Curable resin and process for preparing the same

Claim 2

A curable resin having a number average molecular weight of 1,000 to 100,000 and comprising units of at least one prepolymer selected from the group consisting of a prepolymer (C) having a number average molecular weight of 200 to 60,000 and a prepolymer (F) having a number average molecular weight of 250 to 60,000, said prepolymer (C) having the formula (I): wherein R 1 is an alkyl, aryl or aralkyl group having 1 to 10 carbon atoms; R 2 is a bivalent group having 1 to 10 carbon atoms selected from the group consisting of alkylene, arylene or aralkylene groups; Rand R 5 are the same or different and each is hydrogen atom or an alkyl group having 1 to 10 carbon atoms; X is a hydrolyzable group selected from the group consisting of a halogen atom, an alkoxyl group, an acyloxyl group, a ketoxymate group, amino group, an acid amide group, aminooxy group, mercapto group and an alkenyloxy group; Y is -S- or in which R 3 is hydrogen atom or an alkyl group having 1 to 10 carbon atoms; Z is a residue of an oligomer (A) having a number average molecular weight of 100 to 50,000 and having at least two groups selected from the group consisting of acryloyloxy group and methacryloyloxy group; p and q are an integer of one or more satisfying the equation of 2 ≦ p + q ≦ 8; n is an integer of 1 to 3, and m is an integer of 1 to 10; and said prepolymer (F) having the formula (III): wherein R 6 is an alkyl, aryl or an aralkyl group having 1 to 30 carbon atoms or a group having the formula: (C 2 H 5 O) 3 -Si(̵CH 2 ; and X, Z, R1 , R2 , R4 , R 5 , p , q, m and n are as defined above.

Claim 3

The curable resin of Claim 1, which is a homopolymer of at least one prepolymer selected from the group consisting of said prepolymer (C) and said prepolymer (D).

Claim 4

The curable resin of Claim 1, which is a copolymer of at least one prepolymer selected from the group consisting of said prepolymer (C) and said prepolymer (F) with a vinyl monomer (D), the amount of the prepolymer being at least 0.1 part by weight per 100 parts by weight of said vinyl monomr (D).

Claim 5

The curable resin of Claim 1, wherein said prepolymer (C) is prepared by reacting at least one group selected from the group consisting of acryloyl group and methacryloyl group of said oligomer (A) with said silane coupling agent (B) in the substantial absence of water.

Claim 6

The curable resin of Claim 1, wherein said prepolymer (F) is prepared from said prepolymer (C) prepared by reacting at least one group selected from the group consisting of acryloyl group and methacryloyl group of said oligomer (A) with said silane coupling agent (B) in the substantial absence of water.

Claim 7

The curable resin of Claim 1, wherein said prepolymer (C) is prepared by selectively reacting acryloyl group of said oligomer (A) having both acryloyl group and methacryloyl group with said silane coupling agent (B) in the substantial absence of water.

Claim 8

The curable resin of Claim 1, wherein said prepolymer (F) is prepared from said prepolymer (C) prepared by selectively reacting acryloyl group of said oligomer (A) having both acryloyl group and methacryloyl group with said silane coupling agent (B) in the substantial absence of water.

Claim 9

The curable resin of Claim 1, wherein the main chain of said oligomer (A) is mainly a polyether.

Claim 10

The curable resin of Claim 1, wherein the main chain of said oligomer (A) is mainly a polyester.

Claim 11

The curable resin of Claim 1, wherein the main chain of said oligomer (A) is mainly a polyuretane.

Claim 12

The curable resin of Claim 1, wherein the main chain said oligomer (A) is mainly a silicone.

Claim 13

A process for preparing a curable resin having a number average molecular weight of 1,000 to 100,000, which comprises copolymerizing at least one prepolymer selected from a prepolymer (C) having a number average molecular weight of 200 to 60,000 and a prepolymer (F) having a number average molecular weight of 250 to 60,000, with a vinyl monomer (D) in a weight ratio of said vinyl monomer (D) to said prepolymer of 100 : 0.1 to 10,000; said prepolymer (C) having the formula (I): wherein R 1 is an alkyl, aryl or aralkyl group having 1 to 10 carbon atoms; R 2 is a bivalent group having 1 to 10 carbon atoms selected from the group consisting of alkylene, arylene and aralkylene groups; R 4 and R 5 are the same or different and each is hydrogen atom or an alkyl group having 1 to 10 carbon atoms; X is a hydrolyzable group selected from the group consisting of a halogen atom, an alkoxyl group, an acyloxyl group, a ketoxymate group, amino group, an acid amide group, aminooxy group, mercapto group and an alkenyloxy group; Y is -S- or -N- in which R 3 is hydrogen atom or an alkyl R 1 3 group having 1 to 10 carbon atoms; Z is a residue of an oligomer (A) having at least two groups selected from the group consisting of acryloyl group and methacryloyl group; and p and q are same or different and each is an integer of one or more satisfying the equation of 2 ≦ p + q ≦ 8; n is an integer of 1 to 3, and m is an integer of 1 to 10; and said prepolymer (F) having the formula (III): wherein R 6 is an alkyl, aryl or an aralkyl group having 1 to 30 carbon atoms or a group having the formula: (C 2 H 5 O) 3 -Si(̵CH 2 X, Z, R 1 , R 2 , R 4 , R 5 , p, q, m and n are as defined above.

Claim 14

A process for preparing a curable resin having a number average molecular weight of 1,000 to 100,000, which comprises copolymerizing at least one prepolymer selected from a prepolymer (C) having a number average molecular weight of 200 to 60,000 and a prepolymer (F) having a number average molecular weight of 250 to 60,000, with a vinyl monomer (D) in a weight ratio of said vinyl monomer (D) to said prepolymer of 100 : 0.1 to 10,000; said prepolymer (C) having the formula (I): wherein R 1 is an alkyl, aryl or aralkyl group having 1 to 10 carbon atoms; R 2 is a bivalent group having 1 to 10 carbon atoms selected from the group consisting of alkylene, arylene and aralkylene groups; R 4 and R 5 are the same or different and each is hydrogen atom or an alkyl group having 1 to 10 carbon atoms; X is a hydrolyzable group selected from the group consisting of a halogen atom, an alkoxyl group, an acyloxyl group, a ketoxymate group, amino group, an acid amide group, aminooxy group, mercapto group and an alkenyloxy group; Y is -S- or -N- in which R 3 is hydrogen atom or an alkyl R 1 3 group having 1 to 10 carbon atoms; Z is a residue of an oligomer (A) having at least two groups selected from the group consisting of acryloyl group and methacryloyl group; and p and q are same or different and each is an integer of one or more satisfying the equation of 2 ≦ p + q ≦ 8; n is an integer of 1 to 3, and m is an integer of 1 to 10; and said prepolymer (F) having the formula (III): wherein R 6 is an alkyl, aryl or an aralkyl group having 1 to 30 carbon atoms or a group having the formula: (C 2 H 5 O) 3 -Si(̵CH 2 X, Z, R 1 , R 2 , R 4 , R 5 , p, q, m and n are as defined above.

Claim 15

The process of Claim 10, wherein said prepolymer (c) is prepared by blocking at least one group selected from the group consisting of acryloyl group and methacryloyl group in said oligomer (A) having at least two groups selected from the group consisting of acryloyl group and methacryloyl group in its molecule and having a number average molecular weight of 100 to 50,000 with a silane coupling agent (B) having at least one group selected from the group consisting of amino group and mercapto group having the formula (II): wherein X , Y, R 1 , R 2 n and m are as defined above.

Claim 16

The process of Claim 10, wherein said prepolymer (F) is prepared by blocking active hydrogen of the amino group in said prepolymer (C) with a monofunctional isocyanate compound (E) having the formula (IV): wherein R 6 is as defined above.