Dow Corning Corporation

Dow Silicones Corporation

Matthew J McLaughlin

Dimitris Katsoulis

Robert Thomas Larsen

Jonathan David Wineland

Aswini K Dash

Wendy Sparschu

Charles Alan Hall

Unnikrishnan R Pillai

Stephanie Berger

Robert Morgan

Kurt E Anderson

A method for preparing a reaction product including an aryl-functional silane includes sequential steps (1) and (2). Step (1) is contacting, under silicon deposition conditions, (A) an ingredient including (I) a halosilane such as silicon tetrahalide and optionally (II) hydrogen (H); and (B) a metal combination comprising copper (Cu) and at least one other metal, where the at least one other metal is selected from the group consisting of gold (Au), cobalt (Co), chromium (Cr), iron (Fe), magnesium (Mg), manganese (Mn), nickel (Ni), palladium (Pd), and silver (Ag); thereby forming a silicon alloy catalyst comprising Si, Cu and the at least one other metal. Step (2) is contacting the silicon alloy catalyst and (C) a reactant including an aryl halide under silicon etching conditions.

Method for producing aryl-functional silanes

A method of making a trihalosilane comprising contacting an organotrihalosilane according to the formula RS1X3 (I), wherein R is C-Chydrocarbyl and each X independently is halo, with hydrogen, wherein the mole ratio of the organotrihalosilane to hydrogen is from 0.009:1 to 1:2300, in the presence of a catalyst comprising a metal selected from (i) Re, (ii) a mixture comprising Re and at least one element selected from Pd, Ru, Mn, Cu, and Rh, (iii) a mixture comprising Ir and at least one element selected from Pd and Rh, (iv) Mn, (v) a mixture comprising Mn and Rh, (vi) Ag, (vii) Mg, and (viii) Rh at from 300 to 800&#xb0; C. to form a trihalosilane.

Method of making a trihalosilane

A method comprises separate and consecutive steps (i) and (ii). Step (i) includes contacting a copper catalyst with hydrogen gas and a halogenated silane monomer at a temperature of 500&#xb0; C. to 1400&#xb0; C. to form a silicon-containing copper catalyst comprising at least 0.1% (w/w) of silicon. Step (ii) includes contacting the silicon-containing copper catalyst with an organohalide at a temperature of 100&#xb0; C. to 600&#xb0; C. to form a reaction product. The organohalide has formula HCX, where X is a halogen atom, subscript a is an integer of 0 or more, subscript b is an integer of 1 or more, and subscript c is an integer of 2 or more. The method produces a reaction product. The reaction product includes a halogenated silahydrocarbylene.

Method of preparing halogenated silahydrocarbylenes

A method of preparing organohalosilanes comprising combining an organohalide having the formula RX (I), wherein R is a hydrocarbyl group having 1 to 10 carbon atoms and X is fluoro, chloro, bromo, or iodo, with a contact mass comprising at least 2% (w/w) of a palladium suicide of the formula PdSi(II), wherein x is an integer from 1 to 5 and y is 1 to 8, or a platinum suicide of formula PtSi (III), wherein z is 1 or 2, in a reactor at a temperature from 250 to 700&#xb0; C. to form an organohalosilane.

Method of preparing an organohalosilane

A method of preparing a diorganodihalosilane, the method comprising the following separate and consecutive steps: (a) treating a metal catalyst comprising a metal selected from the groups consisting of i) gold, ii) gold and copper, iii) gold, copper and magnesium, iv) copper, rhodium and gold, v) copper, rhodium, and rhenium, vi) rhenium and palladium, vii) copper, and viii) copper and magnesium with a mixture comprising hydrogen gas and an organotrihalosilane at a temperature from 500 to 1400&#xb0; C. to form a silicon-containing metal intermediate; and (b) reacting the silicon-containing metal intermediate with an organohalide according to the formula RX, wherein R is C-Chydrocarbyl and X is halo, at a temperature from 100 to 600&#xb0; C. to form a diorganodihalosilane and a depleted silicon-containing metal intermediate.

Method for preparing a diorganodihalosilane

A method of preparing a trihalosilane comprising the separate and consecutive steps of (i) contacting a copper catalyst with hydrogen gas and a silicon tetrahalide at a temperature of from 500 to 1400&#xb0; C. to form a silicon-containing copper catalyst comprising at least 0.1% (w/w) of silicon, wherein the copper catalyst comprises a metal selected from copper and a mixture comprising copper and at least one element selected from gold, magnesium, and platinum; and (ii) contacting the silicon-containing copper catalyst with a hydrogen halide at a temperature of from 100 to 600&#xb0; C. to form a trihalosilane.

Method for preparing a trihalosilane

A process for preparing organohalosilanes comprising combining hydrogen, a halosilane having the formula HSiX(I) and an organohalide having the formula RX (II), wherein R is C-Calkyl or C-Ccycloalkyl, each X is independently halo, and the subscript a is 0, 1, or 2, in the presence of a sufficient amount of a catalyst effective in enabling the replacement of one or more of the halo groups of the halosilane with the R group from the organohalide, at a temperature from 200 to 800&#xb0; C., to form an organohalosilane and a hydrogen halide, wherein the volumetric ratio of hydrogen to halosilane is from 1:3 to 1:0.001 and the volumetric ratio of hydrogen to organohalide is from 1:1 to 1:0.001, and wherein the catalyst is optionally treated with the hydrogen or the halosilane prior to the combining.

Preparation of organohalosilanes

A method of making a diorganodihalosilane contacting an organotrihalosilane according to the formula RSiX(I) with hydrogen in the presence of a metal catalyst comprising at least two metals and at a temperature from 300 to 800&#xb0; C. to form a diorganodihalosilane, wherein R is C-CQ hydrocarbyl, X is halo, and two of the at least two metals are chosen from at least one of (i) copper and palladium, (ii) copper and gold, (iii) indium and iridium or (iv) iridium and rhenium.

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Midland, MI, United States of America

Matthew J McLaughlin