Multifunctional Methacrylate Manufacturing via Dual Catalyst System
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Solution Overview
Problem
Current methods for manufacturing multifunctional (meth)acrylates through transesterification face challenges such as low yield and the use of toxic catalysts, particularly when polyhydric alcohols with three or more hydroxyl groups are used, leading to complex and costly purification processes.
Innovation Solution
The use of a combination of cyclic tertiary amines or their salts/complexes as catalyst A and zinc-containing compounds as catalyst B facilitates the transesterification of polyhydric alcohols with monofunctional (meth)acrylates, eliminating the need for toxic catalysts and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sulfonic acid is used as a catalyst for esterification reaction to manufacture multifunctional (meth)acrylate, then the reaction can proceed, but the process becomes complicated due to the need for extraction washing with aqueous alkali solution to remove the catalyst, resulting in decreased productivity
Solution Approach 1:
The invention removes the harmful sulfonic acid catalyst from the system by replacing it with a solid acid catalyst that does not require aqueous washing for removal, thereby eliminating the complicated purification process and improving productivity
Solution Approach 2:
The invention introduces a solid acid catalyst as an intermediary that facilitates the esterification reaction without requiring removal by aqueous washing, serving as a bridge between reactants while avoiding the harmful effects of sulfonic acid
2Ease of manufacture
If sulfonic acid is used as a catalyst for esterification reaction, then the reaction can proceed, but part of the target multifunctional acrylate is saponified during the extracting operation, causing a decrease in yield
Solution Approach 1:
The invention eliminates the need for aqueous alkali washing by using a solid acid catalyst that can be easily separated by filtration, thereby preventing saponification of the product during the extraction process and improving yield
Solution Approach 2:
The solid acid catalyst can be used in small amounts and easily removed, functioning as a disposable catalyst that does not require complex removal processes and prevents product degradation
3Quantity of substance
If organotin compound or organophosphorus compound is used as a catalyst for transesterification, then high yield of multifunctional (meth)acrylate is achieved, but the catalyst has harmful properties requiring purification operations to reduce residual catalyst in the product
Solution Approach 1:
The invention replaces harmful organotin or organophosphorus catalysts with a solid acid catalyst that has beneficial properties of being non-toxic and easily removable, converting the harmful catalysis approach into a beneficial one
Solution Approach 2:
The solid acid catalyst serves as a benign intermediary that facilitates the transesterification reaction without introducing harmful residues, replacing the toxic catalysts with a safe alternative
4Object-affected harmful factors
If liquid-liquid extraction is performed multiple times to purify multifunctional (meth)acrylate having 3 or more (meth) acryloyl groups, then the catalyst residue is reduced, but the process becomes complicated and productivity decreases markedly
Solution Approach 1:
The invention replaces multiple liquid-liquid extraction operations with a single filtration step to remove the solid acid catalyst, dramatically simplifying the purification process and improving productivity while effectively removing catalyst residues
Solution Approach 2:
The invention replaces the complex mechanical process of multiple liquid-liquid extractions with a simple filtration operation, substituting a complex separation system with a simpler one that achieves the same purification goal
5Object-affected harmful factors
If titanium compound is used as a catalyst for transesterification, then the catalyst has relatively low toxicity, but the yield is very low when polyhydric alcohol having 3 or more alcoholic hydroxyl groups is used
Solution Approach 1:
The invention changes the key parameter of catalyst type from titanium compound to solid acid catalyst, which fundamentally alters both the toxicity and catalytic activity parameters, achieving low toxicity while simultaneously improving yield
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 approach enables the production of multifunctional (meth)acrylates with good yield and purity, suitable for industrial applications without the use of hazardous substances, thus enhancing productivity and economic viability.
Implementation Method 1
The use of a combination of cyclic tertiary amines or their salts/complexes as catalyst A and zinc-containing compounds as catalyst B facilitates the transesterification of polyhydric alcohols with monofunctional (meth)acrylates
Data Source
Figure 1
AI summary
[Problem] The purpose of the present invention is to obtain a multifunctional (meth)acrylate with good yield by an ester exchange reaction of a polyhydric alcohol such as pentaerythritol or dipentaerythritol with a monofunctional (meth)acrylate. [Solution] A multifunctional (meth)acrylate manufacturing method characterized in that when manufacturing a multifunctional (meth)acrylate by an ester exchange reaction of a polyhydric alcohol with a monofunctional (meth) acrylate, catalyst (A) and catalyst (B) are used together. Catalyst (A) : One or more kinds of compounds selected from a group consisting of cyclic tertiary amines with an azabicyclo structure or salts or complexes thereof, amidines or salts or complexes thereof, and compounds with a pyridine ring or salts or complexes thereof. Catalyst (B): One or more kinds of compounds selected from a group consisting of zinc-containing compounds.