Appeal 2007-1639
Application 09/974,092
DISCUSSION
“The present invention relates to the production of trialkoxysilanes by
the Direct Synthesis of silicon with alcohols in the presence of a [nanosized]
copper catalyst” (Spec. 1: 10-12, and 6: 16-18). “This Direct Synthesis
exhibits short induction times, high selectivity for trialkoxysilanes, high
overall silicon conversion, and high, stable reaction rates” (id. at 1: 12-14).
Claim 1, the only independent claim, is representative:
1. A process for using a nanosized copper catalyst precursor
selected from the group consisting of nanosized copper,
nanosized copper oxides, nanosized copper chlorides, other
nanosized copper salts, and mixtures thereof as sources of
catalytic copper in the direct synthesis of trialkoxysilane of
formula HSi(OR)3 wherein R is an alkyl group containing from
1 to 6 carbon atoms inclusive, said process comprising:
(a) forming a reaction mixture comprising a thermally
stable solvent, silicon metal, a catalytically effective amount of
said nanosized copper catalyst precursor having an average
particle size in a range from about 30 to about 60 nanometers;
(b) agitating and heating this mixture to form copper-
activated silicon in situ and injecting into said reaction mixture
an alcohol to react with said copper-activated silicon to produce
said trialkoxysilane; and
(c) recovering said trialkoxysilane from the reaction
product.
The Examiner relies on the following reference as evidence of
obviousness:
Mendicino US 5,783,720 Jul. 21, 1998
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