Trichlorodisilane Synthesis via Alkylaluminum Hydride Reduction
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Solution Overview
Problem
Existing methods for producing trichlorodisilane suffer from insufficient selectivity, inadequate yields, the production of undesirable byproducts, and the use of costly or hazardous starting materials, making them unsuitable for industrial-scale production.
Innovation Solution
A method involving the combination of an alkylaluminum hydride, a halodisilane with at least 4 halogen atoms, and a solvent at a temperature below 80°C, which reduces the halodisilane to form a reaction product mixture comprising trihalodisilane, alkylaluminum halide, and solvent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hexachlorodisilane is reduced with diethylaluminum hydride, then trichlorodisilane can be produced, but unacceptable amounts of ethylsilane byproduct are generated
Solution Approach 1:
The patent extracts and removes the harmful ethylsilane byproduct from the reaction system by using ethylaluminum dichloride as a selective reactant that converts the unwanted byproduct into a separable complex, enabling its removal from the product stream
Solution Approach 2:
Ethylaluminum dichloride acts as an intermediary substance that mediates between the unwanted ethylsilane byproduct and the desired trichlorodisilane product, converting the harmful byproduct into a complex that can be selectively removed while preserving the main product
2Productivity
If known methods are used to produce trichlorodisilane, then production can be achieved, but insufficient selectivity and inadequate yields are obtained
Solution Approach 1:
The patent changes the chemical parameters of the reaction system by introducing ethylaluminum dichloride as a selective reactant and controlling the molar ratio of reactants, which improves both the selectivity and yield of trichlorodisilane production
Solution Approach 2:
The patent employs feedback control by monitoring the reaction progress and adjusting the addition rate of ethylaluminum dichloride to maintain optimal conditions for high selectivity and yield, preventing formation of unwanted byproducts
3Productivity
If known methods are used, then trichlorodisilane can be produced, but undesirable byproducts are generated that are hard to separate
Solution Approach 1:
The patent extracts unwanted byproducts from the reaction mixture by forming separable complexes with ethylaluminum dichloride, which can be removed through simple filtration or distillation, greatly simplifying the separation process
Solution Approach 2:
Ethylaluminum dichloride serves as an intermediary that converts difficult-to-separate byproducts into separable complexes, enabling easy separation through standard purification techniques while maintaining high product yield
4Productivity
If conventional methods are used, then production can be achieved, but costly or hazardous starting materials are required
Solution Approach 1:
The patent uses ethylaluminum dichloride as a catalytic or stoichiometric additive that is inexpensive and can be easily disposed of or recovered, replacing the need for expensive or hazardous starting materials in the reduction process
Solution Approach 2:
The patent changes the reactant parameters by using alternative, safer, and more cost-effective starting materials combined with ethylaluminum dichloride, which achieves the same production goal with improved safety and economic characteristics
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 produces trichlorodisilane cost-effectively with good selectivity and yield, minimal undesirable byproducts, and efficiently separates the product from byproducts, making it suitable for industrial-scale production.
Implementation Method 1
combining a reductive effective amount of an alkylaluminum hydride, a halodisilane comprising at least 4 halogen atoms, and a solvent at a temperature below 80°C, which reduces the halodisilane to form a reaction product mixture comprising trihalodisilane, alkylaluminum halide, and solvent
Data Source
AI summary
A method of making a trihalodisilane, the method comprising: combining a reductive effective amount of an alkylaluminum hydride, a halodisilane comprising at least 4 halogen atoms, and a solvent at a temperature <80° C. and reducing the halodisilane to form a reaction product mixture comprising a trihalodisilane and an alkylaluminum halide.