Arco Chemical Technology, L.p.

Bayer Materialscience, LLC

Covestro LLC

Bayer Antwerp, N.v.

Kenneth G McDaniel

John E Hayes

Jianzhong Shen

George Combs

Edward T Shawl

Karl W Haider

Don S Wardius

Harry R Hinney

Xinhau Zhou

Uli B Holeschovsky

Rick L Adkins

Jose F Pazos

Edward Browne

Mark J Perry

James R Reese, Ii

Maureen T Pence

George G Combs

Jack R Ii Reese

This invention relates to novel double metal cyanide catalysts and to a process for the production of these double metal cyanide catalysts. These DMC catalysts can be used to prepare polyoxyalkylene polyols which have low amounts of high molecular weight tail compared polyoxyalkylene polyols prepared from DMC catalysts of the prior art.

Catalyst for the production of polyols having lower amounts of high molecular weight tail

This invention relates to a process for preparation of polyether alkoxylated carbonates. These products may also be referred to as polyether polycarbonates. This process simultaneously transcarbonates and alkoxylates a mixture of one or more carbonate compounds, and one more hydroxyl group containing compounds, with at least one alkylene oxide in the presence of a mixture of catalysts. The catalyst mixture contains at least one DMC catalyst and at least one non-alkaline transesterification catalyst. This invention also relates to novel polyether polycarbonates, a process for preparing polyurethane foams from these novel polyether polycarbonates and to foams comprising these novel polyether polycarbonates.

Polyether carbonates by DMC catalysis

This invention relates to a novel process for preparing an aliphatic hybrid ester/ether polyol. This process simultaneously transesterifies and alkoxylates a mixture of at least one ester group containing compound which is free of ether groups, and at least one or more hydroxyl group containing compound which is free of ester groups; with the proviso that the mixture has an overall hydroxyl number of less than or equal to 350; with at least one alkylene oxide; in the presence of a mixture of catalysts. The catalyst mixture comprises at least one DMC catalyst, and at least one non-alkaline transesterification catalyst.

DMC catalyzed alkoxylation of esters

The present invention relates to a polyether carbonate polyol made by copolymerizing a starter molecule with carbon dioxide, at a pressure ranging from about 10 psia to about 2,000 psia, and an alkylene oxide, at a temperature ranging from about 50&#xb0; C. to about 190&#xb0; C. and in the presence of from about 0.001 wt. % to about 0.2 wt. % of a substantially non-crystalline double metal cyanide (DMC) catalyst, wherein the polyol has an incorporated carbon dioxide content of from about 1 wt. % to about 40 wt. %, wherein the ratio of cyclic carbonate by-product to total carbonate is less than about 0.3 and wherein the weight percentages are based on the weight of the polyol. The inventive polyether carbonate polyols may find use in producing polyurethane foams, elastomers, coatings, sealants and adhesives with improved properties.

Polyether carbonate polyols made via double metal cyanide (DMC) catalysis

The present invention provides a process for the production of an alkylphenol ethoxylate involving charging a portion of product from a previous preparation (a 'heel') or an ethoxylate to a reactor, optionally, charging from about 0.2 wt. % to an amount equal to or greater than the weight of the heel of an alkylphenol starter to the reactor, charging ethylene oxide to activate a double metal cyanide ('DMC') catalyst, adding the alkylphenol starter simultaneously with ethylene oxide for a portion of the process and continuing ethylene oxide addition following completion of the simultaneous alkylphenol starter and ethylene oxide addition. The process of the present invention provides significant improvements in cycle time and safety in producing ethoxylates which may find use in or as surfactants.

High productivity process for alkylphenol ethoxylates

The present invention provides a process for the double metal cyanide (DMC)-catalyzed production of low unsaturation polyethers from boron-containing starters. The polyethers produced by the inventive process may be reacted with one or more isocyanates to provide polyurethane products including coatings, adhesives, sealants, elastomers, foams and the like. The inventive process may be used to prepare fuel additives from C-Cboron-containing polyethers, more particularly from Calcohols.

Double metal cyanide-catalyzed, low unsaturation polyethers from boron-containing starters

Oleophilic polyoxyalkylene monoethers having reduced water affinity are disclosed. The monoethers have a hydrocarbyl residue, a polyoxyalkylene moiety, and a hydroxyl end group. The monoethers contain less than about 6 mole percent of alkoxylated unsaturates, and preferably less than about 5 mole percent of polyoxyalkylene diols. The monoethers offer substantial advantages for fuel compositions, particularly reduced water affinity. By using deposit-control additives based on the monoethers, formulators can offer better fuels for cleaner engines.

Polyoxyalkylene monoethers with reduced water affinity

Acidification, neutralization, or removal of basic impurities from acid sensitive low molecular weight starter or acidification of a reactor heel prior to addition of acid sensitive low molecular weight starter allows direct oxyalkylation of continuously added acid sensitive low molecular weight starter to produce polyoxyalkylene acid sensitive low molecular weight starter-initiated or co-initiated polyols in the presence of a double metal cyanide catalyst. The preferred acid sensitive low molecular weight starter is glycerine.

Direct polyoxyalkylation of glycerine with double metal cyanide catalysis

Unique, well defined macromonomers containing hydroxyl-functionality, unsaturation-functionality, and polyoxyalkylene segments are prepared by oxyalkylating an unsaturated initiator molecule having at least one oxyalkylatable hydrogen in the presence of an effective amount of a double metal cyanide complex catalyst, optionally, when necessary, in the presence of a free radical polymerization inhibitor. The resulting unsaturated macromonomers are eminently suitable for such uses as copolymerization with ethylenically unsaturated monomers containing carboxylic acid-based groups such as acrylic acid to form effective superplasticizers and water reducers for cement and concrete applications.

Copolymers useful as cement additives and a process for their preparation

Unique, well defined polyethers containing both hydroxyl-functionality and unsaturation-functionality are prepared by oxyalkylating an unsaturated monomer having at least two free carboxylic acid groups in the presence of an effective amount of a double metal cyanide complex catalyst, optionally, when necessary, in the presence of a free radical polymerization inhibitor. The resulting polyethers are eminently suitable for such uses as polymer polyol stabilizers or stabilizer precursors, and both in situ and ex situ impact modifiers for thermoplastics.

Stabilizers for polymer polyols

Unique, well defined polyethers containing both hydroxyl-functionality and unsaturation-functionality are prepared by oxyalkylating an unsaturated monomer having at least one oxyalkylatable hydrogen in the presence of an effective amount of a double metal cyanide complex catalyst, optionally, when necessary, in the presence of a free radical polymerization inhibitor. The resulting polyethers are eminently suitable for such uses as polymer polyol stabilizers or stabilizer precursors, and both in situ and ex situ impact modifiers for thermoplastics.

There is provided a cement composition having improved fluidity comprising cement and an addition copolymer of (a) an adduct of a polyether polyol and an ethylenically unsaturated isocyanate with (b) an ethylenically unsaturated carboxylic acid.

Cement composition

Reaction injection molded (RIM) or structural RIM (SRIM) resins having improved (prolonged) set times, that is, reduced reactivity, may be produced by the addition of an acid blocked amino acid salt catalyst as co-catalyst, or even as a sole catalyst. This permits large molds to be filled completely before cure. However, cure rates are not affected permitting high production rates. The physical properties of RIM and SRIM compositions do not suffer from the addition of these co-catalysts. The amino acid salts may have the formula: ##STR1## where R and R' are independently selected from the group consisting of hydrogen and alkyl having 1 to 12 carbon atoms; where the R' groups are independently alkylene groups having from 1 to 4 carbon atoms; where M is an alkali metal; and where x ranges from 1 to 4.

Rim compositions using amino acid salt catalysts

Polyols containing polyether and polyester moieties, based on phthalic acid are described. A phthalic acid derivative is reacted with a polyether polyol to give the novel polyols which are useful not only in polyisocyanurate foams, but also polyurethane foams as well. The phthalic acid derivative may be phthalic acid, phthalic anhydride and an ester of phthalic acid, for example. The polyester polyol is made from an initiator selected from the group consisting of alkanolamines, alkyleneamines, arylamines, sucrose, glycerin, sorbitol, .alpha.-methylglucoside, .beta.-methylglucoside, and mixtures thereof. The polyester polyol may be made by alkoxylating the initiators.

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Charleston, WV, United States of America

Kenneth G McDaniel