Method of preparation of a polyol block copolymer
AssigneeEconic Technologies Ltd.
InventorMichael Kember
Life of this patent
Estimating the term…
Abstract
A processfor producing a (poly)ol block copolymer comprising the reaction of a DMC catalyst with a polycarbonate or polyester (poly)ol (co)polymer and ethylene oxide, and optionally one or more other alkylene oxides, to produce a (poly)ol block copolymer wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups, and the copolymers and products incorporating such copolymers.
Claims32
A process for producing a (poly)ol block copolymer comprising the reaction of a DMC catalyst with a polycarbonate or polyester (poly)ol (co)polymer and ethylene oxide and optionally one or more other alkylene oxides to produce a (poly)ol block copolymer wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.
2-99. (canceled)
A process for producing a (poly)ol block copolymer comprising a first reaction in a first reactor and a second reaction in a second reactor;
- wherein the first reaction is the reaction of a carbonate catalyst with CO2 and alkylene oxide, in the presence of a starter and optionally a solvent to produce a polycarbonate (poly)ol copolymer and the second reaction is the reaction of a DMC catalyst with the polycarbonate (poly)ol copolymer of the first reaction, ethylene oxide and optionally one or more other alkylene oxides to produce a (poly)ol block copolymer, wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.
The process for producing a (poly)ol block copolymer according to claim 2, wherein the starter compound has the formula (III):
- .
- wherein Z can be any group which can have 1 or more, typically, 2 or more -RZ groups attached to it and may be selected from optionally substituted alkylene, alkenylene, alkynylene, heteroalkylene, heteroalkenylene, heteroalkynylene, cycloalkylene, cycloalkenylene, hererocycloalkylene, heterocycloalkenylene, arylene, heteroarylene, or Z may be a combination of any of these groups, for example Z may be an alkylarylene, heteroalkylarylene, heteroalkylheteroarylene or alkylheteroarylene group;
- a is an integer which is at least 1, typically, at least 2, optionally a is in the range of between 1 or 2 and 8, optionally a is in the range of between 2 and 6;
- wherein each RZ may be —OH, —NHR′, —SH, —C(O)OH, —P(O)(OR′)(OH), —PR′(O)(OH)2 or —PR′(O)OH, optionally RZ is selected from —OH, —NHR′ or —C(O)OH, optionally each Rz is —OH, —C(O)OH or a combination thereof (e.g. each Rz is -OH);
- wherein R′ may be H, or optionally substituted alkyl, heteroalkyl, aryl, heteroaryl, cycloalkyl or heterocycloalkyl, optionally R′ is H or optionally substituted alkyl;
- and
- wherein Z′ corresponds to Rz, except that a bond replaces the labile hydrogen atom.
The process according to claim 2, wherein the first reaction is carried out under CO2 pressure of less than 20 bar.
The process according to claim 2, wherein the first reaction is a batch, semi-batch, or continuous process.
The process according to claim 2, wherein the reactors are located in series.
The process according to claim 2, wherein the first and second reactors are effective to provide different reaction conditions, such as temperature and/or pressure, to each other simultaneously.
The process according to claim 2, wherein the temperature of reaction in the first reactor is in the range about 0° C. to 250° C.
The process according to claim 2 wherein the carbonate catalyst is a catalyst capable of producing polycarbonate chains with greater than 76% carbonate linkages.
The process according to claim 2, wherein the carbonate catalyst is a metal catalyst comprising phenol or phenolate ligands.
The process according to claim 2, wherein the product of the first reaction is used to pre-activate the DMC catalyst in the second reaction, prior to addition of ethylene oxide and optionally, alkylene oxide.
The process according to claim 2, wherein the same or different alkylene oxides are used in the first or second reactions.
An isocyanate terminated polyurethane prepolymer comprising a block copolymer residue according to claim 27.
Dependencies are inferred from the claim text.