Polyether Polyols Primary Hydroxyl End Groups Double Metal Cyanide Catalysis

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Solution Overview

Problem

Current methods for producing polyether polyols with primary hydroxyl end groups using double metal cyanide catalysis are inefficient, leading to unwanted olefinic end groups and increased processing complexity, which affects the quality of polyurethane products.

Innovation Solution

A process involving reacting a starter compound with an epoxide in the presence of a double metal cyanide catalyst, followed by reaction with a cyclic carboxylic anhydride and then ethylene oxide using a nitrogen-containing catalyst, without the need for extensive purification, to produce polyether polyols with a high proportion of primary hydroxyl groups.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If KOH catalysis is used to produce polyether polyols with primary hydroxyl end groups, then the primary hydroxyl content is improved, but the process complexity and purification difficulty increase significantly

Engineering Contradiction:
Improveprimary hydroxyl end group contentVSAvoidpurification process complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a double metal cyanide catalyst as an intermediary substance to enable the polymerization reaction to produce polyether polyols with primary hydroxyl end groups. This catalyst mediates the reaction between the starter compound and epoxide, achieving the desired product structure without requiring complex purification processes. The catalyst works by facilitating the ring-opening polymerization of epoxide monomers while maintaining primary hydroxyl end groups, thus resolving the contradiction between product quality and process complexity.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If KOH catalysis is used for long-chain polyether production, then primary hydroxyl groups are formed, but olefinic end groups are generated as unwanted secondary products

Engineering Contradiction:
Improveprimary hydroxyl end group contentVSAvoidolefinic end group formation
Core Design Contradiction:
Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent changes the catalytic parameters from conventional KOH base catalysis to double metal cyanide catalysis. This parameter change fundamentally alters the reaction mechanism, allowing the polymerization to proceed without generating olefinic end groups as secondary products. The double metal cyanide catalyst enables a different reaction pathway that maintains primary hydroxyl end groups while avoiding the formation of unwanted olefinic groups, thus resolving the contradiction between achieving primary hydroxyl content and avoiding harmful byproducts.

Inventive Principle:
Principle #35Parameter changes

3Manufacturing precision

If conventional base catalysis is used, then polyether polyols with primary hydroxyl end groups can be obtained, but laborious separation and neutralization steps are required

Engineering Contradiction:
Improveprimary hydroxyl end group contentVSAvoidpurification time
Core Design Contradiction:
Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent employs a double metal cyanide catalyst that can be used in small quantities and does not require extensive purification or neutralization steps. Unlike KOH which requires laborious separation and neutralization, the double metal cyanide catalyst system is designed to be easily removable or deactivatable, significantly reducing the time and complexity of purification steps. This approach treats the catalyst as a disposable or easily removable component, resolving the contradiction between achieving primary hydroxyl content and minimizing purification time.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This process simplifies the production of polyether polyols by avoiding costly purification steps and minimizing the formation of unwanted olefinic end groups, resulting in polyols with high primary hydroxyl functionality and improved polyurethane product quality.

Implementation Method 1

reacting a starter compound containing active hydrogen atoms with an epoxide under double metal cyanide catalysis

Methodology Applied
Scientific EffectCatalysis: Catalysis

Implementation Method 2

reacting this resulting product with ethylene oxide in the presence of a catalyst containing at least one nitrogen atom per molecule

Methodology Applied
Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9029495B2Process for producing polyether polyols having primary hydroxyl end groups
Publication Date: 2015.05.12 COVESTRO DEUTSCHLAND AG
  • US9029495B2 patent drawing
  • US9029495B2 patent drawing
  • US9029495B2 patent drawing

AI summary

The present invention relates to a process for producing polyether polyols having primary hydroxyl end groups, comprising the steps of reacting a starter compound containing active hydrogen atoms with an epoxide under double metal cyanide catalysis, reacting the resulting product with a cyclic carboxylic anhydride and reacting this resulting product with ethylene oxide in the presence of a catalyst containing at least one nitrogen atom per molecule, excluding non-cyclic, identically substituted tertiary amines. The invention further relates to polyether polyols obtainable by this process, compositions containing said polyols and polyurethane polymers based on said polyols.