Alkylene oxide polymerisation catalysts

Abstract: A catalyst for the polymerization of an alkylene oxide compound is composed of a phosphazene compound or a phosphazenium salt which is derived from the phosphazene compound and an active hydrogen compound. A poly(alkylene oxide) can be efficiently produced by polymerizing the alkylene oxide compound in the presence of the catalyst and, when the catalyst is composed of the phosphazene compound, the active hydrogen compound. The poly(alkylene oxide) contains no residual metal components and compared with those produced using conventional amine-base catalysts, has also significantly improved odor.

Description: This invention relates to a process for producing a poly(alkylene oxide) by polymerizing an alkylene oxide compound selected from propylene oxide, 1,2 butylene oxide and styrene oxide in the presence of an active hydrogen compound and a phosphazene compound. A poly(alkylene oxide) is an important polymer for its utility as a raw material for the production of polyurethane foams and elastomers through its reaction with organopolyisocyanate compounds and also as a surfactant. As practical catalysts for use in the production of a poly(alkylene oxide), basic alkali metal compounds such as potassium hydroxide have found wide-spread utility, for example. Concerning catalysts other than such catalyst, U.S. Patent No. 3,829,505 discloses to obtain a polymer from propylene oxide in the presence of an initiator while using, for example, a compound represented by Zn 3 [Fe(CN) 6 ] 2 ·H 2 O·dioxane as a catalyst. Japanese Patent Laid-Open No. 276821/1990 discloses to obtain a polymer by reacting sodium methylate with a polyol, which has been prepared using zinc hexacyanocobaltate as a catalyst, and polymerizing ethylene oxide in the presence of the reaction product. Further, Japanese Patent Laid-Open No. 232433/1987 discloses to obtain a polymer by polymerizing ethylene oxide while using a reaction product which has been obtained by adding a solution of diethyl zinc in hexane to a dispersion formed by adding 1,4-butanediol and a nonionic surfactant to a slurry of fumed silica in hexane. It is however known that, when a poly(alkylene oxide) is produced using a metal-containing catalyst such as those described above, a residue of the metal catalyst adversely affects a reaction upon production of polyurethane or physical properties of the resulting polyurethane. A special process or complex steps are therefore needed for the full elimination of such a metal residue upon production of a poly(alkylene oxide). Concerning metal-free catalysts, on the other hand, Japanese Patent Laid-Open No. 159595/1975 discloses the preparation of a polymer from ethylene oxide while using an ether adduct of boron trifluoride in the presence of an alkanepolyol. This catalyst is however also known to require extremely complex steps for the thorough elimination of its residue and moreover, a particular impurity in the polymer gives deleterious effects on certain physical properties of urethane. Further, according to Japanese Patent Laid-Open No. 12026/1982, a polymer of an alkylene oxide is obtained in the presence of an alcohol while using aminophenol or the like as a catalyst. According to Japanese Patent Laid-Open No. 38323/1981, on the other hand, propylene oxide is polymerized in the presence of sorbitol as an initiator and tetramethylammonium hydroxide as a catalyst. These processes are however accompanied by problems such that the catalysts do not have sufficient polymerization activities and an amine-like odor remains in the resulting polymers. Macromol. Symp 107 , 331-340 (1996), Esswein et al., is a lecture paper reportedly presented in Turkey on 4-8 September 1995. The paper discloses the use of a polyiminophosphazene base (t-Bu-P 4 ) as an activator or promoter for the polymerization of ethylene oxide, the polymerization being initiated in conjunction with 1-octanol or methanol. However, the rate of polymerization decreases with time until it becomes immeasurably low, which may be explained by a deactivation of the chain ends because of deactivation of the counter ion [t-Bu-P 4 ,H] + . The paper also discloses polymerization of ethylene oxide with butyl lithium in conjunction with t-Bu-P 4 , when the number of chain ends remained constant. An object of the present invention however is to provide a process using an improved catalyst system, which efficiently produces a poly(alkylene oxide) by polymerizing an alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide, and which does not cause an odor to remain in the product. To achieve the above-described object, the present inventors have proceeded with an extensive investigation. As a result, it has been found extremely effective to produce a poly(alkylene oxide) by polymerizing an alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide in the presence of specific active hydrogen compounds and specific metal-free phosphazene compounds. According to the present invention, there is provided a process for the production of a poly(alkylene oxide), which comprises reacting an alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide in the presence of an active hydrogen compound selected from polyhydric alcohols having 2 to 10 hydroxyl groups, and 2 to 20 carbon atoms saccharides or derivatives thereof, and oligo(alkylene oxide)s or poly(alkylene oxide)s, which are obtained by polymerizing alkylene oxides while using said active hydrogen compounds and a phosphazene compound selected from 1-tert-butyl-2,2,2-tri(dimethylamino)phosphazene, 1-(1,1,3,3-tetramethylbutyl)-2,2,2-tris(dimethylamino)phosphazene, 1-ethyl-2,2,4,4,4-pentakis(dimethylamino)-2λ 5 ,4λ 5 -catenadi(phosphazene), 1-tert-butyl-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene), 1-(1,1,3,3-tetramethylbutyl)-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene), 1-tert-butyl-2,2,2-tri(1-pyrrolidinyl)phosphazene, and 7-ethyl-5,11-dimethyl-1,5,7,11-tetraaza-6λ 5 -phosphaspiro[5.5]undeca-1(6)-ene, wherein said phosphazene compound is used in a range of from 1.0 x 10 -7 to 1.0 x 10 -2 mole per mole of the alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide, and said alkylene oxide compound is used in a range of from 2 to 1.0 x 10 5 moles per mole of said co-existing active hydrogen compound. The term "active hydrogen compound" as used in the process according to the present invention means a compound containing active hydrogen, selected from polyhydric alcohols having 2 to 10 hydroxyl groups and 2 to 20 carbon atoms such as ethylene glycol, propylene glycol, dipropylene glycol, trimethylolpropane, glycerin, diglycerin, triglycerin, pentaerythritol, dipentaerythritol, tripentaerythritol, 1,4-butanediol, 2-bentene-1,4-diol, 2-butyn-1,4-diol, 1,6-hexanediol and 1,4-cyclohexanediol; saccharides or derivatives thereof, such as sorbitol, dextrose and sucrose; and oligo(alkylene oxide)s or poly(alkylene oxide)s, which are obtained by polymerizing alkylene oxides while using these active hydrogen compounds described above as initiators. Of these, preferred are ethylene glycol; propylene glycol; glycerin; pentaerythritol; sorbitol; dextrose; sucrose; and poly(ethylene glycol), poly(propylene glycol) and copolymers thereof, whose molecular weights range from 90 to 10,000. The most preferred are propylene glycol or glycerin. If necessary, two or more of these active hydrogen compounds may be used in combination without any inconvenience. Among the phosphazene compounds, following can be mentioned, and they are used in the process of this invention : 1-tert-butyl-2,2,2-tris(dimethylamino)phosphazene [chemical formula (5)] 1-(1,1,3,3-tetramethylbutyl)-2,2,2-tris(dimethylamino)phosphazene [chemical formula (6)] 1-ethyl-2,2,4,4,4-pentakis(dimethylamino)-2λ 5 ,4λ 5 -catenadi(phosphazene) [chemical formula (7)] 1-tert-butyl-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene) [chemical formula (8)] 1-(1,1,3,3-tetramethylbutyl)-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene) [chemical formula (9)] 1-tert-butyl-2,2,2-tri(1-pyrrolidinyl)phosphazene [chemical formula (10)] 7-ethyl-5,11-dimethyl-1,5,7,11-tetraaza-6λ 5 -phosphaspiro[5.5]undeca-1(6)-ene [chemical formula (11)] In the process according to the present invention, these phosphazene compounds (5) to (11) can be used either singly or in combination. Synthesis processes of these phosphazene compounds are described in detail inter alia in H.R. Allcock, Phosphorus-Nitrogen Compounds, Academic Press 1972, Reinhard Schwesinger, Nachr. Chem. Tec. Lab., 38 (1990), Nr. 10, 1214-1226, and Reinhard Schwesinger, Chem. Ber., 1994, 127 2435-2454. In the process of this invention, two or more alkylene oxide compounds selected from propylene oxide, 1,2-butylene oxide and styrene oxide may also be used in combination. When a plurality of said alkylene oxide compounds are used and polymerized in combination at the same time, a copolymer of relatively high randomness is obtained although the randomness varies depending on a difference in reactivity between such compounds. When two or more of said alkylene oxide compounds are successively polymerized, a block copolymer containing blocks of two or more poly(alkylene oxide) compounds is obtained. For example, when a second alkylene oxide compound is successively polymerized subsequent to the completion of a polymerization reaction of a first alkylene oxide compound, a block copolymer containing two kinds of blocks is obtained. Further, an alternating block copolymer can be obtained by polymerizing the first alkylene oxide compound again subsequent to the completion of the polymerization of the second alkylene oxide compound or by repeating such alternate polymerization of the first and second alkylene oxide compounds. If three or more alkylene oxide compounds are used in combination in such a manner as described above, a more complex block copolymer can be obtained. Among these copolymerization processes, it is preferred to obtain a block copolymer, which contains blocks of poly(propylene oxide) (also called "polyoxypropylene") and poly(ethylene oxide) (also called "polyoxyethylene"), by successively polymerizing propylene oxide and ethylene oxide as alkylene oxide compounds. The alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide is used in an amount of 2 to 1.0 x 10 5 moles, preferably in a range of from 4 to 5 x 10 4 moles per mole of the co-existing active hydrogen compound when the polymerization is conducted in the presence of the active hydrogen compound and the phosphazene compound The amount of the phosphazene compound is in a range of from 1 x 10 -7 to 1 x 10 -2 mole per mole of the alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide. The polymerization temperature varies depending on the amounts of the raw material, initiator and catalyst. It is however generally 150°C or lower, preferably from 10 to 130°C, more preferably from 50 to 120°C. The reaction pressure upon polymerization of the alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide is dependent on the kinds and amounts of the raw material, initiator and catalyst and the polymerization temperature, and cannot be defined in a wholesale manner. In general, the pressure at the time of the reaction is 30 kg/cm 2 or lower (absolute pressure, this will hereinafter apply equally), with a range of from 0.1 to 10 kg/cm 2 being preferred and a range of from 1 to 5 kg/cm 2 being more preferred. The reaction time is dependent on the kinds and amounts of the raw material, initiator and catalyst and the polymerization temperature, and cannot be defined in a wholesale manner. It is however generally 40 hours or less, preferably 30 hours or less, more preferably 0.5 to 24 hours. The phosphazene compound catalyst in the process of the present invention can be used in combination with a conventionally-known catalyst with a view to reducing the work load which will be required for the removal of the catalyst subsequent to the polymerization. In the process of the present invention, no particular limitation is imposed on the method by which the polymerization reaction is carried out. However it is generally practiced to feed the alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide in an amount as much as needed at once, intermittently or continuously to a reactor which contains the active hydrogen compound and the phosphazene compound. In the process of the present invention, a solvent can also be used, as needed, for the dilution or dissolution of the active hydrogen compound and the phosphazene compound and the alkylene oxide compound or as a medium for the polymerization reaction. Usable examples of such a solvent include hydrocarbon compounds such as pentane, hexane, heptane and cyclohexane; aromatic hydrocarbons such as benzene and toluene; and ether compounds such as diethyl ether, dioxane and anisole. Any other solvents can also be used insofar as they do not interfere with the polymerization reaction in the process of the present invention. Further, the polymerization reaction in the process of this invention can also be conducted in the presence of an inert gas such as nitrogen or argon if necessary. The poly(alkylene oxide) obtained in accordance with the process of the present invention can be used, as is, as a raw material for a polyurethane foam or elastomer or as a surfactant but, if necessary, can also be used after treating it with a mineral acid such as hydrochloric acid, phosphoric acid or sulfuric acid, an organic carboxylic acid such as formic acid, acetic acid or propionic acid, carbon dioxide gas, an acid-form ion-exchange resin, or the like. Further, it can also be subjected to conventional purification such as washing in water, an organic solvent or a mixture thereof. The present invention will hereinafter be described by the following non-limiting examples. Example 1 In a 300-mℓ autoclave connected with a feed pump and a flowmeter, fitted with a temperature measuring tube, a pressure gauge and a stirrer, and purged with dry nitrogen, were charged 254 mmol of glycerin and 0.50 mmol of 1-(1,1,3,3-tetramethylbutyl)-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene) [chemical formula (9), product of Fulka Corp.; hereinafter referred to as the "catalyst A"]. Propylene oxide was polymerized at a reaction temperature of 100°C for 17.5 hours while intermittently charging it to maintain a reaction pressure of around 3.0 kg/cm 2 (absolute pressure; this will hereinafter apply equally). Polyoxypropylenetriol having a hydroxyl number of 358 (KOH mg/g polymer; this will hereinafter apply equally) was obtained in an amount of 119 g. It was in the form of a colorless clear odorless liquid. Example 2 In the same autoclave as that employed in Example 1, were charged 50 mmol of polyoxypropylenetriol (hereinafter abbreviated as the "triol A"), which had been industrially produced in the presence of potassium hydroxide as a catalyst while using glycerin as an initiator and had a hydroxyl number of 337, as an initiator and 0.50 mmol of 1-tert-butyl-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene) [chemical formula (8), product of Fulka Corp.; hereinafter referred to as the "catalyst B"]. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 4.8 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 84 was obtained in an amount of 75 g. It was in the form of a colorless clear odorless liquid. Example 3 In the same autoclave as that employed in Example 1, were charged 28.4 mmol of polyoxypropylenetriol (hereinafter abbreviated as the "triol B"), which had been industrially produced in the presence of potassium hydroxide as a catalyst while using glycerin as an initiator and had a hydroxyl number of 168, and 0.50 mmol of the catalyst B. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 2.3 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 78 was obtained in an amount of 61 g. It was in the form of a colorless clear odorless liquid. Further, using a PLgel column (5µ, "Mixed-D", trade name; manufactured by Polymer Laboratories Inc.) in combination with a GPC instrument ("Labchart 180II", trade name; manufactured by JIC Corp.), a molecular weight distribution of the polyoxypropylenetriol was measured (eluent: tetrahydrofuran). The molecular weight distribution as calculated based on a calibration curve which used the standard polystyrene was found to be narrow, that is, 1.03 in terms of Mw/Mn [a ratio of a weight average molecular weight (Mw) to a number average molecular weight (Mn)]. Example 4 In the same autoclave as that employed in Example 1, were charged 254 mmol of propylene glycol and 0.50 mmol of the catalyst B. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 16 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 200 was obtained in an amount of 123 g. It was in the form of a colorless clear odorless liquid. Example 5 In the same autoclave as that employed in Example 1, were charged 167 mmol of glycerin together with 83 mmol of sorbitol and 2.5 mmol of the catalyst A. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 120°C for 1.1 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 126 was obtained in an amount of 181 g. It was in the form of a colorless clear odorless liquid. Referential Example 6 The autoclave of Example 1 was additionally fitted with a piping to permit feeding of ethylene oxide in a liquid form under pressure from an ethylene oxide tank, which was designed to be maintained under a pressure of 5 kg/cm 2 with nitrogen, through a flowmeter arranged exclusively for ethylene oxide. The autoclave was charged with 150 mmol of ethylene glycol and 3.0 mmol of 1-ethyl-2,2,4,4,4-pentakis(dimethylamino)2λ 5 ,4λ 5 -catenadi(phosphazene) [chemical formula (5), product of Fulka Corp.; hereinafter referred to as the "catalyst C"] and further with 2.0 kg/cm 2 of nitrogen. Ethylene oxide was polymerized at a temperature of 80°C for 2.3 hours while intermittently charging it from the tank to maintain a reaction pressure of around 4.0 kg/cm 2 . Polyoxyethylenediol having a hydroxyl number of 197 was obtained in an amount of 76 g. It was in the form of a white odorless solid. Example 7 In the same autoclave as that employed in Example 1, were charged 125 mmol of ethylene glycol and 2.5 mmol of the catalyst A. 1,2-Butylene oxide was polymerized at a reaction pressure of around 2.0 kg/cm 2 and a reaction temperature of 100°C for 2.3 hours as in Example 1. Polyoxybutylenediol having a hydroxyl number of 184 was obtained in an amount of 69 g. It was in the form of a colorless clear odorless liquid. Example 8 In the same autoclave as that employed in Example 1, were charged 125 mmol of ethylene glycol and 2.5 mmol of the catalyst B. Further, 321 mmol of styrene oxide were added at once, followed by polymerization at a reaction temperature of 120°C and a reaction pressure of around 1.1 kg/cm 2 for 2.3 hours. Polyoxystyrenediol having a hydroxyl number of 303 was obtained in an amount of 38 g. It was colorless, clear and odorless. Referential Example 9 In the same autoclave as that employed in Referential Example 6, 50 mmol of the triol A and 0.50 mmol of the catalyst B were charged. Propylene oxide and ethylene oxide were polymerized at a reaction temperature of 100°C for 2.3 hours while continuously feeding them at a molar ratio of 7:3 so that a reaction pressure of around 4.0 kg/cm 2 was maintained. Polyoxypropylenepolyoxyethylenetriol copolymer having a hydroxyl number of 105 was obtained in an amount of 59 g. It was colorless, clear and odorless. Referential Example 10 In the same autoclave as that employed in Example 6, 254 mmol of trimethylolpropane and 0.50 mmol of the catalyst A were charged, followed by further charging of nitrogen to 2.0 kg/cm 2 . As in Example 6, ethylene oxide was polymerized at a reaction temperature of 80°C for 2.3 hours while intermittently feeding it to maintain a reaction pressure of around 4.0 kg/cm 2 . Polyoxyethylenetriol having a hydroxyl number of 580 was obtained in an amount of 47 g. It was a white odorless solid. Referential Example 11 In the same autoclave as that employed in Example 1, 100 mmol of N,N'-dimethylethylenediamine and 0.50 mmol of the catalyst A were charged. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 2.3 hours as in Example 1. Polyoxypropylenediol having a hydroxyl number of 590 was obtained in an amount of 69 g. It was in the form of a colorless clear odorless liquid. Example 12 In the same autoclave as that employed in Example 1, 502 mmol of pentaerythritol and 1 mmol of the catalyst A were charged. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 8.0 hours as in Example 1. Polyoxypropylenetetraol having a hydroxyl number of 662 was obtained in an amount of 69 g. It was in the form of a colorless clear odorless liquid. Example 13 In the same autoclave as that employed in Example 1, 50 mmol of the polyoxypropylenetriol obtained in Example 1 and 0.42 mmol of the catalyst A were charged. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 4.8 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 78 was obtained in an amount of 84 g. It was in the form of a colorless clear odorless liquid. Referential Example 14 In the same autoclave as that employed in Example 6, 20 mmol of 2-naphthol, 10 mℓ of toluene and 2.0 mmol of 1-tert-butyl-2,2,2-tris(dimethylamino)phosphazene [chemical formula (5), product of Fulka Corp.; hereinafter abbreviated as the "catalyst D"], followed by further charging of nitrogen to 2 kg/cm 2 . As in Example 6, ethylene oxide was polymerized at a reaction temperature of 80°C for 24 hours while intermittently feeding it to maintain a reaction pressure of around 4.0 kg/cm 2 . Polyoxyethylenemonool having a hydroxyl number of 5.8 was obtained in an amount of 192 g. It was a white odorless solid. Comparative Example 1 In the same autoclave as that employed in Example 1, 1 mole of glycerin and a (10 wt.%) solution of 2 mmol of tetramethylammonium hydroxide in methanol were charged. While heating the contents at 110°C under stirring, the methanol was removed under reduced pressure. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 36 hours as in Example 1. After that, the contents were heated at 150°C for 5 hours while eliminating volatiles under reduced pressure. The thus-obtained polyoxypropylenetriol still had a substantial amine odor. Its hydroxyl number was 1100, and its yield was 153 g. Comparative Example 2 In the same autoclave as that employed in Example 1, 106 mmol of the triol B employed in Example 3 and a (10 wt.%) solution of 1.9 mmol of tetramethylammonium hydroxide in methanol were charged. While heating the contents at 110°C under stirring, the methanol was removed under reduced pressure. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 9 hours as in Example 1. After that, the contents were heated at 150°C for 5 hours while eliminating volatiles under reduced pressure. The thus-obtained polyoxypropylenetriol had an amine odor. Its hydroxyl number was 110, and its yield was 56 g. Comparative Example 3 In the same autoclave as that employed in Referential Example 6, 425 mmol of trimethylolpropane and 1.8 mmol of 2,4,6-tris(dimethylaminomethyl)phenol (hereinafter abbreviated as "DMP-30") were charged, followed by further charging of nitrogen to 2 kg/cm 2 . As in Referential Example 6, ethylene oxide was polymerized at a reaction temperature of 80°C for 12 hours while intermittently feeding it to maintain a reaction pressure of around 4.0 kg/cm 2 . The contents were then cooled to 90°C, followed by the addition of a solution of 4 mg of 2,6-di-tert-butyl-p-cresol in 10 mℓ of methanol. After that, volatiles were eliminated under reduced pressure. The thus-obtained polyoxyethylenetriol had an amine odor. Its hydroxyl number was 647, and its yield was 67 g. Polymerization activities of the catalysts in Examples 1 to 14 and Comparative Examples 1 to 3 are summarized in Table 1. Example No. Catalyst Initiator Polymerization activities (g/mol-catalyst·Hr) Ex. 1 A Glycerin 13,600 Ex. 2 B Triol A 31,000 Ex. 3 B Triol B 53,000 Ex. 4 B Propylene glycol 15,400 Ex. 5 A Glycerin + Sorbitol 66,000 Ref. Ex. 6 C Ethylene glycol 11,000 Ex. 7 A Ethylene glycol 12,000 Ex. 8 B Ethylene Glycol 6,700 Ref. Ex. 9 B Triol A 51,000 Ref. Ex. 10 A Trimethylolpropane 41,300 Ref. Ex. 11 A N,N-dimethylethylenediamine 27,500 Ex. 12 A Pentaerythritol 12,700 Ex. 13 A Triol obtained in Example 1 35,000 Ref. Ex. 14 D 2-Naphthol 4,000 Comp. Ex. 1 (CH 3 ) 4 N·OH Glycerin 850 Comp. Ex. 2 (CH 3 ) 4 N·OH Triol B 3,300 Comp. Ex. 3 DMP-30 Trimethylolpropane 3,100 Referential Example 15 In a polymerization reactor similar to the autoclave in Referential Example 6, 254 mmol of glycerin and 0.50 mmol of the catalyst A were charged. 100 g of propylene oxide was polymerized at a reaction temperature of 100°C for 20 hours while intermittently feeding it to maintain the reaction pressure around 3.0 kg/cm 2 . After the reaction system was maintained at 10 mmHg for 30 minutes, the pressure of the reaction system was allowed to rise back to normal pressure with dry nitrogen. 80 g of ethylene oxide was then polymerized at a reaction temperature of 100°C for 15 hours while intermittently feeding it to maintain a reaction pressure of approximately 4.0 kg/cm 2 . After the reaction system was maintained at 10 mmHg for 30 minutes, the pressure of the reaction system was allowed to rise back to normal pressure with dry nitrogen. A block copolymer was obtained as a colorless clear odorless liquid in an amount of 192 g. Its hydroxyl number was 221. This block copolymer was polyoxypropylenepolyoxyethylenetriol which contained poly(propylene oxide) blocks and poly(ethylene oxide) blocks. The molar ratio of the monomer units in the respective blocks is about 1:1. Example 16 In a polymerization reactor similar to the autoclave in Example 1, 96 g of the catalyst-containing polyoxypropylenepolyoxyethylenetriol obtained in Referential Example 15 were charged. While intermittently feeding 49 g of propylene oxide again to the reactor to maintain the reaction pressure around 3.0 kg/cm 2 , it was polymerized at a reaction temperature of 110°C for 20 hours. After the reaction system was maintained at 10 mmHg for 30 minutes, the pressure of the reaction system was allowed to rise back to normal pressure with dry nitrogen and the contents were allowed to cooled down to room temperature. A block copolymer was obtained as a colorless clear odorless liquid in an amount of 144 g. Its hydroxyl number was 147. This block copolymer was polyoxypropylenepolyoxyethylenepolyoxypropylenetriol which contained poly(propylene oxide) blocks, poly(ethylene oxide) blocks and polypropylene oxide blocks. The molar ratio of the monomer units in respective blocks is 1:1:1 in this order. Referential Example 17 By reacting the catalyst A and methanol, 1,1,3,3-tetramethylbutylaminotris[tris(dimethylamino)phosphrany lideneamino]phosphonium methoxide (hereinafter called the "catalyst E") was synthesized as a phosphazenium salt. In a 300-mℓ of an eggplant type flask fitted with a reflux condenser, 10 mmol of the above-synthesized phosphazenium salt, 50 mℓ of toluene and 116 g of propylene oxide were charged. The propylene oxide was polymerized for 20 hours while maintaining the reaction temperature within a range of from 35 to 40°C. The contents were washed twice with 50 mℓ portions of 1 N HCl solution, and the toluene layer was concentrated to dryness. Polyoxypropylenemonool having a hydroxyl number of 5.4 was obtained in an amount of 112 g. It was a colorless clear odorless liquid. Referential Example 18 By reacting the catalyst B and phenol, tert-butylaminotris[tris(dimethylamino)phosphranilideneamino]phosphonium phenoxide was synthesized as a phosphazenium salt. In a 300-mℓ of an eggplant type flask fitted with a reflux condenser, 10 mmol of the above-synthesized phosphazenium salt, 50 mℓ of toluene and 116 g of propylene oxide were charged. The propylene oxide was polymerized for 20 hours while maintaining the reaction temperature within a range of from 35 to 40°C. The contents were subjected to similar post treatment as in Referential Example 17. Polyoxypropylenemonool having a hydroxyl number of 5.6 was obtained in an amount of 108 g. It was a colorless clear odorless liquid. Referential Example 19 In the same autoclave as that employed in Example 1, 254 mmol of methanol and 0.50 mmol of the catalyst E were charged. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 16 hours as in Example 1. Polyoxypropylenemonool having a hydroxyl number of 170 was obtained in an amount of 85 g. It was in the form of a colorless clear odorless liquid. Referential Example 20 By reacting the catalyst A and water, 1,1,3,3,-tetramethylbutylaminotris[(tris(dimethylamino)phosphora nylideneamino]phosphonium hydroxide (hereinafter called the "catalyst F") was synthesized as a phosphazenium salt. In the same autoclave as that employed in Example 1, 254 mmol of glycerin and 0.50 mmol of the above-synthesized phosphazenium salt were charged. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 100°C for 19 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 342 was obtained in an amount of 125 g. It was in the form of a colorless clear odorless liquid. Referential Example 21 By reacting 1-tert-butyl-2,4,4,4-tetra(pyrrolidin-1-yl)-2-tri(pyrrolidin-1-yl)phosphranilideneamino-2λ 5 ,4λ 5 -catenadi(phosphazene) and acetic acid, tert-butylaminopyrrolidin-1-ylbis[tri(pyrrolidin-1-yl)phosphoranilideneamino]phosphonium acetate was synthesized as a phosphazenium salt. In the same autoclave as that employed in Example 1, 254 mmol of glycerin and 5.10 mmol of the above phosphazenium salt were charged. Propylene oxide was polymerized at a reaction pressure of around 3.0 kg/cm 2 and a reaction temperature of 110°C for 17 hours as in Example 1. Polyoxypropylenetriol having a hydroxyl number of 464 was obtained in an amount of 95 g. It was in the form of a colorless clear odorless liquid. Referential Example 22 In a polymerization reactor similar to the autoclave in Referential Example 6, 254 mmol of glycerin and 3.05 mmol of the catalyst F were charged. While intermittently feeding 100 g of propylene oxide to maintain the reaction pressure around 3.0 kg/cm 2 , it was polymerized at a reaction temperature of 80°C for 12 hours. After the reaction system was maintained at 10 mmHg for 30 minutes, the pressure of the reaction system was allowed to rise back to normal pressure with dry nitrogen. While intermittently feeding 80 g of ethylene oxide again to the reactor to maintain the reaction pressure around 4.0 kg/cm 2 , it was polymerized at a reaction temperature of 100°C for 15 hours. After the reaction system was maintained at 10 mmHg for 30 minutes, the pressure of the reaction system was allowed to rise back to normal pressure with dry nitrogen and the contents were allowed to cool down to room temperature. A block copolymer was obtained as a colorless clear odorless liquid in an amount of 103 g. Its hydroxyl number was 213. This block copolymer was polyoxypropylenepolyoxyethylenetriol which contained poly(propylene oxide) blocks and poly(ethylene oxide) blocks. The molar ratio of the monomer units in the respective blocks is about 1:1. Example 23 In a polymerization reactor similar to the autoclave in Example 1, 101 g of the catalyst-containing polyoxypropylenepolyoxyethylenetriol obtained in Referential Example 22 were charged. While intermittently feeding 50 g of propylene oxide again to the reactor to maintain the reaction pressure around 3.0 kg/cm 2 , it was polymerized at a reaction temperature of 80°C for 12 hours. After the reaction system was maintained at 10 mmHg for 30 minutes, the pressure of the reaction system was allowed to rise back to normal pressure with dry nitrogen and the contents were allowed to cooled down to room temperature. A block copolymer was obtained as a colorless clear odorless liquid in an amount of 150 g. Its hydroxyl number was 145. This block copolymer was polyoxypropylenepolyoxyethylenepolyoxypropylenetriol which contained poly(propylene oxide) blocks, poly(ethylene oxide) blocks and polypropylene oxide blocks. The molar ratio of the monomer units in the respective blocks is about 1:1:1 in this order. By the present invention, a polyalkylene oxide can be efficiently produced by polymerizing an alkylene oxide compound, selected from propylene oxide, 1,2-butylene oxide and styrene oxide, in the presence of an active hydrogen compound and a phosphazene compound or in the presence of a phosphazenium salt of the active hydrogen compound derived from the active hydrogen compound and the phosphazene compound. Further, the thus-obtained polymer has the excellent features that it is free of any metal component and has been significantly improved in odor over polymers obtained using the conventional amine-base catalysts.

Claims: A process for the production of a poly(alkylene oxide), which comprises reacting an alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide in the presence of an active hydrogen compound selected from polyhydric alcohols having 2 to 10 hydroxyl groups and 2 to 20 carbon atoms, saccharides or derivatives thereof, and oligo(alkylene oxide)s or poly(alkylene oxide)s, which are obtained by polymerizing alkylene oxides while using said active hydrogen compounds and a phosphazene compound selected from 1-tert-butyl-2,2,2-tris(dimethylamino)phosphazene, 1-(1,1,3,3-tetramethylbutyl)-2,2,2-tris(dimethylamino-phosphazene, 1-ethyl-2,2,4,4,4-pentakis(dimethylamino)-2λ 5 ,4λ 5 -catenadi(phosphazene), 1-tert-butyl-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene), 1-(1,1,3,3-tetramethylbutyl)-4,4,4-tris(dimethylamino)-2,2-bis[tris(dimethylamino)phosphoranylideneamino]-2λ 5 ,4λ 5 -catenadi(phosphazene), 1-tert-butyl-2,2,2-tris(1-pyrrolidinyl)phosphazene, and 7-ethyl-5,11-dimethyl-1,5,7,11-tetraaza-6λ 5 -phosphaspiro[5.5]undeca-1(6)-ene, wherein said phosphazene compound is used in a range of from 1.0 x 10 -7 to 1.0 x 10 -2 mole per mole of the alkylene oxide compound selected from propylene oxide, 1,2-butylene oxide and styrene oxide, and said alkylene oxide compound is used in a range of from 2 to 1.0 x 10 5 moles per mole of said co-existing active hydrogen compound. The process of claim 1, wherein said active hydrogen compound is propylene glycol or glycerin.

Inventors: KOUNO MASAHIRO, MIZUTANI KAZUMI, NOBORI TADAHITO, TAKAKI USAJI, KOUNO, MASAHIRO, MIZUTANI, KAZUMI, NOBORI, TADAHITO, TAKAKI, USAJI
Applicants: MITSUI CHEMICALS INC, MITSUI CHEMICALS, INC.
Application year: 1996
Main classification: C08G65
IPC codes: C08G65