Patent ID: 8470927

Claim:
A continuous process for the preparation of a polymer polyol (PMPO) comprising: a) introducing into a continuous reactor sufficient DMC catalyst/initial starter mixture to initiate polyoxyalkylation of the initial starter after introduction of alkylene oxide into the reactor; b) continuously introducing into the reactor at least one continuously added starter; c) continuously introducing into the reactor fresh DMC catalyst and/or further DMC catalyst/further starter mixture such that catalytic activity is maintained; d) continuously introducing into the reactor at least one unsaturated monomer; e) continuously introducing into the reactor at least one radical initiator; f) continuously introducing into the reactor at least one alkylene oxide and optionally, at least one polymer polyol (PMPO) stabilizer, to produce the polymer polyol (PMPO); and g) continuously removing the polymer polyol (PMPO) from the reactor, wherein the process simultaneously alkoxylates the starter and polymerizes the unsaturated monomer, thereby simultaneously forming a polyoxyalkylene polyol and forming discrete polymer particles to produce a polymer polyol (PMPO) in one reactor.