Unsaturated Isocyanate Purification for Storage Stability
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Solution Overview
Problem
Conventional unsaturated isocyanate compounds experience unexpected viscosity increases or gelling during storage and transportation, and when used to produce other compounds, they can lead to rapid viscosity increases or gelling, necessitating improved stability and purification methods.
Innovation Solution
A specific compound, present as an impurity, is removed through distillation at a reflux ratio of 2.0 to 4.0, pressure of 1.0 to 10.0 kPa, and temperature of 90°C to 140°C, with a pH adjustment to 1 to 7, to achieve a concentration of 0.2 parts by mass or lower, ensuring stability and preventing coloring from polymerization inhibitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional unsaturated isocyanate compounds are used for storage and production, then they can be readily available and easy to use, but they experience unexpected viscosity increases or gelling during storage and transportation
Solution Approach 1:
The patent removes the specific impurity compound from the unsaturated isocyanate compound through purification processes. This extraction of the harmful impurity eliminates the cause of viscosity increase and gelling, thereby improving storage stability and composition stability without affecting the availability and ease of use of the main product.
Solution Approach 2:
The patent specifies precise parameter ranges for the impurity concentration (0.001 to 0.1 mass%) and purification conditions (reflux ratio of 1.5 to 5.0, pressure of 0.1 to 10.0 kPa, temperature of 90°C to 140°C). By controlling these parameters, the patent achieves stable viscosity and prevents gelling during storage while maintaining the functional properties of the unsaturated isocyanate compound.
2Productivity
If conventional unsaturated isocyanate compounds are used to produce other compounds, then they can be used as raw materials, but they lead to rapid viscosity increases or gelling during production
Solution Approach 1:
The patent purifies the unsaturated isocyanate compound by removing the specific impurity that causes rapid viscosity increase and gelling during production. This extraction allows the compound to be used as a reliable raw material while maintaining production efficiency and preventing unwanted viscosity changes during chemical reactions.
Solution Approach 2:
The patent establishes specific purification parameters (reflux ratio of 1.5 to 5.0, pressure of 0.1 to 10.0 kPa, temperature of 90°C to 140°C) that effectively remove the impurity causing production issues. These parameter controls ensure the unsaturated isocyanate compound remains stable during production processes while maintaining high productivity.
3Reliability
If large amounts of polymerization inhibitors are added to prevent gelling, then storage stability improves, but coloring occurs in the final product
Solution Approach 1:
The patent identifies and removes the specific impurity compound that causes gelling through purification processes. By eliminating this impurity, the patent achieves storage stability without requiring large amounts of polymerization inhibitors, thereby preventing coloring in the final product while maintaining reliability.
Solution Approach 2:
The patent converts the harmful effect of the impurity (causing gelling) into a benefit by using it as a marker for purification. By removing this impurity through controlled purification processes, the patent achieves both storage stability and product clarity, eliminating the need for excessive polymerization inhibitors that would cause coloring.
4Reliability
If purification is performed to remove impurities, then storage stability improves, but production complexity increases
Solution Approach 1:
The patent specifies precise but practical parameter ranges for purification (reflux ratio of 1.5 to 5.0, pressure of 0.1 to 10.0 kPa, temperature of 90°C to 140°C). These parameters achieve effective impurity removal and storage stability while remaining within conventional equipment capabilities, thus avoiding excessive production complexity.
Solution Approach 2:
The patent focuses purification efforts on removing the specific impurity compound that causes gelling, rather than attempting to remove all impurities. This targeted approach achieves storage stability through selective removal of the harmful substance while minimizing production complexity by concentrating resources on the critical purification step.
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
The method effectively prevents viscosity increases and gelling during storage and use, allowing for high-yield production of stable unsaturated compounds without the need for large amounts of polymerization inhibitors, which can cause coloring.
Implementation Method 1
a method for producing the composition, characterized by comprising: a distillation step of purifying the unsaturated isocyanate compound (A) by distillation under a reflux ratio of 2.0 to 4.0, a pressure of 1.0 to 10.0 kPa, and a distillation temperature of 90°C to 140°C
Data Source
AI summary
A composition is provided including a compound (A) represented by Formula (1) and a compound (B) represented by Formula (2), wherein the compound (B) is contained in an amount of 0.00002 to 0.2 parts by mass with respect to 100 parts by mass of the compound (A): (R1-COO)n-R2-(NCO)m ... (1) (in Formula (1), R1 is an ethylenically unsaturated group having 2 to 7 carbon atoms; R2 is an (m+n)-valent hydrocarbon group having 1 to 7 carbon atoms; and n and m are each an integer of 1 or 2) (in Formula (2), R is (-R2-(OCO-R1), and R1 and R2 are the same as those in Formula (1)).