Acylphosphine Oxide Solidification via Melt Shearing
Solution Overview
Problem
The existing methods for preparing solid acylphosphine oxides involve solvent-based crystallization, which is costly, requires extensive processing, and results in reduced yield due to residual solvent issues, making the process inefficient and environmentally challenging.
Innovation Solution
A process that converts acylphosphine oxide melts into the solid state through mechanical stress, such as shearing or internal agitation, eliminating the need for solvents and reducing processing costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If crystallization from solution is used, then solid acylphosphine oxide can be obtained with final purity, but solvent costs increase and extensive processing is required
Solution Approach 1:
The invention extracts and eliminates the solvent from the crystallization process entirely. Instead of using solvent-based crystallization, the patent employs melt processing where the acylphosphine oxide is heated above its melting point and then cooled to form solids directly, removing all solvent-related complexity including filtration, drying, and solvent recovery operations.
Solution Approach 2:
The invention changes the physical state parameter of the acylphosphine oxide from solid to liquid (melt) during processing. By heating the material above its melting point and then cooling the melt, the process achieves solid formation without requiring solvent dissolution and recrystallization, thereby simplifying the overall processing while maintaining purity.
2Manufacturing precision
If crystallization from solution is used, then solid acylphosphine oxide can be obtained, but expenditure for separating crystals from residual solution increases
Solution Approach 1:
The invention removes the solvent phase entirely from the process, eliminating the need for crystal-solution separation operations. The acylphosphine oxide is processed directly in the melt state and solidifies upon cooling, producing solids that require no separation from residual solvent.
3Manufacturing precision
If crystallization from solution is used, then solid acylphosphine oxide can be obtained, but costly drying is required to remove residual moisture
Solution Approach 1:
The invention extracts and eliminates the solvent from the process, thereby eliminating residual moisture that would require energy-intensive drying. The melt-cooling process produces solids directly without adhering solvent, removing the drying step entirely.
4Manufacturing precision
If crystallization from solution is used, then solid acylphosphine oxide can be obtained, but yield is reduced due to product remaining in dissolved form
Solution Approach 1:
The invention changes the processing state from dissolved-in-solvent to pure melt, allowing complete solidification of the acylphosphine oxide. Since no solvent remains to hold product in dissolved form, essentially 100% of the material converts to solid, maximizing yield.
5Manufacturing precision
If organic solvents are used, then crystallization can proceed, but high processing expenditure is required for safe handling and emission avoidance
Solution Approach 1:
The invention extracts and eliminates organic solvents from the entire process. By using melt processing instead of solution crystallization, all hazards associated with organic solvents including flammability, toxicity, and emissions are completely removed, while the crystallization/solidification process continues uninterrupted.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the efficient and cost-effective production of solid acylphosphine oxides with controlled particle size distribution, minimizing solvent usage and environmental concerns while achieving rapid solidification in a few minutes.
Implementation Method 1
the acylphosphine oxide present following reaction or work-up as a continuous melt phase or disperse melt phase into the solid state of aggregation
Implementation Method 2
with externally exerted mechanical stress, shearing and/or internal agitation of the melt
Data Source
AI summary
The present invention relates to a process for the preparation of solid acylphosphine oxides by converting an acylphosphine oxide which is in the form of a melt or in dispersed form into the solid state of aggregation with mechanical stress, shearing/internal agitation of the melt.