Base-catalyzed, long chain, active polyethers from short chain DMC-catalyzed starters
View Patent ↗The present invention provides long chain, active polyether polyols which are characterized by a functionality of 2 to 6 and an equivalent weight of 1000 to 2200 Da. These long chain polyethers comprise the alkoxylation product of (1) a starter composition having an equivalent weight of 350 Da or less, with (2) one or more alkylene oxides, in which up to 20% of ethylene oxide may be added as a cap, in the presence of (3) at least one basic catalyst. Suitable starter compositions (1) comprise the alkoxylation product of (a) a low molecular weight polyether having a functionality of 3 and an equivalent weight of less than 350 Da, (b) at least one low molecular weight starter compound comprising glycerin, and (c) propylene oxide or a mixture of propylene oxide and ethylene oxide, in the presence of (d) at least one double metal cyanide catalyst. A process for preparing these long chain polyether polyols is also disclosed.
1. A long chain polyether polyol characterized by a functionality of 2 to 6 and an equivalent weight of 1000 to 2200 Da, and which comprises the alkoxylation product of
(1) a starter composition having an equivalent weight of 350 Da or less, and which comprises the alkoxylation product of
(a) a low molecular weight polyether having a functionality of 3 and an equivalent weight of less than 350 Da,
(b) at least one low molecular weight starter compound comprising glycerin,
and
(c) propylene oxide or a mixture of propylene oxide and ethylene oxide, with the weight ratio of propylene oxide to ethylene oxide ranging from 80:20 to 100:0,
in the presence of
(d) at least one double metal cyanide catalyst;
and
(4) a sorbitol started polyether polyol having a molecular weight of 1,000 to 2,000 and which is base catalyzed;
with
(2) one or more alkylene oxides, wherein up to 20% of ethylene oxide is added as a cap,
in the presence of
(3) at least one basic catalyst.
2. The long chain polyether polyol of claim 1 , wherein (3) said basic catalyst comprises a potassium hydroxide catalyst.
3. The long chain polyether polyol of claim 1 , which is characterized by a functionality of 2 to 4 and an equivalent weight of 1500 to 2000 Da.
4. The long chain polyether polyol of claim 1 , wherein (1)(a) said low molecular weight polyether has an equivalent weight of 150 to 280 Da, and (1)(c) comprises a mixture of propylene oxide and ethylene oxide in a weight ratio of 90:10 to 100:0.
5. The long chain polyether polyol of claim 1 , wherein (2) said one or more alkylene oxides are selected from the group consisting of propylene oxide and a mixture of propylene oxide and ethylene oxide.
6. A process for preparing a long chain polyether polyol characterized by a functionality of 2 to 6 and an equivalent weight of 1000 to 2200 Da, comprising:
(A) alkoxylating
(1) a starter composition having an equivalent weight of 350 Da or less, and which comprises the alkoxylation product of
(a) a low molecular weight polyether having a functionality of 3 and an equivalent weight of less than 350 Da,
(b) at least one low molecular weight starter compound comprising glycerin,
and
(c) propylene oxide or a mixture of propylene oxide and ethylene oxide, with the weight ratio of propylene oxide to ethylene oxide ranging from 80:20 to 100:0,
in the presence of
(d) at least one double metal cyanide catalyst;
and
(4) a sorbitol started polyether polyol having a molecular weight of 1,000 to 2,000;
(2) one or more alkylene oxides, wherein up to 20% of ethylene oxide is added as a cap,
in the presence of
(3) at least one basic catalyst.
7. The process of claim 6 in which the resultant long chain polyether polyol which is characterized by a functionality of 2 to 4 and an equivalent weight of 1500 to 2000 Da.
8. The process of claim 6 , wherein (1)(a) said low molecular weight polyether has an equivalent weight of 150 to 280 Da, and (1)(c) comprises a mixture of propylene oxide and ethylene oxide in a weight ratio of 90:10 to 100:0.
9. The process of claim 6 , wherein (2) said one or more alkylene oxides are selected from the group consisting of propylene oxide and a mixture of propylene oxide and ethylene oxide.
10. A polyurethane foam comprising the reaction product of a polyisocyanate component with an isocyanate-reactive component which comprises the long chain polyether polyol of claim 1 , in the presence of at least one blowing agent, at least one catalyst and at least one surfactant.
11. A process for preparing a polyurethane foam, comprising reacting a polyisocyanate component with an isocyanate-reactive component which comprises the long chain polyether polyol of claim 1 , in the presence of at least one blowing agent, at least one catalyst and at least one surfactant.
12. The process of claim 6 , wherein (3) said basic catalyst comprises a potassium hydroxide catalyst.