US20230278264A1 - Method for producing silicone elastomer molds - Google Patents

Method for producing silicone elastomer molds Download PDF

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Publication number
US20230278264A1
US20230278264A1 US18/104,429 US202318104429A US2023278264A1 US 20230278264 A1 US20230278264 A1 US 20230278264A1 US 202318104429 A US202318104429 A US 202318104429A US 2023278264 A1 US2023278264 A1 US 2023278264A1
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silicone elastomer
radicals
polyorganosiloxane
master
silicone
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David Mariot
Christian Maliverney
Aurélie PELLE
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Elkem Silicones France SAS
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Elkem Silicones France SAS
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/40Plastics, e.g. foam or rubber
    • B29C33/405Elastomers, e.g. rubber
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3842Manufacturing moulds, e.g. shaping the mould surface by machining
    • B29C33/3857Manufacturing moulds, e.g. shaping the mould surface by machining by making impressions of one or more parts of models, e.g. shaped articles and including possible subsequent assembly of the parts
    • B29C33/3878Manufacturing moulds, e.g. shaping the mould surface by machining by making impressions of one or more parts of models, e.g. shaped articles and including possible subsequent assembly of the parts used as masters for making successive impressions
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G77/00Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
    • C08G77/04Polysiloxanes
    • C08G77/06Preparatory processes
    • C08G77/08Preparatory processes characterised by the catalysts used
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • C08L77/06Polyamides derived from polyamines and polycarboxylic acids
    • C08L77/08Polyamides derived from polyamines and polycarboxylic acids from polyamines and polymerised unsaturated fatty acids
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L83/00Compositions of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon only; Compositions of derivatives of such polymers
    • C08L83/04Polysiloxanes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2083/00Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G77/00Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
    • C08G77/04Polysiloxanes
    • C08G77/14Polysiloxanes containing silicon bound to oxygen-containing groups
    • C08G77/16Polysiloxanes containing silicon bound to oxygen-containing groups to hydroxyl groups
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/16Nitrogen-containing compounds
    • C08K5/17Amines; Quaternary ammonium compounds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/54Silicon-containing compounds
    • C08K5/541Silicon-containing compounds containing oxygen
    • C08K5/5415Silicon-containing compounds containing oxygen containing at least one Si—O bond
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/54Silicon-containing compounds
    • C08K5/541Silicon-containing compounds containing oxygen
    • C08K5/5415Silicon-containing compounds containing oxygen containing at least one Si—O bond
    • C08K5/5419Silicon-containing compounds containing oxygen containing at least one Si—O bond containing at least one Si—C bond
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K5/00Use of organic ingredients
    • C08K5/54Silicon-containing compounds
    • C08K5/541Silicon-containing compounds containing oxygen
    • C08K5/5425Silicon-containing compounds containing oxygen containing at least one C=C bond

Definitions

  • the field of the invention relates to the use of silicone compounds for the manufacture of negative molds formed from silicone elastomer for use in the manufacture of molded articles.
  • Bicomponent organopolysiloxane compositions that can be used for the preparation of molds produced from silicone elastomer have already been proposed on the industrial market and in the chemical literature (FR 1 418 114 and JP 50066553). These compositions may include a variety of additives (which facilitate processing them or transforming them into elastomers), such as low viscosity dihydroxydiorganopolysiloxane oils (FR 2 272 145 and FR 2 300 114).
  • Patent application EP 586 153 describes a curable silicone composition comprising, in addition to the constituents which are routinely used in such a composition, reinforcing co-fillers such as acicular fillers based on CaO and SiO 2 , or in fact on CaSiO 3 ; and ceramic-based spherical fillers, and in particular on silica-alumina ceramics.
  • co-fillers such as acicular fillers based on CaO and SiO 2 , or in fact on CaSiO 3 ; and ceramic-based spherical fillers, and in particular on silica-alumina ceramics.
  • silicone compositions which can be cured at ambient temperature by condensation in order to produce molds, further comprising the constituents which are conventionally used in this type of composition, additives selected from the group constituted by sterically hindered phenols, sterically hindered thio bisphenols, zinc dialkyl dithiophosphates, zinc diaryl dithiophosphates, aromatic amines, sterically hindered amines, or in fact preparations based on those compounds.
  • Patent application WO 03/074602 describes the use of silica pre-treated in a silicone composition which can be cured by polycondensation, as a stabilization agent for molds obtained from that composition.
  • Patent application WO 06/106238 teaches a method for stabilizing molds composed of a silicone elastomer.
  • silicone compositions that can be cured to produce an elastomer which are known for this type of application, those which cure from ambient temperature form a category which catches the attention, because they do not have to be placed in an energy-consuming oven.
  • RTV monocomponent compositions
  • RTV-2 bicomponent compositions
  • RTV Room Temperature Vulcanizing
  • water (either supplied via moisture from the atmosphere in the case of RTV-1, or introduced into a part of the composition in the case of RTV-2) allows the polycondensation reaction to take place, which leads to the formation of the elastomeric network.
  • bicomponent compositions (RTV-2), these are sold and stored in the form of two components, a first component containing the basic polymer materials and the second component containing the catalyst. The two components are mixed for use and the mixture cures into the form of a relatively hard elastomer.
  • RTV-2 bicomponent compositions
  • compositions essentially comprise 4 different ingredients:
  • the condensation catalyst is based on an organic tin compound.
  • many tin-based catalysts have already been proposed as a catalyst for curing these RTV-1s or RTV-2s.
  • Conventional polycondensation catalysts comprise dialkyltin compounds, in particular dialkyltin dicarboxylates such as dibutyltin dilaurate and diacetate, alkyl titanate compounds such as tetrabutyl or tetraisopropyl titanate, and titanium chelates (EP-A-0 885 933, US-5 519 104, US-A-4 515 932, US-A-4 563 498, US-A-4 528 353).
  • alkyltin-based catalysts while being highly efficient, and usually colorless, liquid and soluble in silicone oils, suffer from the disadvantage of being toxic (CMR2 toxic for reproduction).
  • one of the essential aims of the present invention is to propose a novel method for the preparation of negative molds produced from silicone elastomer that can be used for the manufacture of molded articles in which the silicone elastomer is prepared from a silicone composition that does not contain a metallic catalyst such as tin, for example, and which cures by polycondensation reactions in the presence of water (for example ambient moisture) with a curing rate that is sufficient to ensure industrial rates of production.
  • a metallic catalyst such as tin
  • a further aim is to propose a novel method for forming molded articles starting from a negative mold produced from silicone elastomer having a good resistance to successive molding/demolding cycles and prepared from silicone compositions containing no tin.
  • a further aim is to propose a silicone composition containing no tin and hardening to form a silicone elastomer in the presence of moisture with rapid surface solidification kinetics, followed by a complete core solidification, i.e. homogeneous solidification, in a manner such as to prepare negative molds produced from silicone elastomers which do not adhere on the one hand to the master to be reproduced and on the other hand to the molded articles, and thus have a good resistance to successive molding/demolding cycles and which can be used for the preparation of molded articles produced from different materials.
  • the invention also concerns negative molds produced from silicone elastomer for use in the manufacture of molded articles produced from different reproduction materials such as from polyester, polystyrene, polyethylene, polyvinyl chloride, polyurethane, polyurethane foam, plaster, concrete, wax and soap. This list is not limiting.
  • the parts molded from different reproduction materials that are obtained represent a wide variety of articles, with a utilitarian or decorative purpose, such as dashboards, armrests, furniture, or works of art.
  • One advantage linked to the method in accordance with the invention is that the number of cycles for molding/demolding articles molded in this negative mold MN is preferably more than 37, for example when demolding polyurethane replicas.
  • the technique for molding in silicone elastomer consists of producing a “negative” mold, i.e. an impression, from a “positive” model termed the “master”.
  • the silicone elastomer mold that is generated thereby can be used to produce many “copies” or “prints” or “replicas” from the master, with no limits as to size or undercuts.
  • molding techniques are known to the person skilled in the art. Examples of molding techniques that may be cited are:
  • compositions in accordance with the invention When using the compositions in accordance with the invention in this application, casting techniques or techniques for application by means of a spatula, brush or by spraying are useful.
  • the manufactured molds have the particular feature of reproducing the details of the masters accurately and in fine detail; furthermore, because of the non-stick nature of silicone rubber, they can improve demolding rates.
  • a release agent may, however, be applied to the item to be reproduced prior to molding it.
  • These release agents are well known to the person skilled in the art.
  • the present invention concerns a method for molding replicas R, characterized in that it comprises steps a) to d) in accordance with the invention, followed by the following steps e) to h):
  • An advantage linked to the method in accordance with the invention is that the number of cycles e) to g) that can be carried out with the negative mold MN produced from silicone elastomer is more than 37, for example when demolding polyurethane replicas.
  • reproduction materials are known to the person skilled in the art, such as polyester, polystyrene, polyethylene, polyvinyl chloride, polyurethane, polyurethane foam, plaster, concrete, wax and soap. This list is not limiting. Before molding, these reproduction materials are in different forms, namely liquid which is viscous to a greater or lesser extent, a dispersion, suspension, with a single or with multiple components.
  • the present invention concerns an organopolysiloxane composition that can be vulcanized to form a silicone elastomer from ambient temperature by polycondensation reactions comprising:
  • the reactive ⁇ , ⁇ -dihydroxydiorganopolysiloxane polymers A that may be used in the silicone bases in accordance with the invention are more particularly those having the following formula (1):
  • hydroxylated polyorganosiloxanes with formula (1) may optionally comprise motifs T with formula R 1 SiO 3/2 and/or motifs Q with formula SiO 4/2 in a proportion of at most 1% (these % expressing the number of T and/or Q motifs per 100 silicon atoms).
  • the substituent R 1 mentioned above for the reactive polyorganosiloxanes (A) may be selected from the following radicals:
  • radicals R 1 examples include alkyl radicals containing 1 to 8 carbon atoms, such as methyl, ethyl, propyl, butyl, hexyl and octyl, vinyl radicals, and phenyl radicals.
  • substituted radicals R 1 examples include 3, 3, 3-trifluoropropyl, chlorophenyl and betacyanoethyl radicals.
  • radicals R 1 are methyl radicals, the other radicals generally being phenyl and/or vinyl radicals.
  • C 3 -C 6 oxyalkylene radicals that may be cited are the following radicals:
  • R 2 represents a C 1 -C 10 hydrocarbon radical encompassing:
  • the curing agents AR with formula (2) are products that are available on the silicones market; in addition, their use in ambient temperature-curing compositions is known; they are mentioned in particular in the French patents FR-A-1 126 411, FR-A-1 179 969, FR-A-1 189 216, FR-A-1 198 749, FR-A-1 248 826, FR-A-1 314 649, FR-A-1 423 477, FR-A-1 432 799 and FR-A-2 067 636.
  • curing agents AR are alkyltrialkoxysilanes, alkyl silicates and alkyl polysilicates, in which the organic radicals are alkyl radicals containing 1 to 4 carbon atoms.
  • the alkyl silicates may be selected from methyl silicate, ethyl silicate, isopropyl silicate, n-propyl silicate and polysilicates selected from the products of partial hydrolysis and condensation of these silicates; these are polymers constituted by a large proportion of motifs with formula: (R 4 O) 3 SiO 1 ⁇ 2 , R 4 OSiO 3/2 , (R 4 O) 2 SiO 2/2 and SiO 4/2 ; the symbol R 4 representing methyl, ethyl, isopropyl and/or n-propyl radicals. They are usually characterized on the basis of their silicon content, which is established by assaying the hydrolysis product of a sample.
  • curing agents AR that may be used and that may in particular be cited are the following silanes:
  • curing agent AR examples include ethyl polysilicate or n-propyl polysilicate.
  • R′′ which may be identical or different, represent aliphatic hydrocarbon radicals containing 1 to 30 carbon atoms, preferably 4 to 12 carbon atoms and more preferably those containing 6 to 10 carbon atoms.
  • the polycondensation C has the general formula (I):
  • R′′ which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms, preferably 8 to 10 carbon atoms.
  • the catalyst C which has just been described is used to enable or facilitate hardening into silicone elastomers, from ambient temperature, of polyorganosiloxane bases that can be cured by polycondensation reactions in the form of a bicomponent compound, the catalytic system being incorporated into one of the fractions with a curing agent AR, while the other fraction contains a reactive polyorganosiloxane A and water.
  • ambient temperature means a temperature in the range 10° C. to 40° C.
  • the invention concerns a polyorganosiloxane composition X that can be cured to produce an elastomer by polycondensation reactions, which does not contain a metallic catalyst, and which comprises:
  • an effective quantity of at least one polycondensation catalyst C means a quantity in the range 0.01 to 50 parts by weight of polycondensation catalyst C.
  • the catalysts employed in the silicone compositions used during the preparation of silicone elastomer molds in accordance with the invention mean that the following can be obtained at the same time:
  • the polycondensation catalysts C have the general formula (I):
  • R′′ which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms.
  • compositions in accordance with the invention may furthermore comprise reinforcing or semi-reinforcing fillers or packing fillers CH, which are preferably selected from siliceous fillers.
  • the reinforcing fillers are preferably selected from fumed silicas and precipitated silicones. They generally have a specific surface area, measured using BET methods, of at least 50 m 2 /g, preferably more than 70 m 2 /g, a mean primary particle dimension of less than 0.1 ⁇ m (micrometers) and an apparent density of less than 200 g/liter.
  • silicas may be incorporated as is or after having been treated with organosilicon compounds that are normally employed for this use.
  • organosilicon compounds that are normally employed for this use.
  • These compounds include methylpolysiloxanes such as hexamethyldisiloxane, octamethyldisiloxane, octamethylcyclotetrasiloxane, methylpolysilazanes such as hexamethyldisilazane, hexamethylcyclotrisilazane, chlorosilanes such as dimethylchlorosilane, trimethylchlorosilane, methylvinyldichlorosilane, dimethylvinylchlorosilane, alkoxysilanes such as dimethyldimethoxysilane, dimethylvinylethoxysilane and trimethylmethoxysilane.
  • the initial weight of the silicas can increase by up to an amount of 20%.
  • the semi-reinforcing fillers or packing fillers have a particle diameter of more than 0.1 ⁇ m (micrometer) and are selected from ground quartz, calcined clays and diatomaceous earth.
  • non-reactive linear polyorganosiloxane polymers E may be introduced with the aim of acting on the physical characteristics of the compositions in accordance with the invention and/or on the mechanical properties of the elastomers obtained from hardening these compositions.
  • non-reactive linear polyorganosiloxane polymers E are well known; more particularly, they comprise: ⁇ , ⁇ -bis(triorganosiloxy)diorganopolysiloxanes with viscosities of at least 10 mPa.s at 25° C., essentially formed by diorganosiloxy motifs and at most 1% of monoorganosiloxy and/or siloxy motifs, the organic radicals bonded to the silicon atoms being selected from methyl, vinyl and phenyl radicals, at least 60% of these organic radicals being methyl radicals and at most 10% being vinyl radicals.
  • the viscosity of these polymers may be as high as several tens of millions of mPa.s at 25° C.; thus, they include oils with a fluid to viscous appearance, and soft to hard gums. They are prepared in accordance with the usual techniques described more precisely in the French patents FR-A-978 058, FR-A-1 025 150, FR-A-1 108 764, and FR-A-1 370 884.
  • ⁇ , ⁇ - bis(trimethylsiloxy) dimethylpolysiloxane oils with a viscosity of 10 mPa.s to 1000 mPa.s at 25° C. are used.
  • These polymers act as plasticizers and may be introduced in an amount of at most 70 parts, preferably 5 to 20 parts, per 100 parts of reactive ⁇ , ⁇ -dihydroxydiorganopolysiloxane polymer A.
  • compositions in accordance with the invention may furthermore advantageously comprise at least one silicone resin G.
  • silicone resins are branched organopolysiloxane polymers which are well known and commercially available. Per molecule, they have at least two different motifs selected from those with formula R′′′ 3 SiO 1 ⁇ 2 (motif M), R′′′ 2 SiO 2/2 (motif D), R′′′SiO 3/2 (motif T) and SiO 4 , 2 (motif Q).
  • the radicals R′′′ are identical or different and are selected from linear or branched alkyl radicals, vinyl, phenyl, 3,3,3-trifluoropropyl radicals.
  • the alkyl radicals contain 1 to 6 carbon atoms inclusive.
  • radicals R′′′ that may be cited are methyl, ethyl, isopropyl, tertiobutyl and n-hexyl radicals. These resins are preferably hydroxylated, and in this case have a weight content of the hydroxy group in the range 5 to 500 meq/100 g.
  • resins examples include MQ resins, MDQ resins, TD resins and MDT resins.
  • the polyorganosiloxane composition X comprises:
  • each composition is produced in the form of a bicomponent system formed by two parts P1 and P2 intended to be brought into contact with each other in order to produce the polycondensation-cured elastomer.
  • the present invention relates to a bicomponent system that is a precursor of the polyorganosiloxane composition X that can be vulcanized to produce a silicone elastomer from ambient temperature by polycondensation reactions, characterized in that:
  • the precursor bicomponent system of the polyorganosiloxane composition X that can be vulcanized to form a silicone elastomer from ambient temperature by the polycondensation reactions in accordance with the invention is characterized in that:
  • the invention also concerns the negative mold produced from silicone elastomer MN obtained at the end of step d) of the methods in accordance with the invention.
  • the invention also concerns the use of a negative mold produced from silicone elastomer MN obtained at the end of step d) of the methods in accordance with the invention, for the manufacture of molded articles.
  • the bicomponent precursors of the polyorganosiloxane compositions that can be vulcanized to silicone elastomers were composed of a part P1 and a part P2.
  • part P1 The various constituents of part P1 were mixed using a DAC400 speed-mixer type appliance or using a propeller in a plastic pot.
  • Part P1 and part P2 were mixed with a spatula for three minutes, then with a speed mixer (planetary mixer) for twenty seconds at 1800 rpm. The mixture was then vacuum degassed so that there were no defects (bubbles).
  • the weight ratio was 100 parts of P1 to 5 parts of P2.
  • Negative molds were produced by applying the pre-mixed formulation (mixture of part P1 and of part P2) to a master to be duplicated placed at the bottom of a pot.
  • part P1 and 2.25 g of part P2 were mixed with a spatula for three minutes then with a speed mixer for twenty seconds at 1800 rpm. The mixture was then degassed under a vacuum bell jar for 5 minutes so that there were no defects (bubbles, air incorporated during mixing with the spatula) in the negative mold.
  • a master parallelepipedal rectangle with a height of 8 mm; a width of 35 mm, and a length of 35 mm
  • a plastic pot which had been degreased with ethanol
  • the master + pot were tared and between 40 and 42 g of the formulation P1 + P2 was applied to the master.
  • control negative molds denoted MN Ck, in which k was from 1 to 3 and the negative molds in accordance with the invention, denoted MN m, in which m was from 1 to 11, were obtained after curing the mixtures P1 + P2. The mixture was allowed to cure at 23° C. for 24 hours.
  • the negative mold produced from silicone elastomer was separated from the master to be duplicated.
  • the negative molds produced from silicone elastomer were filled a first time with polyurethane casting resin (reproduction material).
  • F190 Fastcast polyurethane resin from Axson was prepared in transparent plastic pots (so that the homogeneity of the mixture could be observed) with a height of 48 mm and an internal diameter of 51 mm.
  • the polyol part was charged and underwent decantation; it was therefore mixed with a spatula prior to use (homogeneous color and appearance without sedimentation at the bottom of the receptacle). This operation was easy to carry out manually.
  • the reproduction material was allowed to harden for 90 minutes at ambient temperature inside the silicone negative molds in order to produce a first replica.
  • the replica was separated from the silicone negative mold by detaching each rim of the negative mold. If no adhesion to the negative mold was observed, a new replica was prepared and so on until the negative mold produced from silicone elastomer deteriorated.
  • the silicone elastomer must not adhere to the master in order to facilitate its removal from the mold. A large number of demolding operations is an indication of great durability of the silicone elastomer mold.
  • a 22 mm, diameter plunger weighing 11.4 g immersed in a sample is actuated with an alternating vertical movement with a period of one minute.
  • the gel point has been reached.
  • An electrical contact stops the timer started at the beginning of the test. This time, expressed in minutes (min), is then taken to be the pot life.
  • a pot life of between 20 and 200 min is desired.
  • the curing kinetics were evaluated using the Shore A hardness (SAH) in accordance with the standards DIN 53505 and ISO 868. This hardness is generally measured 24 hours then 4 days and then 14 days after mixing the parts P1 + P2. A hardness after 24 h equal to at least 68% of the final hardness at 14 days was desired. Hardnesses above and below the indenter are measured in order to evaluate the homogeneity of curing. Preferably, a difference of 2 Shore A or less is desired.
  • Post-curing expresses the difference in hardness between 14 days and 4 days: a difference of 2 Shore A or less is desired for below the indenter.
  • the evaluated materials were: an organic plastic, namely polyurethane, and plaster.
  • the master used was a parallelepipedal rectangle with a height of 8 mm, a width of 35 mm and a length of 35 mm. The surface of this part was smooth.
  • a mark of 0 or + was desired in order to use the negative mold for the preparation of replicas.
  • the master used was a parallelepipedal rectangle produced from metal with a height of 8 mm, a width of 35 mm and a length of 35 mm. The surface of this part was smooth.
  • test molds were produced in a method for casting the pre-mixed formulation (mixture of part P1 and of part P2) onto the metal part placed at the bottom of a pot.
  • the polyurethane resin used to evaluate the resistance of the silicone elastomer negative mold was Fastcast F190 resin from Axson. This resin is in the form of a bicomponent product which, once mixed at ambient temperature (1:1 mixture), has a pot life of 8 minutes and can be demolded after 90 minutes.
  • Demolding of the molded resin replicas was carried out by detaching each rim of the silicone elastomer negative mold, one after the other, in order to evaluate the resistance to demolding.
  • part P2 was observed visually.
  • part P2 P2-C1 Dimethyltin neodecanoate Transparent single phase liquid
  • P2-C3 Dodecylamine Liquid/solid, two-phase P2-1 Diisononylamine Transparent single-phase liquid
  • P2-2 Diisononylamine Transparent single-phase liquid
  • P2-3 Dioctylamine Transparent single-phase liquid
  • P2-4 Dibutylamine Transparent single-phase liquid
  • P2-5 Dihexyl amine Transparet single-phase liquid
  • P2-6 Didecylamine Transparent single-phase liquid
  • P2-7 Didodecylamine Liquid/solid, two-phase
  • the catalysts employed in the silicone compositions used during the preparation of silicone elastomer molds in accordance with the invention can be used to simultaneously obtain:
  • the polycondensation catalysts C satisfy the general formula (I):
  • R′′ which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Silicon Polymers (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

Silicone compositions are described for the production of negative molds that include a silicone elastomer. The molds can be used in the production of molded articles.

Description

  • The field of the invention relates to the use of silicone compounds for the manufacture of negative molds formed from silicone elastomer for use in the manufacture of molded articles.
  • Bicomponent organopolysiloxane compositions that can be used for the preparation of molds produced from silicone elastomer have already been proposed on the industrial market and in the chemical literature (FR 1 418 114 and JP 50066553). These compositions may include a variety of additives (which facilitate processing them or transforming them into elastomers), such as low viscosity dihydroxydiorganopolysiloxane oils (FR 2 272 145 and FR 2 300 114).
  • Patent application EP 586 153 describes a curable silicone composition comprising, in addition to the constituents which are routinely used in such a composition, reinforcing co-fillers such as acicular fillers based on CaO and SiO2, or in fact on CaSiO3; and ceramic-based spherical fillers, and in particular on silica-alumina ceramics.
  • Another approach is described in the document EP 787 766. That document describes silicone compositions which can be cured at ambient temperature by condensation in order to produce molds, further comprising the constituents which are conventionally used in this type of composition, additives selected from the group constituted by sterically hindered phenols, sterically hindered thio bisphenols, zinc dialkyl dithiophosphates, zinc diaryl dithiophosphates, aromatic amines, sterically hindered amines, or in fact preparations based on those compounds.
  • Patent application WO 03/074602 describes the use of silica pre-treated in a silicone composition which can be cured by polycondensation, as a stabilization agent for molds obtained from that composition.
  • Patent application WO 06/106238 teaches a method for stabilizing molds composed of a silicone elastomer.
  • Among the silicone compositions that can be cured to produce an elastomer which are known for this type of application, those which cure from ambient temperature form a category which catches the attention, because they do not have to be placed in an energy-consuming oven.
  • These silicone compositions are classified into 2 distinct groups: monocomponent compositions (RTV-1) and bicomponent compositions (RTV-2). The term “RTV” is the acronym for “Room Temperature Vulcanizing”.
  • During curing, water (either supplied via moisture from the atmosphere in the case of RTV-1, or introduced into a part of the composition in the case of RTV-2) allows the polycondensation reaction to take place, which leads to the formation of the elastomeric network.
  • In general, monocomponent compositions (RTV-1) cure when they are exposed to the moisture of the air. Usually, the polycondensation reaction kinetics are extremely slow: these reactions are therefore catalyzed by an appropriate catalyst.
  • Regarding bicomponent compositions (RTV-2), these are sold and stored in the form of two components, a first component containing the basic polymer materials and the second component containing the catalyst. The two components are mixed for use and the mixture cures into the form of a relatively hard elastomer. These bicomponent compositions are well known and have in particular been described in the work by Walter Noll, “Chemistry and Technology of Silicones” 1968, 2nd edition, pages 395 to 398.
  • These compositions essentially comprise 4 different ingredients:
    • a reactive α,ω -dihydroxydiorganopolysiloxane polymer,
    • a curing agent, generally a silicate or a polysilicate,
    • a catalyst, and
    • water.
  • The mechanical properties of these compositions are then adjusted by adding fillers.
  • Usually, the condensation catalyst is based on an organic tin compound. In fact, many tin-based catalysts have already been proposed as a catalyst for curing these RTV-1s or RTV-2s. Conventional polycondensation catalysts comprise dialkyltin compounds, in particular dialkyltin dicarboxylates such as dibutyltin dilaurate and diacetate, alkyl titanate compounds such as tetrabutyl or tetraisopropyl titanate, and titanium chelates (EP-A-0 885 933, US-5 519 104, US-A-4 515 932, US-A-4 563 498, US-A-4 528 353).
  • However, alkyltin-based catalysts, while being highly efficient, and usually colorless, liquid and soluble in silicone oils, suffer from the disadvantage of being toxic (CMR2 toxic for reproduction).
  • In addition, in the face of a molding industry which is evolving rapidly with the development of 3D printing, fresh constraints are appearing which are linked to the increase in successive molding/demolding cycles.
  • For sustainable development, there is an ongoing need for improvements to methods for the preparation of negative molds produced from silicone elastomer starting from silicone compositions that cure by polycondensation in the absence of tin, while improving the resistance to successive molding/demolding cycles carried out on said molds obtained. The silicone compositions must also have suitable curing kinetics and good stability on storage. Preferably, in the absence of a release agent applied to the master to be reproduced, the negative molds produced from silicone must not adhere to said master.
  • Thus, one of the essential aims of the present invention is to propose a novel method for the preparation of negative molds produced from silicone elastomer that can be used for the manufacture of molded articles in which the silicone elastomer is prepared from a silicone composition that does not contain a metallic catalyst such as tin, for example, and which cures by polycondensation reactions in the presence of water (for example ambient moisture) with a curing rate that is sufficient to ensure industrial rates of production.
  • A further aim is to propose a novel method for forming molded articles starting from a negative mold produced from silicone elastomer having a good resistance to successive molding/demolding cycles and prepared from silicone compositions containing no tin.
  • A further aim is to propose a silicone composition containing no tin and hardening to form a silicone elastomer in the presence of moisture with rapid surface solidification kinetics, followed by a complete core solidification, i.e. homogeneous solidification, in a manner such as to prepare negative molds produced from silicone elastomers which do not adhere on the one hand to the master to be reproduced and on the other hand to the molded articles, and thus have a good resistance to successive molding/demolding cycles and which can be used for the preparation of molded articles produced from different materials.
  • The invention also concerns negative molds produced from silicone elastomer for use in the manufacture of molded articles produced from different reproduction materials such as from polyester, polystyrene, polyethylene, polyvinyl chloride, polyurethane, polyurethane foam, plaster, concrete, wax and soap. This list is not limiting.
  • The parts molded from different reproduction materials that are obtained represent a wide variety of articles, with a utilitarian or decorative purpose, such as dashboards, armrests, furniture, or works of art.
  • These aims, inter alia, are achieved by means of the present invention, which concerns a method for preparing a negative mold MN produced from silicone elastomer for use in the manufacture of molded articles produced from different reproduction materials, characterized in that it comprises the following steps a) to d) :
    • a) preparing a polyorganosiloxane composition X that can be cured to produce an elastomer by polycondensation reactions, which does not contain a metallic catalyst, and comprising:
      • -- a silicone base B comprising at least one polyorganosiloxane oil A that can be cured by a polycondensation reaction, and
      • a catalytically effective quantity of at least one polycondensation catalyst C, which is an organic compound having the general formula (I): (R″)2NH
      in which the symbols R″, which may be identical or different, represent aliphatic hydrocarbon radicals containing 1 to 30 carbon atoms,
    • b) applying said polyorganosiloxane X to a master to be duplicated, optionally already covered with a release agent,
    • c) allowing said polyorganosiloxane composition X to cure in the presence of moisture supplied by the ambient air or by the prior addition of water, in order to form a negative mold MN produced from silicone elastomer, which is an impression corresponding to the exterior contour of the master to be duplicated, and
    • d) separating the negative mold MN produced from silicone elastomer from the master to be duplicated.
  • One advantage linked to the method in accordance with the invention is that the number of cycles for molding/demolding articles molded in this negative mold MN is preferably more than 37, for example when demolding polyurethane replicas.
  • The technique for molding in silicone elastomer consists of producing a “negative” mold, i.e. an impression, from a “positive” model termed the “master”. The silicone elastomer mold that is generated thereby can be used to produce many “copies” or “prints” or “replicas” from the master, with no limits as to size or undercuts.
  • A variety of molding techniques are known to the person skilled in the art. Examples of molding techniques that may be cited are:
    • “block molding”, which is intended for the manufacture of self-supporting molds, produced from one or more parts, by simple casting of the composition over the initial master inside a sealed counter-mold after mixing the two parts of the RTV-2 in the liquid state. This method is preferred for relatively simple shapes without major undercuts;
    • “one or two-part shell molding”, and
    • “stamping molding”, which is preferred for taking an impression of inclined, vertical or overhanging masters, in general with large dimensions, or when it is impossible to move the master.
  • When using the compositions in accordance with the invention in this application, casting techniques or techniques for application by means of a spatula, brush or by spraying are useful.
  • The manufactured molds have the particular feature of reproducing the details of the masters accurately and in fine detail; furthermore, because of the non-stick nature of silicone rubber, they can improve demolding rates.
  • A release agent may, however, be applied to the item to be reproduced prior to molding it. These release agents are well known to the person skilled in the art. By way of non-limiting example, it is possible to use an aqueous solution of soap or a suspension of wax.
  • In a further aspect, the present invention concerns a method for molding replicas R, characterized in that it comprises steps a) to d) in accordance with the invention, followed by the following steps e) to h):
    • e) filling this negative mold MN produced from silicone elastomer with a reproduction material,
    • f) allowing the reproduction material to harden inside the negative mold MN produced from silicone elastomer, in order to produce a replica R of the master to be duplicated,
    • g) separating the replica R from the negative mold MN produced from silicone elastomer, and
    • h) optionally, submitting the negative mold MN produced from silicone elastomer to steps e) to g) again, in order to form a new replica R.
  • An advantage linked to the method in accordance with the invention is that the number of cycles e) to g) that can be carried out with the negative mold MN produced from silicone elastomer is more than 37, for example when demolding polyurethane replicas.
  • Various reproduction materials are known to the person skilled in the art, such as polyester, polystyrene, polyethylene, polyvinyl chloride, polyurethane, polyurethane foam, plaster, concrete, wax and soap. This list is not limiting. Before molding, these reproduction materials are in different forms, namely liquid which is viscous to a greater or lesser extent, a dispersion, suspension, with a single or with multiple components.
  • More precisely, the present invention concerns an organopolysiloxane composition that can be vulcanized to form a silicone elastomer from ambient temperature by polycondensation reactions comprising:
    • (a) a silicone base that is capable of hardening into a silicone elastomer in the presence of a catalyst by polycondensation reactions, comprising:
      • for 100 parts by weight of at least one α,ω-dihydroxydiorganopolysiloxane A,
      • 0.1 to 60 parts by weight of at least one curing agent AR, and
      • 0.001 to 10 parts by weight of water, and
    • (b) a catalytically effective quantity of a polycondensation catalyst C.
  • The reactive α,ω-dihydroxydiorganopolysiloxane polymers A that may be used in the silicone bases in accordance with the invention are more particularly those having the following formula (1):
  • Figure US20230278264A1-20230907-C00001
  • in which formula:
    • the substituents R1, which may be identical or different, each represent a monovalent C1 to C13 hydrocarbon, which may or may not be saturated, which may or may not be substituted, aliphatic, cyclic or aromatic, and preferably R1 is methyl; and
    • n has a sufficient value to provide the polyorganosiloxane with formula (1) with a dynamic viscosity at 25° C. of 10 to 1000000 mPa.s.
  • It should be understood that, in the context of the present invention, a mixture constituted by a plurality of hydroxylated polyorganosiloxanes which differ among themselves by the value of the viscosity and/or the nature of the substituents bonded to the silicon atoms may be used as the reactive polyorganosiloxane A. It should also be pointed out that the hydroxylated polyorganosiloxanes with formula (1) may optionally comprise motifs T with formula R1SiO3/2 and/or motifs Q with formula SiO4/2 in a proportion of at most 1% (these % expressing the number of T and/or Q motifs per 100 silicon atoms).
  • Reactive linear hydroxylated diorganopolysiloxane polymers A with a dynamic viscosity at 25° C. of 10 to 1000000 mPa.s and preferably from 50 to 200000 mPa.s are employed.
  • These basic polyorganosiloxanes are for the most part marketed by silicone manufacturers. In addition, their manufacturing techniques are well known: they are described, for example, in French patents FR-A-1 134 005, FR-A-1 198 749, and FR-A-1 226 745.
  • All of the viscosities in question in the present description correspond to a dynamic viscosity parameter at 25° C. known as “Newtonian”, i.e. the dynamic viscosity, which is measured, in a manner which is known per se, using a Brookfield viscosimeter at a shear rate gradient which is sufficiently low for the measured viscosity to be independent of the speed gradient.
  • The substituent R1 mentioned above for the reactive polyorganosiloxanes (A) may be selected from the following radicals:
    • alkyl and haloalkyl radicals containing 1 to 13 carbon atoms, such as methyl, ethyl, propyl, isopropyl, butyl, pentyl, hexyl, 2-ethylhexyl, octyl, decyl, 3,3,3-trifluoropropyl, 4,4,4-trifluorobutyl, 4, 4, 4, 3, 3-pentafluorobutyl radicals,
    • cycloalkyl and halocycloalkyl radicals containing 5 to 13 carbon atoms, such as cyclopentyl, cyclohexyl, methylcyclohexyl, propylcyclohexyl radicals, 2,3-difluorocyclobutyl, 3, 4-difluoro--5--methylcycloheptyl,
    • alkenyl radicals containing 2 to 8 carbon atoms, such as vinyl, allyl, buten-2-yl radicals,
    • mononuclear aryl and haloaryl radicals containing 6 to 13 carbon atoms, such as phenyl, tolyl, xylyl, chlorophenyl, dichlorophenyl, trichlorophenyl radicals, and
    • cyanoalkyl radicals the alkyl links of which contain 2 to 3 carbon atoms, such as β-cyanoethyl and γ-cyanopropyl radicals.
  • Examples of radicals R1 that may be cited are alkyl radicals containing 1 to 8 carbon atoms, such as methyl, ethyl, propyl, butyl, hexyl and octyl, vinyl radicals, and phenyl radicals.
  • Examples of substituted radicals R1 that may be cited are 3, 3, 3-trifluoropropyl, chlorophenyl and betacyanoethyl radicals.
  • In the products with formula (1) in general industrial use, at least 60% by number of the radicals R1 are methyl radicals, the other radicals generally being phenyl and/or vinyl radicals.
  • The following curing agents AR may be cited:
    • silanes with the following general formula (2):
    • Figure US20230278264A1-20230907-C00002
    • in which the symbols R3, which may be identical or different, represent alkyl radicals containing 1 to 8 carbon atoms such as methyl, ethyl, propyl, butyl, pentyl, 2-ethylhexyl radicals, C3-C6 oxyalkylene radicals, the symbol R2 representing a saturated or unsaturated, linear or branched aliphatic hydrocarbon group, a saturated or unsaturated and/or aromatic, monocyclic or polycyclic carbocyclic group, and k is equal to 0 or 1; and
    • partial hydrolysis and condensation products of a silane with formula (2).
  • Examples of C3-C6 oxyalkylene radicals that may be cited are the following radicals:
  • Figure US20230278264A1-20230907-C00003
  • Figure US20230278264A1-20230907-C00004
  • Figure US20230278264A1-20230907-C00005
  • Figure US20230278264A1-20230907-C00006
  • Advantageously, the symbol R2 represents a C1-C10 hydrocarbon radical encompassing:
    • C1-C10 alkyl radicals such as methyl, ethyl, propyl, butyl, pentyl, 2-ethylhexyl, octyl, decyl radicals,
    • vinyl, allyl radicals, and
    • C5-C8 cycloalkyl radicals such as phenyl, tolyl and xylyl radicals.
  • The curing agents AR with formula (2) are products that are available on the silicones market; in addition, their use in ambient temperature-curing compositions is known; they are mentioned in particular in the French patents FR-A-1 126 411, FR-A-1 179 969, FR-A-1 189 216, FR-A-1 198 749, FR-A-1 248 826, FR-A-1 314 649, FR-A-1 423 477, FR-A-1 432 799 and FR-A-2 067 636.
  • More particularly preferred of the curing agents AR are alkyltrialkoxysilanes, alkyl silicates and alkyl polysilicates, in which the organic radicals are alkyl radicals containing 1 to 4 carbon atoms.
  • The alkyl silicates may be selected from methyl silicate, ethyl silicate, isopropyl silicate, n-propyl silicate and polysilicates selected from the products of partial hydrolysis and condensation of these silicates; these are polymers constituted by a large proportion of motifs with formula: (R4O)3SiO½, R4OSiO3/2, (R4O)2SiO2/2 and SiO4/2; the symbol R4 representing methyl, ethyl, isopropyl and/or n-propyl radicals. They are usually characterized on the basis of their silicon content, which is established by assaying the hydrolysis product of a sample.
  • Other examples of curing agents AR that may be used and that may in particular be cited are the following silanes:
    • CH3Si (OCH3)3; C2H5Si (OC2H5)3; C2H5Si (OCH3)3
    • CH2=CHSi (OCH3)3; CH2=CHSi (OCH2CH2OCH3)3
    • C6H5Si (OCH3)3; [CH3] [OCH (CH3) CH2OCH3] Si [OCH3] 2
    • Si (OCH3) 4; Si (OC2H5) 4; Si (OCH2CH2CH3)4; Si (OCH2CH2CH2CH3) 4 Si (OC2H4OCH3)4; CH3Si (OC2H4OCH3)3; ClCH2Si (OC2H5)3.
  • Other examples of the curing agent AR that may be cited are ethyl polysilicate or n-propyl polysilicate.
  • In general, 0.1 to 6 parts by weight of curing agent with formula (2) are used per 100 parts by weight of reactive polymer with formula (1).
  • Organic compounds from the secondary amine family with the following general formula (I) may be cited as the catalyst C:
  • Figure US20230278264A1-20230907-C00007
  • in which the symbols R″, which may be identical or different, represent aliphatic hydrocarbon radicals containing 1 to 30 carbon atoms, preferably 4 to 12 carbon atoms and more preferably those containing 6 to 10 carbon atoms.
  • Preferably, during step a) of the methods in accordance with the invention, the polycondensation C has the general formula (I):
  • Figure US20230278264A1-20230907-C00008
  • in which the symbols R″, which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms, preferably 8 to 10 carbon atoms.
  • The catalyst C which has just been described is used to enable or facilitate hardening into silicone elastomers, from ambient temperature, of polyorganosiloxane bases that can be cured by polycondensation reactions in the form of a bicomponent compound, the catalytic system being incorporated into one of the fractions with a curing agent AR, while the other fraction contains a reactive polyorganosiloxane A and water.
  • In the present invention, the term “ambient temperature” means a temperature in the range 10° C. to 40° C.
  • In accordance with another aspect, the invention concerns a polyorganosiloxane composition X that can be cured to produce an elastomer by polycondensation reactions, which does not contain a metallic catalyst, and which comprises:
    • a silicone base B comprising at least one polyorganosiloxane oil A that can be cured by a polycondensation reaction in a manner such as to form a silicone elastomer, and
    • a catalytically effective quantity of at least one polycondensation catalyst C which is an organic compound having general formula (I):
    • Figure US20230278264A1-20230907-C00009
    • in which the symbols R″, which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms, preferably 8 to 10 carbon atoms.
  • In the present invention, the term “an effective quantity of at least one polycondensation catalyst C” means a quantity in the range 0.01 to 50 parts by weight of polycondensation catalyst C.
  • The catalysts employed in the silicone compositions used during the preparation of silicone elastomer molds in accordance with the invention mean that the following can be obtained at the same time:
    • a sufficiently long pot life for using the mixture of part P1 + part P2 (between 20 and 200 min),
    • “fast” curing (post-curing a maximum of +2 and SAH 24 h x 100/SAH 14 days > 68%),
    • silicone elastomer molds obtained by the method in accordance with the invention, which means that a substantial number of parts, for example produced from polyurethane, can be molded (number of successive molding/demolding cycles > 37),
    and all this in the absence of tin-based compounds.
  • In order to satisfy the supplemental conditions that the part containing the catalyst has to be homogeneous (transparent, single phase) and that the silicone elastomer molds obtained by the method in accordance with the invention do not stick to the master in the absence of a release agent applied to the master to be reproduced, the polycondensation catalysts C have the general formula (I):
  • Figure US20230278264A1-20230907-C00010
  • in which the symbols R″, which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms.
  • The compositions in accordance with the invention may furthermore comprise reinforcing or semi-reinforcing fillers or packing fillers CH, which are preferably selected from siliceous fillers.
  • The reinforcing fillers are preferably selected from fumed silicas and precipitated silicones. They generally have a specific surface area, measured using BET methods, of at least 50 m2/g, preferably more than 70 m2/g, a mean primary particle dimension of less than 0.1 µm (micrometers) and an apparent density of less than 200 g/liter.
  • These silicas may be incorporated as is or after having been treated with organosilicon compounds that are normally employed for this use. These compounds include methylpolysiloxanes such as hexamethyldisiloxane, octamethyldisiloxane, octamethylcyclotetrasiloxane, methylpolysilazanes such as hexamethyldisilazane, hexamethylcyclotrisilazane, chlorosilanes such as dimethylchlorosilane, trimethylchlorosilane, methylvinyldichlorosilane, dimethylvinylchlorosilane, alkoxysilanes such as dimethyldimethoxysilane, dimethylvinylethoxysilane and trimethylmethoxysilane.
  • During this treatment, the initial weight of the silicas can increase by up to an amount of 20%.
  • The semi-reinforcing fillers or packing fillers have a particle diameter of more than 0.1 µm (micrometer) and are selected from ground quartz, calcined clays and diatomaceous earth.
  • In addition to the principal constituents A, AR, C and CH, non-reactive linear polyorganosiloxane polymers E may be introduced with the aim of acting on the physical characteristics of the compositions in accordance with the invention and/or on the mechanical properties of the elastomers obtained from hardening these compositions.
  • These non-reactive linear polyorganosiloxane polymers E are well known; more particularly, they comprise: α,ω-bis(triorganosiloxy)diorganopolysiloxanes with viscosities of at least 10 mPa.s at 25° C., essentially formed by diorganosiloxy motifs and at most 1% of monoorganosiloxy and/or siloxy motifs, the organic radicals bonded to the silicon atoms being selected from methyl, vinyl and phenyl radicals, at least 60% of these organic radicals being methyl radicals and at most 10% being vinyl radicals. The viscosity of these polymers may be as high as several tens of millions of mPa.s at 25° C.; thus, they include oils with a fluid to viscous appearance, and soft to hard gums. They are prepared in accordance with the usual techniques described more precisely in the French patents FR-A-978 058, FR-A-1 025 150, FR-A-1 108 764, and FR-A-1 370 884. Preferably, α,ω- bis(trimethylsiloxy) dimethylpolysiloxane oils with a viscosity of 10 mPa.s to 1000 mPa.s at 25° C. are used. These polymers act as plasticizers and may be introduced in an amount of at most 70 parts, preferably 5 to 20 parts, per 100 parts of reactive α,ω-dihydroxydiorganopolysiloxane polymer A.
  • The compositions in accordance with the invention may furthermore advantageously comprise at least one silicone resin G. These silicone resins are branched organopolysiloxane polymers which are well known and commercially available. Per molecule, they have at least two different motifs selected from those with formula R‴3SiO½ (motif M), R‴2SiO2/2 (motif D), R‴SiO3/2 (motif T) and SiO4,2 (motif Q). The radicals R‴ are identical or different and are selected from linear or branched alkyl radicals, vinyl, phenyl, 3,3,3-trifluoropropyl radicals. Preferably, the alkyl radicals contain 1 to 6 carbon atoms inclusive. More particular radicals R‴ that may be cited are methyl, ethyl, isopropyl, tertiobutyl and n-hexyl radicals. These resins are preferably hydroxylated, and in this case have a weight content of the hydroxy group in the range 5 to 500 meq/100 g.
  • Examples of resins that may be cited are MQ resins, MDQ resins, TD resins and MDT resins.
  • In accordance with an embodiment of the invention, the polyorganosiloxane composition X comprises:
    • (a) the silicone base B, which is capable of hardening to form a silicone elastomer in the presence of a catalyst by polycondensation reactions comprising:
      • for 100 parts by weight of at least one reactive a,ω-dihydroxydiorganopolysiloxane polymer A wherein the organic radicals are hydrocarbon radicals preferably selected from the group constituted by: alkyls containing 1 to 20 carbon atoms; cycloalkyls containing 3 to 8 carbon atoms; alkenyls containing 2 to 8 carbon atoms and cycloalkenyls containing 5 to 8 carbon atoms;
      • 0.1 to 60 parts by weight of at least one curing agent AR selected from the group constituted by: polyalkoxysilanes, the products deriving from the partial hydrolysis of a polyalkoxysilane and polyalkoxysiloxanes;
      • 0 to 250 parts by weight, preferably 5 to 200 parts by weight, of at least one filler CH;
      • 0.001 to 10 parts by weight of water,
      • 0 to 100 parts by weight of at least one linear nonreactive polyorganosiloxane polymer E consisting of a linear homopolymer or copolymer wherein, per molecule, the monovalent organic substituents bonded to the silicon atoms, which may be identical or different, are selected from alkyl, cycoalkyl, alkenyl, aryl, alkylarylene and arylalkylene radicals,
      • 0 to 20 parts by weight of a coloring base or a coloration agent F,
      • 0 to 70 parts by weight of polyorganosiloxane resins G, and
      • 0 to 20 parts of auxiliary additives A known to the person skilled in the art, such as plasticizers, curing inhibitors, mineral oils, antimicrobial agents, heat resisting additives such as titanium, iron or cerium oxide, and
    • (b) 0.01 to 50 parts by weight of a polycondensation catalyst C.
  • In order to use the silicone compositions X in accordance with the invention, each composition is produced in the form of a bicomponent system formed by two parts P1 and P2 intended to be brought into contact with each other in order to produce the polycondensation-cured elastomer.
  • In accordance with another aspect, the present invention relates to a bicomponent system that is a precursor of the polyorganosiloxane composition X that can be vulcanized to produce a silicone elastomer from ambient temperature by polycondensation reactions, characterized in that:
    • it has two distinct parts P1 and P2 intended to be mixed in order to form said composition, and
    • one of these parts comprises the catalyst c, while the other part is free from it and comprises:
      • per 100 parts by weight of the reactive α,ω-dihydroxydiorganopolysiloxane polymer(s) A, and
      • 0.001 to 10 part(s) by weight of water.
  • In accordance with a preferred embodiment, the precursor bicomponent system of the polyorganosiloxane composition X that can be vulcanized to form a silicone elastomer from ambient temperature by the polycondensation reactions in accordance with the invention is characterized in that:
    • the part P1 comprises:
      • per 100 parts by weight of the reactive α,ω-dihydroxydiorganopolysiloxane polymer (A) wherein the organic radicals are hydrocarbon radicals preferably selected from the group constituted by: alkyls containing 1 to 20 carbon atoms; cycloalkyls containing 3 to 8 carbon atoms; alkenyls containing 2 to 8 carbon atoms and cycloalkenyls containing 5 to 8 carbon atoms;
      • 0.001 to 10 parts by weight of water,
      • 0 to 200 parts by weight, preferably 5 to 150 parts, of at least one filler (CH);
      • 0 to 150 parts by weight of at least one linear non-reactive polyorganosiloxane polymer (E) consisting of a linear homopolymer or copolymer wherein, per molecule, the monovalent organic substituents, which may be identical or different between them and are bonded to silicon atoms, are selected from alkyl, cycloalkyl, alkenyl, aryl, alkylarylene and arylalkylene radicals,
      • 0 to 70 parts by weight of polyorganosiloxane resins (G), and
      • 0 to 20 parts by weight of a coloring base or a coloration agent F; and
    • the part P2 comprises:
      • 0.1 to 60 parts by weight of at least one curing agent AR selected from the group constituted by: polyalkoxysiloxanes, products deriving from the partial hydrolysis of a polyalkoxysiloxane and polyalkoxysiloxanes;
      • 0.01 to 50 parts by weight of polycondensation catalyst c,
      • 0 to 20 parts by weight of a coloring base or a coloration agent F,
      • 0 to 70 parts by weight of at least one linear non-reactive polyorganosiloxane polymer (E) consisting of a linear homopolymer or copolymer wherein, per molecule, the monovalent organic substituents, which may be identical or different between them and are bonded to silicon atoms, are selected from alkyl, cycloalkyl, alkenyl, aryl, alkylarylene and arylalkylene radicals, and
      • 0 to 125 parts by weight, preferably 0.1 to 40 parts, of at least one filler CH.
  • The invention also concerns the negative mold produced from silicone elastomer MN obtained at the end of step d) of the methods in accordance with the invention.
  • The invention also concerns the use of a negative mold produced from silicone elastomer MN obtained at the end of step d) of the methods in accordance with the invention, for the manufacture of molded articles.
  • Other advantages and characteristics of the present invention will become apparent from the following examples, given purely by way of non-limiting illustration.
  • EXAMPLES 1) Starting Materials Used
    • Paste preparation: Mixture of A200 fumed silica (supplied by Evonik - 200 m2/g) treated with trimethylsilyl groups (approximately 30%) (CH1), 47V500 silicone oil (approximately 42%) (E1) and 48V14000 silicone oil (approximately 28%) (A1).
    • Sifraco® E600 (supplied by Sibelco) = quartz = silica flour, crystalline silica, ground silica (CH2)
    • Bluesil® FLD 48V14000 (α,ω-dihydroxydiorganopolysiloxane oil), viscosity 14000 mPa.s - MW approx 48 kg/mol (A1)
    • Bluesil® FLD 48V3500 (α,ω-dihydroxydiorganopolysiloxane oil), viscosity 3500 mPa.s - MW approx 30 kg/mol (A2)
    • Bluesil® FLD 48V750 (α,ω-dihydroxydiorganopolysiloxane oil), viscosity 750 mPa.s - MW approx 15 kg/mol (A3)
    • Bluesil® RP 120PA (α,ω-dihydroxydiorganopolysiloxane oil), viscosity 45 mPa.s - MW approx 0.5 kg/mol (A4)
    • Bluesil® FLD 47V50 (non-functional silicone oil) Viscosity 50 mPa.s, MW approx 3 - 4 kg/mol (E1)
    • Base Color 552 (supplied by Sioen) = white base color based on TiO2 (F1)
    • Silane 51005 - advanced or partially condensed ethyl silicate (SiOEt4), tetraethyl ester, hydrolyzed (AR1)
    • Dynasilan® P (supplied by Evonik) or propyl silicate or tetra n-propylorthosilicate or tetrapropyl orthosilicate (AR2)
    • Mediaplast® VP 5071/A (supplied by Kettlitz Chemie)mixture of polyalkylbenzene and high molecular weight hydrocarbons (comprises between 25% and 50% of alkylbenzene (C10-C13)) (H1)
    • Dimethyltin neodecanoate (supplied by Momentive) Decylamine CAS 2016-57-1 (supplied by Sigma-Aldrich) (C1)
    • Dodecylamine CAS 124-22-1 (supplied by Sigma-Aldrich) (C2)
    • Dibutylamine CAS 111-92-2 (supplied by Sigma-Aldrich) (C3)
    • Dihexylamine CAS 143-16-8 (supplied by Sigma-Aldrich) (C4)
    • Dioctylamine CAS 1120-48-5 (supplied by Sigma-Aldrich) (C5)
    • Diisononylamine CAS 28454-70-8 (supplied by Sigma-Aldrich) (C6)
    • Didodecylamine CAS 3007-31-6 (supplied by Sigma-Aldrich) (C7)
    • Didecylamine CAS 1120-49-6 (supplied by Sigma-Aldrich) (C8)
    2) Preparation of Examples in Accordance With the Invention and Comparative Examples
  • In all of the compositions, the percentages (%) mentioned are expressed by weight with respect to the total weight of all of the constituents of the formulation.
  • The bicomponent precursors of the polyorganosiloxane compositions that can be vulcanized to silicone elastomers were composed of a part P1 and a part P2.
  • Preparation of Parts P1
  • The various constituents of part P1 were mixed using a DAC400 speed-mixer type appliance or using a propeller in a plastic pot.
  • TABLE 1
    Composition of parts P1
    Composition Part P1--1 Part P1 -- 2
    Paste 60.2 60.2
    Sifraco E600 18 18
    48V3500 20 -
    48V14000 - 20
    Base Color 552 0.5 0.5
    48V750 1 1
    Bluesil RP 120PA 0.2 0.2
    Water 0.1 0.1
    Total 100 100
  • Preparation of Parts P2
  • The various constituents of parts P2 were manually mixed in a glass flask.
  • TABLE 2
    Part P2 for comparative examples
    Part P2
    Reference Part P2-C1 for comparative test C1 Part P2-C2 for comparative test C2 Part P2-C3 for comparative test C3
    Catalyst 6.6 2.11 2.49
    Dimethyltin naodecanoate Decylamine Dodecylamine
    Silane 51005 40 35 35
    Propyl silicate 5.3 5.3
    Mediaplast VP 5071/A 12.95 13.96 13.87
    47V50 40.45 43.63 43.34
    Total 100 100 100
  • TABLE 3
    Part P2 for examples in accordance with the invention
    Reference P2-1 P2-2 P2-3 P2-4 P2-5 P2-6 P2-7 P2-8 P2-9 P2-10
    Catalyst 3.62 3.62 3.24 3.47 2.49 4 9.5 1.74 2.49 4
    Diisononyl amine Diisononyl amine Dioctyl amine Dibutyl amine Dihexyl amine Didecyl amine Didodecyl amine Dibutyl amine Dihexyl amine Didecyl amine
    Silane 51005 40 35 35 40 35 40 40 35 40 35
    Propyl silicate 5.3 5.3 5.3 5.3 5.3
    Mediaplast VP 5071/A 13.67 13.6 13.69 13.7 13.87 13.58 12.24 14.06 13.94 13.5
    47V50 42.71 42.48 42.77 42.83 43.34 42.42 38.26 43.9 43.57 42.2
    Total 100 100 100 100 100 100 100 100 100 100
  • Preparation of Mixtures P1 + P2
  • The parts P1 and P2 employed in the comparative bicomponent systems denoted Ck, in which k is 1 to 3, and the bicomponent systems in accordance with the invention, denoted Ex.m, in which m is from 1 to 11, are detailed in Table 4.
  • TABLE 4
    Composition of bicomponent systems
    Bicomponent reference P1+P2 C1 C2 C3 Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. 5 Ex. 6 Ex. 7 Ex. 8 Ex. 9 Ex. 10 Ex. 11
    Part P1 P1 - 1 P1 - 1 P1 -1 P1 -1 P1 -1 P1 - 1 P1 -1 P1 - 1 P1 -1 P1 - 1 P1 -1 P1 -2 P1 -1 P1 - 2
    Part P2 P2 -C1 P2 -C2 P2 -C3 P2 - 1 P2 -2 P2 -3 P2 -4 P2 -5 P2 -6 P2 -7 P2 -8 P2 -9 P2 -10 P2 -11
  • Part P1 and part P2 were mixed with a spatula for three minutes, then with a speed mixer (planetary mixer) for twenty seconds at 1800 rpm. The mixture was then vacuum degassed so that there were no defects (bubbles).
  • The weight ratio was 100 parts of P1 to 5 parts of P2.
  • Preparation of Negative Molds Produced From Silicone Elastomer
  • Negative molds were produced by applying the pre-mixed formulation (mixture of part P1 and of part P2) to a master to be duplicated placed at the bottom of a pot.
  • 45 g of part P1 and 2.25 g of part P2 were mixed with a spatula for three minutes then with a speed mixer for twenty seconds at 1800 rpm. The mixture was then degassed under a vacuum bell jar for 5 minutes so that there were no defects (bubbles, air incorporated during mixing with the spatula) in the negative mold.
  • A master (parallelepipedal rectangle with a height of 8 mm; a width of 35 mm, and a length of 35 mm) to be duplicated was placed and centered at the bottom of a plastic pot (which had been degreased with ethanol) with a height of 27 mm and an internal diameter of 63 mm.
  • The master + pot were tared and between 40 and 42 g of the formulation P1 + P2 was applied to the master.
  • The control negative molds denoted MN Ck, in which k was from 1 to 3, and the negative molds in accordance with the invention, denoted MN m, in which m was from 1 to 11, were obtained after curing the mixtures P1 + P2. The mixture was allowed to cure at 23° C. for 24 hours. The negative mold produced from silicone elastomer was separated from the master to be duplicated.
  • TABLE 5
    Reference for control negative molds and negative molds in accordance with the invention
    Reference negative mold MR C1 MN C2 MN C3 MN 1 MN 2 MN 3 MN 4 MN 5 MN 6 MN 7 MN 8 MN 9 MN 10 MN 11
    Reference mixture P1+P2 C1 C2 C3 Ex. 1 Ex. 2 Ex. 3 EX. 4 Ex. 5 EX. 6 EX. Ex. 8 Ex. 9 Ex. 10 Ex. 11
  • Preparation of Replicas
  • The negative molds produced from silicone elastomer were filled a first time with polyurethane casting resin (reproduction material).
  • F190 Fastcast polyurethane resin from Axson was prepared in transparent plastic pots (so that the homogeneity of the mixture could be observed) with a height of 48 mm and an internal diameter of 51 mm. The polyol part was charged and underwent decantation; it was therefore mixed with a spatula prior to use (homogeneous color and appearance without sedimentation at the bottom of the receptacle). This operation was easy to carry out manually.
  • 12.5 g ± 0.1 g of the polyol part (white color) and 12.5 g ± 0.1 g of the isocyanate part (brown color) were weighed out. The two parts were mixed with a spatula for one minute, checking the homogeneity of the mixture (a yellow colored mixture was obtained). Two negative molds were then filled with this preparation (the cavity corresponding to the master to be duplicated was filled to the rim).
  • The reproduction material was allowed to harden for 90 minutes at ambient temperature inside the silicone negative molds in order to produce a first replica.
  • The replica was separated from the silicone negative mold by detaching each rim of the negative mold. If no adhesion to the negative mold was observed, a new replica was prepared and so on until the negative mold produced from silicone elastomer deteriorated.
  • 3) Characterization Characterization Tests for Mixture P1+P2
  • The properties of the mixture P1+P2 allowing molds to be produced from silicone elastomers were characterized by a pot life and curing kinetics expressed in Shore A Hardness.
  • In addition, the silicone elastomer must not adhere to the master in order to facilitate its removal from the mold. A large number of demolding operations is an indication of great durability of the silicone elastomer mold.
  • Measurement of Pot Life (with a “Techne Gelation Timer GT3”) in Accordance With the French Standard NF T 77 107
  • A 22 mm, diameter plunger weighing 11.4 g immersed in a sample is actuated with an alternating vertical movement with a period of one minute. When the consistency of the product is sufficient to support the weight of the disk for ½ minute, the gel point has been reached. An electrical contact then stops the timer started at the beginning of the test. This time, expressed in minutes (min), is then taken to be the pot life. A pot life of between 20 and 200 min is desired.
  • Measurement of Curing Kinetics
  • The curing kinetics were evaluated using the Shore A hardness (SAH) in accordance with the standards DIN 53505 and ISO 868. This hardness is generally measured 24 hours then 4 days and then 14 days after mixing the parts P1 + P2. A hardness after 24 h equal to at least 68% of the final hardness at 14 days was desired. Hardnesses above and below the indenter are measured in order to evaluate the homogeneity of curing. Preferably, a difference of 2 Shore A or less is desired.
  • Post-curing expresses the difference in hardness between 14 days and 4 days: a difference of 2 Shore A or less is desired for below the indenter.
  • Tests for Adhesion of Silicone Elastomer Mold to Master to be Reproduced
  • Masters to be duplicated formed from different materials were used in order to evaluate the development of adhesion of the silicone elastomer during the preparation of the negative mold.
  • The evaluated materials were: an organic plastic, namely polyurethane, and plaster. For each of the materials, the master used was a parallelepipedal rectangle with a height of 8 mm, a width of 35 mm and a length of 35 mm. The surface of this part was smooth.
  • After 24 hours, adhesion of the negative mold to the master was evaluated qualitatively during demolding. Demolding of the master was carried out by detaching each rim of the negative mold, one after the other, in order to evaluate the resistance to demolding.
  • If there was no resistance, the adhesion was evaluated at 0.
  • If a slight force had to be applied in order to remove the master, the adhesion was evaluated as +.
  • If a large force had to be applied in order to remove the master, but it was possible to remove the master without tearing the silicone mold, the adhesion was evaluated as ++.
  • When it was not possible to demold the master without tearing the silicone mold, the adhesion was evaluated as +++.
  • A mark of 0 or + was desired in order to use the negative mold for the preparation of replicas.
  • Demolding Test
  • The master used was a parallelepipedal rectangle produced from metal with a height of 8 mm, a width of 35 mm and a length of 35 mm. The surface of this part was smooth.
  • The test molds were produced in a method for casting the pre-mixed formulation (mixture of part P1 and of part P2) onto the metal part placed at the bottom of a pot.
  • After 24 hours, the master was demolded.
  • Six days after demolding the master, the negative molds were filled for the first time with polyurethane casting resin (reproduction material).
  • The polyurethane resin used to evaluate the resistance of the silicone elastomer negative mold was Fastcast F190 resin from Axson. This resin is in the form of a bicomponent product which, once mixed at ambient temperature (1:1 mixture), has a pot life of 8 minutes and can be demolded after 90 minutes.
  • Next, between 3 and 5 polyurethane replicas were produced each day, each time with approximately 12.5 g of polyurethane resin. Each time, the replicas molded from resin were left in the silicone elastomer negative mold for a minimum of 1.5 hours in order to obtain complete polymerization.
  • Demolding of the molded resin replicas was carried out by detaching each rim of the silicone elastomer negative mold, one after the other, in order to evaluate the resistance to demolding.
  • The number of reproductions which were obtained without degradation of the silicone elastomer negative mold (i.e. without tearing off small pieces of silicone) is presented in one of the tables below. This enables the polyurethane resistance of the various silicone elastomer negative molds to be compared.
  • The results of the various tests carried out were as follows:
  • TABLE 6
    The appearance of part P2 was observed visually.
    Reference Nature of catalyst Observations, part P2
    P2-C1 Dimethyltin neodecanoate Transparent single phase liquid
    P2-C2 Decylamine Transparent single phase liquid
    P2-C3 Dodecylamine Liquid/solid, two-phase
    P2-1 Diisononylamine Transparent single-phase liquid
    P2-2 Diisononylamine Transparent single-phase liquid
    P2-3 Dioctylamine Transparent single-phase liquid
    P2-4 Dibutylamine Transparent single-phase liquid
    P2-5 Dihexyl amine Transparet single-phase liquid
    P2-6 Didecylamine Transparent single-phase liquid
    P2-7 Didodecylamine Liquid/solid, two-phase
  • TABLE 7
    Curing kinetics
    Reference Nature of catalyst Pot life (min) SAH Post-curing SAH 24h x 100/SAH 14d (%)
    24h 4 days 14 days
    Below Above Below Above Below Above
    C1 Dimethyltin neodecanoate 193 19 23 27 28 28 28 +1 68
    C2 Decylamine 669 Not cured NM Too soft. NM Too soft. NM 16 16 At 24 hrs, not yet cured
    C3 Dodecylamine 669 Not cured NM Too soft . NM 14 14 At 24 hrs, not yet cured
    EX. 1 Diisononylamine 90 19 20 24 25 26 26 +2 73
    Ex. 2 Diisononylamine 120 18 18 23 24 24 25 +1 75
    Ex. 3 Dioctylamine 125 18 17 23 24 25 26 +2 72
    Ex. 4 Dibutylamine 68 18 16 23 22 25 23 +2 72
    EX. 5 Dihexylamine 134 17 17 23 23 24 25 +1 71
    Ex. 6 Didecylamine 109 17 18 23 24 25 26 +2 68
    Ex. 7 Didodecylamine 92 19 20 24 25 25 26 +1 76
    Ex. 10 Didecylamine 124 17 17 23 24 25 26 +2 68
  • TABLE 8
    Results of test for evaluating the adhesion of the silicone elastomer negative mold to different masters
    Reference for negative mold Composition employed during manufacture of negative mold Nature of catalyst used in the composition Adhesion of silicone negative mold
    to polyurethane (PU) master to plaster master
    MN C1 C1 Dimethyltin neodecanoate 0 0
    MN C2 C2 Decylamine +++
    MN C3 C3 Dodecylamine +++ +++
    MN 2 Ex. 2 Diisononylamine 0 0
    MN 3 Ex. 3 Dioctylamine + 0
    MN 5 Ex. 5 Dihexylamine 0
    MN 8 Ex. 8 Dibutylamine ++ +++
    MN10 Ex. 10 Didecylamine 0 0
  • TABLE 9
    Number of successive molding/demolding cycles (durability of silicone elastomer mold)
    Reference for negative mold Composition employed during manufacture of negative mold Nature of catalyst used in the composition Number of successive moldings/demoldings of articles molded from PU
    MN C1 C1 Dimethyltin neodecanoate 37
    MN C2 C2 Decylamine Sticks to master - not evaluated
    MN C3 C3 Dodecylamine Sticks to master - not evaluated
    MN 1 Ex. 1 Diisononylamine 46
    MN 2 Ex. 2 Diisononylamine 41
    MN 3 Ex. 3 Dioctylamine 47
    MN 8 Ex. 8 Dibutylamine 58
    MN 9 Ex. 9 Dihexylamine 52
    MN 11 Ex. 11 Diisononylamine 54
  • In conclusion, the catalysts employed in the silicone compositions used during the preparation of silicone elastomer molds in accordance with the invention can be used to simultaneously obtain:
    • a sufficiently long pot life to use the part P1 + part P2 mixture (between 20 and 200 min),
    • “fast” curing (post-curing a maximum +2 and SAH ratio of 24h x 100/SAH 14 days > 68%),
    • -silicone elastomer molds obtained using the method in accordance with the invention which can be used to mold a large number of parts, for example from polyurethane (number of successive molding/demolding cycles > 37), and all this in the absence of tin-based compounds.
  • In order to satisfy the supplemental conditions that the part containing the catalyst must be homogeneous (transparent single phase) and that the silicone elastomer negative molds obtained by the method in accordance with the invention must not adhere to the master even in the absence of release agent applied to the master to be reproduced, the polycondensation catalysts C satisfy the general formula (I):
  • Figure US20230278264A1-20230907-C00011
  • in which the symbols R″, which may be identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms.

Claims (19)

1. (canceled)
2. (canceled)
3. (canceled)
4. A polyorganosiloxane composition X that can be cured into an elastomer by polycondensation reactions, wherein the composition X does not contain a metallic catalyst and comprises:
a silicone base B comprising at least one polyorganosiloxane oil A that can be cured by a polycondensation reaction in a manner such as to form a silicone elastomer, and
a catalytic quantity of at least one polycondensation catalyst C which is an organic compound having a general formula (I):
Figure US20230278264A1-20230907-C00012
in which the symbols R″, which are identical or different, represent aliphatic hydrocarbon radicals containing 6 to 10 carbon atoms.
5. A negative mold MN produced from silicone elastomer by:
a) preparing a polyorganosiloxane composition X that can be cured to produce an elastomer by polycondensation reactions, which does not contain a metallic catalyst, and comprising:
a silicone base B comprising at least one polyorganosiloxane oil A that can be cured by a polycondensation reaction, and
a catalytic quantity of at least one polycondensation catalyst C, which is an organic compound having a general formula (I):
Figure US20230278264A1-20230907-C00013
in which the symbols R″, which are identical or different, represent aliphatic hydrocarbon radicals containing 1 to 30 carbon atoms,
b) applying said polyorganosiloxane X to a master to be duplicated, optionally already covered with a release agent,
c) curing said polyorganosiloxane composition X in the presence of moisture supplied by ambient air or by a prior addition of water, in order to form the negative mold MN produced from silicone elastomer, which is an impression corresponding to the exterior contour of the master to be duplicated, and
d) separating the negative mold MN produced from silicone elastomer from the master to be duplicated.
6. (canceled)
7. A method of manufacturing a molded article, the method comprising:
a) preparing a negative mold comprising:
i) preparing a polyorganosiloxane composition X that can be cured to produce an elastomer by polycondensation reactions, which does not contain a metallic catalyst, and comprising:
a silicone base B comprising at least one polyorganosiloxane oil A that can be cured by a polycondensation reaction, and
a catalytically effective quantity of at least one polycondensation catalyst C, which is an organic compound having the general formula (I):
Figure US20230278264A1-20230907-C00014
in which the symbols R″, which are identical or different, represent aliphatic hydrocarbon radicals containing 1 to 30 carbon atoms,
ii) applying said polyorganosiloxane X to a master to be duplicated, optionally already covered with a release agent,
iii) curing said polyorganosiloxane composition X in the presence of moisture supplied by ambient air or by a prior addition of water, in order to form the negative mold MN produced from silicone elastomer, which is an impression corresponding to the exterior contour of the master to be duplicated, and
iv) separating the negative mold MN produced from silicone elastomer from the master to be duplicated and
b) applying a reproduction material to the negative mold MN.
8. The method of claim 7, further comprising:
c) allowing the reproduction material to harden inside the negative mold MN produced from silicone elastomer, in order to produce a replica R of the master to be duplicated, and
d) separating the replica R from the negative mold MN produced from silicone elastomer, wherein steps c) and d) are performed sequentially after step b.
9. The negative mold MN of claim 5, wherein in step c), the homogeneity of curing, as determined by measuring the Shore A hardness above and below the indenter and the difference is 2 or less.
10. The method of claim 7, wherein the at least one polyorganosiloxane oil A comprises a reactive α,ω-dihydroxydiorganopolysiloxane polymer having the general formula:
Figure US20230278264A1-20230907-C00015
in which the substituents R
1, which may be identical or different, each represent a monovalent C1 to C13 hydrocarbon, which may or may not be saturated, which may or may not be substituted, aliphatic, cyclic or aromatic, and n has a sufficient value to provide the α,ω-dihydroxydiorganopolysiloxane polymer with a dynamic viscosity at 25° C. of 10 to 1000000 mPas.
11. The method of claim 10, wherein the at least one polyorganosiloxane oil A has a dynamic viscosity at 25° C. of from 50 to 200000 mPas.
12. The method of claim 10, wherein at least 60% by number of the radicals R1 are methyl radicals.
13. The method of claim 10, where the radicals R1 that are not methyl radicals are phenyl and/or vinyl radicals.
14. The method of claim 7, wherein the polyorganosiloxane composition X comprises:
(a) a silicone base that is capable of hardening into a silicone elastomer in the presence of a catalyst by polycondensation reactions, comprising:
for 100 parts by weight of at least one α, ω-dihydroxydiorganopolysiloxane A,
0.1 to 60 parts by weight of at least one curing agent AR, and
0.001 to 10 parts by weight of water, and
(b) a catalytically effective quantity of a polycondensation catalyst C.
15. The method of claim 14, wherein the curing agent AR is:
a) a silane with the general formula (2):
Figure US20230278264A1-20230907-C00016
in which the symbols R3, which may be identical or different, represent alkyl radicals containing 1 to 8 carbon atoms, or C3-C6 oxyalkylene radicals,
the symbols R2 representing a saturated or unsaturated, linear or branched aliphatic hydrocarbon group, a saturated or unsaturated and/or aromatic, monocyclic or polycyclic carbocyclic group, and
k is equal to 0 or 1; and
b) partial hydrolysis and condensation products of a silane with formula (2).
16. The method of claim 14, wherein 0.1 to 6 parts by weight of curing agent AR are used per 100 parts by weight of the at least one polyorganosiloxane oil A.
17. The method of claim 12, wherein the compositions further comprises reinforcing fillers, semi-reinforcing fillers or packing fillers CH.
18. The method of claim 17, wherein the reinforcing fillers are fumed silicas or precipitated silicones having a specific surface area, measured using a BET method, of at least 50 m2/g, a mean primary particle dimension of less than 0.1 µm (micrometers) and an apparent density of less than 200 g/liter.
19. The method of claim 17, wherein the semi-reinforcing fillers or packing fillers are selected from ground quartz, calcined clays and diatomaceous earth and have a particle diameter of more than 0.1 µm.
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