Stabile silane modified polymer composition and method

1 . A stabilized moisture curable alkoxysilyl-containing polyurethane polymer composition comprising:

(a) at least one alkoxysilyl-containing polyurethane polymer;

(b) at least one urethane-forming organometallic catalyst selected from the group consisting of: (i) catalytic organometallic salts of Sn, and (ii) catalytic organometallic complexes of Sn; and

(c) at least one mercapto-containing compound in the amount of from about 100 to about 5,000 parts per million (ppm), based on the weight of the alkoxysilyl-containing polyurethane polymer;

wherein the urethane-forming organometallic catalyst is used in the amount of from 1 to 100 parts per million, based on the weight of the metal in the polyol brought to reaction with isocyanato-containing alkoxysilane or polyisocyanate in the preparation of the alkoxysilyl-containing polyurethane, wherein the metal is the metal portion of the organometallic catalyst.

2 . The composition of claim 1 , wherein the alkoxysilyl-containing polyurethane polymer has the general formula (I):

wherein

each R 1 is independently a monovalent alkyl group of from 1 to 6 carbon atoms;

each R 2 is independently a monovalent alkyl group of from 1 to 4 carbon atoms or phenyl group;

each R 3 is independently a divalent alkyl group of from 1 to 12 carbon atoms;

each R 4 is independently a monovalent alkyl group of from 1 to 6 carbon atoms, phenyl group, hydrogen or —R 3 SiR 2 3-a (OR 1 ) a group;

each R 5 is independently a divalent organic group selected from the group consisting of a divalent alkyl group having 1 to 16 carbon atoms, a divalent cycloalkyl group having 5 to 16 carbon atoms and the group X 1 having the general formula (II):

where each R 6 is independently an alkylene group of from 1 to 12 carbon atoms or a cycloalkylene group of from 5 to 16 carbon atoms and each R 7 is independently a divalent organic group selected from the group consisting of a divalent alkyl group having 1 to 16 carbon atoms and a divalent cycloalkyl group having 5 to 16 carbon atoms;

each G is a polyvalent organic group derived from a polyol or a monovalent organic group derived from a monol; and

the subscripts a, b and c are integers wherein a is 1, 2 or 3, b is 0 or 1 and c is 1 to 5, with the proviso that if b is 0, then R 4 is hydrogen.

3 . The composition of claim 2 , wherein G is a polyvalent organic group derived from a polyol or monol and formed by the removing the hydroxyl group of the polyol and wherein the polyol is selected from the group consisting of a polyester polyol, polyether polyol, polycarbonate polyol, polybutadiene polyol, polybutylene polyol, polyol derived from polystyrene/butadiene copolymer, polyisoprene polyol, poly(meth)acrylate polyol, polyisocyanate extended polyester polyol, polyisocyanate extended polyether polyols, polyisocyanate extended polycarbonate polyol, polyisocyanate extended polyol derived from polystyrene/butadiene copolymer, polyisocyanate extended polyisoprene polyol, polyisocyanate extended poly(meth)acrylate polyol, polyisocyanate extended polybutadiene polyol, polyisocyanate extended polybutylene polyol and mixtures thereof.

4 . The composition of claim 1 , wherein the urethane-forming organometallic catalyst is metal complexes obtained from acetylacetone, benzoylacetone, trifluoroacetylacetone, ethyl acetoacetate, salicylaldehyde, cyclopentanone-2-carboxylate, acetylacetoneimine, bis-acetylaceone-alkylenediimines, salicylaldehydeimine chelate and Sn; organometallic salts selected from the group consisting of Sn(OR 7 ) 4 , Sn(OR 7 ) 2 , Sn(O(C═O)R 7 ) 4 , Sn(O(C═O)R 7 ) 2 , R 8 2 Sn(O(C—O)R 7 ) 2 , where R 7 is monovalent alkyl or aryl of from 1 to 18 carbon atoms and R 8 is monovalent alkyl or aryl of from 1 to 18 carbon atoms and combinations thereof.

5 . The composition of claim 4 , wherein the organometallic salts are selected from the group consisting of dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate, dilauryltin diacetate, dioctyltin diacetate, dibutyltin-bis(4-methylaminobenzoate), dibutyltin-bis(6-methylaminocaproate) and combinations thereof.

6 . The composition of claim 4 , wherein the organometallic salts are selected from the group consisting of trialkyltin hydroxide, dialkyltin oxide, dialkyltin dialkoxide, and dialkyltin dichloride and combinations thereof.

7 . The composition of claim 6 , wherein the organometallic salts are selected from the group consisting of trimethyltin hydroxide, tributyltin hydroxide, trioctyltin hydroxide, dibutyltin oxide, dioctyltin oxide, dilauryltin oxide, dibutyltin-bis(isopropoxide), dibutyltin-bis(2-dimethylaminopentylate), dibutyltin dichloride, dioctyltin dichloride and combinations thereof.

8 . The composition of claim 1 , wherein the urethane-forming catalyst is used in the amount of from 5 to 50 parts per million, based on the weight of the metal portion of the organometallic catalyst added in the polyol.

9 . The composition of claim 1 , wherein the mercapto-containing compound has the general formula (IX):

(HS) o R 11 X 2 p   (IX)

wherein:

each R 11 is independently a divalent or polyvalent hydrocarbon containing 1 to 20 carbon atoms or a divalent or polyvalent hydrocarbon containing 1 to 20 carbon atoms and at least one oxygen atom;

each X 2 is independently a functional group selected from the group consisting of hydroxyl (—OH), carboxyl (—C(═O) OH), ester (—C(═O)OR 17 , where R 17 is a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group), carboxylate salt (—C(═O) − OHN + (R 12 )(R 13 ) 2 , where R 12 is a chemical bond to R 11 , hydrogen or a monovalent hydrocarbon group of from 1 to 12 carbon atoms, and each R 13 is independently a hydrogen or a monovalent hydrocarbon group of from 1 to 12 carbon atoms), amino —NR 13 2 (where each R 13 is independently a hydrogen, a hydrocarbon group of from 1 to 12 carbon atoms, or an alkoxysilyl group (—Si(OR 14 ) c (R 15 ) 3-e where each R 14 is independently a monovalent alkyl group of from 1 to 10 carbon atoms, a monovalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group, a monovalent alkyl group of containing from 3 to 30 carbon atoms and at least one oxygen atom, or a —R 16 O[Si(R 11 (SH) o )(OR 17 ) f (R 15 ) 1-f ] q OR 18 group wherein each R 15 is independently methyl or phenyl, each R 16 is independently a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group; each R 17 is independently a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group, each R 18 is independently a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group and the subscripts e, f and q are integers where e is 2 or 3, f is 0 or 1, and q is 1 to 5), with the provisos that

(i) when R 13 is a monovalent hydrocarbon group of from 1 to 12 carbon atoms, then two R 13 groups are bonded together through a covalent bond to generate a divalent group —R 13 —R 13 -which forms a ring containing the nitrogen atom;

(ii) when f is 1, then R 17 and R 18 are bonded together by a covalent bond to form a divalent group —R 17 —R 18 —, which forms a ring containing the silicon atom and two oxygen atoms; and

(iii) when R 14 is an alkyl group of 1 to 10 carbon atoms, then two R 14 groups are bonded together through a covalent bond to from a divalent —R 14 —R 14 — group, which forms a ring containing a silicon atom and two oxygen atoms; and

the subscripts o and p are integers where o is 1, 2 or 3 and p is 0, 1 or 2.

10 . The composition of claim 9 , wherein R 11 is a divalent alkyl group of from 1 to 20 carbons, X 2 is —OH, —C(═O)OR 17 , where R 17 is independently a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group, or C(═O) OH, and o is 1 and p is 1.

11 . The composition of claim 9 , wherein R 11 is a divalent alkyl group of from 1 to 20 carbon atoms, X 2 is Si(OR 14 ) e (R 15 ) 3-e , where each R 14 is independently a monovalent alkyl group of from 1 to 6 carbon atoms, a monovalent alkyl group of from 1 to 6 carbon atoms and substituted with one hydroxyl group or a monovalent alkyl group containing from 3 to 30 carbon atoms and from 1 to 13 oxygen atoms, with the proviso that the oxygen atoms are separated from each other by at least two carbon atoms, R 15 is methyl, e is 2 or 3, o is 1 and p is 1.

12 . The composition of claim 9 , wherein R 11 is a divalent alkyl group of from 1 to 20 carbon atoms, X 2 is Si(OR 14 ) c (R 15 ) 3-e , where each R 14 is a monovalent alkyl group of from 1 to 10 carbon atom and substituted with one hydroxyl group or where one R 14 is a monovalent alkyl group of from 1 to 10 carbon atom and substituted with one hydroxyl group, and the other two R 14 groups are monovalent alkyl groups of from 1 to 10 carbon atoms which are bonded together through a covalent bond to generate a divalent group-R 14 —R 14 —, which forms a ring containing a silicon atom and two oxygen atoms, e is 3, o is 1 and p is 1.

13 . The composition of claim 9 , wherein R 11 is a divalent alkyl group of from 1 to 20 carbon atoms, X 2 is Si(OR 14 ) e (R 15 ) 3-e , where each R 14 is a monovalent alkyl group of from 1 to 10 carbon atom and substituted with one hydroxyl group or a —R 16 O [Si(R 11 (SH) o )(OR 17 ) f (R 15 ) 1-f ] q OR 18 group wherein each R 15 is methyl, each R 16 is independently a divalent alkyl group of from 1 to 10 carbon atoms; each R 17 is independently a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group, each R 18 is independently a divalent alkyl group of from 1 to 10 carbon atoms or a divalent alkyl group of from 1 to 10 carbon atom and substituted with at least one hydroxyl group and the subscripts e, f and q are integers where e is 2 or 3, f is 0 or 1, and q is 1 to 5, with the proviso that when f is 1, then R 17 and R 18 are bonded together by a covalent bond to form a divalent group —R 17 —R 18 —, which forms a ring containing the silicon atom and two oxygen atoms.

14 . The composition of claim 9 , wherein the mercapto-containing compound is selected from the group consisting of 1-mercaptododecane, 1-mercapto-2-hydroxyethane, 1-mercapto-3-hydroxypropane, 2-mercaptoacetic acid, methyl 3-mercaptopropropanoic acid, cysteine, 2-mercaptoethyl trimethoxysilane, 3-mercaptopropyl trimethoxysilane, 2-mercaptopropyl triethoxysilane, 3-mercaptopropyl triethoxysilane, 2-mercaptoethyl tripropoxysilane, 2-mercaptoethyl tri sec-butoxysilane, 3-mercaptopropyl tri-t-butoxysilane, 3-mercaptopropyl triisopropoxysilane, 2-mercaptoethyl dimethoxy ethoxysilane, 3-mercaptopropyl methoxyethoxypropoxysilane, 3-mercaptopropyl dimethoxy methylsilane, 3-mercaptopropyl methoxy dimethylsilane, 3-mercaptopropyl ethoxy dimethylsilane, 3-mercaptopropyl diethoxy methylsilane, 3-mercaptopropyl cyclohexoxy dimethyl silane, 4-mercaptobutyl trimethoxysilane, 3-mercapto-3-methylpropyltrimethoxysilane, 3-mercapto-3-methylpropyl-tripropoxysilane, 3-mercapto-3-ethylpropyl-dimethoxy methylsilane, 3-mercapto-2-methylpropyl trimethoxysilane, 3-mercapto-2-methylpropyl dimethoxy phenylsilane, 3-mercaptocyclohexyl-trimethoxysilane, 12-mercaptododecyl trimethoxy silane, 12-mercaptododecyl triethoxy silane, 2-mercapto-2-methylethyl-tripropoxysilane, 2-mercaptophenyl trimethoxysilane, 2-mercaptophenyl triethoxysilane, 2-mercaptotolyl trimethoxysilane, 2-mercaptotolyl triethoxysilane, 1-mercaptomethyltolyltrimethoxysilane, 1-mercaptomethyltolyl triethoxysilane, 2-mercaptoethylphenyl trimethoxysilane, 2-mercaptoethylphenyl triethoxysilane, 2-mercaptoethyltolyl trimethoxysilane, 2-mercaptoethyltolyl triethoxysilane, 3-mercaptopropylphenyl trimethoxysilane, 3-mercaptopropylphenyl triethoxysilane; 3-(2-{3-[2-(3-mercapto-propyl)-5-methyl-[1,3,2]dioxasilinan-2-yloxy]-2-methyl-propoxy}-5-methyl-[1,3,2]dioxasilinan-2-yl)-propane-1-thiol; 3-(2-{3-[2-(3-mercapto-propy)-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yloxy]-2-methyl-propoxy}-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yl)-propane-thiol; 3-(2-{3-[2-(3-mercapto-propyl)-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yloxy]-1,1-dimethyl-butoxy}-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yl)-propane-1-thiol; 3-({3-[2-mercapto-propyl)-5-methyl-[1,3,2]dioxasilinan-yloxy]-2-methyl-propoxy}-bis-[3-hydroxy-2-methyl-propoxy]-silanyl)-propane-1-thiol; 3-[{3-[{3-bis-(3-hydroxy-2-methyl-propyl)-(3-mercapto-propyl)-silanyloxy]-1-methyl-propoxy}-(3-hydroxy-2-methyl-propoxy)-(3-mercapto-propyl)-silanyloxy]-2-methyl-propan-1-ol; 3-[[3-((3-hydroxy-3-methyl-propoxy)-3-mercapto-propyl)-{3-[2-(3-mercapto-propyl)-5-methyl-[1,3,2]dioxasilinan-2-yloxy]-1-methyl-propoxy}-silanyloxy)-2-methyl-propoxy-(3-hydroxy-2-methyl-propoxy)-3-mercapto-propyl)-silanyl]-2-methylpropan-1-ol; 3-(2-{3-[2-(3-mercapato-butyl)-[1,3,2]dioxasilinan-2-yloxy]-propoxy}-[1,3,2]dioxasilinan-2-yl)-butane-1-thiol; 3-(2-{3-[2-(3-mercapto-phenyl)-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yloxy]-2-methyl-propoxy}-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yl)-3-benzene-thiol; 3-(2-{3-[2-(3-mercapto-cyclohexyl)-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yloxy]-1,1-dimethyl-butoxy}-4,4,6-trimethyl-[1,3,2]dioxasilinan-2-yl)-cyclohexane-1-thiol; 3-({3-[2-mercapto-methyl)-5-methyl-[1,3,2]dioxasilinan-2-yloxy]-2-methyl-propoxy}-diethoxy]-silanyl)-methane-1-thiol; 3-[{3-[{3-bis-(3-hydroxy-2,2-dimethyl-propyl)-(3-mercapto-propyl)-silanyloxy]-2,2-dimethyl-propoxy}-(3-hydroxy-2,2-dimethyl-propoxy)-(3-mercapto-propyl)-silanyloxy]-2,2-dimethyl-propan-1-ol; 3-[[3-((3-hydroxy-3-phenyl-propoxy)-3-mercapto-propyl)-{3-[2-(3-mercapto-propyl)-5-phenyl-[1,3,2]dioxasilinan-2-yloxy]-2-phenyl-1-propoxy}-silanyloxy)-2-phenyl-propoxy-(3-hydroxy-2-phenyl-propoxy)-3-mercapto-propyl)-silanyl]-2-phenylpropan-1-ol; 3-[{3-[(methyl)-(3-hydroxy-2-methyl-propoxy)-(3-mercapto-propyl)-silanyloxy]-2-methyl-propoxy}-methyl)-(3-mercapto-propyl)-silanyloxy]-2-methyl-propan-1-ol and combinations thereof.

15 . The composition of claim 1 , wherein the mercapto-containing compound is in the amount of from about 4 to about 100 equivalents of mercapto (—SH) per one equivalent of metal in the urethane-forming organometallic catalyst.

16 . The composition of claim 1 , wherein the mercapto-containing compound is in the amount of from about 12 to about 25 equivalents of mercapto (—SH) per one equivalent of metal in the urethane-forming organometallic catalyst.

17 . The composition of claim 1 , wherein the stabilized moisture curable alkoxysilyl-containing polyurethane polymer composition further comprises a hydrolysis and condensation catalyst to catalyze moisture curing of the formed urethane, in addition to the urethane-forming catalyst (b).

18 . The composition of claim 17 , wherein the hydrolysis and condensation catalyst is an organometallic salt or organometallic complex.

19 . The composition of claim 17 , wherein the hydrolysis and condensation catalyst is selected from the group consisting of complexes obtained from acetylacetone, benzoylacetone, trifluoroacetylacetone, ethyl acetoacetate, salicylaldehyde, cyclopentanone-2-carboxylate, acetylacetoneimine, bis-acetylaceone-alkylenediimines and salicylaldehydeimine complexing with Ti, Al, Sn, Zr, Fe, Co, Mn, Ni, Bi and Zn, Ti(OR 8 ) 4 , Al(OR 8 ) 3 , Zr(OR 8 ) 2 , Sn(OR 8 ) 4 , Sn(OR 8 ) 2 , Bi(OR 8 ) 3 Zr(O(C═O)R 8 ) 2 , Sn(O(C═O)R 8 ) 4 , Sn(O(C═O)R 8 ) 2 , Bi(O(C═O)R 8 ) 3 , R 9 2 Sn(O(C═O)R 8 ) 2 , where R 8 is monovalent alkyl or aryl of from 1 to 18 carbon atoms and R 9 is monovalent alkyl or aryl of from 1 to 18 carbon atoms; dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate, dilauryltin diacetate, dioctyltin diacetate, dibutyltin-bis(4-methylaminobenzoate), dibutyltin-bis(6-methylaminocaproate), trimethyltin hydroxide, tributyltin hydroxide, trioctyltin hydroxide, dibutyltin oxide, dioctyltin oxide, dilauryltin oxide, dibutyltin-bis(isopropoxide), dibutyltin-bis(2-dimethylaminopentylate), dibutyltin dichloride, dioctyltin dichloride and combinations thereof.

20 . The composition of claim 18 , where the hydrolysis and condensation catalyst is in the amount of from about 0.02 to about 1.0 weight percent metal t, based on weight of the alkoxysilyl-containing polyurethane polymer, wherein the metal is the metal portion of the organometallic catalyst.

21 . The composition of claim 20 , wherein the hydrolysis and condensation catalyst is in the amount of from about 0.05 to about 0.3 weight percent metal, based on weight of the alkoxysilyl-containing polyurethane polymer, wherein the metal is the metal portion of the organometallic catalyst.

22 . The composition of claim 1 , further comprising at least one additional additive.

23 . The composition of claim 22 , wherein the composition is a moisture curable composition selected from the group consisting of a coating, adhesive, sealant, consumer good or industrial good.

24 . The composition of claim 1 , wherein the mercapto-containing compound is present in an effective amount to increase the stability when exposure up to about 50% relative humidity for 12 days, as compared to the composition without the effective amount of mercapto-containing compound.

25 . A process for preparing the composition of claim 1 comprising:

(i) reacting a polyol with an isocyanato-containing alkoxysilane in the presence of a urethane-forming catalyst to form a alkoxysilyl-containing polyurethane polymer composition; and

(ii) adding a mercapto-containing compound to the product of step (i) to form a stabilized moisture-curable alkoxysilyl-containing polyurethane polymer composition.

26 . A process for preparing the composition of claim 1 comprising:

(i) reacting a polyol with an excess of polyisocyanate in the presence of a urethane-forming catalyst to form an isocyanato-containing polyurethane prepolymer composition;

(ii) reacting the isocyanato-containing polyurethane prepolymer of step (i) with an amino-containing alkoxysilane to form an alkoxysilyl-containing polyurethane polymer composition;

(iii) adding a mercapto-containing compound to the product of step (i) or step (ii) to form a stabilized moisture-curable alkoxysilyl-containing polyurethane polymer composition.