METHOD FOR THE PRODUCTION OF ISOCYANATE-GROUP TERMINATED POLYOXAZOLIDINONES

1 . A process for producing an isocyanate-group terminated polyoxazolidinone comprising the copolymerization of a polyisocyanate compound (A) having two or more isocyanate groups with a polyepoxide compound (B) having two or more epoxy groups in the presence of a catalyst (C);

wherein the molar ratio of the isocyanate groups of the polyisocyanate compound (A) to the epoxy groups of the polyepoxide compound (B) is larger than 2:1 and less than 25:1;

and wherein the catalyst (C) is at least one compound selected from the group consisting of

Li(I), Rb(I), Cs(I), Ag(I), Au(I),

Mg(II), Ca(II), Sr(II), Ba(II), Dy(II), Cu(II), Zn(II), V(II), Mo(II), Mn(II), Fe(II), Co(II)

Ni(II), Pd(II), Pt(II), Ge(II), Sn(II),

Sc(III), Y(III), La(III), Ce(III), Pr(III), Nd(III), Sm(III), Eu(III), Gd(III), Tb(III), Dy(III), Ho(III),

Er(III), Tm(III), Lu(III), Hf(III), Nb(III), Ta(III), Cr(III), Ru(III), Os(III), Rh(III), Ir(III),

Al(III), Ga(III), In(III), Tl(III), Ge(III),

Ce(IV), Ti(IV), Zr(IV), Hf(IV), Nb(IV), Mo(IV), W(IV), Ir(IV), Pt(IV), Sn(IV), Pb(IV),

Nb(V), Ta(V), Bi(V),

Mo(VI), W(VI), and

compounds represented by the formula (I)

[M(R1)(R2)(R3)(R4)]+ n Y n -  (I)

wherein M is phosphorous or antimony,

wherein (R1), (R2), (R3), (R4) are independently of one another selected from the group consisting of linear or branched alkyl groups containing 1 to 22 carbon atoms, linear or branched alkyl groups containing 1 to 22 carbon atoms substituted with heteroatoms and/or heteroatom containing substituents, cycloaliphatic groups containing 3 to 22 carbon atoms, cycloaliphatic groups containing 3 to 22 carbon atoms substituted with heteroatoms and/or heteroatom containing substituents, C1 to C3 alkyl-bridged cycloaliphatic groups containing 3 to 22 carbon atoms, C1 to C3 alkyl-bridged cycloaliphatic groups containing 3 to 22 carbon atoms substituted with heteroatoms and/or heteroatom containing substituents, aryl groups containing 6 to 18 carbon atoms, and aryl groups containing 6 to 18 carbon atoms substituted with one or more alkyl groups containing 1 to 10 carbon atoms and/or heteroatom containing substituents and/or heteroatoms,

wherein Y is a halide, carbonate, nitrate, sulfate or phosphate anion, and

wherein n is an integer of 1, 2 or 3.

2 . A process according to claim 1 , wherein the molar ratio of the isocyanate groups of the polyisocyanate compound (A) to the epoxy groups of the polyepoxide compound (B) is from 2.6:1 to 7:1.

3 . A process according to claim 1 , wherein the polyisocyanate compound (A) is an aliphatic polyisocyanate compound (A-1) and/or an aromatic polyisocyanate compound (A-2).

4 . A process according to claim 1 , wherein the polyepoxide compound (B) is an aliphatic polyepoxide compound (B-1) and/or aromatic polyepoxide compound (B-2).

5 . A process according to claim 1 , wherein the polyisocyanate compound (A) is an aliphatic polyisocyanate compound (A-1) and the polyepoxide compound (B) is an aliphatic polyepoxide compound (B-1).

6 . A process according to claim 1 , wherein the polyisocyanate compound (A) is an aliphatic polyisocyanate compound (A-1) and the polyepoxide compound (B) is an aromatic polyepoxide compound (B-2).

7 . A process according to claim 1 , wherein the polyisocyanate compound (A) is an aromatic polyisocyanate compound (A-2) and the polyepoxide compound (B) is an aliphatic polyepoxide compound (B-1).

8 . A process according to claim 1 , wherein the polyisocyanate compound (A) is an aromatic polyisocyanate compound (A-2) and the polyepoxide compound (B) is an aromatic polyepoxide compound (B-2).

9 . The process according to claim 1 , wherein the catalyst (C) is at least one compound selected from the group consisting of LiCl, LiBr, LiI, MgCl2, MgBr2, MgI2, SmI3, Ph4SbBr, Ph4SbCl, Ph4PBr, Ph4PCl, Ph3(C6H4-OCH3)PBr, Ph3(C6H4-OCH3)PCl, Ph3(C6H4F)PCl, and Ph3(C6H4F)PBr.

10 . The process according to claim 1 , wherein the catalyst (C) is used in a molar amount of 0.001 to 2.0 mol-%, based on the polyepoxide compound (B).

11 . The process according to claim 1 comprising the steps:

i) Mixing the polyisocyanate compound (A), the polyepoxide compound (B), and the catalyst (C) forming a mixture (i); and

ii) Copolymerizing the mixture (i) forming an isocyanate-group terminated polyoxazolidinone mixture (ii).

12 . The process according to claim 1 comprising the steps:

alpha) Mixing the polyepoxide compound (B), at least part of the catalyst (C), and at least part of a solvent (D) forming a mixture (alpha); and

beta) Addition of the polyisocyanate compound (A) to the mixture (alpha) at copolymerization conditions forming an isocyanate-group terminated polyoxazolidinone mixture (beta).

13 . A process according to claim 1 , wherein the non-reacted polyisocyanate compound (A) is removed by a thermal treatment method.

14 . An isocyanate-group terminated polyoxazolidinone obtained from a process obtainable according to claim 1 .

15 . The isocyanate-group terminated polyoxazolidinone according to claim 14 with an isocyanate equivalent weight (IEW) of from 100 g/eq to 10000 g/eq wherein determined via titration according to DIN EN ISO 11909:2007.

16 . The process according to claim 1 , wherein the process comprises the copolymerization of a polyisocyanate compound (A) having two or more isocyanate groups with a polyepoxide compound (B) having two or more epoxy groups in the presence of a catalyst (C) and in a solvent (D).

17 . The process according to claim 1 , wherein Y is a halide or carbonate.

18 . The process according to claim 1 , wherein M is phosphorous.

19 . The process according to claim 11 , wherein the process further comprises

iii) removal of unreacted polyisocyanate compound (A) from the isocyanate-group terminated polyoxazolidinone mixture (ii).

20 . The process according to claim 12 , wherein the process further comprises

gamma) removal of solvent (D) and/or unreacted polyisocyanate compound (A) from the isocyanate-group terminated polyoxazolidinone mixture (beta).