Metal alkoxides, apparatus for manufacturing metal alkoxides, related methods and uses thereof

Abstract

Compounds, synthesis of, and methods for synthesizing metal alkoxide derivatives; and metal alkoxide derivatives for use as flame retardants are described. Group 13 metal alkoxides having flame retardant properties may be prepared by reacting the group 13 metal trihydroxide with an alcohol.

1 . A synthesis method comprising:
 contacting a first amount of a metal compound and a first amount of an alcohol in a reaction-distillation zone and, resulting from said contacting, forming a metal alkoxide from a reaction of said metal compound and said alcohol;   simultaneously with said contacting, removing reaction products from a vapor phase of said reaction-distillation zone;   simultaneously with said contacting, removing reaction products from a liquid phase of said reaction-distillation zone; and   simultaneously with said contacting, introducing into said reaction-distillation zone a second amount of said metal compound and a second amount of said alcohol.   
     
     
         2 . The synthesis method of  claim 1 , wherein said contacting is continuous. 
     
     
         3 . The synthesis method of  claim 2 , wherein said metal compound is a metal trihydroxide and said metal is selected from the group consisting of boron, aluminum and/or a combination thereof. 
     
     
         4 . The synthesis method of  claim 1 , wherein said alcohol is selected from the group consisting of glycerol, sorbitol, xylitol, mannitol, glyceroloxyglycerol, 1,3-propanediol, triethylene glycol monomethyl ether, glycerin laurate, di-N-butylethanolamine, beta-branched alcohols, salicylamide, lactamide, and/or a combination thereof. 
     
     
         5 . The synthesis method of  claim 1 , wherein said metal is a transition metal. 
     
     
         6 . The synthesis method of  claim 5 , wherein said transition metal is selected from the group consisting of titanium, zinc, manganese, cobalt, goethite, copper, silver, zirconium, nickel, chromium and/or a combination thereof. 
     
     
         7 . The synthesis method of  claim 1 , having a metal to alcohol ratio in the range of from 1 to 1 to about 1 to 6. 
     
     
         8 . The synthesis method of  claim 7 , wherein the metal to alcohol ratio is about 1 to 2. 
     
     
         9 . A reaction apparatus comprising:
 a reactor body comprising a corrosion resistant material, said reactor body having a hollow interior;   a rotor disposed within said hollow interior of said reactor body, said rotor configured to rotate and mix reaction components within said reaction body;   a condenser disposed within said hollow interior; and   a temperature regulating device disposed on an outside surface of said reactor body.   
     
     
         10 . The reaction apparatus of  claim 9 , further comprising at least one temperature regulating device to regulate temperature inside the reactor body within a temperature range of from about 0 to about 250° C. 
     
     
         11 . The reaction apparatus of  claim 9 , wherein said corrosion resistant material comprises steel and/or glass-lined steel. 
     
     
         12 . The reaction apparatus of  claim 9 , wherein said rotor comprises a corrosion resistant material. 
     
     
         13 . The reaction apparatus of  claim 12 , wherein said corrosion resistant material is selected from the group consisting of steel, glass-lined steel and/or 25% glass-filled PTFE. 
     
     
         14 . A reaction system comprising:
 a reactor comprising an acid resistant reactor body, said reactor body having a first inlet port, a first outlet port, a second outlet port, and a hollow interior, said hollow interior having a reaction-distillation zone disposed therein, said reaction-distillation zone comprising a vapor phase and a liquid phase;   a stream of reactants entering said first inlet port, said reactants comprising a metal compound and an alcohol;   a stream of vapor phase products exiting said first outlet port, said vapor phase products derived from a reaction of said metal compound and said alcohol; and   a stream of liquid phase products exiting said second outlet port said liquid phase products derived from a reaction of said metal compound and said alcohol.   
     
     
         15 . A reaction system comprising:
 a reaction apparatus comprising an acid resistant reactor body with a hollow interior having a reaction-distillation zone disposed therein, said reaction-distillation zone comprising a vapor phase and a liquid phase of a reaction between at least two reactants, said reactor body having at least one inlet port in contact with said reaction-distillation zone, a first outlet port in contact with said vapor phase, and a second outlet port in contact with said liquid phase;   a first feed vessel operably connected to said at least one inlet port, said feed vessel configured to continuously introduce said at least two reactants into said reaction-distillation zone;   a vapor phase removal device operably connected to said first outlet port, said vapor phase removal device configured to remove reaction products of said reaction from said vapor phase; and   an extraction device operably connected to said second outlet port, said extraction device configured to remove reaction products from said liquid phase.   
     
     
         16 . A flame retardant composition comprising a metal alkoxide additive of the formula M(OR) x , wherein x is an integer from 1 to 4, M is a group 13 metal, and R independently comprises a hydrogen, substituted alkyl group, unsubstituted alkyl group, substituted aryl group, unsubstituted aryl group, and/or a combination thereof. 
     
     
         17 . The flame retardant composition of  claim 16 , wherein M is selected from the group consisting of boron, aluminum and/or mixtures thereof. 
     
     
         18 . The flame retardant composition of  claim 16 , further comprising an amine stabilizing agent. 
     
     
         19 . The flame retardant composition of  claim 18 , wherein the amount of amine stabilizing agent is less than about 10% by weight of the flame retardant composition. 
     
     
         20 . The flame retardant composition of  claim 16 , wherein the metal alkoxide additive is in an amount of at least about 0.001 percent by weight of the flame retardant composition. 
     
     
         21 . The flame retardant composition of  claim 20 , wherein the metal alkoxide additive is in an amount of at least about 5% by weight of the flame retardant composition. 
     
     
         22 . The flame retardant composition of  claim 21 , wherein the metal alkoxide additive in an amount in of at least about 10% by weight of the flame retardant composition. 
     
     
         23 . The flame retardant composition of  claim 16 , wherein the metal alkoxide additive is in an amount of less than about 50% by weight of the flame retardant composition. 
     
     
         24 . The flame retardant composition of  claim 23 , wherein the metal alkoxide additive is in an amount of less than about 40% by weight of the flame retardant composition. 
     
     
         25 . The flame retardant composition of  claim 24 , wherein the metal alkoxide additive is in an amount of less than about 30% by weight of the flame retardant composition. 
     
     
         26 . The flame retardant composition of  claim 16 , wherein the metal alkoxide additive is hydroxylaluminum glycerolate. 
     
     
         27 . The flame retardant composition of  claim 16 , wherein the metal alkoxide additive is diglycerol borate.