Phosphate Ester Composition Using Preliminary Action for Low TPP
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Solution Overview
Problem
Existing phosphate ester compositions contain significant amounts of triphenyl phosphate (TPP), which are classified as substances of very high concern (SVHC) and difficult to remove post-synthesis, posing regulatory and environmental risks.
Innovation Solution
Developed compositions with very low to no TPP content by optimizing the synthesis process, specifically through adjusting the molar ratios and reaction times of reactants in multi-step reactions, ensuring TPP is reduced to less than 0.1% in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional phosphate ester synthesis is used, then production efficiency is maintained, but TPP content becomes high (regulatory non-compliant)
Solution Approach 1:
The patent applies preliminary action by adding excess alcohol (at least 1.10 equivalent moles) before the main reaction occurs. This excess alcohol pre-reacts with POCl3 to form alkyl dichlorophosphate intermediates, which then react with phenol in a second step. This preliminary formation of intermediates prevents TPP byproduct formation and achieves less than 0.1% TPP content while maintaining industrial production efficiency.
2Manufacturing precision
If TPP removal techniques are applied after synthesis, then TPP content can be reduced, but the process becomes complex and less effective
Solution Approach 1:
The patent eliminates the need for complex post-synthesis purification by applying preliminary action during the synthesis phase. By adding excess alcohol before the reaction and forming alkyl dichlorophosphate intermediates first, the process prevents TPP byproduct formation at the source. This approach achieves less than 0.1% TPP content without requiring additional removal steps, thereby avoiding increased device complexity.
3Manufacturing precision
If excess alcohol is added in the first step, then TPP content is reduced to below 0.1%, but reactant ratio control becomes more critical
Solution Approach 1:
The patent applies parameter changes by modifying the stoichiometric ratio of alcohol to POCl3 to at least 1.10:1 in the first reaction step. This parameter change ensures excess alcohol is present to pre-react with POCl3, forming intermediates that prevent TPP formation. The method also specifies controlling the reaction temperature between -78°C and 0°C during this step, further optimizing the parameter control to achieve less than 0.1% TPP content while maintaining ease of manufacture.
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
Achieves a significant reduction in TPP content to below regulatory thresholds, enhancing the safety and compliance of phosphate ester-based products used in flame retardants and plasticizers, while maintaining their effectiveness.
Implementation Method 1
reacting an alcohol having the formula R0OH with POCl3 to produce a reaction mixture with an intermediate
Implementation Method 2
reacting the intermediate with a phenate compound to form a composition including a phosphate monoester
Data Source
AI summary
A composition includes phosphate esters, such as alkyl and aryl phosphate esters, with very low to no triphenyl phosphate (TPP) contents. Methods to synthesize phosphate esters with the goal of controlling TPP to be less than 0.1%, sharply reducing the potential toxicity of products including phosphate esters, are also disclosed.