Hydrocarbylhydrocarbyloxysilane Synthesis Without Halogen By-products
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Solution Overview
Problem
The silicones industry faces challenges in producing hydrocarbylhydrocarbyloxysilanes as existing methods often require halosilanes and halogenated hydrocarbons, leading to the generation of undesirable by-products and environmental concerns.
Innovation Solution
A method involving the heating of a hydrocarbyl carbonate and a catalyzed source of silicon, such as copper silicide, at temperatures between 150°C to 400°C to form hydrocarbylhydrocarbyloxysilanes, thereby minimizing the use of halogenated hydrocarbons and reducing by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hydrocarbylhalosilanes are produced by the Mueller-Rochow Direct Process using halogenated hydrocarbons, then hydrocarbylhydrocarbyloxysilanes can be produced commercially, but halogenated hydrocarbons and hydrogen halide by-products are generated causing environmental concerns
Solution Approach 1:
The patent extracts and removes the harmful halogenated components from the synthesis process. Instead of using halogenated hydrocarbons as reactants, the invention employs non-halogenated alternatives (such as using aluminum or zinc with hydrocarbyl chlorosilanes, or other metal-based systems), thereby eliminating the generation of hydrogen halide by-products while maintaining commercial production capability
Solution Approach 2:
The patent changes the chemical parameters of the reactants and reaction conditions. By substituting halogenated hydrocarbons with alternative reagents and adjusting reaction conditions (temperature, catalysts, metal ratios), the process achieves the same product formation without generating harmful halogenated by-products, thus resolving the contradiction between manufacturability and environmental harm
2Ease of manufacture
If alkylhalosilanes are produced by alkylation of silicon tetrachloride using aluminum or zinc, then alkylalkoxysilanes can be produced, but large amounts of aluminum chloride or zinc chloride by-products are generated which are costly to dispose of
Solution Approach 1:
The patent extracts the problematic aluminum or zinc metals from the reaction system and replaces them with alternative reagents. By removing these specific metals that generate costly chloride by-products, the invention maintains the alkylation function while eliminating the disposal burden of large amounts of aluminum chloride or zinc chloride waste
Solution Approach 2:
The patent employs alternative reagents that are either easier to dispose of or can be regenerated, replacing the expensive-to-dispose aluminum chloride or zinc chloride by-products. The new reagent system uses materials that are more environmentally friendly and less costly to manage as waste, thus resolving the contradiction between production feasibility and waste disposal costs
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 method effectively produces hydrocarbylhydrocarbyloxysilanes while reducing the need for halogenated hydrocarbons and minimizing the production of undesirable by-products, offering an environmentally friendlier alternative to traditional processes.
Implementation Method 1
heating at a temperature of 150°C to 400°C, ingredients comprising a) a hydrocarbyl carbonate, and b) a source of silicon and catalyst, where starting material b) is selected from the group consisting of copper silicide and a contact mass used in the Mueller-Rochow direct process which comprises silicon and a copper catalyst
Data Source
AI summary
A method for preparing a hydrocarbylhydrocarbyloxysilane of formula RaHpSi(OR)(4-a-b),, where each R is independently a hydrocarbyl group and subscript a is 1 to 4 and subscript b is 1 to 2 is disclosed. The method includes heating ingredients including a hydrocarbyl carbonate and a source of silicon and catalyst. The method can be used to make dimethyldimethoxysilane.