Isocyanatosilane Production via Liquid Phase Cracking and Purge Trimerization

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Solution Overview

Problem

Existing processes for producing isocyanatosilanes and silylisocyanurates face challenges such as high capital investment requirements, toxicity of solvents, difficult separation of intermediates, and environmental concerns due to the use of toxic catalysts and solvents, which result in inefficient production and waste generation.

Innovation Solution

A process involving a cracking reaction medium with silylorganocarbamate and a catalytically effective amount of cracking catalyst, where a portion of the reaction medium is purged to maintain steady-state conditions, remove impurities, and stabilize isocyanatosilane, followed by trimerization to produce silylisocyanurate, thereby achieving near-quantitative yields and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high temperature vapor phase processes are used to make isocyanatosilanes, then conversion efficiency is improved, but capital investment requirements increase due to specialized equipment needed for high temperature operation

Engineering Contradiction:

Improveconversion efficiencyVSAvoidcapital investment requirements

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention changes the temperature parameter from high temperature (300-600°C vapor phase) to moderate temperature (150-300°C liquid phase), and changes the phase parameter from vapor to liquid, thereby maintaining good conversion efficiency while avoiding the need for specialized high temperature equipment

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention introduces an inert liquid medium as an intermediary to enable the cracking reaction to proceed at moderate temperatures. The liquid medium acts as a heat transfer medium and reaction environment, allowing the carbamatoorganosilane to crack efficiently without requiring high temperature vapor phase conditions

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If toxic solvents and catalysts are used in existing processes, then reaction efficiency is improved, but environmental harm and toxicity increase

Engineering Contradiction:

Improvereaction efficiencyVSAvoidenvironmental harm and toxicity

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The invention replaces persistent toxic catalysts with a system where the inert liquid medium can be easily separated and reused. The catalyst function is achieved through the reaction conditions and the liquid medium itself rather than through toxic catalytic substances, eliminating the need for catalyst separation and disposal

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention converts the potential harm of requiring high temperature operation into a benefit by using moderate temperature liquid phase conditions that achieve comparable or better conversion efficiency, thereby eliminating the environmental and safety hazards associated with high temperature vapor phase processes

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Temperature

If intermediate preparation steps are used in low temperature cracking processes, then conversion conditions are improved, but separation difficulty increases due to solvent and salt removal

Engineering Contradiction:

Improvecracking temperatureVSAvoidseparation difficulty

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention extracts the problematic intermediate preparation steps and salt formation from the process by using an inert liquid medium that does not require separation. The reaction is designed to proceed directly in the liquid phase without forming separable salt byproducts, eliminating the difficult separation step

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention creates a homogeneous liquid phase reaction system where all components remain in the same phase throughout the process. This homogeneity allows for easy separation of products from the inert liquid medium through simple distillation or evaporation, avoiding the complex separation required when salts and solvents are involved

Inventive Principle:

Principle #33Homogeneity

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 process provides a cost-effective and environmentally friendly method for producing isocyanatosilane and silylisocyanurate with reduced waste and toxicity, maintaining reaction kinetics and product stability, and utilizing a common silylorganocarbamate feedstock for both products.

Implementation Method 1

providing a cracking reaction medium comprising silylorganocarbamate and, optionally, a catalytically effective amount of cracking catalyst

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

introducing purged cracking-reaction medium to a trimerization reaction zone; and, subjecting the purged cracking reaction medium in the trimerization reaction zone to trimerization reaction conditions to provide silyisocyanurate

Methodology Applied

Scientific EffectTrimerization: Chemical Bonding

Data Source

PatentUS7825243B2Process for the production of isocyanatosilane and silylisocyanurate

Publication Date: 2010.11.02 MOMENTIVE PERFORMANCE MATERIALS INC

AI summary

A process is provided for the production of isocyanatosilane from silylorganocarbamate in a cracking zone with a predetermined portion of purged reaction medium undergoing conversion in a trimerization zone to silylisocyanurate.