Supported Double Metal Cyanide Catalyst for Epoxide Polymerization
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Solution Overview
Problem
There is a need for a cost-efficient and controllable method to catalyze the polymerization of epoxides, enabling the production of homo- and copolymers with high reaction rates and controlled molecular weight distribution, as existing DMC catalysts often require complex operations and additional reagents for residue removal.
Innovation Solution
A supported catalyst system comprising a double metal cyanide complex, organic complexing agents, and a hydrophobic support material, specifically designed for the ring-opening polymerization of epoxide monomers, which enhances reaction control and reduces catalyst agglomeration, allowing for efficient production of polyethers and polycarbonates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If DMC catalysts are used for epoxide polymerization, then polymerization activity and catalyst efficiency are improved, but catalyst residue removal complexity and process difficulty increase
Solution Approach 1:
The patent extracts and removes the harmful catalyst residues from the polymerization system by using a filtration system that selectively removes DMC catalyst complexes from the reaction mixture, allowing efficient polymerization to occur while simplifying residue removal through physical filtration rather than complex chemical treatment processes
Solution Approach 2:
The patent introduces an intermediary filtration medium that acts as a mediator between the catalyst and the polymerization products, enabling the catalyst to be removed from the system without interfering with the polymerization reaction or requiring complex additional reagents for residue elimination
2Reliability
If additional reagents are used for catalyst residue removal, then residue elimination effectiveness is improved, but process complexity and cost increase
Solution Approach 1:
The patent employs a self-service filtration approach where the filtration system automatically removes catalyst residues without requiring additional chemical reagents or complex processing steps, enabling the system to eliminate residues through physical separation mechanisms that are already integral to the polymerization process
3Ease of manufacture
If DMC catalysts are used without complexing agents, then catalyst synthesis simplicity is improved, but catalytic activity decreases
Solution Approach 1:
The patent incorporates complexing agents into the catalyst synthesis process in advance, preparing the DMC catalyst complexes with their associated ligands already bound during the formation stage, which ensures high catalytic activity is achieved from the outset without requiring subsequent complexing steps or additional reagents
Solution Approach 2:
The patent merges the catalyst formation and complexing agent incorporation into a single integrated synthesis process, combining the DMC complex preparation with the ligand binding step to produce active catalyst complexes that maintain both synthesis efficiency and high catalytic activity without requiring separate processing stages
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
The supported catalyst system achieves high reaction rates and controlled polymerization, reducing the amount of expensive transition metals and simplifying the removal of catalytic residues, thereby improving the efficiency and cost-effectiveness of epoxide-based polymer production.
Implementation Method 1
Double metal cyanide (DMC) compounds... are known in the art as catalysts for inter alia the ring-opening polymerization of epoxides to produce polyethers
Implementation Method 2
the supports can enable a reduction of the quantity of the DMC catalyst phase, thereby reducing the amount of expensive transition metals in the mixture
Data Source
AI summary
The present invention is directed to supported catalyst having utility in the polymerization and co-polymerization of epoxide monomers, said supported catalyst having the general Formula (I):[DMCC]*b Supp (I)wherein:[DMCC] denotes a double metal cyanide complex which comprises a double metal cyanide (DMC) compound, at least one organic complexing agent and a metal salt;Supp denotes a hydrophobic support material; and,b represents the average proportion by weight of said support material, based on the total weight of [DMCC] and Supp, and is preferably in the range 1 wt. %≤b≤99 wt. %.