Epoxy-polysiloxane polymer composition

An epoxy-polysiloxane polymer composition prepared by combining:

• a polysiloxane selected from the group consisting of alkoxy- and silanol-functional polysiloxanes having a molecular weight in the range of from about 400 to 10,000;
• with
• non-aromatic epoxy resin having more than one epoxide group per molecule;
• a sufficient amount of an aminosilane hardener component having two amine hydrogens providing in the range of from 0.7 to 1.2 amine equivalent weight per one epoxide equivalent weight having the general formula
• Y--Si--(O--X).sub.3
• where Y is H(HNR).sub.a and where a is one, R is a difunctional organic radical independently selected from the group consisting of aryl, alkyl, dialkylaryl, alkoxyalkyl, and cycloalkyl radicals, and where X is limited to alkyl, hydroxalkyl, alkoxyalkyl or hydroxyalkoxyalkyl groups containing less than about six carbon atoms, wherein the aminosilane hardener reacts with the epoxy resin to form epoxy chain polymers, and reacts with the polysiloxane to form polysiloxane polymers that copolymerize with the epoxy chain polymers to form a cross-linked epoxy-polysiloxane composition;
• an organotin catalyst;
• and
• a sufficient amount of water to facilitate hydrolysis and polycondensation reactions to form the fully-cured cross-linked epoxy-polysiloxane polymer composition at ambient temperature.

A non-interpenetrating polymer network epoxy-polysiloxane polymer composition prepared by combining:

• water;
• with
• a polysiloxane having the formula ##STR5## where each R.sub.1 is selected from the group consisting of the hydroxy group and alkyl, aryl and alkoxy groups having up to six carbon atoms, each R.sub.2 is selected from the group consisting of hydrogen and alkyl and aryl groups having up to six carbon atoms and, wherein n is selected so that the molecular weight for the polysiloxane is in the range of from about 400 to 10,000;
• a non-aromatic epoxy resin having more than one 1,2-epoxide group per molecule with an epoxide equivalent weight in the range of from 100 to about 5,000;
• and
• a stoichiometric amount of an aminosilane hardener component to react both with the epoxy resin to form epoxy resin polymers and the polysiloxane to form polysiloxane polymers, and has the general formula
• Y--Si--(O--X).sub.3
• where Y is H(HNR).sub.a and where a is one, R is a difunctional organic radical independently selected from the group consisting of aryl, alkyl, dialkylaryl, alkoxyalkyl, and cycloalkyl radicals, and where X is limited to alkyl, hydroxalkyl, alkoxyalkyl or hydroxyalkoxyalkyl groups containing less than about six carbon atoms;
• wherein the epoxy resin polymers and polysiloxane polymers react together to form a cross-linked non-interpenetrating polymer network epoxy-polysiloxane polymer.

A method for making a fully-cured thermosetting epoxy-polysiloxane polymer composition comprising the steps of:

• forming a resin component by combining:
• a non-aromatic epoxy resin;
• a polysiloxane selected from the group consisting of alkoxy- and silanol-functional polysiloxanes having a molecular weight in the range of from 400 to 10,000;
• with
• water;
• and
• curing the resin component at ambient temperature by adding thereto:
• an aminosilane with two active hydrogens that reacts both with the epoxide resin to form epoxy chain polymers and with the polysiloxane to form polysiloxane polymers, wherein the epoxy chain polymers react with the polysiloxane polymers to form a fully-cured cross-linked epoxy-polysiloxane polymer;
• and
• an organotin catalyst to facilitate curing the resin component at ambient temperature.

A method for making a fully-cured epoxy-polysiloxane copolymer composition comprising the steps of:

• forming a resin component by combining:
• a polysiloxane having the formula ##STR6## where each R.sub.1 is selected from the group consisting of the hydroxy group and alkyl, aryl and alkoxy groups having up to six carbon atoms, each R.sub.2 is selected from the group consisting of hydrogen and alkyl and aryl groups having up to six carbon atoms and, wherein n is selected so that the molecular weight for the polysiloxane is in the range of from about 400 to 10,000;
• a non-aromatic epoxy resin having more than one 1,2-epoxide groups per molecule with an epoxide equivalent weight in the range of from 100 to about 5,000;
• and
• water;
• curing the resin component at an ambient temperature by adding to it:
• an organotin catalyst;
• and
• a stoichiometric amount of an aminosilane component having two active hydrogens to react both with the epoxy resin to form epoxy resin chain polymers and react with the polysiloxane to form polysiloxane polymers, wherein the epoxy resin chain polymers react with the polysiloxane polymers to form a fully-cured cross-linked epoxy-polysiloxane polymer.

A cross-linked epoxy-polysiloxane copolymer composition that is prepared by combining:

• a polysiloxane selected from the group consisting of alkoxy- and silanol-functional polysiloxanes having a molecular weight in the range of from 400 to 10,000;
• with
• a non-aromatic epoxy resin having more than one epoxide group per molecule;
• a sufficient amount of an aminosilane ingredient to provide in the range of from 0.7 to 1.2 amine equivalent weight amine per one epoxide equivalent weight to both react with the epoxy resin to form epoxy chain polymers, and polysiloxane to form polysiloxane polymers that copolymerize to form a cross-linked epoxy-polysiloxane copolymer composition.