Patent Application
20080216948
The present invention provides a method of using a hand-mouldable self-adhesive silicone elastomer composition, which readily cures and which can easily be moulded by the consumer into a wide variety of shapes, to form hand grips for a variety of implements, tools, kitchen equipment etc.
Hand mouldable RTV (Room Temperature Vulcanising) silicone compositions are known in the art (U.S. Pat. No. 3,943,091; GB2403723), and typically comprise either two part condensation or addition cure compositions. Compositions of this type have in the past been formulated primarily for mould making applications, where the elastomer is moulded onto a substrate to form a cast of the object, and then removed when cured to provide a mould for replication of the substrate. Such compositions are used in applications such as: rapid prototyping; reproduction of figurines, collectibles, jewellery, candles, and artefacts; creation of silicone rubber pads for transfer printing; and architectural fabrication. In all of these applications, the ability of the cured silicone elastomer to release cleanly from the substrate is crucial, and thus the composition should be non-adhesive.
There are many cases in which handles and grips of products and equipment of all kinds could be made more effective if there was a way in which consumers could more easily and successfully customize and individualise them for their individual comfort, fun or excitement.
We have now discovered that self adhesive, hand mouldable elastomers may also be used for the production of a composition which may be moulded by the consumer to produce a variety of different products. This invention is based on a two part RTV silicone composition. Compositions of this type are well known in the art. Once mixed completely, this composition may be moulded into any three dimensional shape, or may be moulded around other three dimensional objects to adapt or modify them. Once the desired shape is achieved, the composition will hold its shape without slump or flow during cure, and complete and consistent cure may be achieved, even for very thick profiles of 20 cm or more.
U.S. Pat. No. 4,696,842 describes the use of a sheet of polymeric material to produce a customisable hand grip for sports implements, hand tools etc. However, the sheet is of a polyurethane or a copolymer, such as styrene-butadiene rubber, rather than the silicone used in the present invention, and cures in a different way.
U.S. Pat. No. 5,155,878 provides a similar material to that described in U.S. Pat. No. 4,696,842, except that it is a two-layer construction designed to allow the hand grip to be remoulded to suit a variety of different individuals. No specific material is suggested for use in preparing such hand grips.
US2002010251 describes the use of a silicone composition which includes (A) an organopolysiloxane terminated with hydroxyl groups, having a viscosity of from 25 mPa·s to 1,000,000 mPa·s at 25° C.; (B) a hydrolysable silane or a partial hydrolysis-condensation product thereof; and (C) a water-containing wet-process silica having an average particle diameter of 100 μm or smaller, which is the chief source of water for the condensation curing reaction. However, this is primarily used for sealant applications.
Thus, the present invention consists in a method of providing a self-adhesive mouldable hand grip, which comprises mixing:
a) a first component comprising a room temperature vulcanising silicone composition; and
b) a second component, one of the first and second components comprising a moist, powdered filler, and the other of the first and second components comprising a hydrolysable cross-linking agent,
to produce a self-adhesive RTV silicone elastomer composition, applying the RTV silicone elastomer composition to a substrate, and moulding it by hand to form a grip.
The components used in the present invention may be packaged in a two part package, one part containing the first component, and the other containing the second component, together with associated instructions for use, and possibly ideas for using the material.
It is an advantage of the invention that a wide range of consumers will be able very easily to customize and improve their products and equipment without the need for any tools or equipment, power supply, high temperatures or solvents. In fact only the composition of the present invention and the user's fingers are needed.
It is another advantage of the invention that the composition is self-adhesive. It will bond permanently (unless purposely cut off) to a wide range of substrates including but not limited to wood, metal, glass, ceramics and plastics.
It is another advantage of the invention, that the consumer is able to remove (by simply cutting and prising off) and/or replace customisations they have made without damaging the original surface.
The composition is comfortable at a wide range of temperatures. It can be formed and cured at room temperature, and can be used to customize products/equipment for very hot and very cold environments without any change in state.
A further advantage of the invention is that the composition is temperature resistant. It can be applied easily by users to surfaces that become very hot for protection and safety for example on equipment and machinery, e.g. cooking equipment. In very cold conditions, the temperature resistant nature of the composition of the present invention becomes an advantage, giving users the opportunity to improve workability of equipment in these conditions—e.g. by applying to metal tools they can be used more comfortably without gloves.
These benefits are achieved by formulating a package comprising a self adhesive, two part room temperature vulcanising elastomer. The two components of the elastomer are conveniently and easily mixed and moulded by hand to any desired shape and, in the uncured form, adhere to a wide range of substrates such as wood, metal, glass, ceramic and plastic. Once moulded, the elastomers will hold their shape exactly during cure without slump or flow, and provide rapid and consistent deep section cure at room temperature cured elastomer is a non tacky elastomeric material with excellent tactility.
The invention is further illustrated by the accompanying drawings, in which:
In each case, in the Figures, the dark shaded area represents the composition of the present invention.
The package of the invention utilises a self adhesive, two part room temperature vulcanising silicone elastomer. The overall formulation includes a hydroxy terminated polyorganosiloxane, a tri or tetra functional hydrolysable silane crosslinker where the functional groups are selected from a group comprising alkoxy groups, alkenoxy groups, ketoxime groups and acyloxy groups, and one or more fillers, optionally containing water. The formulation may optionally contain other components such as a curing catalyst, trimethylsilyl terminated polyorganosiloxane, adhesion promoters, functional additives such as pigments, including environmentally sensitive pigments such as thermochromic or pH-sensitive dyes, or thermally or electrically conducting fillers, fragrances etc. These components can be packaged in a number of alternative formats to provide a convenient to use two part system.
In a preferred formulation, the first component comprises a hydroxy-terminated polyorganosiloxane, an effective quantity of a curing catalyst and one or more fillers optionally containing at least 5% by weight of water. The second component comprises hydroxy-terminated polyorganosiloxane, and a hydrolysable crosslinker. The second component may also optionally contain adhesion promoters, trimethylsilyl terminated polyorganosiloxane and/or additional fillers which must be dry. Other additives may be included in either component with the proviso that any water containing additives must be included in the first component.
In an alternative formulation, the first component comprises a hydroxy-terminated polyorganosiloxane, and one or more fillers optionally containing at least 5% by weight of water. The second component comprises an effective quantity of a curing catalyst, and a hydrolysable crosslinker. The second component may also optionally contain adhesion promoters, trimethylsilyl terminated polyorganosiloxane and/or additional fillers which must be dry. Other additives may be included in either component with the proviso that any water containing additives must be included in the first component.
In a further formulation, the first component comprises a hydroxy-terminated polyorganosiloxane and one or more fillers optionally containing at least 5% by weight of water, whilst the second component includes the hydrolysable crosslinker. The second component may also optionally contain an effective quantity of a condensation catalyst, adhesion promoters, trimethylsilyl terminated polyorganosiloxane and/or additional fillers which must be dry. Other additives may be included in either component with the proviso that any water containing additives must be included in the first component.
In yet another formulation, the first component comprises hydroxy-terminated polyorganosiloxane, the hydrolysable crosslinker, adhesion promoters, and optionally one or more fillers which must be dry. The second component comprises one or more fillers containing at least 5% by weight of water. These fillers may optionally be dispersed in a trimethylsilyl terminated polyorganosiloxane for ease of handling. Other additives may be included in either component with the proviso that any water-containing additives must be included in the second component. In this formulation, the first component must be packaged in an airtight container to prevent premature cure of the material. In this formulation, the filler in the second component must contain at least 5% water in order to ensure rapid deep section cure of the material.
The polyorganosiloxane preferably comprises a material of general formula HO—(R1R2SiO)n—H, where R1 and R2 are any monovalent hydrocarbon group such as alkyl radicals of 1 to 8 carbon atoms; mononuclear aryl radicals such as phenyl, methyl phenyl; cycloalkyl radicals such as cyclohexyl; and/or halogenated monovalent hydrocarbon radicals such as 3,3,3-trifluoropropyl; and n is a number such that the viscosity of the polymer lies in the range 25 mPa·s to 1,000,000 mPa·s at 25° C.
The hydrolysable crosslinker preferably comprises a hydrolysable silane of general formula RnSiX(4-n), wherein R represents a monovalent hydrocarbon group having from 1 to 12 carbon atoms; X represents a ketoxime group, an alkoxy group, an alkenoxy group or an acyloxy group; and n represents 0, 1 or 2, or a partial hydrolysis-condensation product thereof. Examples include, but are not limited to: hydrolysable silanes having a ketoxime group, e.g., dimethyldi(butanoxime)silane, methyltri(butanoxime)silane, vinyltri(butanoxime)silane, phenyltri(butanoxime)silane, propyltri(butanoxime)silane, tetra(butanoxime)silane, 3,3,3-trifluoropropyltri(butanoxime)silane, 3-chloropropyltri(butanoxime)silane, methyltri(propanoxime)silane, methyltri(pentanoxime)silane, methyltri(isopentanoxime)silane, vinyltri(cyclopentanoxime)silane and methyltri(cyclohexanoxime)silane; hydrolysable silanes having an alkoxy group, e.g., dimethyldimethoxysilane, methyltrimethoxysilane. vinyltrimethoxysilane, phenyltrimethoxysilane, methyltriethoxysilane, tetramethoxysilane and tetraethoxysilane; hydrolysable silanes having an alkenoxy group, e.g., vinyltripropenoxysilane and phenyltripropenoxysilane; and hydrolysable silanes having an acyloxy group, e.g., methyltriacetoxysilane, ethyltriacetoxysilane, phenyltriacetoxysilane, vinyltriacetoxysilane and tetraacetoxysilane.
The curing catalyst may be selected from a wide range of options including organometallic compounds, aminoalkyl-substituted alkoxysilanes, amine compounds, salts of the amine compound, quaternary ammonium salts, alkali metal lower fatty acid salts, dialkylhydroxylamines, silanes containing a guanidyl group, or siloxanes containing a guanidyl group, as is well known in the art.
Adhesion promoters may be compounds containing at least one alkoxysilyl, amino, epoxy, hydrosilyl, acrylic or a hydroxysilyl group, or a mixture of these. Preferred promoters include trimethoxysilanes such as 3-methacryloxypropyltrimethoxysilane, 3-glycidoxypropyltrimethoxysilane, aminopropyltrimethoxysilane, and alkyl or aryltrimethoxysilanes.
The filler may comprise a non reinforcing filler such as talc, calcium carbonate, wood powder, wheat flour, or an extending filler such as precipitated or fumed silica, or carbon black. More specifically, examples of such fillers include: calcium carbonate (such as dry ground grades of calcium carbonate, wet ground grades of calcium carbonate, beneficiated grades of calcium carbonate, precipitated grades of calcium carbonate, surface treated grades of calcium carbonate); kaolin and other clay-based minerals (such as water fractionated clays, air floated clays, delaminated clays, calcined clays, surface treated clays); talc (such as dry ground talc, beneficiated ground talc, calcined talc, surface-treated talc); quartz and silica, including natural silicas (such as crystalline silica, fused silica, microcrystalline silica, microcrystalline novaculite, diatomaceous silica, perlite) or synthetic silicas (such as fumed silica, precipitated silicas); mica (including ground grades of mica, white grades of mica, surface-modified grades of mica, metal-coated mica grades); metal oxides and other compounds (such as titanium dioxide, alumina trihydrate, wollastonite, barium sulphate, antimony oxide, magnesium hydroxide, calcium sulphate, anhydrous calcium sulphate, dihydrate calcium sulphate, feldspar and nepheline syenite); microspheres, solid microspheres, hollow microspheres (such as coated hollow microsphere fillers, metalite aluminium microspheres, metalite silver microspheres, magnetisable microspheres, hybrid composite microsphere fillers, mini-microspheres, polymer-encapsulated gas microspheres); synthetic silicates (such as aluminium silicate, mullite, sillimanite, cyanite, andalusite, synthetic alkali metal aluminosilicates, calcium silicate, zirconium silicate); carbon black (such as furnace black fillers, thermal black fillers); organic fillers (such as bagasse fillers, coconut hull/fibre fillers, cork fillers, corn cob fillers, cotton-based fillers, gilsonite fillers, nutshell flour fillers, rice hull fillers, sisal/hemp fillers, soybean fillers, starch fillers, wood flour); glass, metals and any solid polymer.
The filler may also include functional additives such as pigments, including environmentally sensitive pigments such as thermochromic or pH-sensitive dyes, thermally insulating fillers, or thermally or electrically conducting fillers. The moist filler must have a moisture content of no less than 1%, preferably no less than 5% by weight. There is no specific limitation on the maximum moisture content of the filler; however in general, the maximum moisture content would normally be no more than 25% by weight. The moisture content is more preferably from 5% to 15% by weight. Where varied texture and surface characteristics are required e.g. to achieve increased ‘grip’ or ‘non-slip’ or aesthetic variety, loose powders/particles may be supplied and pressed into the surface by the user. For this same purpose, surface moulds may be supplied and pressed into the surface by the user to emboss a texture, or to brand a product.
These formulations provide easily mouldable, self adhesive elastomers that cure rapidly and consistently in deep section at room temperature. Similar formulations are known in the art (US2002010251, U.S. Pat. No. 5,346,940) but they are formulated primarily for industrial applications such as forming gaskets or as sealants or coating materials. They have never been used for the applications envisaged by this present invention or been formulated and packaged for the easy, safe and convenient use by non-experts in a consumer environment.
The self adhesive, two part room temperature vulcanising silicone elastomer, may be packaged and delivered to the consumer in a number of straightforward and user-friendly ways. In the simplest format, the two components may be supplied in simple resealable containers such as screw top jars. The user simply mixes appropriate, e.g. equal or approximately equal, quantities of the two components, kneads by hand to ensure complete mixing, and then moulds to shape for the desired application. Optionally, the two components may be coloured with different pigments to assist the user in determining when a complete mix has been achieved. Alternatively, the two components may be packaged in premeasured portions, for example in a blister pack, in order to simplify measurement of the correct doses of each component. The two components may also be packaged in tubes such as those typically used for sealants, or squeezable tubes similar to toothpaste tubes. This latter packaging is particularly desirable for the alternative formulation described above where the first component must be stored in an airtight container. The components may also be packaged in laminated layers in sheets, or in concentric layers, and suitable portions may be cut off by the user and kneaded by hand to form the curable elastomer.
The cure time and consistency of cure is unaffected by the size or thickness of the object moulded. For example, objects with a cross section of up to 170 mm have been prepared which cure completely and consistently in the same time as objects of much smaller cross section. In principle, objects of any size could be prepared without compromise to cure speed or consistency.
The ease of handling of these compositions and their ability to adhere to many substrates opens up a very wide range of applications for the invention in both consumer and industrial markets. The compositions can be used by end-users to adapt and modify existing products to their individual and specific needs, or to create new products. The invention can be used in applications as areas such as (but not limited to):
The invention is further illustrated by the following non-limiting Examples.
The procedure for Examples 1-7 below is as follows:
The powder mix (part b), comprising filler and optional pigment, was premixed as a dry powder. The silicone polymer was then weighed and kneaded by hand into the powder mix for approximately 3 minutes to form a consistent compound that was dry to the touch and no longer tacky. The compound was then shaped for the desired application and allowed to cure. Cure was considered complete when the shaped polymer could no longer be reshaped and had reached a consistent hardness.
(b) Filler: Mix of wheat flour (moisture content about 11% by weight) and wood powder (moisture content about 6% by weight) in the proportion 55% Flour/45% Wood powder by weight
Ratio Polymer: Filler 55%:45% by weight
The same wheat flour and wood powder were used in the Examples hereafter.
After compounding, the elastomer was moulded into a ball and allowed to cure. The elastomer was fully cured after three hours. This formulation was found to provide the best qualitative balance of materials properties, namely surface texture, overall material texture, durability/tear resistance and adhesion to other materials. The particle size distribution for the filler is as shown in Table 1.
Ratio Polymer: Filler 55%:45% by weight
After compounding, the elastomer was moulded into a ball and allowed to cure. The elastomer was fully cured after three hours. This formulation was found to provide the best qualitative performance for surface texture and overall material texture. The particle size distribution for the filler is as shown in Table 2.
Ratio Polymer: Filler 55%:45% by weight
After compounding, the elastomer was moulded into a ball and allowed to cure. The elastomer was fully cured after three hours. This formulation was found to provide the best qualitative performance for durability and tear resistance. The particle size distribution for the filler is as shown in Table 3.
Ratio Polymer: Filler 55%:45% by weight
After compounding, the elastomer was moulded into a ball and allowed to cure. The elastomer was fully cured after three hours. This formulation was found to provide the best qualitative performance for adhesion to other materials. The particle size distribution for the filler is as shown in Table 4.
Ratio Polymer: Filler 50%:50% by weight
After compounding, the elastomer was moulded into a ball and allowed to cure. The elastomer cured more rapidly than those described in Examples 1-4, with the shape of the moulded ball fixed after approximately 10 minutes and was fully cured after 40 minutes.
This example demonstrates the effect of the moisture content of the filler on cure performance
Ratio Polymer: Filler 50%:50% by weight
Flour particles were dried 3 times in the oven at 170° C. for 2 hours each time.
Two identical mixes were made; composition A using dried filler and composition B using non-dried filler. Each composition comprising 15 g silicone and 15 g filler, was mixed for 3 minutes in a similar manner, and was allowed to cure in the same conditions.
Composition A was found to be much stiffer and less malleable and also less sticky/less adhesive than composition B. Composition A was not at all tacky to touch while composition B was slightly tacky but still convenient to work. Composition B was also much smoother when shaped while the surface of composition A tended to crack when being moulded.
Table 5 compares the properties of compositions A and B during cure.
The effect of drying the filler can be summarised as:
1. Makes the formulation more difficult to shape and smooth.
2. Reduces adhesiveness of formulation.
3. Extended cure times and inconsistent cure.
Ratio Polymer: Filler 50%:50% by weight
When mixed this composition was divided into two samples. Sample 1: 3100 g and 170 mm diameter; and Sample 2: 50 g and 45 mm diameter.
In both cases the samples cured completely in 3.5 hours. After this time both samples were cut in half and were found to be completely cured throughout the sample. This experiment demonstrates that very deep section, consistent cure can be achieved with this invention. The cross sections are shown in
In this example, a two part formulation was developed in which both components have a putty like consistency prior to mixing and curing. The formulation of the two components is as shown in Table 6:
Component A was prepared by preblending the water with the fillers, then in turn blending this with the hydroxy-terminated polydimethylsiloxane and then the catalyst. Component B was made in a similar way (excluding water), replacing the catalyst with the silane mixture which acts as both crosslinker and adhesion promoter. Equal parts of component A and B were then moulded together by hand. Cure was complete within 10 minutes, and the material showed good adhesion to a range of substrates including glass, wood and metal.
In this example, a putty like component A is blended with component B which includes both crosslinker and curing catalyst. The component formulations are as shown in Table 7:
To produce a cured elastomer, 19 g of component A was mixed with 2 ml of component B, and 1 ml of Aminopropyltrimethoxysilane (Dow Corning Z-6020 Silane). The components were mixed manually for 90 seconds and the cure observed. Complete cure of the sample took approximately two hours, with a sample working time of approximately 10 minutes. Adhesion to a range of substrates was tested and good adhesion to glass, metal and wood was observed. Complete and consistent deep section cure of the sample was achieved.
It can be seen from the Examples above that the compositions of the present invention have several advantages, specifically:
| Number | Date | Country | Kind |
|---|---|---|---|
| 0510949.1 | May 2005 | GB | national |
| 0526179.7 | Dec 2005 | GB | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/GB2006/001931 | 5/26/2006 | WO | 00 | 5/2/2008 |
