Arco Chemical Technology, L.p.

Lyondell Chemical Technology, L.p.

Ici Americas, Inc.

Equistar Chemicals, LP

Lau S Yang

Jeffrey A Klang

Gangfeng Cai

Diane A Macarevich

Diandre Armstead

Paul Puckett

Shau-Hua Guo

David W Leyshon

Russell J McCready

Lawrence J Karas

Alfred J Restaino

Charalambos J Phalangas

Krishnan Viswanathan

Jeffrey M McFarland

Ellen S Lenz

Daniel M Trauth

Patrice Gosset

Paul A Albano

Edmund Baylis

Keith G Johnson

Diane A Kooker

A method is disclosed for upgrading drip oil comprising subjecting the drip oil to multiple distillation steps to form a stream rich in aromatics and a separate stream rich in dicyclopentadiene.

Upgrading drip oil

A process for making dicyclopentadiene (DCPD)-containing polyesters is disclosed. The process comprises reacting 2-methyl-1,3-propanediol with maleic anhydride to form an acid terminated prepolymer and then reacting the prepolymer with a low grade DCPD to form DCPD-containing polyesters. The reaction of the prepolymer with DCPD is catalyzed by a transition metal triflate catalyst.

Preparation of dicyclopentadiene-containing unsaturated polyesters

A high performance UPR (unsaturated polyester resin) is disclosed. The UPR comprises recurring units of phthalic anhydride, 2-methyl-1,3-propanediol, and maleic anhydride. It has a fumarate/maleate ratio 85/15 or greater. It has a bi- or multi-modal molecular weight distribution. A high molecular weight portion of the UPR has a peak molecular weight (Mp) 50,000 or greater. It has a weight average molecular weight (Mw) 15,000 or greater. An ortho UPR of the invention performs as well as or better than traditional iso UPR.

High performance ortho UPR

A process for making unsaturated polyesters from 2-methyl-1,3-propanediol (MPD) is disclosed. The process comprises reacting one equivalent of an aromatic diacid with about two equivalents of MPD to produce an ester diol and then reacting one equivalent of the ester diol with from about 1.1 to about 1.9 equivalents of maleic anhydride to produce the polyester. The polyester has a fumarate/maleate ratio of 90/10 or greater.

Preparation of unsaturated polyesters

A two-step process for making reactive unsaturated polyester resins is disclosed. First, an aromatic dicarboxylic acid derivative reacts with 2-methyl-1,3-propanediol (MPD) to produce an ester diol intermediate. The intermediate reacts with maleic anhydride and from about 15 to about 40 mole percent, based on the total glycol requirement, of propylene glycol. By shifting some glycol to the second step, and by using propylene glycol there, resin producers can easily make MPD-based UPR having a fumarate content greater than 85%. The resins give thermosets with improved physical properties, including excellent water resistance.

Process for making reactive unsaturated polyester resins from 2-methyl-1, 3-propanediol

Miscible blends of epoxy-extended polyetherester resins and commercial polymer resins are disclosed. Thermosets from the resin blends offer high-performance physical properties at a reduced cost compared with that of commercial high-performance resins. The thermosets have improved physical properties, including excellent water resistance, compared with many commercial systems. Resin blends of the invention are readily thickened, and are thus useful for SMC applications.

Miscible blends of epoxy-extended polyetherester resins and commercial polymer resins

A general approach to making water-resistant polyetherester resins and thermosets is disclosed. In one aspect, an unsaturated polyetherester resin prepared by inserting a carboxylic acid derivative into a polyether is co-cured with a vinyl monomer and a di- or polyisocyanate to give a water-resistant, thermoset that has excellent dimensional stability, flexibility, and strength properties. Processes for making low-viscosity resins that give thermosets with good water resistance are also described. In one process, an unsaturated polyetherester resin intermediate reacts with a mono-functional isocyanate or fatty alcohol to produce an easy-to-formulate, low-viscosity, low-molecular-weight capped resin.

Process for making water-resistant polyetherester resins and thermosets

A process for making polyetherester resins is disclosed. A glycol ester of an aromatic diacid such as terephthalic acid is reacted with a polyether and a source of a dicarboxylic acid such as maleic anhydride to produce a polyetherester resin, wherein the aromatic diester content may be conveniently adjusted as desired. The process permits the preparation of unsaturated polyetherester resins with relatively high levels of terephthalate repeating units while avoiding the difficulties associated with the direct use of terephthalic acid in previously known procedures. Such unsaturated polyetheresters are useful for making thermoset resins with excellent mechanical and physical properties. New glycol esters based on 2-methyl-1,3-propanediol, and polyester resins and thermosets made from the glycol esters, are also disclosed.

Process for making polyetherester resins having high aromatic diester

Cured, thermoset plastic articles derived from scrap polyurethanes are disclosed. The polyurethane is converted to a liquified mixture containing digested polyurethane and cyclic, unsaturated anhydride. A Lewis acid then catalyzes insertion of the cyclic, unsaturated anhydride into the polyether backbone of the polyurethane to give a liquid, unsaturated resin. The unsaturated resin can cured with a vinyl monomer in the presence of a free-radical initiator to give a cured, thermoset plastic.

Cured polyester plastic compositions derived from recycled polyurethanes

A process for making polyetherester resins is disclosed. A glycol ester of an aromatic diacid such as terephthalic acid is reacted with a polyether and a source of a dicarboxylic acid such as maleic anhydride to produce a polyetherester resin, wherein the aromatic diester content may be conveniently adjusted as desired. The process permits the preparation of unsaturated polyetherester resins with relatively high levels of terephthalate repeating units while avoiding the difficulties associated with the direct use of terephthalic acid in previously known procedures. Such unsaturated polyetheresters are useful for making thermoset resins with excellent mechanical and physical properties.

A low-cost way to modulate the reactivity and acid number of polyetherester thermoset resins is disclosed. 'Beginning' and 'end' methods for making dicyclopentadiene (DCPD)-modified polyetherester resins are described. The 'beginning' method comprises first heating a polyether, DCPD, a diol, an insertion catalyst, and a carboxylic acid derivative to produce a mixture that contains the polyether and a DCPD-diol diester adduct. Increasing the temperature causes insertion of the DCPD-diol diester into the polyether to give a DCPD polyetherester resin. The 'end' method reacts a polyetherester resin made by insertion with DCPD to give a DCPD polyetherester resin. Compared with DCPD polyester resins, those of the invention give more flexible thermosets. Compared with unmodified polyetherester resins, the DCPD polyetherester resins offer formulators more control over curing, which eliminates mold distortion and shrinking or cracking of thermoset parts. Thermosets from blends of the subject resins and DCPD polyester resins show synergistic property improvements compared with thermosets from either resin alone.

Process for making dicyclopentadiene polyetherester resins

Processes for making storage-stable epoxy-capped polyetherester resins are disclosed. In one process, a polyetherester resin is first made by inserting a carboxylic acid derivative into a polyether. Reacting the resin with a capping agent gives an intermediate resin with a reduced content of free carboxylic acid groups. Finally, the intermediate resin reacts with an epoxy compound in the presence of a finishing catalyst under conditions effective to give an epoxy-capped resin. The resins have low weight average molecular weights (less than about 8000), narrow molecular weight distributions (less than 6), and low viscosities, making them an excellent choice for low-VOC formulations. The finishing catalyst helps to minimize resin viscosity drift and improves shelf stability. Curing the resins with a vinyl monomer gives thermosets with an excellent balance of physical properties, including excellent water resistance.

Process for making storage-stable epoxy-capped polyetherester resins

A process for making high-performance polyetherester resins and thermosets is disclosed. A polyether polyol reacts with a dicarboxylic acid or anhydride in the presence of an insertion catalyst to produce an acid-terminated polyetherester resin. Reaction of this resin reacts with a primary diol or a diepoxy compound gives a chain-extended polyetherester resin that can be cured with a vinyl monomer to produce a high-performance polyetherester thermoset. Properties of the thermosets rival or exceed those of more expensive high-performance iso and vinyl ester resins.

Process for making high-performance polyetherester resins and thermosets

Polymer blends of unsaturated polyetherester resins and dicyclopentadiene polyester resins give single-phase, cured thermosets having high tensile and flexural strength. The thermosets exhibit a single glass-transition temperature within the range of about 70.degree. C. to about 150.degree. C. The synergism resulting from polymer blending provides a cost-effective way to improve the strength properties of cured polyetherester thermosets, and coincidentally, gives a way to improve the flexibility and toughness of cured DCPD polyester thermosets. Glass-reinforced thermosets made from polyetherester resin blends show exceptional structural fatigue resistance.

Cured thermosets and glass-reinforced composites from unsaturated

Stable emulsions based on unsaturated polyetherester resins are disclosed. The emulsions have high stability compared with conventional emulsions that are based on unsaturated polyester resins. The invention includes base-stabilized emulsions, as well as emulsions containing fillers or functional additives. The emulsions, which are storage stable for weeks or months, are useful for making water-extended polyetherester thermosets having excellent physical properties, even at high water contents.

Growing community of inventors

Wilmington, DE, United States of America

Lau S Yang