US5498583A
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US
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Polyurethane foam-supported double metal cyanide catalysts for polyol synthesis
Assignee: Lyondell Chemical Technology LP
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Filing: 1994-12-01
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Granted: 1996-03-12
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Expires: 2014-12-01
Abstract
Abstract Polyurethane foam-supported double metal cyanide (DMC) catalysts are disclosed as useful catalysts for epoxide polymerization. The foam-supported catalysts are easy to prepare, and are more active and show reduced induction periods compared with conventional powdered DMC catalysts. The catalysts of the invention can be recovered from the epoxide polymer products and can be reused to catalyze additional epoxide polymerizations.
Inventors
- 👤 Bi Le-Khac
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 21:58
CPC Classifications
B; B01; B01J; B01J27/00; B01J27/24; B01J27/26; B01J23/00; B01J23/70; B01J23/76; B01J23/80; B01J31/00; B01J31/02; B01J31/06; B01J31/068; B01J31/16; B01J31/22; B01J31/40; B01J31/4007; B01J31/4015; B01J31/4023; B01J31/403; B01J35/00; B01J35/50; B01J35/56; B01J37/00; B01J37/0009; C; C08; C08G; C08G18/00; C08G18/06; C08G18/28; C08G18/40; C08G18/48; C08G18/4829; C08G65/00; C08G65/02; C08G65/04; C08G65/06; C08G65/08; C08G65/10; C08G65/26; C08G65/2642; C08G65/2645; C08G65/2663; C08G65/2693; B01J2531/00; B01J2531/10; B01J2531/13; B01J2531/20; B01J2531/26; C08G2110/00; C08G2110/0008; C08G2110/0083; Y; Y02; Y02P; Y02P20/00; Y02P20/50; Y02P20/584
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
22 words
A polyurethane foam-supported DMC catalyst, wherein the DMC catalyst comprises at least about 70 wt. % of a substantially amorphous DMC complex.
Claim 2
Dependent Claim
22 words
A polyurethane foam-supported DMC catalyst, wherein the DMC catalyst comprises at least about 70 wt. % of a substantially amorphous DMC complex.
Claim 3
Dependent Claim
23 words
The foam-supported catalyst of claim 1 wherein the DMC catalyst comprises at least about 90 wt. % of a substantially amorphous DMC complex.
Claim 4
Dependent Claim
23 words
The foam-supported catalyst of claim 1 wherein the DMC catalyst comprises at least about 99 wt. % of a substantially amorphous DMC complex.
Claim 5
Dependent Claim
14 words
The foam-supported catalyst of claim 1 wherein the DMC catalyst is a zinc hexacyanocobaltate.
Claim 6
Dependent Claim
20 words
The foam-supported catalyst of claim 1 wherein the DMC catalyst is prepared using tert-butyl alcohol as an organic complexing agent.
Claim 7
Dependent Claim
97 words
A process for making a polyurethane foam-supported DMC catalyst, said process comprising: (a) intimately combining and reacting aqueous solutions of a water-soluble metal salt and a water-soluble metal cyanide salt in the presence of an organic complexing agent to produce an aqueous mixture that contains a precipitated DMC catalyst; (b) isolating the DMC catalyst, which comprises at least about 70 wt. % of a substantially amorphous DMC complex; and (c) reacting a polyol, a polyisocyanate, and water in the presence of a surfactant, a foaming catalyst, and the DMC catalyst, to produce a polyurethane foam-supported DMC catalyst.
Claim 8
Dependent Claim
97 words
A process for making a polyurethane foam-supported DMC catalyst, said process comprising: (a) intimately combining and reacting aqueous solutions of a water-soluble metal salt and a water-soluble metal cyanide salt in the presence of an organic complexing agent to produce an aqueous mixture that contains a precipitated DMC catalyst; (b) isolating the DMC catalyst, which comprises at least about 70 wt. % of a substantially amorphous DMC complex; and (c) reacting a polyol, a polyisocyanate, and water in the presence of a surfactant, a foaming catalyst, and the DMC catalyst, to produce a polyurethane foam-supported DMC catalyst.
Claim 9
Dependent Claim
22 words
The process of claim 6 wherein the DMC catalyst comprises at least about 90 wt. % of the substantially amorphous DMC complex.
Claim 10
Dependent Claim
22 words
The process of claim 6 wherein the DMC catalyst comprises at least about 99 wt. % of the substantially amorphous DMC complex.
Claim 11
Dependent Claim
13 words
The process of claim 6 wherein the DMC catalyst is a zinc hexacyanocobaltate.
Claim 12
Dependent Claim
13 words
The process of claim 6 wherein the organic complexing agent is tert-butyl alcohol.
Claim 13
Dependent Claim
48 words
A polyurethane foam-supported DMC catalyst which comprises: (a) a DMC catalyst; and (b) a polyurethane foam support; wherein the DMC catalyst comprises a DMC compound, an organic complexing agent, and from about 5 to about 80 wt. %, based on the amount of DMC catalyst, of a polyether.
Claim 14
Dependent Claim
48 words
A polyurethane foam-supported DMC catalyst which comprises: (a) a DMC catalyst; and (b) a polyurethane foam support; wherein the DMC catalyst comprises a DMC compound, an organic complexing agent, and from about 5 to about 80 wt. %, based on the amount of DMC catalyst, of a polyether.
Claim 15
Dependent Claim
25 words
The foam-supported catalyst of claim 11 wherein the polyether is not miscible with water and has a number average molecular weight greater than about 500.
Claim 16
Dependent Claim
14 words
The foam-supported catalyst of claim 11 wherein the DMC compound is a zinc hexacyanocobaltate.
Claim 17
Dependent Claim
14 words
The foam-supported catalyst of claim 11 wherein the organic complexing agent is tert-butyl alcohol.
Claim 18
Dependent Claim
28 words
The foam-supported catalyst of claim 11 wherein the polyether is a polyether polyol having a number average molecular weight within the range of about 1000 to about 10,000.
Claim 19
Dependent Claim
33 words
The foam-supported catalyst of claim 11 wherein the DMC catalyst is present in an amount within the range of about 1 to about 20 wt. % based on the amount of foam-supported catalyst.
Claim 20
Dependent Claim
85 words
A process for making a polyurethane foam-supported catalyst, said process comprising: (a) preparing a solid DMC catalyst comprising a DMC compound, an organic complexing agent, and from about 5 to about 80 wt. %, based on the amount of solid DMC catalyst, of a polyether having a number average molecular weight greater than about 500; and (b) reacting a polyol, a polyisocyanate, and water in the presence of a surfactant, a foaming catalyst, and the solid DMC catalyst, to produce a polyurethane foam-supported DMC catalyst.
Claim 21
Dependent Claim
85 words
A process for making a polyurethane foam-supported catalyst, said process comprising: (a) preparing a solid DMC catalyst comprising a DMC compound, an organic complexing agent, and from about 5 to about 80 wt. %, based on the amount of solid DMC catalyst, of a polyether having a number average molecular weight greater than about 500; and (b) reacting a polyol, a polyisocyanate, and water in the presence of a surfactant, a foaming catalyst, and the solid DMC catalyst, to produce a polyurethane foam-supported DMC catalyst.
Claim 22
Dependent Claim
13 words
The process of claim 17 wherein the DMC compound is a zinc hexacyanocobaltate.
Claim 23
Dependent Claim
13 words
The process of claim 17 wherein the organic complexing agent is tert-butyl alcohol.
Claim 24
Dependent Claim
39 words
A polyurethane foam-supported DMC catalyst which comprises: (a) a DMC catalyst; and (b) a polyurethane foam support; wherein the DMC catalyst contains a slight excess of a metal halide salt and is substantially crystalline by powder X-ray diffraction analysis.
Claim 25
Dependent Claim
39 words
A polyurethane foam-supported DMC catalyst which comprises: (a) a DMC catalyst; and (b) a polyurethane foam support; wherein the DMC catalyst contains a slight excess of a metal halide salt and is substantially crystalline by powder X-ray diffraction analysis.
Claim 26
Dependent Claim
32 words
The foam-supported catalyst of claim 20 wherein the DMC catalyst is a zinc hexacyanocobaltate, and the DMC catalyst has a Zn/Co molar ratio within the range of about 1.5 to about 1.8.
Claim 27
Dependent Claim
113 words
A process for making a polyurethane foam-supported DMC catalyst, said process comprising: (a) intimately combining and reacting aqueous solutions of a water-soluble metal salt and a water-soluble metal cyanide salt in the presence of an organic complexing agent to produce an aqueous mixture that contains a precipitated DMC catalyst, said water-soluble metal salt being used in an amount sufficient to produce a DMC catalyst containing a slight excess of the water-soluble metal salt; (b) isolating the DMC catalyst, which comprises a crystalline DMC complex; and (c) reacting a polyol, a polyisocyanate, and water in the presence of a surfactant, a foaming catalyst, and the DMC catalyst, to produce a polyurethane foam-supported DMC catalyst.
Claim 28
Dependent Claim
113 words
A process for making a polyurethane foam-supported DMC catalyst, said process comprising: (a) intimately combining and reacting aqueous solutions of a water-soluble metal salt and a water-soluble metal cyanide salt in the presence of an organic complexing agent to produce an aqueous mixture that contains a precipitated DMC catalyst, said water-soluble metal salt being used in an amount sufficient to produce a DMC catalyst containing a slight excess of the water-soluble metal salt; (b) isolating the DMC catalyst, which comprises a crystalline DMC complex; and (c) reacting a polyol, a polyisocyanate, and water in the presence of a surfactant, a foaming catalyst, and the DMC catalyst, to produce a polyurethane foam-supported DMC catalyst.
Claim 29
Dependent Claim
13 words
The process of claim 22 wherein the DMC compound is a zinc hexacyanocobaltate.
Claim 30
Dependent Claim
13 words
The process of claim 22 wherein the organic complexing agent is tert-butyl alcohol.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1999-03-12 | 1999-09-11 | 2000-03-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-03-12 | 2003-09-11 | 2004-03-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-03-12 | 2007-09-11 | 2008-03-12 | $7700.00 | Window Closed / Lapsed |