Pre-hydrolyzed Polysilicate Synthesis via Hydration
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Solution Overview
Problem
The existing methods for synthesizing pre-hydrolyzed polysilicate require a condensation reaction, leading to high energy costs, increased production costs due to the use of alkoxysilane-based monomers, and difficulties in controlling molecular weight and gelation time, which affects the efficiency and stability of the final product.
Innovation Solution
A method that omits the condensation reaction by using a polysilicate as a reactant, involving the introduction of polysilicate and alcohol into a reactor, followed by an acidic aqueous solution to perform a hydration reaction, allowing for control of water and acid catalyst amounts to achieve the desired degree of hydration and pH, resulting in a pre-hydrolyzed polysilicate with improved storage stability and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a condensation reaction is performed under acidic conditions to synthesize pre-hydrolyzed polysilicate from alkoxysilane-based monomers, then the degree of condensation can be controlled, but the reaction time becomes excessively long and energy costs increase
Solution Approach 1:
The patent extracts the condensation reaction step from the synthesis process by directly using polysilicate as the starting material instead of performing condensation on alkoxysilane monomers. This eliminates the time-consuming condensation step while maintaining control over the degree of condensation through selection of appropriate polysilicate feedstock.
Solution Approach 2:
The patent performs the condensation action in advance by using pre-formed polysilicate oligomers as the starting material. The condensation has already occurred to form the desired oligomeric structure before the hydrolysis step, thereby eliminating the need for a separate, time-consuming condensation reaction step in the synthesis process.
2Speed
If a condensation catalyst is used to increase the condensation rate, then the reaction speed improves, but molecular weight control becomes difficult and additional catalyst separation processes are required
Solution Approach 1:
The patent removes the catalyst from the synthesis process entirely by using polysilicate as the starting material. Since the condensation has already occurred in the formation of polysilicate, no additional catalyst is needed to promote condensation during the synthesis step, thereby eliminating catalyst separation requirements and simplifying the process.
Solution Approach 2:
The polysilicate feedstock itself provides the condensed structure without requiring external catalyst assistance during the synthesis step. The material is self-sufficient in terms of having already achieved the condensed oligomeric state, eliminating the need for catalyst-mediated condensation and subsequent catalyst removal operations.
3Ease of manufacture
If alkoxysilane-based monomer compounds are used as reactants, then the synthesis can proceed through standard hydrolysis and condensation, but the unit cost of raw materials increases
Solution Approach 1:
The patent extracts the expensive alkoxysilane monomer from the reactant list and replaces it with polysilicate, which is a more cost-effective starting material. This substitution maintains synthesis feasibility through simple hydrolysis while significantly reducing raw material costs.
4Productivity
If polysilicate is used as a reactant to omit condensation reaction, then synthesis time and production costs are reduced, but control over hydration degree and pH becomes critical
Solution Approach 1:
The patent controls the hydration degree by precisely adjusting parameters such as water-to-polysilicate ratio, acid catalyst concentration, and reaction temperature. By changing these parameters within optimized ranges, the process achieves both high productivity through omitted condensation step and precise control over the degree of hydrolysis and final product properties.
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 significantly reduces synthesis time and production costs, allows for easier control of gelation reaction time and molecular weight, and produces a pre-hydrolyzed polysilicate with excellent storage stability and processability, suitable for manufacturing silica aerogels and aerogel blankets with enhanced thermal insulation properties.
Implementation Method 1
introducing an acidic aqueous solution into the reactor to prepare a reaction mixture, and stirring the reaction mixture to perform a hydration reaction
Data Source
AI summary
A method for synthesizing a pre-hydrolyzed polysilicate, wherein a polysilicate is applied as a reactant when synthesizing the pre-hydrolyzed polysilicate, and the total amount of water added in the reaction system is specified. The method is capable of omitting a condensation reaction by applying a polysilicate as a reactant, thereby significantly shortening synthesis time and reducing production costs when compared with a typical synthesis method in which alkoxysilane-based monomer compound is used as a reactant. In addition, the gelation reaction time and the weight average molecular weight can be easily controlled, and a pre-hydrolyzed polysilicate excellent in storage stability and processability can be synthesized.