High activity catalyst for hydrosilylation reactions and methods of making the same

A method of synthesizing supported nanoparticle catalysts, the method comprising:

• (a) forming a metal-containing polymer matrix comprising metal nanoparticles by forming a colloidal suspension of metal nano-particles by reacting metal complexes with a silicon hydride-containing polyorganohydrosiloxane solution to form a colloidal suspension of metal nano-particles and subsequently reacting the suspension to form a polymer matrix and encapsulate the metal nano-particles in a siloxane matrix, wherein the polymer matrix comprises a crosslinked or partially crosslinked network of hydrosiloxanes with a vinyl silicone compound, and the hydrosiloxanes are chosen from a silicon hydride-containing polyorganohydrosiloxane of the general formula:
• M1aM2bD1cD2dT1eT2fQJ
• wherein:
• M1=R1R2R3SiO1/2;
• M2=R4R5R6SiO1/2;
• D1=R7R8SiO2/2;
• D2=R9R10SiO2/2;
• T1=R11SiO3/2;
• T2=R12SiO3/2;
• Q=SiO4/2;
• R1, R2, R3,R4, R5, R6, R7, R8, R9, R10, R11, and R12 are aliphatic, aromatic or fluoro monovalent hydrocarbon having from 1 to 60 carbon atoms;
• at least one of R9 or R12 is hydrogen;
• and the subscript a, b, c, d, e, f, and j are zero or positive subject to the following limitations:
• 2≤a+b+c+d+e+f+j≤6000, and b+d+f>0;
• and
• (b) attaching the metal-containing polymer matrix to a support material via covalent chemical bonds, wherein the support material is chosen from silicon, a sodium silicate, a borosilicate, a calcium aluminum silicate, clay, silica, metal oxide, and mixtures of two or more thereof;
• and wherein the support material comprises a functional group chosen from silanol, alkoxy, acetoxy, silazane, oximino-functional silyl group, hydroxyl, acyloxy, ketoximino, amine, aminoxy, alkylamide, hydrogen, an aliphatic olefinic group, aryl, hydrosulfide, or a combination of two or more thereof.

A process comprising:

• (a) conducting a metal catalyzed reaction with a catalyst comprising a metal-containing polymer matrix of metal nanoparticles encapsulated in a siloxane polymer matrix covalently bonded to a support material,
• wherein the siloxane polymer matrix comprises a crosslinked or partially crosslinked network of hydrosiloxanes with a vinyl silicone compound, the hydrosiloxanes are chosen from a silicon hydride-containing polyorganohydrosiloxane of the formula
• M1aM2bD1cD2dT1eT2fQj
• wherein:
• M1=R1R2R3SiO1/2;
• M2=R4R5R6SiO1/2;
• D1=R7R8SiO2/2;
• D2=R9R10SiO2/2;
• T1=R11SiO3/2;
• T2=R12SiO3/2;
• Q=SiO4/2;
• R1, R2, R3, R4, R5, R6, R7, R8, R9, R10, R11, and R12 are aliphatic, aromatic or fluoro monovalent hydrocarbon having from 1 to 60 carbon atoms;
• at least one of R9or R12 is hydrogen;
• and the subscript a, b, c, d, e, f, and j are zero or positive subject to the following limitations:
• 2≤a+b+c+d+e+f+j≤6000, and b+d+f>0, or (b) a monomer having a general formula R′mHnSiX4−m−n, where each R′ is independently selected from the group consisting of alkyls comprising one to 20 carbon atoms, cycloalkyls comprising four to 12 carbon atoms, and aryls;
• m=0 to 3, n=1 to 3, and m+n=1 to 4;
• each X is independently selected from a OR′ group or a halide;
• (b) recovering the catalyst;
• and
• (c) conducting a subsequent metal catalyzed reaction with the recovered catalyst.