Preparation of lactone polymers using double metal cyanide catalysts

Claim 2

A process for producing a lactone polymer comprising contacting a reaction mixture containing at least one lactone monomer with a catalytically effective amount of a double metal cyanide compound for a time and at a temperature effective to polymerize the lactone monomer.

Claim 3

The process of claim 1 wherein the lactone has the general structure ##STR1## wherein n is an integer from 2 to 8, provided n is not 3, and R and R', which may be the same or different, are selected from the group consisting of hydrogen, alkyl, aryl, alkoxyl, and aralkyl.

Claim 4

The process of claim 1 wherein the reaction mixture additionally contains an active hydrogen-containing initiator.

Claim 5

The process of claim 1 wherein the reaction mixture additionally contains an organic solvent.

Claim 6

The process of claim 1 wherein the temperature is from about 40° C. to 125° C.

Claim 7

The process of claim 1 wherein the amount of double metal cyanide compound is from about 50 to 10,000 parts per million based on the weight of lactone monomer.

Claim 8

A process for producing a lactone polyol comprising contacting a reaction mixture containing at least one lactone monomer having the general structure ##STR2## wherein n is an integer from 2 to 8, provided n is not 3, and R and R', which may be the same or different, are selected from the group consisting of hydrogen, alkyl, aryl, alkoxyl, and aralkyl, an active-hydrogen containing initiator, and an organic solvent with from about 50 to 10,000 parts per million of a double metal cyanide compound at a temperature of from about 40° C. to 125° C. for a time effective to polymerize the lactone monomer.

Claim 9

A process for producing a lactone polyol comprising contacting a reaction mixture containing at least one lactone monomer having the general structure ##STR2## wherein n is an integer from 2 to 8, provided n is not 3, and R and R', which may be the same or different, are selected from the group consisting of hydrogen, alkyl, aryl, alkoxyl, and aralkyl, an active-hydrogen containing initiator, and an organic solvent with from about 50 to 10,000 parts per million of a double metal cyanide compound at a temperature of from about 40° C. to 125° C. for a time effective to polymerize the lactone monomer.

Claim 10

The process of claim 7 wherein the lactone monomer is ε-caprolactone.

Claim 11

The process of claim 7 wherein the active-hydrogen containing initiator is a polyalcohol having from 2 to 8 hydroxyl groups and a molecular weight of from about 50 to 1000.

Claim 12

The process of claim 7 wherein the organic solvent is an ether.

Claim 13

The process of claim 7 wherein the double metal cyanide compound is a zinc hexacyanocobaltate.

Claim 14

The process of claim 11 wherein the zinc hexacyanocobaltate is a zinc hexacyanocobaltate/zinc chloride/ glyme/water complex catalyst.

Claim 15

A process for producing a lactone-epoxide copolymer comprising contacting a reaction mixture containing at least one lactone monomer and at least one epoxide monomer with a catalytically effective amount of a double metal cyanide compound for a time and at a temperature effective to copolymerize the lactone monomer and epoxide monomer.

Claim 16

A process for producing a lactone-epoxide copolymer comprising contacting a reaction mixture containing at least one lactone monomer and at least one epoxide monomer with a catalytically effective amount of a double metal cyanide compound for a time and at a temperature effective to copolymerize the lactone monomer and epoxide monomer.

Claim 17

The process of claim 13 wherein the lactone has the general structure ##STR3## wherein n is an integer from 2 to 8, provided n is not 3, and R and R', which may be the same or different, are selected from the group consisting of hydrogen, alkyl, aryl, alkoxyl, and aralkyl.

Claim 18

The process of claim 13 wherein the epoxide monomer is selected from the group consisting of ethylene oxide, propylene oxide, 1,2-butene oxide, 2,3-butene oxide, styrene oxide, 1,2-pentene oxide, cyclohexene oxide, allyl glycidyl ether, and phenyl glycidyl ether.

Claim 19

The process of claim 13 wherein the reaction mixture additionally contains an organic solvent.

Claim 20

A process for producing a copolymer comprising contacting a reaction mixture of (1) a polymeric active hydrogen-containing initiator selected from the group consisting of epoxide polymers, lactone polymers, and epoxide-lactone copolymers, and (2) at least one cyclic monomer selected from the group consisting of lactones and lactone/epoxide mixtures with a catalytically effective amount of a double metal cyanide compound for a time and at a temperature effective to polymerize the cyclic monomer.

Claim 21

A process for producing a copolymer comprising contacting a reaction mixture of (1) a polymeric active hydrogen-containing initiator selected from the group consisting of epoxide polymers, lactone polymers, and epoxide-lactone copolymers, and (2) at least one cyclic monomer selected from the group consisting of lactones and lactone/epoxide mixtures with a catalytically effective amount of a double metal cyanide compound for a time and at a temperature effective to polymerize the cyclic monomer.

Claim 22

The process of claim 17 wherein the reaction mixture additionally contains an organic solvent.

Claim 23

The process of claim 17 wherein the polymeric active hydrogen-containing initiator is an epoxide polymer and the lactone is ε-caprolactone.

Claim 24

The process of claim 17 wherein the double metal cyanide compound is a zinc hexacyanocobaltate.