Continuous manufacture of silicone copolymers via static mixing plug flow reactors

Abstract

A continuous process for the manufacture of silicone copolymer utilizing at least one static mixing plug flow reactor, and optionally two static mixing plug flow reactors in a series or parallel. Silicone copolymers produced in accordance thereof are substantially free of unreacted hydrogen siloxane starting material and may be used without further purification. The static mixing plug flow reactor contains static mixing elements capable of creating eddies and vortices of sufficient intensity that a biphasic liquid mixture such as a hydrogen siloxane fluid and an polyether olefinic reactant, undergoes shearing of the droplets of each material so that one phase disperses into another to provide intimate contact between the two phases to allow the reaction to proceed.

What is claimed is:  
     
         1 . An apparatus for continuous manufacture of silicone copolymers comprising: 
 one or more plug flow reactors having 
 a static mixing element adapted to create turbulence of such intensity that a biphasic liquid mixture undergoes shearing of droplets sufficient to disperse one phase into another,  
 an inlet means for introduction of reactants into said one or more plug flow reactors, and  
 an outlet means for removal or reaction products from said one or more plug flow reactors.  
   
     
     
         2  The apparatus of  claim 1  wherein said one or more plug flow reactors are in series.  
     
     
         3 . The apparatus of  claim 1  wherein said one or more plug flow reactors are in parallel.  
     
     
         4 . The apparatus of  claim 1  having at least two plug flow reactors.  
     
     
         5 . The apparatus of  claim 1  wherein the static mixing element is adapted to create eddies and vortices of such intensity that a biphasic liquid mixture undergoes shearing of droplets sufficient to disperse one phase into another such that the biphasic liquid mixture does not readily separate into distinct phases more rapidly than 2 to 3 half-lives of a hydrosilation reaction.  
     
     
         6 . The apparatus of  claim 1  further including a stripper attached to the outlet means for removing any volatiles.  
     
     
         7 . The apparatus of  claim 1  further including a recycling means between the inlet means and the outlet means such that crude product exiting said one or more plug flow reactors is carried back into said one or more plug flow reactors via the inlet means.  
     
     
         8 . A silicone copolymer manufactured by: 
 feeding at least one hydrogen siloxane, at least one olefinic reactant capable of reacting with the at least one hydrogen siloxane, and a catalyst into one or more static mixing plug flow reactors having a static mixing element adapted to create turbulence of such intensity that a biphasic liquid mixture such as the at least one hydrogen siloxane and the at least one olefinic reactant undergo shearing of droplets sufficient to disperse one phase into another;    allowing the at least one hydrogen siloxane, the at least one olefinic reactant capable of reacting with the at least one hydrogen siloxane, and the catalyst to reside in the one or more static mixing plug flow reactors such that substantially complete hydrosilation is effectuated; and    continuously withdrawing said silicone copolymer, said silicone copolymer being substantially free of unreacted hydrogen siloxane.    
     
     
         9 . A polyurethane foam produced by the reaction of: 
 a polyol;    polyisocyanate prepolymer;    a catalyst;    an optional auxiliary blowing agent; and    a silicone copolymer produced by feeding at least one hydrogen siloxane, at least one olefinic reactant capable of reacting with the at least one hydrogen siloxane, and a catalyst into one or more static mixing plug flow reactors having a static mixing element adapted to create turbulence of such intensity that a biphasic liquid mixture such as the at least one hydrogen siloxane and the at least one olefinic reactant undergo shearing of droplets sufficient to disperse one phase into another,    allowing the at least one hydrogen siloxane, the at least one olefinic reactant capable of reacting with the at least one hydrogen siloxane, and the catalyst to reside in the one or more static mixing plug flow reactors such that substantially complete hydrosilation is effectuated, and    continuously withdrawing said silicone copolymer, said silicone copolymer being substantially free of unreacted hydrogen siloxane.