SILICONE-BASED THERMOPLASTIC MATERIALS FOR 3D-PRINTING

Abstract

The invention relates to a process for preparing a polyurea or a polyurethane organopolysiloxane block copolymer having a silicone content of at least 90% in weight relative to the total weight of the organosiloxane block copolymer. The invention further relates to a polyurea or a polyurethane organopolysiloxane block copolymer obtained according to this process and its use in a method for manufacturing a 3D article by an additive technique.

Claims

1.-23. (canceled)

24. A process for preparing a polyurea or polyurethane organopolysiloxane block copolymer (I) having a silicone content of at least 90% in weight relative to the total weight of the organosiloxane block copolymer and comprising the steps of: 1) providing the following compounds: a) a long-chain hydroxyl or amino difunctionalised polysiloxane of formula (A): ##STR00008## b) a chain extender which is a short-chain hydroxyl or amino difunctionalised polysiloxane of formula (B): ##STR00009## c) at least one diisocyanate of formula (C):
O═C═N—Y—N═C═O  (C), d) optionally a branching agent which is a hydroxyl or amino monofunctional polysiloxane of formula (D): ##STR00010## e) and a catalyst (E), 2) adding Nb mol of the chain extender of formula (B), Nc mol of the at least one diisocyanate of formula (C) and optionally Nd mol of the branching agent of formula (D), to Na mol of the long-chain hydroxyl or amino difunctionalised polysiloxane of formula (A), wherein: -Q-, -T- and —X— are identical or different, and represent a (C1-C20) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represent a (C6-C22) arylene group, -M, —W and —Z are identical or different, and represent —OH or —NHR′, with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-22) aryl group, —U is a (C1-C20) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C22) aryl group, —Y— represents a (C1-C36) alkylene group, a (C6-C13) arylene group or an organopolysiloxane, —R1, —R2 and —R3 are identical or different, and represent a (C1-C20) alkyl group, eventually substituted by one or more —F and/or —Cl, a is an integer ranging from 30 to 1000, b is an integer ranging from 2 to 15, c is an integer ranging from 10 to 200, d is an integer ranging from 10 to 200, the ratio a/b ranges from 2 to 200, the molar ratio Nb/(Na+Nb+Nd) ranges from 5% to 60%, the molar ratio Nc/(Na+Nb+Nc+Nd) ranges from 45 to 55%, the molar ratio Nd/(Na+Nd) ranges from 0 to 20%, and the hard segment ratio ranges from 1 to 94%, the hard segment ratio being defined by HS=(Nb*Mb+Nc*Mc)/(Na*Ma+Nb*Mb+Nc*Mc+Nd*Md), with Ma, Mb, Mc and Md representing respectively the molecular weight of compounds of formula (A), (B), (C) and (D).

25. The process according to claim 24 wherein —R1, —R2 and —R3 are identical or different and represent a (C1-C10) alkyl group, optionally substituted by —F and/or —Cl.

26. The process according to claim 24 wherein -Q-, -T- and —X— are identical or different and represent a (C1-C10) alkylene group.

27. The process according to claim 24 wherein -M, —W and —Z are identical.

28. The process according to claim 24 wherein —Y— represents a (C3-C13) alkylene.

29. The process according to claim 24 wherein only one diisocyanate of formula (C) is used.

30. The process according to claim 24 wherein the at least one diisocyanate of formula (C) is present in stoichiometric proportions compared to compounds of formula (A), (B) and (D) if present, meaning that the value of the stoichiometric index ratio Ic is equal to 1, the stoichiometric index ratio being defined by Ic=2Nc/(2Na+2Nb+Nd).

31. The process according to claim 24 wherein the at least one diisocyanate (C) is present in non-stoichiometric proportions compared to compounds of formula (A), (B) and (D) if present, meaning that the value of the stoichiometric index ratio Ic is different from 1, the stoichiometric index ratio being defined by Ic=2Nc/(2Na+2Nb+Nd).

32. The process according to claim 24 wherein the catalyst (E) is chosen among copper based catalysts, zirconium based catalysts, tin based catalysts and titanium based catalysts.

33. The process according to claim 24, wherein the reaction is carried out in a chemical reactor.

34. The process according to claim 33 wherein the long-chain polysiloxane of formula (A) is dissolved in a solvent, or a mixture of solvents, before the addition of the chain extender of formula (B), the at least one diisocyanate of formula (C), optionally the branching agent of formula (D), and the catalyst (E).

35. The process according to claim 33 wherein the chain extender of formula (B), the at least one diisocyanate of formula (C), the branching agent of formula (D) if present, and the catalyst (E) are added simultaneously to the long-chain polysiloxane of formula (A).

36. The process according to claim 33 wherein the chain extender of formula (B), the at least one diisocyanate of formula (C), the branching agent of formula (D) if present, and the catalyst (E) are added one after the other to the polysiloxane of formula (A), in any order.

37. The process according to claim 24 wherein the reaction is carried out in an extruder and the catalyst (E) is introduced in the first heating zone of the extruder.

38. The process according to claim 37 wherein the polysiloxane of formula (A), the chain extender of formula (B), the at least one diisocyanate of formula (C), the branching agent of formula (D) if present, and the catalyst (E) are all introduced in the first heating zone of the extruder.

39. The process according to claim 37 wherein the polysiloxane of formula (A) is introduced in the first heating zone of the extruder, and at least one of the chain extender of formula (B), the at least one diisocyanate of formula (C), the branching agent of formula (D) if present, and the catalyst (E) are introduced in the second or subsequent heating zone of the extruder.

40. The polyurea or polyurethane organopolysiloxane block copolymer (I) obtained according to the process according to claim 24.

41. The polyurea or polyurethane organopolysiloxane block copolymer (I) according to claim 40 having a hardness ranging from 0 to 60 Shore A.

42. The polyurea or polyurethane organopolysiloxane block copolymer (I) according to claim 40 having an elongation at break of at least 200%.

43. The polyurea or polyurethane organopolysiloxane block copolymer (I) according to claim 40 having a melting temperature ranging from 70 to 140° C.

44. The polyurea or polyurethane organopolysiloxane block copolymer (I) according to claim 40 having a melt flow index ranging from 1 to 100 cm.sup.30.10 min.sup.−1 at 120° C. under 2.16 kg.

45. Method for manufacturing a 3D article by an additive technique using the polyurea or polyurethane organopolysiloxane block copolymer (I) according to claim 40.

46. The method according to claim 45 wherein the 3D article is manufactured with a 3D printer selected from a fused filament fabrication printer, a syringe extrusion printer, a droplet deposit printer, a selective laser sintering printer, a selective laser melting printer, and a material jet printer.

Description

[0062] FIG. 1 represents an ear model printed with the silicone based polyurea copolymer CP1.2.

[0063] FIG. 2 represents an ear model printed with the silicone based polyurea copolymer CP1.2.

[0064] FIG. 3 represents dumbbells printed with copolymer CP1.4.

[0065] FIG. 4 represents dumbbells printed with copolymer CP1.4.

[0066] Process of Manufacturing a Polyurea or Polyurethane Organopolysiloxane Block Copolymer According to the Invention

[0067] According to a first aspect, the invention relates to a process for preparing a polyurea or polyurethane organopolysiloxane block copolymer I, abbreviated CP hereafter. This CP is prepared by reaction of a long-chain hydroxyl or amino difunctionalised polysiloxane, a chain extender which is a short-chain hydroxyl or amino difunctionalised polysiloxane, at least one diisocyanate, optionally a branching agent which is a hydroxyl or amino monofunctional polysiloxane, and a catalyst.

[0068] Long-Chain Hydroxyl or Amino Difunctionalised Polysiloxane

[0069] According to the invention, the long chain hydroxyl or amino difunctionalised polysiloxane is of formula A:

##STR00004##

wherein: [0070] -Q- represents a (C1-C20) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C22) arylene group, [0071] —W represents —OH or —NHR′, with R′ representing —H, a (C1-C10) alkyl group, or a (C6-22) aryl group, [0072] —R1 represents a (C1-C20) alkyl group, eventually substituted by one or more —F and/or —Cl, and [0073] a is an integer ranging from 30 to 1000.

[0074] By “alkylene”, it is meant a divalent alkyl group. Unless otherwise specified, the alkyl group may be branched or linear.

[0075] By “arylene”, it is meant a divalent aryl group.

[0076] By “aryl”, it is meant, unless otherwise specified, a mono-, bi- or polycyclic insaturated hydrocarbonated 5-24 membered ring comprising at least one aromatic ring. Phenyl, naphtyl, anthrancenyl, phenanthrenyl and cinnamyl are example of aryl groups.

[0077] Advantageously, —W represents —NHR′. According to this embodiment, —R′ is preferably chosen among —H, a (C1-C10) alkyl group, and a (C6-18) aryl group, more preferably among —H, a (C1-C6) alkyl group, and a (C6-10) aryl group, and even more preferably among —H, a (C1-C6) alkyl group, and a C6-aryl group. In a particularly preferred embodiment, —R′ is chosen among —H, and a (C1-C6) alkyl group such as methyl, ethyl, propyl, butyl, pentyl and hexyl. In a particular embodiment, —W represents —NH.sub.2.

[0078] While not preferred, —W may represent —OH.

[0079] Advantantageously, -Q- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or a (C6-C10) arylene group, and even more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a C6-arylene group. Particularly preferred -Q- groups are (C1-C10) alkylene group, preferably (C2-C10) alkylene group, even more preferably (C2-C6) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—. In a preferred embodiment no —CH.sub.2— of -Q- is replaced by —O—. As examples of preferred -Q groups, ethylene, propylene, butylene, pentylene and hexylene may be cited, and in particular propylene.

[0080] Advantageously, —R1 represents a (C1-C10) alkyl group, eventually substituted by one or more —F and/or —Cl, preferably a (C1-C6) alkyl group eventually substituted by one or more —F and/or —Cl. Preferably, —R1 is not substituted by any —F and/or —Cl. Examples of particularly preferred —R1 groups are methyl, ethyl, propyl, butyl, pentyl and hexyl groups, and in particular methyl.

[0081] Advantageously, a is an integer ranging from 30 to 1000, preferably from 30 to 700, even more preferably from 30 to 400, and even more preferably 30 to 150.

[0082] In a particular embodiment, —W represents —NHR′ with —R′ as defined above, and -Q- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group.

[0083] In a particular embodiment, —W represents —NHR′ with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, and -Q-represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—.

[0084] In a particular embodiment, —W represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and -Q-represents a (C2-C10) alkylene group.

[0085] In a particular embodiment, —W represents —NH.sub.2 and -Q- represents a (C2-C6) alkylene group.

[0086] In a particular embodiment, —R1 represents (C1-C10) alkyl group eventually substituted by one or more —F and/or —Cl, —W represents —NHR′ with —R′ as defined above, and -Q- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group.

[0087] In a particular embodiment, —R1 represents a (C1-C6) alkyl group eventually substituted by one or more —F and/or —Cl, —W represents —NHR′ with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, and -Q- represents a (C2-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—.

[0088] In a particular embodiment, —R1 represents a (C1-C6) alkyl group, —W represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and -Q- represents a (C2-C10) alkylene group.

[0089] In a particular embodiment, —R1 represents a methyl group, —W represents —NH.sub.2 and -Q- represents a (C2-C6) alkylene group.

[0090] In a preferred embodiment, —R1 represents (C1-C10) alkyl group eventually substituted by one or more —F and/or —Cl, —W represents —NHR′ with —R′ as defined above, and -Q- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group and a is an integer ranging from 30 to 1000, preferably 30 to 700.

[0091] In a particularly preferred embodiment, —R1 represents a methyl group, —W represents —NH.sub.2, -Q- represents a (C2-C6) alkylene group, and a is an integer ranging from 30 to 150.

[0092] As example of long chain hydroxyl or amino difunctionalised polysiloxane of formula A that may be used in the context of the invention, one may cite bisaminopropyl-terminated polydimethylsiloxane, such as Silmer NH Di-50 sold by Siltech.

[0093] Chain Extender

[0094] According to the invention, the chain extender is a short-chain hydroxyl or amino difunctionalised polysiloxane of formula B:

##STR00005##

wherein: [0095] —X— represents a (C1-C20) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C22) arylene group, [0096] -M represents —OH or —NHR′, with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-22) aryl group, [0097] —R2 represents a (C1-C20) alkyl group, eventually substituted by one or more —F and/or —Cl, [0098] b is an integer ranging from 2 to 15.

[0099] Advantageously, —X— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or a (C6-C10) arylene group, and even more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a C6-arylene group. Particularly preferred —X— groups are (C1-C10) alkylene group, more preferably (C2-C10) alkylene group, even more preferably (C2-C6) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—. In a preferred embodiment, no —CH.sub.2— of —X— is replaced by —O—. As examples of preferred —X— groups, ethylene, propylene, butylene, pentylene and hexylene may be cited, and in particular propylene.

[0100] Advantageously, -M represents —NHR′. According to this embodiment, —R′ is preferably chosen among —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, more preferably among —H, a (C1-C6) alkyl group, or a (C6-10) aryl group, and even more preferably among —H, a (C1-C6) alkyl group, or a C6-aryl group. In a particularly preferred embodiment, —R′ is chosen among —H, and a (C1-C6) alkyl group such as methyl, ethyl, propyl, butyl, pentyl and hexyl. In a particular embodiment, -M represents —NH.sub.2.

[0101] Advantageously, —R2 represents a (C1-C10) alkyl group, eventually substituted by one or more —F and/or —Cl, preferably a (C1-C6) alkyl group eventually substituted by one or more —F and/or —Cl. Preferably, —R2 is not substituted by any —F and/or —Cl. Examples of particularly preferred —R2 groups are methyl, ethyl, propyl, butyl, pentyl and hexyl groups and in particular methyl.

[0102] Advantageously, b represents an integer ranging from 4 to 15, and preferably from 4 to 10.

[0103] In a particular embodiment, -M represents —NHR′ with —R′ as defined above, and —X— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group.

[0104] In a particular embodiment, -M represents —NHR′ with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, and —X— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—.

[0105] In a particular embodiment, -M represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and —X— represents a (C2-C10) alkylene group.

[0106] In a particular embodiment, -M represents —NH.sub.2 and —X— represents a (C2-C6) alkylene group.

[0107] In a particular embodiment, —R2 represents (C1-C10) alkyl group eventually substituted by —F and/or —Cl, -M represents —NHR′ with —R′ as defined above, and —X— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group.

[0108] In a particular embodiment, —R2 represents a (C1-C6) alkyl group eventually substituted by —F and/or —Cl, -M represents —NHR′ with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, and —X represents a (C2-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—.

[0109] In a particular embodiment, —R2 represents a (C1-C6) alkyl group, -M represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and —X— represents a (C2-C10) alkylene group.

[0110] In a particular embodiment, —R2 represents a methyl group, -M represents —NH.sub.2 and —X— represents a (C2-C6) alkylene group.

[0111] In a preferred embodiment, —R2 represents (C1-C10) alkyl group eventually substituted by —F and/or —Cl, -M represents —NHR′ with —R′ as defined above, —X— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, and b is an integer ranging from 4 to 15.

[0112] In a particularly preferred embodiment, —R2 represents a (C1-C6) alkyl group, -M represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, —X— represents a (C2-C10) alkylene group, and b is an integer ranging from 4 to 10.

[0113] As example of chain extender that may be used in the context of the invention, one may cite bisaminopropyl-terminated polydimethylsiloxane, such as Silmer NH Di-8 sold by Siltech.

[0114] Diisocyanate

[0115] According to the invention, the diisocyanate(s) that may be used is of formula C:

O═C═N—Y—N═C═O  (C),

[0116] wherein —Y— represents a (C1-C36) alkylene group, a (C6-C13) arylene group, or represents an organopolysiloxane.

[0117] When —Y— represents an organopolysiloxane, it may be of formula F:

##STR00006##

[0118] wherein: [0119] —P— represents a (C1-C20) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C22) arylene group, [0120] —Ra and —Rb are identical or different and each represents a (C1-C20) alkyl group, eventually substituted by one or more —F and/or —Cl, [0121] n is an integer ranger from 4 to 50.

[0122] Advantageously, —P— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or a (C6-C10) arylene group, and even more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a C6-arylene group. Particularly preferred —P— groups are (C2-C10) alkylene group, preferably (C2-C6) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—. In a preferred embodiment, no —CH.sub.2— of —P— is replaced by —O—. As examples of preferred —P— groups, ethylene, propylene, butylene, pentylene and hexylene may be cited, and in particular —(CH.sub.2).sub.3—.

[0123] Advantageously, —Ra and —Rb are identical or different and each represents a (C1-C10) alkyl group, eventually substituted by one or more —F and/or —Cl, preferably a (C1-C6) alkyl group eventually substituted by one or more —F and/or —Cl. Preferably, —Ra and —Rb are not substituted by any —F and/or —Cl. Examples of particularly preferred —Ra and —Rb groups are methyl, ethyl, propyl, butyl, pentyl and hexyl groups, and in particular methyl group. Preferably, —Ra and —Rb are identical.

[0124] Preferably, n is an integer ranging from 6 to 30.

[0125] In a particular embodiment, —P— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, and —Ra and —Rb are identical or different and both represent a (C1-C10) alkyl group, eventually substituted by one or more —F and/or —Cl.

[0126] In a particular embodiment, —P— represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a C6-arylene group and —Ra and —Rb are identical or different and both represent a (C1-C6) alkyl group, eventually substituted by one or more —F and/or —Cl.

[0127] In a preferred embodiment, —P— represents a (C2-C10) alkylene group, preferably (C2-C6) alkylene group, and —Ra and —Rb are identical or different and both represent a (C1-C6) alkyl group.

[0128] In a particularly preferred embodiment, —P— represents a propylene group and —Ra and —Rb both represent a methyl.

[0129] Diisocyanates of formula C may be aliphatic or aromatic diisocyanates.

[0130] Examples of aliphatic diisocyanates are isophorone diisocyanate, hexamethylene 1,6-diisocyanate, tetramethylene 1,4-diisocyanate, dimeryl diisocyanate and methylenedicyclohexyl 4,4′-diisocyanate. A particularly preferred aliphatic diisocyanate is hexamethylene 1,6-diisocyanate.

[0131] Examples of aromatic diisocyanates are methylenediphenyl 4,4′-diisocyanate, 2,4-toluene diisocyanate, 2,5-toluene diisocyanate, 2,6-toluene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, m-xylene diisocyanate, tetramethyl m-xylene diisocyanate, naphthalene 1,5-diisocyanate or mixtures of these isocyanates.

[0132] In a preferred embodiment, diisocyanates of formula C are aliphatic diisocyanates. According to this embodiment, —Y— preferably represents a (C2-C36) alkylene, preferably a (C2-C20) alkylene not substituted by any —Cl and/or —F, and even more preferably a (C3-C13) alkylene.

[0133] An example of commercially available compounds are the diisocyanates of the DESMODUR(R) series (H, I, M, T, W) from Bayer AG, Germany.

[0134] Branching Agent

[0135] According to the invention, the branching agent is a hydroxyl or amino monofunctional polysiloxane of formula D:

##STR00007##

[0136] wherein: [0137] -T- represents a (C1-C20) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C22) arylene group, [0138] —Z represents —OH or —NHR′, with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-22) aryl group, [0139] —U is a (C1-C20) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C22) aryl group, [0140] —R3 represents a (C1-C20) alkyl group, eventually substituted by one or more —F and/or —Cl, [0141] c is an integer ranging from 10 to 200, and [0142] d is an integer ranging from 10 to 200.

[0143] Advantageously, -T- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or a (C6-C10) arylene group, and even more preferably (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a C6-arylene group. Particularly preferred -T- groups are (C1-C10) alkylene group, more preferably (C2-C10) alkylene group, even more preferably (C2-C6) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—. In a preferred embodiment no —CH.sub.2— of -T- is replaced by —O—. As examples of preferred -T- groups, ethylene, propylene, butylene, pentylene and hexylene may be cited, and in particular ethylene.

[0144] Advantageously, —Z represents —NHR′. According to this embodiment, —R′ is preferably chosen among —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, more preferably among —H, a (C1-C6) alkyl group, or a (C6-10) aryl group, and even more preferably among —H, a (C1-C6) alkyl group, or a C6-aryl group. In a particularly preferred embodiment, —R′ is chosen among —H, and a (C1-C6) alkyl group such as methyl, ethyl, propyl, butyl, pentyl and hexyl. In a particular embodiment, —Z represents —NH.sub.2.

[0145] Advantageously, —R3 represents a (C1-C10) alkyl group, eventually substituted by one or more —F and/or —Cl, preferably a (C1-C6) alkyl group eventually substituted by one or more —F and/or —Cl. Preferably, —R3 is not substituted by any —F and/or —Cl. Examples of particularly preferred —R3 groups are methyl, ethyl, propyl, butyl, pentyl and hexyl groups, and in particular methyl.

[0146] Advantageously, —U represents a (C1-C10) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) aryl group. Preferably, —U represents a (C1-C6) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C10) aryl group. Even more preferably, —U represents a (C1-C6) alkyl group, or represents a C6-aryl group. Examples of particularly preferred —U groups are phenyl, methyl, ethyl, propyl, butyl, pentyl, hexyl, phenyloxy, methyloxy, ethyloxy, propyloxy, butyloxy, pentyloxy, and hexyloxy groups, and in particular, ethyloxy, propyloxy.

[0147] Advantageously, c represents an integer ranging from 10 to 150, preferably from 50 to 150, and even more preferably from 50 to 120.

[0148] Advantageously, d represents an integer ranging from 10 to 150, preferably from 50 to 150, and even more preferably from 50 to 120.

[0149] In a particular embodiment, both c and d represent an integer ranging from 10 to 150, and preferably from 50 to 120.

[0150] In a particular embodiment, —Z represents —NHR′ with —R′ as defined above, and -T- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group.

[0151] In a particular embodiment, —Z represents —NHR′ with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, and -T- represents a (C2-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—.

[0152] In a particular embodiment, —Z represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and -T- represents a (C2-C10) alkylene group.

[0153] In a particular embodiment, —Z represents —NH.sub.2 and -T- represents a (C2-C6) alkylene group.

[0154] In a particular embodiment, —R3 represents (C1-C10) alkyl group eventually substituted by one or more —F and/or —Cl, —Z represents —NHR′ with —R′ as defined above, —U represents a (C1-C10) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) aryl group and -T- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group.

[0155] In a particular embodiment, —R3 represents a (C1-C6) alkyl group eventually substituted by one or more —F and/or —Cl, —Z represents —NHR′ with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, —U represents a (C1-C6) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C10) aryl group and -T- represents a (C2-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—.

[0156] In a particular embodiment, —R3 represents a (C1-C6) alkyl group, —Z represents —NHR′ with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and -T- represents a (C2-C10) alkylene group.

[0157] In a particular embodiment, —R3 represents a methyl group, —Z represents —NH.sub.2, —U represents a (C1-C6) alkyl group, or represents a C6-aryl group, and -T- represents a (C2-C6) alkylene group.

[0158] In a preferred embodiment, —R3 represents a (C1-C10) alkyl group eventually substituted by —F and/or —Cl, —Z represents —NHR′ with —R′ as defined above, —U represents a (C1-C10) alkyl group eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) aryl group, and -T- represents a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) arylene group, c and d are both integer ranging from 50 to 150.

[0159] In a particularly preferred embodiment, —R3 represents a methyl group, —Z represents —NH.sub.2, —U represents a (C1-C6) alkyl group or represents a C6-aryl group, and -T- represents a (C2-C6) alkylene group, c and d are both integer ranging from 50 to 120.

[0160] As a particular branching agent, one may cite branched monoaminoethyl-functional polydimethylsiloxane.

[0161] Catalyst

[0162] According to the invention, the CP is synthetized using a catalyst E.

[0163] Suitable catalysts are organometallic compounds such as tin-based, titanium-based, copper-based or zirconium-based compounds. In particular, suitable catalysts may be chosen among dialkyl tin derivatives, alkyl titanium derivatives, ester zirconium derivatives and keto copper derivatives.

[0164] According to a first embodiment, the catalyst E is a tin based catalyst. Examples of tin based catalysts that may be used in the process according to the invention are tributyltin methanolate, dilaurate dibutyltin, octoate dibutyltin, and dialkyltin dicarboxylate.

[0165] According to a second embodiment, the catalyst E is a titanium based catalyst, such as tetra-n-butyl titanate, titanium (triethanolaminato)isopropoxide, and titanium 2-ethylhexyloxide.

[0166] According to a third embodiment, the catalyst E is a copper based catalyst, such as β-diketoester, and β-dikenato copper complexes.

[0167] According to a third embodiment, the catalyst E is a zirconium based catalyst, such as tetrakis(2,4-pentanedionate) zirconium, monoalcoholate zirconium, and zirconium acetylacetonate.

Preferred Embodiments

[0168] According to an embodiment: [0169] -Q-, -T- and —X— are identical or different, and represent a (C1-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represent a (C6-C18) arylene group, [0170] -M, —W and —Z are identical or different, and represent —NHR′, with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-22) aryl group, [0171] —U is a (C1-C10) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C18) aryl group, [0172] —Y— represents a (C2-C36) alkylene, [0173] —R1, —R2 and —R3 are identical or different, and represent a (C1-C10) alkyl group, eventually substituted by one or more —F and/or —Cl, [0174] a is an integer ranging from 30 to 1000, [0175] b is an integer ranging from 2 to 15, [0176] c is an integer ranging from 10 to 200, [0177] d is an integer ranging from 10 to 200, [0178] the ratio a/b ranges from 2 to 200.

[0179] According to another embodiment: [0180] -Q-, -T- and —X— are identical or different, and represent a (C2-C10) alkylene group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represent a (C6-C18) arylene group, [0181] -M, —W and —Z are identical or different, and represent —NHR′, with —R′ representing —H, a (C1-C10) alkyl group, or a (C6-18) aryl group, [0182] —U is a (C1-C6) alkyl group, eventually in which one or more —CH.sub.2— are replaced by —O—, or represents a (C6-C10) aryl group, [0183] —Y— represents a (C2-C20) alkylene, [0184] —R1, —R2 and —R3 are identical or different, and represent a (C1-C6) alkyl group, eventually substituted by one or more —F and/or —Cl, [0185] a is an integer ranging from 30 to 700, [0186] b is an integer ranging from 4 to 15, [0187] c is an integer ranging from 10 to 150, [0188] d is an interger ranging from 10 to 150, [0189] the ratio a/b ranges from 2 to 100.

[0190] According to Another Embodiment: [0191] -Q-, -T- and —X— are identical or different, and represent a (C2-C10) alkylene group, or represent a (C6-C10) arylene group, [0192] -M, —W and —Z are identical or different, and represent —NHR′, with —R′ representing —H, a (C1-C6) alkyl group, or a C6-aryl group, and preferably —H, [0193] —U is a (C1-C6) alkyl group, [0194] —Y— represents a (C3-C13) alkylene, [0195] —R1, —R2 and —R3 are identical or different, and represent a (C1-C6) alkyl group, [0196] a is an integer ranging from 30 to 400, [0197] b is an integer ranging from 4 to 10, [0198] c is an integer ranging from 50 to 150, [0199] d is an integer ranging from 50 to 150, [0200] the ratio a/b ranges from 3 to 40.

[0201] Advantageously, the ratio a/b ranges from 2 to 200, preferably from 2 to 100, more preferably from 3 to 40 and even more preferably from 6 to 15.

[0202] Advantageously, —R1, —R2 and —R3 are identical, and preferably represent a (C1-C6) alkyl group.

[0203] Advantageously, -Q-, -T- and —X— are identical and preferably represent a (C2-C10) alkylene group.

[0204] Advantageously, -M, —W and —Z are identical and preferably represent NH.sub.2.

[0205] According to Another Embodiment: [0206] -Q-, -T- and —X— are identical or different, and represent a (C2-C6) alkylene group, or represent a C6-aryl group, [0207] -M, —W and —Z are identical or different, and represent —NHR′, with —R′ representing —H, a (C1-C6) alkyl group and preferably —H, [0208] —U is a (C1-C6) alkyl group, [0209] —Y— represents a (C3-C13) alkylene, [0210] —R1, —R2 and —R3 are identical or different, and represent a (C1-C6) alkyl group, [0211] a is an integer ranging from 30 to 150, [0212] b is an integer ranging from 4 to 10, [0213] c is an integer ranging from 50 to 120, [0214] d is an integer ranging from 50 to 120, [0215] the ratio a/b ranges from 6 to 15.

[0216] Reaction Conditions

[0217] According to a preferred embodiment, only one diisocyanate is used in the process of manufacturing according to the invention. While not preferred, more than one diisocyanate may be used, and for example 2 or 3 diisocyanates. In this latest embodiment, the diisocyanates may be introduced all at the same time, or stepwise.

[0218] In the context of the invention, Na, Nb, Nc, and Nd represent respectively the number of moles of the long-chain hydroxyl or amino difunctionalised polysiloxane of formula A, the chain extender of formula B, the at least one diisocyanate of formula C, and the branching agent of formula D.

[0219] Advantageously, the molar ratio Nb/(Na+Nb+Nd) ranges from 5% to 60%, preferably from 15% to 45%, even more preferably from 20% to 30%.

[0220] Advantageously, the molar ratio Nc/(Na+Nb+Nc+Nd) ranges from 45% to 55%, preferably from 48 to 53% and even more preferably from 49% to 52%.

[0221] Advantageously, the molar ratio Nd/(Na+Nd) ranges from 0 to 20%, preferably from 0% to 5%.

[0222] Catalyst concentration is typically ranging from 5 to 300 ppm in weight, and preferably from 5 to 200 ppm in weight.

[0223] According to a first embodiment, the reagents containing hydroxyl and/or amino functions (compounds of formula A, B and D if present) and the diisocyanate(s) (compound of formula C) are used in stoechiometric proportions. In other words, the stoechiometric index ratio Ic is equal to 1. Advantageously according to this embodiment, CP with high molecular weight are achieved.

[0224] In the context of the invention, the stoichiometric index ratio is defined by Ic=2Nc/(2Na+2Nb+Nd).

[0225] Otherwise, it is possible to use one or more of the reagents in excess.

[0226] According to a second embodiment, the at least one diisocyanate is used in excess. According to this embodiment, the index ratio Ic is above 1, and in particular above 1 and up to 1.1. According to this embodiment, the obtained CP will be a branched copolymer.

[0227] According to a third embodiment, the branching agent of formula D may be introduced in excess. An excess of branching agent leads to a branched CP and improves its mechanical properties.

[0228] Preferably, when the branching agent of formula D is present, the index ratio Ic is equal to 1.

[0229] The CP according to the invention may be prepared in solution in a solvent or mixture of solvents, or without solvent. When used, the solvent should be inert. Examples of solvents that may be used in the context of the invention are m-xylene, THF (tetrahydrofuran), DMSO (dimethylsulfoxide), chloroform, TBAF (tetrabutylammonium fluoride), and PMA (propylene glycol methyl ether acetate).

[0230] In a preferred embodiment, the reaction is performed without solvent.

[0231] Whether prepared with ou without solvent, the reaction mixture should be homogeneous.

[0232] For better reproducibilty, the CP is preferably prepared without moisture and under inert gas, usually under nitrogen, argon or a mixture thereof. Otherwise, pre-dried reagents may be mixed together under non-controlled atmosphere if the mixing time is short (for example up to 15 min). The CP formed is preferentially cured under vacuum or inert gas.

[0233] The process for manufacturing CP according to the invention can be carried out at a temperature ranging from 20 to 80° C.

[0234] The process for manufacturing CP according to the invention typically has a reaction time of from 5 to 240 minutes, depending on the temperature.

[0235] The process for manufacturing CP according to the invention may be carried out in a extruder or in a reactor, as detailed below.

[0236] Preparation in an Extruder

[0237] According to a first embodiment, the CP is prepared by reactive extrusion. If so, the use of a twin-screw corotative extruder is preferred.

[0238] Typically, the length of the extruder is at least of 40 L/D (where L is the length in millimetre of the screws and D their diameter in millimetre). The length of the extruder can be as long as needed and can be fixed by one skilled in the art in order to achieve a reasonable yield. Yield is considered reasonable if the melt flow index is lower than 100 cm.sup.30.10 min.sup.−1 (measured at 120° C. under 2.16 kg), preferably lower than 50 cm.sup.30.10 min.sup.−1, and even more preferably lower than 30 cm.sup.3. 10 min.sup.−1

[0239] Advantageously, the length of the extruder is 80 L/D.

[0240] According to a first embodiment, all reagents are introduced at the same time in the first heating zone of the extruder.

[0241] According to a second embodiment, all the reagents are not introduced simultaneously in the extruder. Advantageously according to this embodiment, the choice of the addition sequence allows to control the polymerisation reaction. For example, it is possible to pre-polymerise the long-chain hydroxyl or amino difunctionalised polysiloxane of formula A with the at least one diisocyanate of formula C before the addition of the chain extender of formula B. Diisocyanate(s) can also be partly introduced in the first heating zone of the extruder and then poured again in the reaction mixture in a further heating zone. In all cases, the long-chain hydroxyl or amino difunctionalised polysiloxane of formula A is introduced in the first heating zone.

[0242] Out of the die, the formed CP can be pelletized or collected in batches.

[0243] Preparation in a Reactor

[0244] According to a second embodiment, the CP is prepared by batch synthesis in a reactor.

[0245] According to this embodiment, all the reagents are introduced simultaneously in the reactor, or stepwise, similarly to what has been detailed above when the CP is prepared in an extruder.

[0246] Copolymer

[0247] The invention further relates to the CP obtained thanks to the process of preparation according to the invention.

[0248] The CP according to the invention has a high silicone content thanks to the use of a short-chain hydroxyl or amino difunctionalised polysiloxane of formula B as chain extender.

[0249] In the sense of the invention, the silicone content is defined by the content in weight of (Si(R).sub.2O) with R representing R1, R2, R3, Ra and Rb if present compared to the total weight of the CP.

[0250] In the context of the invention, the silicone content is of at least 90%, preferably at least 92%, and even more preferably at least 95%. In a particular embodiment, the silicone content is ranging from 92% to 99%, preferably from 95% to 98%. This high silicone content enables to achieve CP with low hardness, a good stability and a low viscosity, while keeping good mechanical properties.

[0251] In order to have such high silicone content, the hard segment ratio ranges from 1 to 94%, preferably from 5 to 50% and even more preferably from 8 to 20%.

[0252] In the context of the invention, the hard segment ratio is defined by HS=(Nb*Mb+Nc*Mc)/(Na*Ma+Nb*Mb+Nc*Mc+Nd*Md), with Ma, Mb, Mc and Md representing respectively the molecular weight of compounds of formula A, B, C and D.

[0253] The formation of hard segments may be achieved by adjusting the proportions of the long-chain difunctional polysiloxane of formula A and of the short-chain difunctional polysiloxane of formula B. In other words, the ratio a/b ranges from 2 to 200, preferentially from 2 to 100, more preferentially from to 3 to 40 and even more preferentially from 6 to 15. In the context of the invention, the short segment have a maximum of 15 siloxanes repetitive units (in other words, b is up to 15) so that they can be considered as chain extender in order to create proper hard segments.

[0254] Advantageously, the CP according to the invention has a low hardness, preferably below 60 Shore A, more preferably below 50 Shore A and even more preferably ranging from 1 to 40 Shore A. In the context of the invention, the hardness is measured with a Shore A durometer.

[0255] The use of siloxane-based chain extender of formula B also allows obtaining glass clear CP, showing that no phase separation occurs (contrary to what may be observed with hydrocarbonated chain extenders, giving opaque final products). In other words, the CP is translucid.

[0256] Advantageously, the CP according to the invention has almost no crystallinity.

[0257] The average molecular weights in number of the CP according to the invention are typically of from 50,000 to 200,000 g.Math.mol.sup.−1 and in from 80,000 to 150,000 g.Math.mol.sup.−1.

[0258] The CP according to the invention has an elastic behavior with high elongation at break. Advantageously, the CP has an elongation at break over 200%, and preferably over 500%. In the context of the invention, the strain at breaking may be measured by tensile test at a speed of 50 mm.Math.min.sup.−1 and the elongation at break is determined according to NF ISO 527 standard.

[0259] Advantageously, the melting temperature of the CP according to the invention is below 140° C. so that CP may be used in FDM-like printers. Typically the melting temperature of the CP ranges from 70 to 140° C. In the context of the invention, the melting temperature is measured by DSC (heating ramp: 10° C.min.sup.−1).

[0260] The CP according to the invention presents a melt flow index ranging from 1 to 100, and preferably from 2 to 30 cm.sup.30.10 min.sup.−1 (measured at 120° C. and under 2.16 kg) which allows to process them by injection moulding, extrusion or even extrusion-like additive manufacturing processes. In the context of the invention, the melt flow index is measured according to NF ISO 1133 standard.

[0261] Method of Manufacturing a 3D Article

[0262] The invention further relates to a method of manufacturing a 3D article thanks to an additive technique.

[0263] The block copolymer I according to the invention is used as sole material in the additive process. In other words, the block copolymer I is not in a composition when used in additive process, but is printed as a sole component.

[0264] According to an advantageous embodiment, the additive technique is performed thanks to a 3D printer, in particular selected from a fused filament fabrication printer, a selective laser sintering printer, a selective laser melting printer, a material jet printer, a syringe extrusion printer and from a droplets deposit printer using for example the APF process (ARBURG Plastic Freeforming process). When a fused filament fabrication printer is used, a thermoplastic filament feeding device, a syringe pump extruder or a hopper/screw pellet conveying system as feeding device are used.

[0265] Additive techniques are known from one skilled in the art and will not be further detailed here.

[0266] Finally, the invention also relates to a 3D article made from the CP according to the invention, or obtained according to the method of manufacturing a 3D article according to the invention. The obtained 3D article may be used in various applications, in particular medical applications such as anatomical models.

[0267] In the context of the invention, a “3D printed article” (or “three dimensional printed article” or “3D article”) refers to an object built by a 3D printing system, such as a fused filament fabrication printer using a thermoplastic filament feeding device, a syringe pump extruder or a hopper/screw pellet conveying system as feeding device, and a droplets deposit printer using for example the APF process (ARBURG Plastic Freeforming process).

EXAMPLES

[0268] In the examples below, the melting temperatures (T.sub.m) are measured by differential scanning calorimetry (DSC), with heating and cooling ramps at 10° C.min.sup.−1. Stress at breaking (σ.sub.b) and strain at breaking (ε.sub.b) are measured by tensile test at a speed of 50 mm.Math.min.sup.−1. Melt volume-flow rates (MVRs) are determined with a melt flow index (MFI) measuring device and hardness is measured with a Shore A durometer.

Example 1: Synthesis in a Reactor

[0269] CP1.1 to CP1.3

[0270] In a 20 L continuous stirred-tank reactor heated at 80° C., 2700 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-50, molar weight 4244 g.Math.mol.sup.−1, sold by Siltech) are charged. Subsequently, 139 g of room temperature 1,6-hexamethylene diisocyanate (Desmodur H, molar weight 168 g.Math.mol.sup.−1, sold by Covestro) are added dropwise to the siloxane. The mixture is stirred during two minutes at 80° C. and then 162 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-8, molar weight 840 g.Math.mol.sup.−1, sold by Siltech) at 80° C. are added to the reaction mixture. The mixture is then stirred at 80° C. for two more minutes and dropped into a plastic container. The mixture is finally cured for two hours at 80° C. under vacuum, to yield CP1.1.

[0271] For CP1.2, the same procedure than for CP1.1 is used except that 216 ppm in weight (1.02×10.sup.−3 mol, 618 ppm in molar) of room temperature dibutyltin dilaurate (DABCO T12N, molar weight 632 g.Math.mol.sup.−1, sold by Air Products) catalyst are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0272] For CP1.3, the same procedure than for CP1.1 is used except that 192 ppm in weight (1.02×10.sup.−3 mol, 618 ppm in molar) of room temperature titanium 2-ethylhexyloxide (Tyzor TOT, molar weight 564 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP1.2) are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0273] Cooling gives a glass-clear polyurea polydimethylsiloxane block copolymer with a hard segments ratio of 10.0% and whose mechanical and thermal properties are described in Table 1. The silicone content (Si(R).sub.2O) is greater than 95% in weight.

TABLE-US-00001 TABLE 1 Properties of CP1.1, CP1.2 and CP1.3 Block T.sub.m MVR 120° C./2.16 kg ε.sub.b Hardness copolymer I.sub.c [° C.] [cm.sup.3 .Math. 10 min.sup.−1] [%] [Sh. A] CP1.1 1.00 — — — — CP1.2 1.00  —* 40 336 ± 23 7 ± 2 CP1.3 1.00 84 31 380 ± 29 8 ± 2 *Very broad and low intensity melting can be observed in the range of 50 to 100° C., nevertheless, MVR measurement at 120° C. exhibit a good melting.

[0274] The results obtained with CP1.1, CP1.2 and CP1.3 show that without a catalyst, the obtained block copolymer cannot be considered as a solid polymer, but only as a visco-elastic material still having the ability to flow under standard pressure and temperature environment. The addition of a catalyst is therefore necessary to obtain high molecular weights and good mechanical properties when the polyurea organopolysiloxane block copolymer is synthetized in a reactor at 80° C.

[0275] CP 1.4 to CP1.6

[0276] In a 20 L continuous stirred-tank reactor heated at 80° C., a mixture composed with 2550 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-50, molar weight 4244 g.Math.mol.sup.−1, sold by Siltech) and 150 g (5% in weight) of a branched monoaminoethyl-functional polydimethylsiloxane (Bluesil FLD 21643, molar weight 7619 g.Math.mol.sup.−1, sold by Elkem) is charged. Subsequently, 136 g of room temperature 1,6-hexamethylene diisocyanate (Desmodur H, molar weight 168 g.Math.mol.sup.−1, sold by Covestro) are added to the mixture. The mixture is stirred for two minutes at 80° C. and then 164 g bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-8, molar weight 840 g.Math.mol.sup.−1, sold by Siltech) at 80° C. are added to the mixture. The mixture is then stirred at 80° C. for two more minutes and dropped into a plastic container. The mixture is finally cured for two hours at 80° C. under vacuum to yield CP1.4.

[0277] For CP1.5, the same procedure than for CP1.4 is used except that 216 ppm in weight (1.02×10.sup.−3 mol, 630 ppm in molar) of room temperature dibutyltin dilaurate (DABCO T12N, molar weight 632 g.Math.mol.sup.−1, sold by Air Products) catalyst are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0278] For CP1.6, the same procedure than for CP1.4 is used except that 192 ppm in weight (1.02×10.sup.−3 mol, 630 ppm in molar) of room temperature titanium 2-ethylhexyloxide (Tyzor TOT, molar weight 564 g.Math.mol.sup.−1, sold by Dort Ketal) catalyst (instead of the DABCO T12N for CP1.5) are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0279] Cooling gives a glass-clear polydimethylsiloxane/polyurea block copolymers with a hard segment ratio of 10.0% whose mechanical and thermal properties are described in the Table 2. The silicone content (Si(R).sub.2O) is greater than 95% in weight.

TABLE-US-00002 TABLE 2 Properties of CP1.4 to CP 1.6 Block T.sub.m MVR 120° C./2.16 kg ε.sub.b Hardness copolymer I.sub.c [° C.] [cm.sup.3 .Math. 10 min.sup.−1] [%] [Sh. A] CP1.4 1.00 — — — — CP1.5 1.00  —* 26 490 ± 42  9 ± 2 CP1.6 1.00 81 20 542 ± 44 10 ± 2 *Very broad and low intensity melting can be observed in the range of 50 to 100° C., nevertheless, MVR measurement at 120° C. exhibit a good melting

[0280] The results obtained with CP1.4 to CP1.6 demonstrate the interest of a branched copolymer. In these examples, the branching is achieved by adding a branching agent. These examples also highlight that titanium-based catalysts are more efficient for these branched copolymers than tin-based catalysts. It is important to note that without a catalyst the material can still not be considered a solid polymer and flows under standard pressure and temperature environment.

[0281] CP1.7 to CP1.11

[0282] In a 20 L continuous stirred-tank reactor heated at 80° C., 2700 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-50, molar weight 4244 g.Math.mol.sup.−1, sold by Siltech) are charged. Subsequently, 147 g of room temperature 1,6-hexamethylene diisocyanate (Desmodur H, molar weight 168 g.Math.mol.sup.−1, sold by Covestro) are added dropwise to the siloxane. The mixture is stirred for two minutes at 80° C. and then 152 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-8, molar weight 840 g.Math.mol.sup.−1, sold by Siltech) at 80° C. are added to the mixture. The mixture is then stirred at 80° C. for two more minutes and dropped into a plastic container. The mixture is finally cured for two hours at 80° C. under vacuum to yield CP1.7.

[0283] For CP1.8, the same procedure than for CP1.7 is used except that 216 ppm in weight (1.02×10.sup.−3 mol, 605 ppm in molar) of room temperature dibutyltin dilaurate (DABCO T12N, molar weight 632 g.Math.mol.sup.−1, sold by Air Products) catalyst are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0284] For CP1.9, the same procedure than for CP1.7 is used except that 86 ppm in weight (1.02×10.sup.−3 mol, 605 ppm in molar) of room temperature titanium (triethanolaminato)isopropoxide (Tyzor TE, molar weight 253 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP1.8) are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0285] For CP1.10, the same procedure than for CP1.7 is used except that 193 ppm in weight (1.02×10.sup.−3 mol, 605 ppm in molar) of room temperature titanium 2-ethylhexyloxide (Tyzor TOT, molar weight 564 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP1.8) are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0286] For CP1.11, the same procedure than for CP1.7 is used except that 116 ppm in weight (1.02×10.sup.−3 mol, 605 ppm in molar) of room temperature tetra-n-butyl titanate (TnBT, molar weight 340 g.Math.mol.sup.−1, sold by Catalytic Technologies) catalyst (instead of the DABCO T12N for CP1.8) are added to the functionalised PDMS and mixed before the addition of the diisocyanate.

[0287] Cooling gives glass-clear polydimethylsiloxane polyurea block copolymers with a hard segments fraction of 10.0% and whose mechanical and thermal properties are described in the Table 3 below. The silicone content (Si(R).sub.2O) is greater than 95% in weight.

TABLE-US-00003 TABLE 3 Properties of CP1.7 to CP1.11 Block T.sub.m MVR 120° C./2.16 kg Hardness copolymer I.sub.c [° C.] [cm.sup.3 .Math. 10 min.sup.−1] [Sh. A] CP1.7 1.07 — — — CP1.8 1.07  —* 2 30 ± 2 CP1.9 1.07 81 2 35 ± 2 CP1.10 1.07 84 7 33 ± 2 CP1.11 1.07 75 3 37 ± 2 *Very broad and low intensity melting can be observed in the range of 50 to 100° C., nevertheless, MVR measurement at 120° C. exhibit a good melting

[0288] The results obtained with CP1.7 to CP1.11 demonstrate the interest of a branched copolymer. In these examples, the branching is achieved by adding an excess of diisocyanate, forming therefore side branches through the formation of biurets on the copolymer. These examples also highlight that titanium-based catalysts are more efficient for these copolymers than tin-based catalysts. It is important to note that without a catalyst, the material can still not be considered a solid polymer and flows under standard pressure and temperature environment.

Example 2: Synthesis in an Extruder

[0289] CP 2.1 to CP2.3

[0290] In order to prepare CP2.1, an 80 L/D 26 mm co-rotative twin-screw extruder from TSA Industrial with 15 heating zones and a temperature controlled die, a mixture composed with 3600 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-50, molar weight 4244 g.Math.mol.sup.−1, sold by Siltech) and 214 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-8, molar weight 840 g.Math.mol.sup.−1, sold by Siltech) was metered at 60° C. at a flow rate of 3814 g.h.sup.−1 into the first heating zone.

[0291] In the second heating zone, room temperature 1,6-hexamethylene diisocyanate (Desmodur H, molar weight 168 g.Math.mol−1, sold by Covestro) is added dropwise at a flow rate of 186 g.h−1.

[0292] The temperature profile of the heating zones is programmed as detailed in Table 4:

TABLE-US-00004 TABLE 4 Temperature profile used for CP2.1 Zone Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10 Z11 Z12 Z13 Z14 Z15 Die T [° C.] 110 120 130 140 150 150 150 150 140 140 140 140 140 140 150 150

[0293] The Rotational Speed is 250 RPM.

[0294] For CP2.2, the same procedure than for CP2.1 is used except that 216 ppm in weight (1.37×10.sup.−3 mol, 617 ppm in molar) of room temperature dibutyltin dilaurate (DABCO T12N, molar weight 632 g.Math.mol.sup.−1, sold by Air Products) catalyst are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0295] For CP2.3, the same procedure than for CP2.1 is used except that 192 ppm in weight (1.37×10.sup.−3 mol, 617 ppm in molar) of room temperature titanium 2-ethylhexyloxide (Tyzor TOT, molar weight 564 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP2.2) are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0296] The material taken off at the die of the extruder is a polydimethylsiloxane/polyurea block copolymer with a hard segment ratio of 10.0% having the properties described in the Table 5 below. All the final block copolymers have a silicone (Si(R).sub.2O) content that is greater than 95% in weight.

TABLE-US-00005 TABLE 5 Properties of CP2.1 to CP2.3 Block T.sub.m MVR 120° C./2,16 kg ε.sub.b Hardness copolymer I.sub.c [° C.] [cm.sup.3 .Math. 10 min.sup.−1] [%] [Sh. A] CP2.1 1.00 — — — — CP2.2 1.00  —* 81 210 ± 14  7 ± 2 CP2.3 1.00 85 16 580 ± 29 30 ± 2 *Very broad and low intensity melting can be observed in the range of 50 to 100° C., nevertheless, MVR measurement at 120° C. exhibit a good melting

[0297] The results obtained with CP2.1 to CP2.3 show that without a catalyst the obtained block copolymer cannot be considered as a solid polymer, but only as a visco-elastic material still having the ability to flow under standard pressure and temperature environment. The addition of a catalyst is therefore necessary to obtain high molecular weights and good mechanical properties when the organopolysiloxane polyurea block copolymer is synthetized by reactive extrusion.

[0298] CP2.4 to CP2.6

[0299] In order to prepare CP2.4, an 80 L/D 26 mm co-rotative twin-screw extruder from TSA Industrial with 15 heating zones and a temperature controlled die a mixture of 3400 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-50, molar weight 4244 g.Math.mol.sup.−1, sold by Siltech), 218 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-8, molar weight 840 g.Math.mol.sup.−1, sold by Siltech) and 200 g (5% in weight) of a branched monoaminoethyl-functional polydimethylsiloxane (Bluesil FLD 21643, molar weight 7619 g.Math.mol.sup.−1, sold by Elkem) was metered at 60° C. at a flow rate of 3818 g.h.sup.−1 into the first heating zone.

[0300] In the second heating zone, room temperature 1,6-hexamethylene diisocyanate (Desmodur H, molar weight 168 g.Math.mol−1, sold by Covestro) is added dropwise at a flow rate of 181 g.h.sup.−1.

[0301] The temperature profile of the heating zones is programmed as detailed in Table 6:

TABLE-US-00006 TABLE 6 Temperature profile used for CP2.4 Zone Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10 Z11 Z12 Z13 Z14 Z15 Die T [° C.] 110 120 130 140 150 150 150 150 140 140 140 140 140 140 150 150

[0302] The Rotational Speed is 250 RPM.

[0303] For CP2.5, the same procedure than for CP2.4 is used except that 216 ppm in weight (1.37×10.sup.−3 mol, 630 ppm in molar) of room temperature dibutyltin dilaurate (DABCO T12N, molar weight 632 g.Math.mol.sup.−1, sold by Air Products) catalyst are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0304] For CP2.6, the same procedure than for CP2.4 is used except that 193 ppm in weight (1.37×10.sup.−3 mol, 630 ppm in molar) of room temperature titanium 2-ethylhexyloxide (Tyzor TOT, molar weight 564 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP2.5) are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0305] The material taken off at the die of the extruder is a polydimethylsiloxane/polyurea block copolymer with a hard segment ratio of 10.0% having the properties described in Table 7 below. All the final products have a silicone content (Si(R).sub.2O) that is greater than 95% in weight.

TABLE-US-00007 TABLE 7 Properties of CP2.4 to 2.6 Block T.sub.m MVR 120° C./2,16 kg ε.sub.b Hardness copolymer I.sub.c [° C.] [cm.sup.3 .Math. 10 min.sup.−1] [%] [Sh. A] CP2.4 1.00 — — — — CP2.5 1.00  —* 79 234 ± 14  6 ± 2 CP2.6 1.00 84 14 550 ± 55 30 ± 2 *Very broad and low intensity melting can be observed in the range of 50 to 100° C., nevertheless, MVR measurement at 120° C. exhibit a good melting

[0306] The results obtained with CP2.4 to CP2.6 demonstrate the interest of a branched copolymer. In these examples, the branching is achieved by adding a branching agent. These examples also highlight that titanium-based catalysts are more efficient for these block copolymers than tin-based catalysts. It is important to note that without a catalyst, the material cannot be considered a solid polymer and flows under standard pressure and temperature environment.

[0307] CP2.7 to CP2.11

[0308] In order to prepare CP2.7, an 80 L/D 26 mm co-rotative twin-screw extruder from TSA Industrial with 15 heating zones and a temperature controlled die, a mixture composed with 3600 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-50, molar weight 4244 g.Math.mol.sup.−1, sold by Siltech), 205 g of bisaminopropyl-terminated polydimethylsiloxane (Silmer NH Di-8, molar weight 840 g.Math.mol.sup.−1, sold by Siltech) was metered at 60° C. at a flow rate of 3805 g.h.sup.−1 into the first heating zone.

[0309] In the second heating zone, room temperature 1,6-hexamethylene diisocyanate (Desmodur H, molar weight 168 g.Math.mol.sup.−1, sold by Covestro) is added dropwise at a flow rate of 197 g.h.sup.−1.

[0310] The temperature profile of the heating zones is programmed as detailed in Table 8.

TABLE-US-00008 TABLE 8 Temperature profile used for CP2.7 Zone Z1 Z2 Z3 Z4 Z5 Z6 Z7 Z8 Z9 Z10 Z11 Z12 Z13 Z14 Z15 Die T [° C.] 110 120 130 140 150 150 150 150 140 140 140 140 140 140 150 150

[0311] The Rotational Speed is 250 RPM.

[0312] For CP2.8, the same procedure than for CP2.7 is used except that 216 ppm in weight (1.37×10.sup.−3 mol, 602 ppm in molar) of room temperature dibutyltin dilaurate (DABCO T12N, molar weight 632 g.Math.mol.sup.−1, sold by Air Products) are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0313] For CP2.9, the same procedure than for CP2.7 is used except that 86 ppm in weight (1.37×10.sup.−3 mol, 602 ppm in molar) of room temperature titanium (triethanolaminato)isopropoxide (Tyzor TE, molar weight 253 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP2.8) are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0314] For CP2.10, the same procedure than for CP2.7 is used except that 192 ppm in weight (1.37×10.sup.−3 mol, 602 ppm in molar) of room temperature titanium 2-ethylhexyloxide (Tyzor TOT, molar weight 564 g.Math.mol.sup.−1, sold by Dorf Ketal) catalyst (instead of the DABCO T12N for CP2.8) are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0315] For CP2.11, the same procedure than for CP2.7 is used except that 116 ppm in weight (1.37×10.sup.−3 mol, 602 ppm in molar) of room temperature tetra-n-butyl titanate (TnBT, molar weight 340 g.Math.mol.sup.−1, sold by Catalytic Technologies) catalyst (instead of the DABCO T12N for CP2.8) are added and mixed to the functionalised PDMS mixture metered in the first heating zone.

[0316] The material taken off at the die of the extruder is a polydimethylsiloxane/polyurea block copolymer with a hard segment ratio of 10.0% having the properties described in Table 9 below. All the final products have a silicone content (Si(R).sub.2O) that is greater than 95% in weight.

TABLE-US-00009 TABLE 9 Properties of CP2.7 to CP2.11 Block T.sub.m MVR 120° C./2.16 kg ε.sub.b Hardness copolymer I.sub.c [° C.] [cm.sup.3 .Math. 10 min.sup.−1] [%] [Sh. A] CP2.7 1.07 — — — — CP2.8 1.07  —* 10 249 ± 19  7 ± 2 CP2.9 1.07 84 3 680 ± 53 37 ± 2 CP2.10 1.07 80 2 620 ± 21 38 ± 2 CP2.11 1.07 83 9 660 ± 46 37 ± 2 *Very broad and low intensity melting can be observed in the range of 50 to 100° C., nevertheless, MVR measurement at 120° C. exhibit a good melting

[0317] The results obtained with CP2.7 to CP2.11 demonstrate the interest of branched copolymers. In these examples, the branching is achieved by adding an excess of diisocyanate, forming therefore side branches through the formation of biurets on the copolymer. These examples also highlight that titanium-based catalysts are more efficient for these copolymers than tin-based catalysts. It is important to note that without a catalyst, the material can still not be considered a solid polymer and flows under standard pressure and temperature environment.

CONCLUSION

[0318] For all the examples previously described, the silicone-based urethane-urea copolymers have a silicone content greater than 95% in weight. The minimum strain at break is higher than 210% and maximum strain at break as high as 680% can be achieved. The hardness of all the different samples is in the range 0 to 38 Shore A.

[0319] The quantities of all the reactants used are summarised in Table 10 below.

TABLE-US-00010 TABLE 10 quantity of the reactants used in the examples Component Component Component Component Block A B C D copolymers [mol] [mol] [mol] [mol] CP1.1-CP1.3 0.636 0.193 0.827 — CP1.4-CP1.6 0.601 0.195 0.810 0.020 CP1.7-CP1.11 0.636 0.181 0.875 — CP2.1-CP2.3 0.848 0.255 1.107 — CP2.4-CP2.6 0.801 0.260 1.077 0.026 CP2.7-CP2.11 0.848 0.244 1.173 —

[0320] As defined previously, the molar ratio in percentage of the chain extender of formula B regarding all the polysiloxane components used in the formulation is Nb/(Na+Nb+Nd).

[0321] The molar ratio in percentage of the diisocyanate of formula C regarding all the components used in the formulation is Nc/(Na+Nb+Nc+Nd].

[0322] The molar ratio in percentage of the branching agent of formula D regarding all the long-chain polysiloxane components is Nd/(Na+Nd).

[0323] The Table 11 below summarises all these ratios of the exemplified block copolymers.

TABLE-US-00011 TABLE 11 Summary of the compositions synthetized Component Component Component HS C B D Block %.sub.w Molar ratio Molar ratio Molar ratio copolymers I.sub.c [%] [%] [%] [%] CP1.1-CP1.3 1.00 10.0 49.9 23.3 — CP1.4-CP1.6 1.00 10.0 49.8 23.9 3.2 CP1.7-CP1.11 1.07 10.0 51.7 22.1 — CP2.1-CP2.3 1.00 10.0 50.1 23.1 — CP2.4-CP2.6 1.00 10.0 49.7 23.9 3.2 CP2.7-CP2.11 1.07 10.0 51.7 22.3 —

Example 3: 3D Printing of CP1.2

[0324] CP1.2 was printed in a FDM-like 3D printer with the printing conditions described hereafter.

[0325] Materials

A 3D printer Cosmed 333, XY cartesian Z decoupled (TOBECA, FRA) was used with: [0326] Movement limit: 10 μm, [0327] Print volume: 300*300*300 mm, [0328] No control of the external environment, [0329] Type of deposit: Pneumatic with Ultimus V pressure controller 1-7 bars (Nordson EFD, USA), [0330] Syringe Optimum (Nordson EFD, USA) 10 cm.sup.3 with standard piston and cap (Nordson EFD, USA) and 40 μm metal needle (FISNAR, USA).

[0331] Printer Preparation

[0332] Preparation of the feeding cartridges with the silicone-based polyurethane-polyurea copolymer: [0333] Three quarter filling of the syringe with pellets of the material, [0334] Closing the syringe with plunger and stopper, [0335] Melting and thermal stabilisation of the product for 4 hours at a temperature above the melting temperature T.sub.m.

[0336] 3D Printing

[0337] The Following Characteristics are Used: [0338] Printing software: Repetier Host, [0339] Slicing software: Slic3r, [0340] Printing height: 400 μm, [0341] Printing width: 400 μm, [0342] Printing speed: 5 mm.Math.s.sup.−1, [0343] Speed vacuum displacement: 50 mm.Math.s.sup.−1, [0344] Printing temperature: 95° C. [0345] Deposition pressure: 1 to 7 bars (depending on formulation), preferably 4 to 6 bars.

[0346] With CP1.2, an ear model has been printed (FIG. 1 and FIG. 2). As the silicone-based urethane-urea copolymers are viscous thermoplastic material, the printings have been done without any support printing even for the overhanging parts of the objects.

Example 4: 3D Printing of CP 1.4

[0347] CP1.4 was printed in a droplet deposition 3D printer with the printing conditions described hereafter.

[0348] Materials

A 3D printer Arburg Freeformer 200-3X version 2/3: [0349] Units of discharge: 2, [0350] X, Y, Z movement, [0351] Printing chamber dimension: 15×25×0.1 to 40 cm, [0352] Useful printing surface: 200 cm.sup.2.

[0353] 3D printing [0354] Hooper 30° C.-120° C.-130° C.-140° C. (Nozzle), [0355] Chamber temperature: 60° C., [0356] Thickness of the layer 250 μm, [0357] Printing speed 20 mm/s.

[0358] With CP1.4, some dumbbells have been printed (FIG. 3 and FIG. 4).