Fluoroelastomer Catalyst Composition Preventing Scorch
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Solution Overview
Problem
Fluoroelastomers face challenges with premature curing (scorch) during processing due to the use of hydrocarbon-containing alcohols in catalyst compositions, leading to undesirable extractable metal residues and inadequate rheology control, which affects their performance in extreme temperature and chemical environments.
Innovation Solution
A catalyst composition comprising a cation and anion of specific organo-onium and anion structures, with the proviso that the catalyst is essentially free of hydrocarbon-containing alcohol, which eliminates the need for additional processing steps to prevent scorch and enhances rheology control, thereby improving the curing of fluoroelastomers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydrocarbon-containing alcohol is used in catalyst composition, then catalyst activity is improved, but premature curing (scorch) occurs during processing
Solution Approach 1:
The patent removes hydrocarbon-containing alcohol from the catalyst composition to eliminate the source of premature curing while retaining the essential catalytic components. This extraction of the harmful element resolves the contradiction by preventing scorch during processing.
Solution Approach 2:
The patent changes the chemical composition parameters of the catalyst system by eliminating hydrocarbon-containing alcohol and using alternative catalysts such as organo-onium compounds. This parameter change maintains catalyst activity while improving processing stability.
2Reliability
If organotin catalysts are used for curing, then cure performance is improved, but extractable metal residues are generated
Solution Approach 1:
The patent removes organotin catalysts from the curing system to eliminate extractable metal residues. Alternative catalysts such as organo-onium compounds are used to maintain cure performance without generating harmful metal byproducts.
Solution Approach 2:
The patent replaces persistent organotin catalysts with alternative catalyst systems that do not leave extractable residues, improving the environmental and safety profile of the cured product while maintaining curing effectiveness.
3Reliability
If ammonia-generating compounds are used as cure system, then curing is achieved, but rheology control is insufficient
Solution Approach 1:
The patent introduces catalyst compounds as intermediary substances that mediate between the ammonia-generating compounds and the fluoroelastomer. These catalyst compounds provide the necessary rheology control during processing while enabling effective curing through the ammonia generation mechanism.
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
The catalyst composition effectively prevents premature curing and improves the rheology control of fluoroelastomers, resulting in enhanced high-temperature performance and reduced compression set, making them suitable for harsh chemical and high-temperature applications with improved purity and quality.
Implementation Method 1
Fluoroelastomers are cured or crosslinked and generally are tolerant to high temperatures and harsh chemical environments
Implementation Method 2
these cure systems lack the desired level of rheology control during processing
Data Source
AI summary
A catalyst composition comprising a cation and an anion of the formula An q- Qp m+, wherein m, n, p, and q are positive integers, wherein m * p = n * q, wherein Qm+ is an organo onium, and Aq- is an anion, provided that at least one Aq- is selected from the formula (I) wherein each R independently is H, halo, alkyl, aryl, aralkyl, or cycloalkyl, and which also may be halogenated, fluorinated, or perfluorinated, wherein two or more of R and R' groups may together form a ring, wherein each R group independently may contain one or more heteroatom(s), wherein R' can be the same as R, with the proviso that R' cannot be halo, and wherein the catalyst composition is essentially free of hydrocarbon containing alcohol. Also provided are a fluoropolymer composition including this curative, a method of making a fluoropolymer, and fluoropolymer articles containing curable or cured fluoropolymer compositions