Curable Resin Composition

This invention relates to a curable resin composition from which a cured resin having impact chemical resistance, flexural property, heat resistance, mechanical property and moisture resistance can be prepared.

In the prior art, cured compositions having heat resistance, mechanical strength, chemical resistance and moisture resistance can be prepared from a polyfunctional cyanate ester alone or a mixture of a polyfunctional cyanate ester and a polyfunctional maleimide, and optionally epoxy resin. However, such cured resin does not sufficiently have flexural strength and elastic property.

The present inventor carrier out research for obtaining a cured resin having heat resistance, flexural property and elastic property. As a result, it was found that when a composition comprising a cyanate ester and a rubber which is liquid at room temperature or an elastic rubber is cured, flexural property and elastic property of the resulting cured resin can be improved considerably and heat resistance of the cyanate ester resin itself little deteriorates.

This invention relates to a curable resin composition comprising a mixture and/or a preliminary reaction product of (a) a polyfunctional cyanate ester, prepolymer of the cyanate ester or coprepolymer of the cyanate ester and an amine (sometimes hereinunder referred to as component (a)) and (b) a rubber, which is liquid at room temperature or elastic selected from the group consisting of styrene butadiene rubber, isoprene rubber, polychloroprene rubber, butyl rubber, acrylic rubber, natural rubbers, a preliminary reaction product of an epoxy compound and isoprene rubber, a preliminary reaction product of a natural rubber and an epoxy compound, a rubber obtained by introducing an acryloyl or a methacryloyl group into isoprene, and an acid anhydride moiety-containing rubber obtained by adding double bond of an unsaturated acid anhydride to isoprene (sometimes hereinunder referred to as component (b)) and optionally a polyfunctional maleimide, prepolymer of the maleimide or coprepolymer of the maleimide and an amine (sometimes hereinunder referred to as component (c)).

By polyfunctional cyanate ester is meant a compound having at least two cyanate groups in its molecule. The polyfunctional cyanate ester is represented by the formula

wherein R is an aromatic nucleus-containing residue which is selected from the group consisting of a residue derived from an aromatic hydrocarbon selected from the group consisting of benzene, biphenyl and naphthalene, a residue derived from a compound in which at least two benzene rings are bonded to each other by a bridging member selected from the group consisting of ##STR1## wherein R.sup.1 and R.sup.2 are the same or different and each represents a hydrogen atom or an alkyl group containing 1 to 4 carbon atoms, ##STR2## said aromatic nucleus is optionally substituted by a substituent selected from the group consisting of alkyl groups containing 1 to 4 carbon atoms, alkoxy groups, containing 1 to 4 carbon atoms, chlorine and bromine; m is an integer of 2 to 5, and the cyanate group is always directly bonded to the aromatic nucleus.

Examples of the polyfunctional cyanate ester include dicyanatobenzene; 1,3,5-tricyanatobenzene; 1,3-, 1,4-, 1,6-, 1,8-, 2,6- or 2,7-dicyanatonaphthalene; 1,3,6-tricyanatonaphthalene; 4,4'-dicyanatobiphenyl; bis(4-cyanatophenyl)methane; 2,2-bis(4-cyanatophenyl)propane, 2,2-bis(3,5-dichloro-4-cyanatophenyl)propane, 2,2-bis(3,5-diblomo-4-dicyanatophenyl)propane; bis(4-cyanatophenyl)ether; bis(4-cyanatophenyl)thioether; bis(4-cyanatophenyl)sulfone; tris(4-cyanatophenyl)phosphite; tris(4-cyanatophenyl)phosphate; bis(3-chloro-4-cyanatophenyl)methane; cyanated novolak derived from novolak cyanated bisphenol type polycarbonate oligomer derived from bisphenol type polycarbonate oligomer and mixture thereof. Other cyanate esters employed in the practice of this invention are given in Japanese Patent Publication Nos. 1928/1966, 4791/1969, 11712/1970 and 4112/1979 and Japanese Patent Publication (laid open) No. 63149/1976 which are incorporated herein for references. The above mentioned cyanate esters may be used as mixtures.

Prepolymers may be used containing a sym-triazine ring which is prepared by the trimerization of the cyanate groups of the cyanate ester, and which have an average molecular weight of at least 400 but no more than 6,000. Such prepolymers can be prepared by polymerizing the above cyanate esters in the presence of, as a catalyst, an acid such as a mineral acid or Lewis acid, a base such as sodium hydroxide, a sodium alcoholate or a tertiary amine, or a salt such as sodium carbonate or lithium chloride.

The polyfunctional cyanate ester can be used in the form of a mixture of the monomer and the prepolymer. For example, many of the commercially available cyanate esters derived from bisphenol A and cyanogen halide are in the form of mixtures of cyanate monomers and prepolymers, and such materials can also be used in the present invention.

A coprepolymer of the cyanate ester and an amine may be used as the cyanate ester component. Examples of the amines include meta- or para-phenylenediamine, meta- or para-xylylenediamine, 1,4- or 1,3-cyclohexanediamine, hexahydroxylylenediamine, 4,4'-diaminobiphenyl, bis(4-aminophenyl)methane, bis(4-aminophenyl)ether, bis(4-aminophenyl)sulfone, bis(4-amino-3-methylphenyl)methane, bis(3-chloro-4-aminophenyl)methane, bis(4-amino-3,5-dimethylphenyl)methane, bis(4-aminophenyl)cyclohexane, 2,2-bis(4-aminophenyl)propane, 2,2-bis(4-amino-3-methylphenyl)propane, 2,2-bis(3,5-dibromo-4-aminophenyl)propane, bis(4-aminophenyl)phenylmethane, 3,4-diaminophenyl-4'-aminophenylmethane and 1,1-bis(4-aminophenyl)-1-phenylethane.

A mixture of prepolymer of the cyanate ester and coprepolymer of the cyanate ester and an amine may be used as mixture.

The rubbers, which are liquid at room temperature or elastic, employed in the practice of this invention include styrene butadiene rubber, isoprene rubber, polychloroprene rubber, butyl rubber, acrylic rubber, natural rubbers, preliminary reaction product of an epoxy compound and isoprene rubber, a preliminary reaction product of a natural rubber and an epoxy compound, a rubber obtained by introruding an acryloyl or a methacryloyl group into isoprene, and an acid anhydride moiety-containing rubber obtained by adding double bond of an unsaturated acid anhydride to isoprene. Acrylic rubber is preferable. Styrene butadiene rubber, isoprene rubber, polychloroprene rubber, butyl rubber, acrylic rubber, natural rubbers and a preliminary reaction product of an epoxy compound and isoprene rubber and a preliminary reaction product of a natural rubber and an epoxy compound are known. In addition rubbers containing functional group, such as an acryloyl or a methacryloyl group, or an acid anhydride moiety can be produced by known methods.

By epoxy compound is meant a compound having two or more epoxy groups in its molecule, which is known as a heat curable epoxy resin. By unsaturated acid anhydride is meant a compound having olefinically C--C double bond and acid anhydride moiety.

The polyfunctional maleimides employed in the present invention are organic compounds having two or more maleimide groups derived from maleic anhydride and a polyamine and are represented by the following general formula ##STR3## wherein R represents divalent to pentavalent aromatic or alicyclic organic group, each of X.sup.1 and X.sup.2 represents a hydrogen atom, halogen atom or alkyl group, and n represents an integer of 2-5.

The maleimides represented by the above formula can be produced by a method known per se which involves reacting maleic anhydride with polyamine to form a maleamide acid, and then dehydro-cyclizing the maleamide acid. Examples of polyfunctional maleimide include 1,3- or 1,4-dimaleimide benzene, 1,3- or 1,4-bis(maleimido methylene)benzene, 1,3- or 1.4-dimaleimido cyclohexane, 1,3- or 1,4-bis(maleimidomethylene)cyclohexane 4,4'-dimaleimido biphenyl, bis(4-maleimidophenyl)methane, bis(4-maleimidophenyl)ether, bis(4-maleimidophenyl)sulfone, bis(4-maleimido-3-methylphenyl)methane, bis(4-maleimido-3-chlorophenyl)methane, bis(4-maleimido-3,5-dimethylphenyl)methane, 2,2-bis(4-maleimido-3-methylphenyl)propane, 2,2-bis(4-maleimido-3,5-dibromophenyl)propane, bis(4-maleimidophenyl)phenylmethane, 3,4-dimaleimidophenyl-4'-maleimidophenylmethane, 1,1-bis(4-maleimidophenyl)-1-phenylmethane, and maleimides derived from melamine and addition product of formalin and an aniline in which benzene rings of two or more aniline bond through methylene group.

Aromatic amines are preferable as the starting polyamines. The reason is that the resulting object resin has excellent properties, such as heat-resistance, etc. When the resulting object resins have desirable flexibility and pliability, alicyclic amine alone or combination of the alicyclic amines and other amines may be used. Though secondary amines can be used as the starting amine, the primary amines are preferable.

Amines employed in reaction with cyanate esters for preparing coprepolymers of the cyanate ester and the amine may be profitably used as an amine component for preparing maleimides. In addition to the above-mentioned amines, melamine having s-triazine ring and polyamines obtained by reaction aniline with formaldehyde, in which two or more benzene rings are bonded through methylene bond, may also be used.

The functional maleimides as mentioned above may be used alone or as a mixture. Also the prepolymer of the maleimide obtained by heating the maleimide in the presence or absence of a catalyst may be used. In addition, coprepolymers of the maleimide and the amine employed for synthesizing the polyfunctional maleimide may be used.

The ratio of component (a) and component (c) is not critical. In general, the ratio by weight of component (a) and component (c) may be in the range of from 99:1 to 40:60.

The ratio of component (a) and component (b) is not critical. When preparing heat resistant resin having good adhering property, 1-50% by weight of component (b) and preferably 5-40% by weight of component (b) may be used on the basis of total weight of components (a) and (b) or on the basis of total weight of components (a), (b) and (c) (when component (c) is used). In order to improve heat resistance of cured resin derived from component (b), it is preferable to use 5-50% by weight of component (a) or components (a) and (c) on the basis of total weight of components (a) and (b) or components (a), (b) and (c).

The curable composition of this invention comprises a mixture and/or a preliminary reaction product of component (a) and component (b), and optionally component (c) and optionally other functional group-containing compounds (sometimes hereinunder referred to as component (d)). Component (d) includes, for example (methacrylic esters or prepolymers thereof, such as esters of monofunctional or polyfunctional hydroxy compounds and (meth)acrylic acid, epoxy ester of (meth)acrylic acid, and alkenyl ester of (meth)acrylic acid; polyallyl compounds or prepolymers thereof, such as diallyl phthalate, divinylbenzene, diallylbenzene, and trialkenyl isocyanurate, dicyclopentadiene or prepolymer thereof; epoxy resin; polyimide resin and acid anhydrides such as maleic anhydride and tetrahydrophthalic anhydride. The resin component may be a mixture of components (a) and (b) and optionally (c) and/or (d); a preliminary reaction product of components (a) and (b), components (a), (b) and (c) or components (a), (b), (c) and (d); a mixture of preliminary reaction product of two or three of components (a), (b), (c) and (d) and the remainder thereof.

The curable composition of this invention may be reticulated by heating it alone to form a cured resin having heat resistance. In general, a catalyst may be used in order to promote crosslinking reaction of the components in the composition.

Examples of the catalysts include imidazoles, such as 2-methylimidazole, 2-undecylimidazole, 2-heptadecylimidazole, 2-phenylimidazole, 2-ethyl-4-methylimidazole, 1-benzyl-2-methylimidazole, 1-propyl-2-methylimidazole, 1-cyanoethyl-2-methylimidazole, 1-cyanoethyl-2-ethyl-4-methylimidazole, 1-cyanoethyl-2-undecylimidazole, 1-cyanoethyl-2-phenylimidazole, 1-guanaminoethyl-2-methylimidazole and addition product of an imidazole and trimellitic acid; tertiary amines, such as N,N-dimethyl benzylamine, N,N-dimethylaniline, N,N-dimethyltoluidine, N,N-dimethyl-p-anisidine, p-halogeno-N,N-dimethylaniline, 2-N-ethylanilino ethanol, tri-n-butylamine, pyridine, quinoline, N-methylvorpholine, triethanolamine, triethylenediamine, N,N,N',N'-tetramethylbutanediamine, N-methylpiperidine; phenols, such as phenol, cresol, xylenol, resorcine, and phloroglucin; organic metal salts, such as lead naphthenate, lead stearate, zinc naphthenate, zinc octylate, tin oleate, dibutyl tin maleate, manganese naphthenate, cobalt naphthenate, and acetyl acetone iron; and inorganic metal salts, such as stannic chloride, zinc chloride and aluminum chloride; peroxides, such as benzoyl peroxide, lauroyl peroxide, octanoyl peroxide, acetyl peroxide, para-chlorobenzoyl peroxide and di-t-butyl diperphthalate; acid anhydrides, such as maleic anhydride, phthalic anhydride, lauric anhydride, pyromellitic anhydride, trimellitic anhydride, hexahydrophthalic anhydride, lexahydropyromellitic anhydride and hexahydrotrimellitic anhydride; azo compounds, such as azoisobutylonitrile, 2,2'-azobispropane, m,m'-azoxystyrene, hydrozones, and mixtures thereof.

In addition to the above-mentioned catalyst, a curing agent for epoxy resin and a curing catalyst for epoxy resin may be used as a catalyst of this invention.

The amount of the catalyst employed may be less than 5% by weight of the total composition.

A variety of additives may be added to the curable composition to impart specific properties provided that they do not impair the essential properties of the resulting resin. Examples of the additives include natural or synthetic resins, fibrous reinforcement, fillers, pigments, dyestuffs, thickening agents, lubricants, flame-retardants and the like.

The curable compositions of this invention are present in a wide range of forms from liquid to solid at room temperature, depending on the nature of the components constituting the composition, and the preliminary reaction conditions. Solid curable composition, liquid curable composition or solution of the composition in solvent may be used according to the use purpose.

The curing conditions of the curable composition of this invention depend on the proportion of components constituting the composition and the nature of the components employed. In general, the composition of this invention may be cured by heating it at a temperature within the range of 90.degree.-300.degree. C., preferably 100.degree.-270.degree. C.

When the curable composition of this invention is used for preparing molding, laminate, adhesive-assembly, press means is preferably applied to the molding, laminate or adhesive-assembly in the heat curing step. In general, these products may be pressed at a pressure of 0.1-500 Kg/cm.sup.2.

The composition of this invention cures rapidly, even under mild conditions, so is especially suitable when quantity production and ease of workability are desired. The cured resin made from the composition not only has excellent adhesive force, bond strength, heat resistance, and electric properties, but also is excellent in mechanical properties and resistance to impact, chemicals, moisture and the like. The composition of this invention has a variety of uses as a coating material for rust prevention, flame resistance, flame retardance and the like; as electrical insulating varnish; as adhesive; in laminates to be used for furnitures, building materials, sheathing materials, electrical insulating materials, and the like; and in a variety of moldings.

The present invention is further illustrated by the following non-limiting Examples and Controls.

Percent and parts are by weight, unless otherwise specified.

2,2-Bis(4-cyanatophenyl)propane (600 g) was preliminarily polymerized at 150.degree. C. for 300 minutes, and then to the resulting prepolymer, epoxy resin (EPIKOTE 1001, produced by Shell Chemical Co., Ltd.) (100 g), butyl acrylate-acrylonitrile copolymer (Toa Paint Co., Ltd.) (400 g), bis(4-maleimidophenyl)methane (50 g), bis(4-aminophenyl)methane (2 g) and benzoyl peroxide (0.1 g) as a catalyst were added and were preliminarily reacted at 90.degree. C. for 20 minutes with stirring.

The resulting resin solution was cast in a mold, and cured at 120.degree. C. for 3 hours and for additional 5 hours at 150.degree. C.

Properties of the cast product are shown in Table 1.

The procedure of Example 1 was repeated except that 2,2-bis(4-cyanatophenyl)propane was used in amount of 1000 g and butyl acrylate-acrylonitrile copolymer was not used. Properties of the resulting cast product are shown in Table 1.

1,3-Dicyanatobenzene (800 g) was preliminarily polymerized at 150.degree. C. for 340 minutes, and the resulting prepolymer was dissolved in a mixture of methyl ethyl ketone and N,N-dimethylformamide. To the solution, acrylic rubber (AR-31 produced by Nippon Zeon Co., Ltd.) (200 g) and zinc octylate (0.3 g), triethylenediamine (0.1 g), bis(4-aminophenyl)ether (2 g) and benzoyl peroxide (0.1 g) as a catalyst were added and were mixed uniformly. A glass cloth was impregnated with the mixture and dried with heat to form a B-stage prepreg. Four layers of the prepreg were sandwiched between two fluororesin film, and pressed at 40 Kg/cm.sup.2 and 140.degree. C. for 50 minutes, then at 50 Kg/cm.sup.2 and 165.degree. C. for 100 minutes to produce a laminated sheet.

Insulation resistance of the sheet was 4.0.times.10.sup.14 ohms (a normal state), and insulation resistance of the sheet was 6.9.times.10.sup.11 ohms after it was boiled for 2 hours. For comparison, insulation resistance of ethyl acrylate-acrylonitrile copolymer alone was 1.0.times.10.sup.14 ohms (a normal state), and insulation resistance of the copolymer was 5.7.times.10.sup.8 ohms after it was boiled for 2 hours. Insulation resistance of the laminated sheet prepared according to this invention gives superior results to insulation resistance of ethyl acrylate-acrylonitrile copolymer. Glass transition temperature of the sheet was 210.degree. C.

2,2-Bis(4-cyanatophenyl)propane (450 g) was preliminarily polymerized at 150.degree. C. for 450 minutes. To the resulting prepolymer, liquid chloroprene (Denka LCR CX-050 produced by Denki Kagaku Kogyo Co., Ltd.) (550 g), and wollastonite (200 g) were added and then zinc octylate (0.01 g) and benzoyl peroxide (0.1 g) as a catalyst were added to the mixture, and the resulting mixture was mixed uniformly. The mixture was cast in a mold and cured at 110.degree. C. for 150 minutes and then 4 hours at 150.degree. C. Property of the cast product are shown in Table 2.

1,4-Dicyanatobenzene (900 g) and bis(4-maleimidophenyl)methane (100 g) were preliminarily reacted at 150.degree. C. for 100 minutes. The resulting prepolymer was dissolved in a mixture of N,N-dimethylformamide and methyl ethyl ketone. To the solution, epoxy resin (EPIKOTE 1001 produced by Shell Chemical Co., Ltd.) (200 g), polychloroprene (produced by Showa Neoprene Co., Ltd.) (200 g) were added and then azobisisobutylonitrile (0.1 g) and zinc octylate (0.5 g) as a catalyst were added, and the mixture was mixed uniformly.

A coating of the resulting blend was applied to two epoxy resin test panels (125 mm long, 25 mm wide, 0.4 mm thick) and dried with heat to B-stage. The test panels were joined so that the surfaces dried to B-stage contacted each other to provide a 10 mm long overlap along the longitudinal edge, and the joined panels were heat-cured at 100.degree. C. for 5 hours and for additional 3 hours at 140.degree. C. The overlapped portion of the panels was 2.0 mm thick and had a shear bond strength of 87.5 Kg/cm.sup.2, and glass transition temperature of 220.degree. C.

2,2-Bis(4-cyanatophenyl)propane (50 g) was preliminarily polymerized at 150.degree. C. for 400 minutes. The resulting prepolymer and styrene-butadiene copolymer (average molecular weight of 2100 and styrene content of 13% by weight) (200 g) were mixed uniformly at 80.degree. C. and then to the mixture, zinc octylate (0.01 g) and benzoyl peroxide (0.1 g) as a catalyst were added and the mixture was mixed uniformly.

The resulting resin composition was cast in a mold and cured for 120 minutes at 150.degree. C. and for additional 60 minutes at 175.degree. C. to obtain cast product. The cast product had elongation of 250%. It little deteriorated even after it was maintained at 150.degree. C. for 100 hours.

The catalyst-containing resin (250 g) of Example 5 and wollastonite (100 g) were mixed uniformly. The resulting composition was cast and cured in the same way as in Example 5. The cast product had elongation of 210%.

1,4-Dicyanatobenzene (900 g) and bis(4-maleimidophenyl) methane (100 g) were preliminarily reacted at 150.degree. C. for 100 minutes. The resulting prepolymer was cooled to 100.degree. C., and then to the prepolymer, epoxy resin (EPIKOTE 1001 produced by Shell Chemical Co., Ltd.) (200 g), styrene-butadiene copolymer (Nipol 1006, produced by Nippon Zeon Co., Ltd.) (100 g), and azobisbutylonitrile (0.1 g) and zinc octylate (0.5 g) as a catalyst were added and mixed uniformly.

A coating of the resulting blend was applied to two epoxy resin test panels (125 mm long, 25 mm wide, 0.4 mm thick) and dried with heat to B-stage. The test panels were joined so that the surfaces dried to B-stage contacted each other to provide a 10 mm wide overlap along the longitudinal edge, and the joined panels were heat-cured at 110.degree. C. for 300 minutes and for additional 180 minutes at 160.degree. C. The overlapped portion of the panels was 2.0 mm thick and had a shear bond strength of 80.0 Kg/cm.sup.2, and glass transition temperature of 237.degree. C.

2,2-Bis(4-cyanatophenyl)propane (850 g) and bis(4-maleimidophenyl)methane (150 g) were preliminarily reacted at 145.degree. C. for 150 minutes. The resulting resin composition is referred to as composition A.

2,2-Bis(4-cyanatophenyl)propane (1000 g) was preliminarily polymerized at 150.degree. C. for 5 hours. The resulting resin composition is referred to as composition B.

Carboxyl-containing isoprene rubber (LIR-410 produced by Kuraray Isoprene Chemical Co., Ltd.: molecular weight of 30,000 and average carboxy groups of 9.8 in its molecule) (200 g) was dissolved in methyl ethyl ketone (200 g), and was preliminarily polymerized at 80.degree. C. for 2 hours with refluxing. The resulting resin composition is referred to as composition C.

Compositions A, B and C, isoprene rubber not having carboxy group (LIR-30; molecular weight of 29,000, produced by Kuraray Isoprene Chemical Co., Ltd.) and natural rubber (molecular weight of 950,000) were employed as shown in Table 3 and each component was dissolved in methyl ethyl ketone. A glass cloth was impregnated with each solution to obtain prepreg of B-stage.

One sheet of the prepreg was sandwiched between electrolytic copper foils 35.mu. thick and pressed at 175.degree. C. and 30 Kg/cm.sup.2 for 120 minutes. Properties of the resulting copper-clad sheet are shown in Table 4.

2,2-Bis(4-cyanatophenyl)propane (900 g) and bis(4-maleimidophenyl)methane (100 g) were preliminarily reacted at 150.degree. C. for 150 minutes to obtain prepolymer. To the prepolymer, epoxy resin (EPIKOTE 828, produced by Shell Chemical Co., Ltd.) (200 g), bromobutyl rubber (800 g) and zinc octylate (0.5 g) as a catalyst were added. The mixture was blended uniformly by using roll. The mixture was charged in a mold, and heated at 100.degree. C. for 130 minutes and cured at 120.degree. C. for 170 minutes to obtain molding. The properties of the molding are shown in Table 5.

The procedure of Example 15 was repeated except that bromobutyl rubber is not used. The properties of the molding are shown in Table 5.

1,4-Dicyanatobenzene (750 g) and bis(4-maleimidophenyl) ether (150 g) were preliminarily reacted at 150.degree. C. for 150 minutes to obtain prepolymer. The prepolymer was dissolved in a mixture of N,N-dimethylformamide and methyl ethyl ketone. To the solution, butyl rubber (100 g) and zinc octylate (0.5 g), triethylenediamine (0.4 g) and ditert.-butyl peroxide (0.2 g) as a catalyst were added and the mixture was mixed uniformly to obtain a varnish. The vanish was impregnated in a glass cloth and dried to obtain prepreg of B-stage. The six layers of the prepreg were sandwiched between electrolytic copper foils 35.mu. thick and pressed at 35 Kg/cm.sup.2 and 175.degree. C. for 120 minutes to obtain copper-clad laminate sheet. Properties of the sheet are shown in Table 6.

The procedure of Example 16 was repeated except that butyl rubber was not used. Properties of the resulting copper-clad sheet are shown in Table 6.