The invention relates in general to a silicone composition. The invention also relates to a method for making the silicone composition and members made from the same.

Silicone materials are utilized in many applications including insulating and fire safety applications. In some fire safety applications, it is desired that the materials being used are resilient. However, these materials typically do not exhibit high heat reflection. Alternatively, materials utilized to provide excellent heat reflection in such applications are often rigid. Additionally, the materials known for use in such applications are often difficult to process.

Therefore, it would be desirable to provide a composition that overcomes the aforementioned deficiencies.

Embodiments of a composition are provided. In an embodiment, the composition comprises a peroxidically crosslinked or a condensation crosslinked organopolysiloxane material. The composition comprises a silicone polymer. Also, the composition comprises at least one of a metal oxide, a metal containing compound, boric acid, or zinc borate. When present, the metal oxide is selected from a group consisting of magnesium oxide, aluminum oxide, tin oxide, calcium oxide, titanium oxide and barium oxide. When present, the metal-containing compound produces a metal oxide of the group on heating. The composition comprises a platinum complex containing at least one unsaturated group and 33-100 parts by weight of mica based on 100 parts by weight of the organopolysiloxane material. The composition produces a ceramic material at temperatures of 610 °C or more.

In some embodiments, the organopolysiloxane material comprises a peroxide crosslinking agent. In other embodiments, the organopolysiloxane material is elastomeric and comprises a vinyl-functional organopolysiloxane and a hydroxyl- functional organopolysiloxane.

In other embodiments, the mica is of the formula KAI ₂ (F, OH) ₂ or (KF) ₂ (AI ₂ O ₃ ) ₃ (SiO ₂ ) ₆ . In still other embodiments, the silicone polymer is a vinylmethyl polydimethylsiloxane.

In some embodiments, the platinum complex is a platinum-vinyl siloxane complex. In one such embodiment, the platinum-vinyl siloxane complex is a platinum- 1 , 3-di vi ny I- 1 , 1 ,3,3-tetramethyldisiloxane complex.

In certain embodiments, the metal oxide is aluminum oxide. In an embodiment where the metal oxide is aluminum oxide, the platinum complex is a platinum-vinyl siloxane complex.

In certain embodiments, the composition further comprises a reinforcing filler, a nonreinforcing filler, or mixture thereof. In an embodiment, the reinforcing filler comprises silica.

Embodiments of a process for preparing the composition are also provided. In one such embodiment, the process comprises mixing components of the composition.

Additionally, embodiments of a cable and embodiments of a profile, each comprising the composition are provided.

It is to be understood that the invention may assume various alternative compositions and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific components, members, and methods described in the following specification are simply exemplary embodiments of the inventive concepts. Hence, specific properties, conditions, or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise.

In an embodiment, a composition is provided. In some embodiments, the composition is ceramifyable. For example, the composition may produce a ceramic material at elevated temperatures, which are preferably of 610 °C or more. The composition is suitable for use in fire safety applications such as, for example, insulation for electrical conductors. However, the composition may also be suitable in other application such as, for example, for use in profiles or forming other members.

Preferably, the composition comprises an organopolysiloxane material. In some embodiments, the organopolysiloxane material may be composed of units of the general formula (I) where R may be identical or different and are unsubstituted or substituted hydrocarbon radicals, and r is 0, 1 , 2 or 3 and has an average numerical value of from 1.9 to 2.1.

Examples of hydrocarbon radicals R are alkyl radicals such as the methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl or tertpentyl radicals, hexyl radicals such as the n-hexyl radical, heptyl radicals such as the n- heptyl radical, octyl radicals such as the n-octyl radical and isooctyl radicals such as the 2,2,4-trimethylpentyl radical, nonyl radicals such as the n-nonyl radical, decyl radicals such as the n-decyl radical, dodecyl radicals such as the n-dodecyl radical, octadecyl radicals such as the n-octadecyl radical; cycloalkyl radicals such as cyclopentyl, cyclohexyl and cycloheptyl radicals and methylcyclohexyl radicals; aryl radicals such as the phenyl, biphenyl, naphthyl, anthryl and phenanthryl radicals; alkaryl radicals such as o-, m- or p-tolyl radicals, xylyl radicals and ethylphenyl radicals; and aralkyl radicals such as the benzyl radical and the a- and the p-phenylethyl radicals.

Examples of substituted hydrocarbon radicals R are halogenated alkyl radicals, such as the 3-chloropropyl radical, the 3,3,3-trifluoropropyl radical and the perfluorohexylethyl radical, and halogenated aryl radicals, such as the p-chlorophenyl radical and the p-chlorobenzyl radical.

Other examples of radicals R are the vinyl, allyl, methallyl, 1 -propenyl, 1-butenyl and 1 -pentenyl radicals, and the 5-hexenyl, butadienyl, hexadienyl, cyclopentenyl, cyclopentadienyl, cyclohexenyl, ethynyl, propargyl and 1-propynyl radicals.

The radicals R are preferably hydrogen atoms or hydro-carbon radicals having from 1 to 8 carbon atoms, particularly preferably the methyl radical. In some embodiments, it may be preferred that the radicals R are alkenyl radicals having from 2 to 8 carbon atoms, particularly preferably the vinyl radical. Among unsubstituted or substituted hydrocarbon radicals having from 1 to 8 carbon atoms, particular preference is given to the methyl, vinyl, phenyl or 3,3,3-trifluoropropyl radical.

Preferably, alkyl radicals, in particular methyl radicals, are bonded to at least 70 mol-% of the Si atoms present in the organopolysiloxane material composed of units of the formula (I). If the organopolysiloxane material contains, in addition to Si-bonded methyl and/or 3,3, 3-trifluoropropyl radicals, Si-bonded vinyl and/or phenyl radicals, the amounts of these latter are preferably from 0.001 to 30 mol-%.

Preferably, the organopolysiloxane material may be composed predominantly of diorganosiloxane units. The end groups of the organopolysiloxanes may be trialkylsiloxy groups, in particular the tri methyl si I oxy radical or the dimethylvinyl-siloxy radical. However, it is also possible for one or more of these alkyl groups to have been replaced by hydroxyl groups or alkoxy groups, such as methoxy or ethoxy radicals. In some embodiments, the organopolysiloxane material may comprise a mixture of organosiloxanes. For example, in certain embodiments, the organopolysiloxane material may comprise a vinyl-functional organopolysiloxane and a hydroxyl-functional organopolysiloxane.

The organopolysiloxane material may be a liquid or a high-viscosity substance. The organopolysiloxane material preferably has a viscosity of from 10 ³ to 10 ⁸ mm ² /s at 25 °C.

The organopolysiloxane material is peroxidically crosslinked or a condensation crosslinked. Suitable crosslinking agents are utilized to crosslink the organopolysiloxane material. In some embodiments, a peroxide crosslinking agent is utilized to crosslink the organopolysiloxane material. Suitable peroxide crosslinking agents preferably comprise peroxides such as, for example, dibenzoyl peroxide, bis(2,4-dichlorobenzoyl) peroxide, dicumyl peroxide or 2,5-bis(tert-butylperoxy)-2,5-dimethylhexane, or else mixtures of these, preferably bis(2,4-dichlorobenzoyl) peroxide or 2,5-bis(tert-butylperoxy)-2,5- dimethyl-hexane. Preferably, the crosslinking agent comprises a mixture of bis(4- methylbenzoyl) peroxide (PMBP) and 2,5-dimethyl-2,5-di-tert-butylhexane peroxide (DHBP) in a ratio of from 1 : 0.4 to 0.5 : 1 , preferably in a ratio of 1 : 0.4.

The organopolysiloxanes (A) according to the invention preferably also comprise reinforcing and/or nonreinforcing fillers. Examples of reinforcing fillers are pyrogenic or precipitated silicas with BET surface areas of at least 50 m ² /g. The silica fillers mentioned may have hydrophilic properties or may have been hydrophobicized by known processes such as the one described in, for example, U.S. Patent No. 5,057,151. In such cases the hydrophobicization is generally carried out using from 1 to 20 % by weight of hexamethyldisilazane and/or divinyltetramethyldisilazane and from 0.5 to 5 % by weight of water, based in each case on the total weight of the organopolysiloxane material. These reagents are advantageously fed to a suitable mixing apparatus, e.g., a kneader or internal mixer, in which there is an initial charge of the organopolysiloxane material, prior to gradual incorporation of the reinforcing filler.

Examples of non-reinforcing fillers are powdered quartz, diatomaceous earth, calcium silicate, zirconium silicate, zeolites, metal oxide powders, such as aluminum oxide, titanium oxide, iron oxide or zinc oxide, barium silicate, barium sulfate, calcium carbonate, gypsum, and also synthetic polymer powders, such as polyacrylonitrile powder or polytetrafluoroethylene powder. The fillers used may also comprise fibrous components, such as glass fibers or synthetic polymer fibers. The BET surface area of these fillers is preferably less than 50 m ² /g.

The amount of filler present in the organopolysiloxane material is preferably from 1 to 200 parts by weight, particularly preferably from 30 to 100 parts by weight, based in each case on 100 parts by weight of organopolysiloxane material.

Depending on the particular application, additives, such as workability aids, for example plasticizers, pigments, or stabilizers, e.g. heat stabilizers, may be added to the organopolysiloxane material, which can be crosslinked or vulcanized to give an elastomer. Examples of plasticizers which may be used as additives are polydimethylsiloxanes terminated by trimethylsilyl groups, silanol groups, or vinyl siloxanes, and diphenylsilanediol. Combinations of plasticizers like those mentioned may also be utilized. Examples of heat stabilizers which may be used as additives are transition metal salts of fatty acids such as iron octoate, transition metal silanolates such as iron silanolate, and cerium(IV) compounds. The organopolysiloxane material used may also be a conventional condensation-crosslinking organopolysiloxane, as described, for example, in EP0359251 , or other known addition-crosslinking materials.

Each of the components used to prepare the organopolysiloxane material may be of the single material type or a mixture of two or more different materials, which together form the component. In some embodiments, the organopolysiloxane material comprises no additional components other than those described above. For example, in one such embodiment, the organopolysiloxane material is free of hydrophobic metal nitrides and carbides. Preferably, the composition comprises a silicone polymer. Preferably, the silicone polymer is a vinylmethylpolydimethylsiloxane. In certain embodiments, the silicone polymer comprises at least one vinyldimethylsiloxane end unit. In these embodiments, the vinylmethylpolydimethylsiloxane may be of the formula where Y is 1 ,000 to 10,000 siloxane units, preferably, about 7,500 to 10,000 units. In other embodiments, the silicone polymer comprises at least one vinylmethylsiloxane unit included in the main polymer chain. In these embodiments, the vinylmethylpolydimethylsiloxane may be of the formula where X+Y equals about 500 to 10,000 siloxane units, preferably, about 7,500 to 10,000 units. In still other embodiments, the silicone polymer comprises at least one vinyldimethylsiloxane end unit and at least one vinylmethylsiloxane unit included in the main polymer chain. In these embodiments, the vinylmethylpolydimethylsiloxane may be of the formula where X+Y equals about 500 to 10,000 siloxane units, preferably, about 7,500 to 10,000 units. Mixtures of the vinylmethylpolydimethylsiloxanes described above can also be utilized. Preferably, in these embodiments, a vinyl group is provided per every 500- 10,000 siloxane units. In some embodiments, a vinyl group is provided per every 1000- 5000 siloxane units. In one such embodiment, a vinyl group is provided per every 1200 siloxane units. In other embodiments, the silicone polymer is a dimethylpolydimethylsiloxane comprising at least one saturated end unit. In these embodiments, the dimethylpolydimethylsiloxane may be of the formula where Y is 1 ,000 to 10,000 siloxane units, preferably, about 7,500 to 10,000 units.

The composition comprises at least one of a metal oxide, a metal containing compound, boric acid, or zinc borate. When present, the metal oxide is selected from a group consisting of magnesium oxide, aluminum oxide, tin oxide, calcium oxide, titanium oxide and barium oxide. When present, the metal-containing compound produces a metal oxide of the group on heating. Examples of such metal-containing compounds include, for example, metal hydroxides. In some embodiments, the components mentioned above are provided in the composition in an amount of from 1.5 to 40 % by weight, based always on the total weight of the composition, preferably from 10 to 20 % by weight. Mixtures of at least one of the metal oxides described above, metalcontaining compounds, boric acid, and zinc borate may also be used.

The composition comprises a platinum complex containing at least one unsaturated group. Preferably, the unsaturated group is a hydrocarbon group. Examples of preferable platinum complexes include platinum-olefin complexes, platinum-aldehyde complexes, platinum-ketone complexes, platinum-vinyl siloxane complexes or platinum-1 ,3-diviny 1 -1 ,1 ,3,3-tetramethyldisiloxane complexes with or without any detectable content of organic halogen, platinum-norbornadiene- methylacetonate complexes, bis(gamma-picoline)platinum dichloride, trimethylenedipyridineplatinum dichloride, dicyclopentadieneplatinum dichloride, (dimethylsulfoxide)(ethylene)platinum(ll) dichloride, reaction products of platinum tetrachloride with olefins and with primary amines, secondary amine, or both primary and secondary amines for example the reaction product of sec-butylamine with platinum tetrachloride dissolved in 1 -octene. In certain embodiments, the platinum complex is a platinum-vinyl siloxane complex. Preferably, the platinum-vinyl siloxane complex is a platinum-1 , 3-di viny 1-1 , 1 ,3,3-tetramethyldisiloxane complex. However, other platinum- vinyl siloxane complexes may be suitable. The amounts of the platinum complex used are from 5 to 200 ppm, preferably from 10 to 100 ppm. The amount is based on elemental platinum. It is also possible to use mixtures of the platinum complexes in the composition.

The composition comprises mica. Mica may be in the of muscovite or phlogopite variety. Preferably, the mica is of the muscovite variety. In these embodiments, the mica may be of the formula KAI ₂ (F, OH) ₂ or (KF) ₂ (AI ₂ O ₃ ) ₃ (SiO ₂ )6. In some embodiments, the composition comprises at least 33 parts by weight of mica based on 100 parts by weight of the organopolysiloxane material. In one such embodiment, the composition comprises 33-100 parts by weight of mica based on 100 parts by weight of the organopolysiloxane material. In other embodiments, the composition comprises 50- 100 parts by weight of mica based on 100 parts by weight of the organopolysiloxane material. In other embodiments, the composition comprises 65-100 parts by weight of mica based on 100 parts by weight of the organopolysiloxane material.

Preferably, mica is provided as fine powder. In some embodiments, the mica may have a D50 value, which is a value representing the particle size distribution of the mica, of 1- 75 pm. In one such embodiment, the mica may have a D50 value of 25 pm. The mica may also have a desirable aspect ratio (Jennings Factor). For example, the mica may have an aspect ratio of 80.

In certain embodiments, the composition may be formed by a process that comprises mixing the components mentioned above. The components can be mixed in a device such as, for example, an internal mixer or another suitable mixing device. In these embodiments, it is preferred that the mica is added to the mixture in two or more portions. For example, in certain embodiments, mica may be added in equal portions to the mixture. In other embodiments, the portions of mica added to the mixture may not be equal to each other. In these embodiments, mica may be added in portions that are equivalent to 1-30 parts per hundred parts of the mixture. In some embodiments, the mixture may already comprise the other components mentioned above before the mica is added. In these embodiments, mica may be added in portions of not more than 10 kilograms (kg) or in portions of greater than 10 kg.

After mixing, the mixture is cured. The mixture is cured for a predetermined time. In some embodiments, the composition is formed by curing the mixture at an ambient temperature. The time it takes for the mixture to be cured can be reduced by heating the mixture. In certain embodiments, the mixture can be heated to a temperature of 25- 250 °C for curing. Preferably, the mixture is cured at a temperature in the range of about 40 °C to about 200 °C. Other curing mechanisms such as, for example, moisture curing, peroxide curing, and radiation curing may be utilized to form the composition.

Preferably, curing results in the composition being elastomeric. Also, after curing, the composition permits sintering to start at temperatures as low as 610 °C. In certain embodiments, this property allows the composition to produce a ceramic material at temperatures of 610 °C or more. The ceramic material may be formed as a layer and enable the composition to retain function in the event of being exposed to fire. When the composition exhibits a low density, the composition also exhibits a higher level of mechanical properties, better heat-ageing properties, and greater insulating capabilities than conventional silicone compositions, especially when exposed to high temperatures such as, for example, in temperatures above 900 °C. The ceramic material formed in the event of fire is moreover significantly more resistant to impact and shock than are the mixtures described in the prior art, which merely form a stable ash layer.

The composition may exhibit the same electrical and heat-ageing properties as known silicone rubber compositions. Further, the composition exhibits excellent mechanical properties. For example, in certain embodiments, the composition exhibits a tensile strength of 400 psi or more. In one such embodiment, the composition exhibits a tensile strength of 400-1200 psi. The tensile strength of the composition can be measured according to ASTM D 412 using a tensile tester. An example of a tensile tester suitable for use in measuring the tensile strength of the composition according to ASTM D 412 is a TensiTech III tester manufactured by Tech-Pro, Inc. In some embodiments, the composition exhibits an elongation at break of 100 percent or more. In other embodiments, the composition exhibits an elongation at break of 200 percent or more. Preferably, the composition exhibits an elongation at break of 200-400 percent. The elongation of the composition can be measured according to ASTM D412 and when measuring tensile strength. In some embodiments, the composition exhibits a Shore A hardness of 50 or more. In these embodiments, the composition may exhibit a Shore A hardness of 70 or more. Preferably, the composition exhibits a Shore A hardness of 70- 100. The Shore A hardness of the composition can be measured according to ASTM D 2240 using a durometer. An example of a durometer suitable for measuring Shore A hardness according to ASTM D 2240 is a handheld Durometer Type A sold by Instron. In still other embodiments, the composition exhibits a tear strength of 100 N/mm or more. In these embodiments, the composition may exhibit a tear strength of 100-150 pounds per inch. The tear strength of the composition can be measured according to ASTM D 624, test die B specimens using a TensiTech III tester manufactured by Tech- Pro, Inc. Additionally, the composition may exhibit a desirable specific gravity of, for example, 1 .40-1 .60. The specific gravity of the composition can be measured according to ASTM D 792 using a hydrostatic specific gravity tester. An example of a hydrostatic specific gravity tester suitable for measuring specific gravity according to ASTM D 792 is a SECURA224-1 S analytical scale fitted with a density analytical balance kit manufactured and sold by the Sartorius Group.

As noted above, the compostion exhibits good mechanical, heat-ageing, and insulating properties. Additionally, the composition may also exhibit excellent elastomeric and/or heat reflective properties. Thus, the composition has a wide range of applications including fire safety applications. The composition is also workable and easy to use in known processes such as, for example, extrusion processes. Because of these properties, the composition can be utilized to form cables and profiles, which comprise the composition. The cables may be communication or energy cables. The profiles may be foams or compact gaskets for fire-resistant screening for rooms, cabinets or safes, or layers for ablation control in the lining of rocket engines or in other aerospace systems.

Examples

The following examples are presented solely for the purpose of further illustrating and disclosing the embodiments of the composition. Example 2, which is described below, illustrates an embodiment of the composition within the scope of the invention.

Example 1

100 parts of a diorganopolysiloxane end-capped by trimethylsiloxy groups, composed of 99.93 mol percent of dimethylsiloxane units and 0.07 mol percent of vinylmethylsiloxane units and having a viscosity of 8*10 ⁶ mPa*s at 25 °C. are mixed in a kneader operated at 150 °C., first with 50 parts of silicon dioxide produced pyrogenically in the gas phase and having a surface area of 200 m ² /g, then with 1 part of dimethylpolysiloxane end-capped by trimethylsiloxy groups and having a viscosity of 96 mPa*s at 25 °C., next with 7 parts of a dimethylpolysiloxane having an Si-bonded hydroxyl group in each terminal unit and having a viscosity of 40 mPa*s at 25 °C., with 36 parts of aluminum oxide having a particle size >10 p and having an alkali metal oxide content of <0.5 % by weight, and 0.3 % by weight of a platinum-1 ,3-diviny1 -1 , 1 ,3,3- tetramethyldisiloxane complex.

Example 2

Next, 85 parts by weight of Example 1 was mixed with 15 parts by weight of ELASTOSIL® V 1200 A, which is manufactured and sold by Wacker Chemie AG, using an internal 75 liter mixer, which was a Kneader Machinery model KD75-250. Adequate mixing time was applied to achieve a uniform blend. 70 parts by weight of mica (IMERYS Suzorite® 325-HK) and 0.6 parts by weight of a peroxide crosslinking agent (Varox® DBPH, Vanderbilt Chemicals) were also added. The mica is added in three equal portions over time with mixing between each addition. After all of the mica was added to the mixture, the crosslinking agent was added and mixed until the composition is uniform.

The composition of Example 2 was cured for 10 minutes at 350 °F. After curing, the composition of Example 2 exhibited a specific gravity of 1 .48, a tensile strength of 562 psi, an elongation at break of 252 percent, a Shore A hardness of 75, and a tear strength of 122 pounds per inch. The specific gravity, tensile strength at break, elongation at break, Shore A hardness, and tear strength were determined according to the methods specified above.

From the foregoing detailed description, it will be apparent that various modifications, additions, and other alternative embodiments are possible without departing from the true scope and spirit. The embodiments discussed herein were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to use the invention in various embodiments and with various modifications as are suited to the particular use contemplated. As should be appreciated, all such modifications and variations are within the scope of the invention.