Dow Global Technolgoies LLC

The Dow Chemical Company

Covestro LLC

Dow Brasil Sudeste Industrial Ltda

Dow Global Michigan Technologies Inc.

David A. Babb

Katherine S. Clement

Bobby R. Ezzell

David A Babb

Katherine S Clement

Jean-Paul Masy

Bobby R Ezzell

W Frank Richey

Carlos M Villa

Zenon Lysenko

Alan K Schrock

David Laitar

Richard J Keaton

Michael J Mullins

Thoi H Ho

H Craig Silvis

Clark H Cummins

Aaron W Sanders

Che-I Kao

Michael E Rowland

Timothy A Morley

Donald J Perettie

Mari S Rosen

Wendy D Hoenig

Edmund M Carnahan

Richard E Campbell, Jr

Eric S Moyer

Jeffrey Scott Kanel

Marius W Sorenson

Bharat Indu Chaudhary

Mark F Sonnenschein

Francois M Casati

David R Neithamer

James P Godschalx

William Aaron Koonce

Donald L Bunning

Brian Michael Roesch

Pulikkottil Jacob Thomas

Donald Lee Morrison

Grant B Jacobsen

Joe D Phillips

Gary E Spilman

Paul Joseph Popa

William Hoy Heath

Wenwen Li

Ted A Morgan

Edward R Peterson

Phillip S Athey

Seema V Karande

Arjun Raghuraman

Nathan Wilmot

Larry DeLynn Chambers

Hanno R Van Der Wal

Matthew Martin Yonkey

Matthew E Belowich

David K Steelman

Joost Depicker

Jasmijn Kuijper

James H Gilchrist

H Ray Jouett

Wei-Jun Peng

Steven J Martin

John W Weston

Adrian J Birch

Ricco B Borella

Christopher W Derstine

Kurt D Olson

John Tsavalas

Matthias Schaefer

Nima N Nikbin

Flor A Castillo

Larry D Bratton

Alvin P Kennedy

Zdravko P Jezic

Kenneth J Stutts

Robert H Terbrueggen

Bernard E Obi

Irena Amici-Kroutilova

P J Thomas

Dennis W Smith, Jr

Charles A Martin, Ii

Jason S Fisk

Eckel R Lane

Benjamin M DeKoven

Cecile Boyer

Robert E O'Neill

Brian Murdoch

Manjiri R Paradkar

Myriam Linke

Mrunmayi Kumbhalkar

Haifeng Shi

Fabio Aguirre

Robbyn Prange

Rafael Benavides

Min Zhang

Patrick Fontanella

Sweta Somasi

Mattias Schaefer

Donald Cameron

Pavel L Shutov

William L Heaner

Zdravko Jezie

Alvaro Pauperio-Neto

Embodiments relate to a method of producing a modified double metal cyanide complex, a method of producing a monol or polyol that includes providing the modified double metal cyanide complex, an alkylene oxide polymerization process that includes providing the modified double metal cyanide complex, a batch, semi-batch, or continuous manufacturing process that includes providing the modified double metal cyanide complex, and a polyether polyol prepared using the batch, semi-batch, or continuous manufacturing process that includes providing the modified double metal cyanide complex.

Polyether polymerization process

Polyethers are prepared by polymerizing an alkylene oxide in the presence of a double metal cyanide catalyst complex and certain Mmetal or semi-metal compounds. The double metal cyanide catalyst complex contains 0.5 to 2 weight percent potassium. The ability of this catalyst system to tolerate such high amounts of potassium permits the catalyst preparation procedure to be simplified and less expensive.

An alkylene oxide mixture containing greater than 50% by weight ethylene oxide is continuously polymerized in the presence of a double metal cyanide polymerization catalyst and an alkoxylated initiator having a hydroxyl equivalent weight of up to 200. The catalyst remains active, producing a polyol having an equivalent weight of up to 700 with a high oxyethylene content continuously at fast reaction rates.

Continuous process for making polyether polyols

Catalyst complexes include a zinc hexacyanocobaltate with Mmetal and Mmetal or semi-metal phases, wherein Mmetal is gallium, hafnium, manganese, titanium and/or indium and the Mmetal or semi-metal is one or more of aluminum, magnesium, manganese, scandium, molybdenum, cobalt, tungsten, iron, vanadium, tin, titanium, silicon and zinc and is different from the Mmetal. The catalysts are highly efficient propylene oxide polymerization catalysts characterized by rapid activation, short times to the onset of rapid polymerization and high polymerization rates once rapid polymerization has begun.

Catalyst complex

Polycarbonate polyols are made by copolymerizing carbon dioxide and an alkylene oxide in the presence of a starter compound and a carbonate catalyst. The process is operated in semi-batch mode by combining starter, catalyst and a small amount of alkylene oxide in a reaction vessel, pressurizing the vessel with carbon dioxide, initiating polymerization, and then feeding both carbon dioxide and alkylene oxide to the vessel under polymerization conditions without removal of product until the feeds are completed.

Semi-batch process for making polycarbonate polyols via copolymerization of carbon dioxide and an oxirane

A method of manufacturing a poly(ether-carbonate) polyol comprises a polymerization stage that includes polymerizing carbon dioxide and at least one alkylene oxide, with a starter, in the presence of a double metal cyanide polymerization catalyst and a catalyst promoter that is devoid of halide anions and cyanide. The catalyst promoter is separate from the double metal cyanide polymerization catalyst.

Polycarbonate based polyols

Alkylene oxide polymerizations are performed in the presence of a double metal cyanide polymerization catalyst and certain magnesium, Group 3-Group 15 metal or lanthanide series metal compounds. The presence of the magnesium, Group 3-Group 15 metal or lanthanide series metal compound provides several benefits including more rapid catalyst activation, faster polymerization rates and the reduction in the amount of ultra high molecular weight polymers that are formed. The catalyst mixture is unexpectedly useful in making polyethers having low equivalent weights.

Alkylene oxide polymerization using a double metal cyanide catalyst complex and a magnesium, group 3-group 15 metal or lanthanide series metal compound

High resiliency polyurethane foam is made from a polyether polyol having an equivalent weight of at least 1000. At least a portion of the polyether polyol is one or more random copolymer(s) formed by polymerizing a mixture of 70 to 95% by weight propylene oxide and 5 to 30% by weight ethylene oxide onto an initiator compound. The random copolymer(s) has a nominal hydroxyl functionality of at least 5, a hydroxyl equivalent weight of at least 1500 g/equivalent and no more than 0.01 milliequivalents per gram of terminal unsaturation. The randomly polymerized propylene oxide and ethylene oxide constitute at least 80% of the total weight of the random copolymer. At least 70% of the hydroxyl groups of the random copolymer are secondary hydroxyls.

High resiliency polyurethane foams made with high functionality, high equivalent weight polyols with mainly secondary hydroxyl groups

Polyether polyols are made by a process that includes a continuous addition of starter and alkylene oxide. The feed of starter is discontinued when 80 to 95% of the alkylene oxide has been fed to the reactor. This process produces a product with a narrow molecular weight distribution.

Process for preparing polyether polyol using DMC catalyst and continuous addition of starter

Embodiments of the present disclosure are directed to polyether-acetal polyol compositions, more particularly to polyol compositions including a polyether-acetal polyol that can be utilized to form polyurethanes. As an example, a polyurethane formulation can include a polyol composition including a polyether-acetal polyol functionalized with at least one acetal functional group, where the polyol composition has an average hydroxyl functionality from 2 to 8 and a hydroxyl equivalent weight from 150 to 4000, where the portion of the polyether-acetal polyol that is functionalized with the at least one acetal functional group is 1 percent to 40 percent of a total weight of the polyether-acetal polyol, where the polyether-acetal polyol has a primary hydroxyl group content of at least 55 percent, and a polyisocyanate, where the polyurethane formulation has an isocyanate index in a range from 70 to 500.

Polyether-acetal polyol compositions

Random poly(propylene oxide-co-ethylene oxide) polymers are made by polymerizing a mixture of propylene oxide and a small amount of ethylene oxide in the presence of a starter and a double metal cyanide catalyst complex, and then feeding in a mixture of propylene oxide and ethylene oxide while increasing the ethylene oxide concentration in the mixture to at least 90%. This produces a polyol suitable for making high resiliency polyurethane foam without need for adding an ethylene oxide cap.

Method for making propylene oxide/ethylene oxide copolymers using double metal cyanide catalysts, and copolymers so made

The instant invention provides an isocyanate trimerization catalyst system, a precursor formulation, a process for trimerizing isocyanates, rigid foams made therefrom, and a process for making such foams. The trimerization catalyst system comprises: (a) a phosphatrane cation; and (b) an isocyanate-trimer inducing anion; wherein said trimerization catalyst system has a trimerization activation temperature in the range of equal to or less than 73&#xb0; C. The precursor formulation comprises (1) at least 25 percent by weight of polyol, based on the weight of the precursor formulation; (2) less than 15 percent by weight of a trimerization catalyst system, based on the weight of the precursor formulation, comprising; (a) a phosphatrane cation; and (c) an isocyanate-trimer inducing anion; wherein said trimerization catalyst system has a trimerization activation temperature in the range of equal to or less than 73&#xb0; C.; and (4) optionally one or more surfactants, one or more flame retardants, water, one or more antioxidants, one or more auxiliary blowing agents, one or more urethane catalysts, one or more auxiliary trimerization catalysts, or combinations thereof. The process for trimerization of isocyanates comprises the steps of: (1) providing one or more monomers selected from the group consisting of an isocyanate, a diisocyanate, a triisocyanate, oligomeric isocyanate, a salt of any thereof, and a mixture of any thereof; (2) providing a trimerization catalyst system comprising; (a) an phosphatrane cation; and (b) an isocyanate-trimer inducing anion; (c) wherein said trimerization catalyst system has a trimerization activation temperature in the range of equal to or less than 73&#xb0; C.; (3) trimerizing said one or more monomers in the presence of said trimerization catalyst; (4) thereby forming an isocyanurate ring. The process for making the PIR foam comprises the steps of: (1) providing one or more monomers selected from the group consisting of an isocyanate, a diisocyanate, a triisocyanate, oligomeric isocyanate, a salt of any thereof, and a mixture of any thereof; (2) providing polyol; (3) providing a trimerization catalyst system comprising; (a) a phosphatrane cation; and (b) an isocyanate-trimer inducing anion; wherein said trimerization catalyst system has a trimerization activation temperature in the range of equal to or less than 73&#xb0; C.; and (4) optionally providing one or more surfactants, one or more flame retardants, water, one or more antioxidants, one or more auxiliary blowing agents, one or more urethane catalysts, one or more auxiliary trimerization catalysts, or combinations thereof; (5) contacting said one or more monomers, and said polyol, and optionally said one or more surfactants, and optionally said one or more flame retardants, and optionally said water, and optionally said one or more antioxidants, and optionally said one or more auxiliary blowing agents in the presence of said trimerization catalyst system and optionally said one or more urethane catalysts, and optionally said one or more auxiliary trimerization catalysts; (6) thereby forming said polyisocyanurate/polyurethane rigid foam. The PIR foam comprises the reaction product of one or more monomers selected from the group consisting of an isocyanate, a diisocyanate, a triisocyanate, oligomeric isocyanate, a salt of any thereof, and a mixture of any thereof with polyol in the presence of a trimerization catalyst system comprising a phosphatrane cation, and an isocyanate-trimer inducing anion, and optionally one or more surfactants, optionally one or more flame retardants, optionally water, optionally one or more antioxidants, optionally one or more auxiliary blowing agents, optionally one or more additional urethane catalysts, and optionally one or more auxiliary trimerization catalysts, or optionally combinations thereof, wherein the trimerization catalyst system has a trimerization activation temperature in the range of equal to or less than 73&#xb0; C. The PIR foam comprises the reaction product of one or more monomers selected from the group consisting of an isocyanate, a diisocyanate, a triisocyanate, oligomeric isocyanate, a salt of any thereof, and a mixture of any thereof with polyol in the presence of a trimerization catalyst system comprising a phosphatrane cation, and an isocyanate-trimer inducing anion, and optionally one or more surfactants, optionally one or more flame retardants, optionally water, optionally one or more antioxidants, optionally one or more auxiliary blowing agents, optionally one or more additional polyurethane catalysts, and optionally one or more auxiliary trimerization catalysts, or optionally combinations thereof, wherein the PIR foam has a polyisocyanurate trimer ratio (Abs/Abs) of at least 5 at a depth of 12 mm from the rising surface of the rigid foam, measured via ATR-FTIR spectroscopy.

Isocyanate trimerisation catalyst system, a precursor formulation, a process for trimerising isocyanates, rigid polyisocyanurate/polyurethane foams made therefrom, and a process for making such foams

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Lake Jackson, TX, United States of America

David A Babb