate (octyl SO ₃ Na) at the concentrations shown in Table 1. By adding
Methylsilsesquioxane was produced. The addition rate of methyltrichlorosilane was controlled using a syringe pump. Feeding was via a Teflon (trade name) tube, the outlet of which was submerged under the contents of the flask. In Table 1, the heading "Initial reactor charge" refers to the number of grams (g) of material initially charged to the flask. "W
t. The heading "feed rate" refers to the total weight of toluene and trichlorosilane fed to the reactor as a mixture at the stated rate ("flow rate"). The heading "Workup No." refers to the method of processing the sample after the addition of the feed material is completed, in which case the precision assay is referred to as Method 1, 2 or 3 below. . The heading "% yield" is the mole% yield of the methyltrichlorosilane based product added to the flask.

[0039]

[Table 4]

Precision test No. 1. Two hours after the completion of the feed addition, a 64 g sample of the organic phase was taken and washed six times with 100 ml aliquots of deionized water. The sample was dried by azeotropic distillation at 55 ° C. under reduced pressure.

The precision test No. 2. 19 hours after the addition of the feed material was completed, samples 41 and 42 were prepared in the following manner.
Sample 19 was processed immediately after the addition of the feed material was completed. For each sample, the organic phase was separated and one equivalent of Me ₃
SiCl was added to the organic phase and the organic phase was stirred at room temperature for 3 hours. Next, 64g samples of the organic phase was treated with the following washing steps: (1) 2 × 50 wt% H ₂ S in 200ml
O ₂ for 10 minutes, (2) 1 × 200 ml of deionized water,
(3) 1 × 200 ml of a 5% by weight NaHCO ₃ solution, and (4) 2 × 200 ml of deionized water. The resulting washed and neutralized organic phase was azeotropically distilled at 55 ° C. under reduced pressure and dried.

The precision test No. 3. The reaction mixture was poured into a separating funnel and the acidic layer was removed. The organic layer was placed in a three-necked flask equipped with a bottom drain. Next, 100ml of 4
7% sulfuric acid was added and the mixture was stirred. The resulting organic layer was washed three times with 5% sodium bicarbonate and then 100 m
Washed twice with 1 deionized water. The organic layer is then treated with 25 g of calcium carbonate while stirring for 10 minutes,
Of magnesium sulfate was added. The organic layer was filtered and the solvent was removed under reduced pressure to yield the resin as a white powder.

The selected sample as described above was subjected to ²⁹ Si NMR
And GPC (see polystyrene standards). Table 5 shows the results.

In Table 5, the mole percent of silicon atoms having hydroxy substitution is shown in the column "SIOH" and the mole percent of silicon atoms having chlorine substitution is shown in the column "SiCl".

[0045]

[Table 5]

Examples 48-51 Various silicone resins were prepared by simultaneous hydrolysis of different chlorosilanes as described in Table 3. The hydrolysis was performed by providing an initial reactor charge containing toluene, 36% by weight aqueous hydrochloric acid and sodium octyl sulfonate at the weights listed in Table 3. Next, a mixture of chlorosilanes in toluene as described in Table 3 was fed to the reactor at the listed rates. After the addition of the feed material was completed, each sample was precision tested by the method described. The% yield (% yield) of the product based on the mole% of chlorosilane added to the reactor is reported in Table 6.

[0047]

[Table 6]

A = toluene b = trifluoropropyl c = initial reactor charge also contained Me ₃ SiCl.

The precision test No. 4. A sample of 64 g of the organic phase was taken 12 hours after the addition of the feed was completed,
and washed twice with 50 wt% H ₂ SO ₄ in ml. 20 samples
Further washing was performed with 0 ml of a 5% by weight NaHCO ₃ solution, at which point the sample gelled.

The precision test No. 5. A sample of the organic phase was prepared 21 hours after the addition of the feed for sample 22 was completed.
The sample 23 was treated according to the following procedure 16 hours after the addition of the supply material was completed. 64g of each organic phase
The samples were processed by the following washing steps: (1) 2x20
(2) 1 × 2 with 0 ml of 50% by weight H ₂ SO ₄ for 10 minutes
20 minutes with 00 ml of 5% by weight NaHCO ₃ and (3) 20 minutes with 1 × 200 ml of deionized water. The resulting washed and neutralized organic phase was azeotropically distilled at 55 ° C. and dried.

The precision test No. 6. Extra amount of bis (trimethylsilyl) in methyl isobutyl ketone / toluene
The sample of the organic phase was sealed by treatment with trifluoroacetamide.

Analysis by Si NMR and GPC (with reference to MQ resin standards) gave sample no. 49 and 50 were precision tested. The results are shown in Table 7 together with the empirical formula. In the formula, M, D, T and Q represent monofunctional, difunctional, trifunctional and tetrafunctional siloxy units, respectively.

[0053]

[Table 7]

Example 52 1 g in a 1 L flask equipped with a stirrer and addition funnel
Of sodium octyl sulfonate, 199 g of 35% by weight HCl and 333.5 g of toluene were added.
While stirring at 500 rpm, a solution consisting of 50.0 g of phenyltrichlorosilane in 55.5 g of toluene was added dropwise over 150 minutes. After the addition was complete, the contents of the flask were stirred for an additional 70 hours, the stirring was stopped, and the contents of the flask were separated into an aqueous phase and an organic phase. 47 organic phases
Twice with 100 ml of 5% sulfuric acid, 5% sodium bicarbonate solution 1
Wash three times with 00 ml and three times with 100 ml of deionized water,
Neutralized with 25 g of solid calcium carbonate, dried with 50 g of solid magnesium sulfate and filtered. Removal of the toluene from the organic phase yielded 31.0 g of a white powder, which provided a 102 mol% yield based on the phenyltrichlorosilane added to the flask.

Examples 53-55 1.5 kg of 37% hydrochloric acid was placed in a 9 L baffled reactor.
0.010 kg of sodium octyl sulfate and the amount of toluene shown in Table 8 were added. 9 stirrers
A solution of 0.50 kg of methyltrichlorosilane dissolved in 0.50 kg of toluene, set at 00 rpm, was added to the reactor at ambient temperature at 12 ml / min. After the addition, the mixture was allowed to stir at ambient temperature for 14 hours. Stop stirring,
The phases were separated. The organic phase was washed 6-8 times with a 1 L portion of deionized water until the wash water was at pH 4. 50g
The organic phase was dried using MgSO ₄ and then vacuum filtered through filter paper. The organic solution was concentrated at 40 ° C. using a rotary evaporator. The dried resin was left under vacuum overnight to remove residual solvent. The material obtained from the above procedure was a white solid and weighed 0.22 kg. Light scattering triple detection G
The absolute molecular weight information was obtained by the PC method. The molecular weight information of the different substances is listed below.

[0056]

[Table 8]

Example 56 To a 1 L flask equipped with a condenser, nitrogen inlet, mechanical stirrer, addition funnel and temperature probe, 152.37 g of 3
7% by weight hydrochloric acid and 0.9908 g of sodium octyl sulfonate were added. After the sodium octyl sulfonate was dissolved, 335.34 g of toluene was added. 34.57 g of octadecyltrichlorosilane,
52.97 g of methyltrichlorosilane and 87.3
A feed solution was made containing 7 g of toluene. The feed solution was added dropwise to the flask over 1 hour and the resulting mixture was stirred overnight at ambient temperature. At the end of the stirring, the mixture separated into an organic phase and an aqueous phase. The aqueous phase was removed and the organic phase was washed four times at 55 ° C. with 300 ml of deionized water. The organic phase is then dried over magnesium sulfate, concentrated in vacuo,
37.89 g (74% yield) of siloxane resin was obtained.
Mn was 9,680 and Mw was 66,800.

Example 57 A 1 L flask equipped with the same equipment as in Example 56 was charged with 15
2.74 g of 37% by weight hydrochloric acid and 335.14 g of toluene were added. A feed solution was made containing 34.75 g octadecyltrichlorosilane, 52.74 g methyltrichlorosilane, and 87.02 g toluene. The feed solution was added dropwise to the flask over 1 hour and the resulting mixture was stirred overnight at ambient temperature. At the end of the stirring, the reaction mixture separated into an organic phase and an aqueous phase. The aqueous phase is removed and the organic phase is washed with 300 ml of deionized water at 55 ° C.
Washed twice. The organic phase was then dried over magnesium sulfate and concentrated in vacuo to give 27.91 g (55% yield) of a siloxane resin. Mn1,650 and Mw105,
650.

Example 58 A 1 L flask equipped with the same equipment as in Example 56 was charged with 15
1.01 g of 37% by weight hydrochloric acid and 0.9967 g of sodium octyl sulfonate were added. After the sodium octyl sulfonate had dissolved, 200.88 g of toluene was added. A feed solution was made containing 43.55 g octadecyltrichlorosilane, 48.35 g methyltrichlorosilane, and 88.50 g toluene. The feed solution was added dropwise to the flask over a period of 36 minutes, and the resulting mixture was stirred overnight at ambient temperature. At the end of the stirring, the mixture separated into an organic phase and an aqueous phase. The aqueous phase is removed and the organic phase is extracted at 65 ° C. with 300 ml of deionized water.
Washed twice. The organic phase was then dried over magnesium sulfate and concentrated in vacuo to a solid. 200 ml of this solid
In THF and 10 ml of deionized water was added. After stirring for one hour, the mixture was stripped under reduced pressure to a solid, yielding 60.54 g (108% yield) of siloxane resin. Mn 7,260 and Mw 51,00
It was 0.

Example 59 A 1 L flask equipped with the same equipment as in Example 56 was charged with 15
0.83 g of 37% by weight hydrochloric acid and 0.9911 g of sodium octyl sulfonate were added. After dissolution of the sodium octyl sulfonate, 201.28 g of toluene was added. A feed solution was made containing 53.99 g phenethyltrichlorosilane, 34.01 g methyltrichlorosilane and 87.15 g toluene. The feed solution was added dropwise to the flask over 45 minutes and the resulting mixture was stirred overnight at ambient temperature. At the end of the stirring, the mixture separated into an organic phase and an aqueous phase. The aqueous phase was removed and the organic phase was washed four times with 300 ml of deionized water. The organic phase was dried over magnesium sulfate and concentrated in vacuo to give 41.88 g (83% yield) of a siloxane resin. Mn was 9,300 and Mw was 204,500.

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Leslie Earl Carpenter The Second Todd Street, Midland, Michigan, United States 3823 (72) Inventor Russell Keith King Midland, Michigan, United States E. Bay, Mid Company Line Road 433 (72) Inventor Eric Scott Moyer Andre Street, Midland, Michigan, United States 4500 (72) Inventor Craig Laurin Eckle, Michigan, Michigan (72) Inventor Tetsuyuki Michino 3-44 Numashiroshinmachi, Hadano-shi, Kanagawa F-term (reference) 4J035 BA01 BA11 CA01K CA022 EA01 EB02 EB03 LA05

Claims (9)

[Claims] 1. A method for producing a silicone resin, at least one chlorosilane of the formula R ¹ _X SiCl _4-X, a non-polar organic solvents, and 0 to 43 wt% of hydrochloric acid, R ² SO ₄ A method comprising adding to a two-phase mixture containing a surface active compound represented by H and an aqueous phase containing an alkali metal salt thereof, wherein R ¹ is hydrogen and a monovalent hydrocarbon group, and R ² is An alkyl group having 4 to 16 carbon atoms or an alkylphenyl group having 7 to 22 carbon atoms, and X = 0 or 1.) 2. The method of claim 1, wherein the chlorosilane is diluted in a non-polar organic solvent before being added to the method. 3. The method of claim 1, wherein the aqueous hydrochloric acid provides a stoichiometric excess of water in the range of 30 to 1000 mol%.
the method of. 4. The method of claim 1 wherein the aqueous phase contains 15-37% by weight hydrochloric acid. 5. The method of claim 1, wherein the surfactant compound concentration is in the range of 0.1 to 10% by weight based on the weight of water added to the method. 6. The method of claim 1, wherein the two-phase mixture is separated into an organic phase comprising a silicone resin and an aqueous phase, and the organic phase is allowed to stand for a time sufficient for further condensation of residual silicon-bonded hydroxyl and chlorine atoms. Method. 7. The method of claim 1, wherein the two-phase mixture is separated into an organic phase containing the silicone resin and an aqueous phase, and the organic phase is washed with water to reduce residual chlorine content. 8. The method of claim 1, wherein the two-phase mixture is separated into an organic phase comprising a silicone resin and an aqueous phase, and the organic phase is contacted with a neutralizing agent. 9. A method for producing a silicone resin, comprising:¹ _XSiCl_4-XAt least one represented by
Chlorosilane is treated with a non-polar organic solvent,
% Hydrochloric acid, R^TwoSO_FourSurface active compounds represented by H
And an aqueous phase containing an alkali metal salt thereof.
Phase mixture and (B) the two-phase mixture
This is separated into an organic phase containing the
If the silicone resin has the formula (HSiO_3/2)_m, (R¹Si
O_3/2)_m, (HSiO_3/2)_x(R¹SiO_3/2)_y, (H
SiO_3/2)_x(R¹ _TwoSiO)_yAnd (R¹SiO_3/2)_x
(R¹ _TwoSiO)_yA complete condensation resin represented by the formula (HSi
O_3/2)_x(H (HO) SiO)_y, (R¹SiO_3/2)
_x(R¹(HO) SiO)_y, (HSiO _3/2)_w(H (H
O) SiO)_x(R¹SiO_3/2)_y(R¹(HO) Si
O)_z, (HSiO_3/2)_w(H (HO) SiO)_x(R¹ _Two
SiO)_y(R¹ _Two(HO) SiO_1/2)_z, (R¹SiO
_3/2)_w(R¹(HO) SiO)_x(R¹ _TwoSiO)_y(R¹ _Two
(HO) SiO_1/2)_z And (R¹ _ThreeSiO_1/2)_x(S
iO_Two)_y((HO) SiO_3/2) _zSilanol represented by
And a partially condensed resin containing the formula: (R¹ _ThreeSiO
_1/2)_x(HSiO_3/2)_y, (R¹ _ThreeSiO_1/2)_x(R¹S
iO_3/2)_y, (R¹ _ThreeSiO_{1 / Two})_x(HSiO_3/2)_y(R
¹SiO_3/2)_z, (R¹ _ThreeSiO_1/2)_x(HSiO_3/2) _y
(R¹ _TwoSiO)_z, (^R1 _ThreeSiO_1/2)_x(R¹SiO_3/2)
_y(R¹ _TwoSiO)_z, (R¹ _ThreeSiO_1/2)_x(SiO_Two)_y,
(R¹ _ThreeSiO_1/2)_w(HSiO_3/2)_x(R¹ _TwoSiO)_y
(SiO_Two)_zAnd (R¹ _ThreeSiO_1/2)_w(R¹Si
O_3/2)_x(R¹ _TwoSiO)_y(SiO_Two)_zBird represented by
Organosilyl end-capping resin (wherein, R¹Is independently hydrogen
And monovalent hydrocarbons, R^TwoIs carbon number 4-1
6 alkyl groups or alkyl phenyls having 7 to 22 carbon atoms
And X is 0 or 1, and m is 8 or more.
And the molar fraction w + x + y + z = 1)
A method comprising the steps of selecting.