Process and catalyst
United States Patent Udding et al.  
 PROCESS AND CATALYST Inventors: Anne C. Udding; Marie M.  
 Schlesser, both of Amsterdam.  
 Netherlands Assignee: Shell Oil Company, Houston. Tex.  
 Filed: Jan. 7, 1974 Appl. No.2 431,191  
 Foreign Application Priority Data Jan. 2, i973 Netherlands 7300007 vs. C] 260/2 A; 260/2 R; 260/2 D;  
  260/2 XA; 260/446 Int. Cl C08g 23/14 Field of Search 260/2 A, 2 XA, 615 B 51 Apr. 22, 1975 [56] References Cited UNITED STATES PATENTS 3.542.828 1 H1970 Harris 260/446 Primary Examiner-Morris Liebman Assistant Examiner-E. A. Nielsen [57] ABSTRACT 3 Claims, No Drawings PROCESS AND CATALYST BACKGROUND OF THE INVENTION 1. Field of the Invention This invention is drawn to a novel catalyst for the polymerization of organic cyclic ethers, and the polymerization of cyclic ethers using the novel catalyst.  
 2. Prior Art The use of certain ammonium hexafluoroantimonates as an acid catalyst for the polymerization of organic cyclic ethers has already been described in U.S. Pat. No. 3.542.828 issued to James J. Harris on November 24. 1970. The preferred anti&#39;monate was anilinium hexafluoroantimonate. [C.;H NH  
  Two properties are very important in regard to the selection ofa catalyst for commercial use; l the catalyst must give a high yield of polymer per unit catalyst per unit time and (2) the molecular weight of the polymer must be in the desired range. The proper balance between the two properties has not fully been met by existing catalyst. The known organic ammonium hexafluoroantimonates. for example the preferred anilinium hexafluoroantimonate, can be used at higher temperatures in an effort to increase the rate of polymerization but this leads to a lowering of the molecular weight of the resulting polyether. By contrast, the hydroxylamine catalysts of the present invention give yields of polymer per mol. 7( of catalyst per unit of times that are about 9-25 times those obtained with the previously disclosed preferred simple amine catalysts. It is the presence of the hydroxyl group attached to the amine as contrasted with the known simple amines which imparts the unexpected high polymerization activity. This increase in activity allows the catalysts of this invention to be used at temperatures lower than previously claimed, thereby giving control over the molecular weight of the polymer.  
 The polymers made by the process and catalysts of this invention are useful as starting materials in the preparation of polyurethanes.  
 SUMMARY OF THE INVENTION The invention is a novel class of organic hydroxylammonium hexafluoroantimonate catalysts and a process for the polymerization of organic cyclic ethers containing 2-6 carbon atoms inclusive using said catalysts.  
 DESCRIPTION OF THE PREFERRED EMBODIMENTS The catalysts of the present invention are represented by the formula:  
  I OH 2 methyl. ethyl. phenyl. benzyl. o-. m-. or ptolyl. -methoxyphenyl. -fluorophenyl and -chlorophenyl. such as m-chlorophenyl. The preferred groups are tolyl and/or benzyl groups: benzyl is particularly preferred.  
  Preferred catalysts are: monoand diphenylhydroxylammonium hexafluoroantimonate. monoand dibenzylhydroxylammonium hexafluoroantimonate monoand bis(m-chlorophenyl)hydroxylammonium hexafluoroantimonate and monoand bis(p-tolyl)hydroxylammonium hexafluoroantimonate. Dibenzylhydroxylammonium hexafluoroantimonate is particularly preferred.  
  The hydroxylammonium hexafluoroantimontimonates according to the invention may be prepared in any suitable manner.  
  Preferred processes for the preparation of the catalyst of this invention include (I contacting an organic hydroxylamine having the formula RR N-OH where R and R are defined as above with fluoroantimonic acid (HSbF (2). contacting the hydrogen fluoride salt of the relevant hydroxyl amine having the formula [RR-NH--OH] F where R and R are defined as above with antimony pentafluoride (SbF or (3). as particularly preferred. contacting an alkali metal salt or the NH salt of hexafluoroantimonic acid with a salt of the relevant hydroxylamine said salt being derived from an acid which will produce an isopropanol insoluble salt with alkali metal or ammonium ion. A preferred alkali metal is sodium. but particularly preferred is potassium. The preferred acids used to form the hydroxylammonium salts are sulfuric, nitric or a hydrogen halide. The particularly preferred acid for forming the hydroxylammonium salts is hydrogen chloride.  
  The hydroxylammonium hexafluoroantimenates having the general formula (I) have been found to be particularly suitable as catalysts for the homopolymerization and/or copolymerization of cyclic ethers-which in addition to one oxygen atom contain 2 to 6 carbon atoms in a ring or preferably 2 to 4 carbon atoms in a ring. The use of the word polymerization is to be taken to generally mean homopolymerization or copolymerization. The cyclic ether monomers used in the present invention are represented by the formula:  
 where n is an integer from 1 to 5 inclusive, R individually is a hydrogen, alkyl, alkyl halide, alkoxy, aryl or aryl halide or aryloxy group, the total number of carbon atoms in the monomer range from 2 to 20 inclusive preferably 2 to 10 inclusive, and at least one R attached to the carbon atom attached to the oxygen of the cyclic ether ring is a hydrogen. Examples of suitable monomers are: propylene oxide, ethylene oxide, isobutylene oxide, styrene oxide, tetrahydrofuran, epichlorohydrin. and phenyl glycidyl ether. Preferred monomers are propylene oxide and ethylene oxide. With some of the monomers in question the homopolymerization proceeds considerably slower than with certain other more reactive monomers. Thus. for instance. tetrahydrofuran has a relatively low reaction rate as compared with propylene oxide. However, in such cases excellent results are generally obtained if the less reactive monomer is copolymerized with another more reactive monomer. As monomers for the copolymerization it is preferred to select propylene oxide and tetrahydrofuran. However. a homopolymerization is normally preferred and the most preferred monomer is propylene oxide.  
  The amount of catalyst used may vary within wide limits. but is usually not more than about 0.1 mol 7! (based on the monomer), preferably between about 0.005 and about 0.075 mol 7:. and particularly preferred between about 0.010 and about 0.020 mol It has been found favorable to carry out the polymerization according to the invention in the presence of one or more compounds which promote the formation of alcoholic hydroxyl end groups. In the present application such compounds are designated as initiators. The initiators are not necessary for the polymerization but do offer a convenient method of producing polyols. Suitable initiators are organic compounds containing 2 to or preferably 2 to 3 primary and/or secondary hydroxyl groups inclusive. Examples of suitable alkane polyols or polyether polyols, are ethylene glycol. glycerol. 1.4-butanediol. sorbitol. sucrose and pentaerythritol. Polyols having 2-20 carbon atoms. in particular 2-10 carbon atoms in the molecule are usually preferred. The choice of a suitable initiator depends, inter alia. on the desired proportion of the (co)polymer to be prepared. Thus, for example, bifunctional initiators. in particular 1,4-butanediol, are particularly suitable for the preparation of polyether polyols which may serve as base material for the production of polyurethane elastomers. If, on the other hand. it is desired to prepare a polyether polyol which is intended as base material for the production of polyurethane foams. higher functional initiators which cause cross-linking are preferred. In this respect glycerol, for example, is very suitable. The amount of the initiator used determines the molecular weight of the resultant (co)polymer. As the amount of initiator increases. the molecular weight drops. The amount of initiator used is up to 20 mol 7:, based on the monomer. Initiator concentration between about 0.01 and 20 mol 7c is suitable, from about 0.05 to about 5 mol 7: is preferred and between 1.0 and 2.5 mol 72 is particularly preferred. (The use of polyols as initiators&#34; in cationic polymerization has been discussed in the book THE CHEMISTRY OF CATl- ONlC POLYMERlZATlON edited by P. H. Plesch, Macmillan Co., New York. 1963 and is referred to in US. Pat. No. 2,897,163 issued July 28, 1959).  
  The reaction temperature for the polymerization is selected from within a wide range. Suitable temperatures are normally between about 50C and about +150C, preferred between about 10C and about +100C, and particularly preferred between about C and about 60C. While the reaction rate generally increases as the temperature rises, it has been found that a higher reaction temperature often results in a decrease of the molecular weight of the resultant (co)- polymer. Where it is desired to prepare a product having a high molecular weight, for example 1500 (by hydroxyl group determination), it is often advantageous to select a temperature at which the reaction proceeds at a rate lower than the maximum. By using the particularly active catalysts according to the invention it is now possible to prepare products having a high molecular weight within a reasonable period of time at 4 relatively low temperatures. Thus, by polymerizing propylene oxide within 6 hours at approximately 36C polyether polyols having a molecular weight of, for example. 1500-5000 were obtained.  
  The polymerization is carried out at sub-, super or atmospheric pressure, but pressures suitable to contain the monomer in solution at the chosen reaction temperature are sufficient. Suitable pressures range between about 0.5 atmospheres and about 10 atmospheres. preferably between about 0.5 and about 5 atmospheres.  
  The polymerization may be carried out in the presence or absence of one or more inert solvents or diluents. Examples of solvents or diluents which are used, if desired, are benzene,-toluene, methylene chloride and hexane.  
  After completion of the polymerization, the catalyst can be removed from the product by washing with water. However, the catalyst is preferably neutralized by addition of a strong base to the resultant product. 1.4- Diazabicyclo-[2.2.2]octane has been found to be particularly suitable as strong base. The process of the invention is carried out batchwise or as a continuous process.  
 The polymers obtained in accordance with the process of the invention normally contain a considerable number of the hydroxyl groups present as primary OH- groups. for example approximately 50-60%. They are particularly suitable as starting materials for the preparation of polyurethanes by a reaction with, for example, bifunctional isocyanates, such as 4.4-diphenylmethane di-isocyanate and 2,4- and/or 2.6-tolylene diisocyanate. The resultant polyurethane rubbers may be thermoplastic and may be readily processed to shaped articles. Other applications are obviously also possible, for example as starting materials for the preparation of polyurethane foams.  
  To illustrate the manner in which the invention may be carried out, the following Embodiments are given. It is to be understood, however, that the Illustrative Embodiments are for the purpose of illustration and the invention is not to be regarded as limited to any of the specific materials or conditions recited herein,  
 Illustrative Embodiment I Catalyst Preparation A mixture of 600 ml of isopropyl alcohol and 200 ml of benzene was made anhydrous by azeotropic distillation during which distillation ml of distillate was removed. Subsequently, 10 g (0.04 mol) of dibenzylhydroxylammonium chloride and 11 g (0.04 mol) of KSbF were added successively and the resultant mixture was refluxed for 3 hours. After cooling, the resultant KCI (3 g) was removed by filtration, after which the solvents were removed from the filtrate by distillation at reduced pressure (approximately 20 mm Hg). Residues of isopropyl alcohol were removed from the remaining slurry by azeotropic distillation after addition of benzene (two portions of 50 ml). The crystallized product was finally filtered off and analysed. 15 G of dibenzylhydroxylammonium hexafluoroantimonate &#39;(l; R R C,,H CH were obtained which melted between and C. The yield was 83% of theory.  
 Analysis: C H ONsbF Calculated: C 37.36%; H 3.58%; N 3.11%: Sb  
  27.05% Found: C 36.6%; H 3.5%; N 3.03%; Sb 26.5%. In a similar manner p-tolylhydroxylammonium hexa- Illustrative Embodiment Ill Experiment 4 of Illustrative Embodiment II b) was repeated in an analogous manner. with the exception that the catalyst used was p-tolylhydroxylammonium I 2 ll gai ez i lhd yisld 20% o i the d if. CfiHl 5 hexafluoroantimonate. The resultant yield of polypropylene glycol was 80%. P musirdtlw Embodlmem H Illustrative Embodiment IV olymenzanon of propylene Dude Copolymerization of propylene oxide and a hSee tablle I, exgeripientslld and 6. l0 tetrahydrofuran e cata &#39;st an i em 0 ed. an initiator 1.4- butanediol dr glycerol). we se s uccessively introditced In a Smnlar way as diascrlbed m musimnve &#39;P into a 250-ml dry glass reaction vessel which was filled ment H a) a copolymenzauon was calmed out wlth tetwith nitrogen and provided with a cooling jacket. stirrahydmfumn l polypropylne Oxide as f h ref and reflux condenser After the catalyst had which were used in a molar rat1o ofl I. In this experisolved. a quantity of 100 ml of dry propylene oxide merit h PO gradual): added to the tetrahyqm&#39; (P0) was then gradually added to the mixture at a rate g h Presence f dlbengzllhydmxylammomum of approximately l-2 ml/min. with stirring. After exlfluolmdnnmonme caialybt .9 mol based l0-l5 minutes the mixture had reached the boiling gfl l g l4 byllmnedml as f mol temperature (36C), as a result of the exothermic reacon The Held of copollmer was tion. and the mixture was then stirred for another 6 Ill i Embodiment v hours (catalyst B) or 24 hours (catalyst A), while the I reflux condenser was cooled with isopropyl alcohol at Prepdmnon of polyurethane rubber -l0C. To neutralize the catalyst the stoichiometric 25 A quantity of 0.05 mol of polyethcrdio quantity of a strong base, viz.. 1,4-diazabicyclo [2.2.2] 2000) Obtained ZICCOrding I0 21 process analogous to octane was added to the resultant liquid polypropylene the one described in Illustrative Embodiment ll, experiglycol (PPG). ment 3, was carefully dried in a roundbottomed flask b) See Tabl l, e eri ent 4 d 5, by heating in vacuo (2 mm Hg) at 80C with stirring. The catalyst, u der nitr n, w s ha d t d After cooling to 60C.0.l molof4.4&#39;-diphenylmethane 50-ml polymerization tubes, the tubes being sub di-isocyanate was added and the mixture was subsequently sealed with a rubber stopper. A quantity of 10 qu ntly Stirred f r 2 hours at 80C. 0.05 mol of 1.4-  
 ml of propylene oxide and where appropriate 4 butanediol W215 then added added at 60C with stirring.  
 b di l was th dd d b means f i Th The resultant mixture was finally poured into a mold mixture was allowed to stand for 6 hours (catalyst B) and q n y heated un r pr ssure at 00C for or 24 hours (catalyst A). the temperature rising as a re- 24 hourssult of the exothermic reaction and subsequently drop- The resultant rubber Sheet 15 X l5 X m) as ping again. The catalyst was then removed from the retested in accordance with ASTM-melh0d D 12-468 sultant polypropylene glycols by washing with water. with the following results? The yields mentioned in Table A were obtained with 40 modulus at 300% elongation 1.1 MN/m (Mega Newtons per the novel catalyst according to the invention (B) after tensile Strength at break gsqh hzgtlimngeterl only 6 hours. whereas the yields obtained in the comelongation t br k 12457.  
 parative tests with a known catalyst (A), which in any musmnive Embodiment VI case were much lower, could only be obtained after 24 hours. Experiment 4 Illustrative Embodiment II is repeatedexcept dimethyammonium hexafluoroantimonate is TABLE I used as the catalyst. A satisfactory yield of polymer is Polymerization of propylene oxide with a known catobtained alyst A and with a catalyst according to the invention musmmve Embodlmem B Experiment 4 Illustrative Embodiment II is repeated A anilinium hexafluoroantimonate except p-tolylammonium hexafluoroantimonate is used B =dibenzylhydroxylammonium hexafluoroantimonas the catalyst. A satisfactory yield of polymer is obate tained.  
 Exp. Propylene/ Cat, 1.4-Butane- Yield of PPG Mol weight No. oxyde. ml mol &#39;7: diol, mol 7r A B B I) ll (7 mol/I00 mol of propylene oxide. Glycerol Illustrative Embodiment Vlll Experiment 4 Illustrative Embodiment ll is repeated except diphenylammonium hexafluoroantimonate is used as the catalyst. A satisfactory yield of polymer is obtained.  
 Illustrative Embodiment IX Experiment 4 lllustrative Embodiment II is repeated except methoxyphenylammonium hexafluoroantemonate is used as the catalyst. A satisfactory yield of polymer is obtained.  
 Illustrative Embodiment X Experiment 4 Illustrative Embodiment li is repeated except di(m-chlorophenyl)ammonium hexafluoroantimonate is used as the catalyst. A satisfactory yield of polymer is obtained.  
 I claim as my invention:  
  1. In the process of acid-catalyzed polymerization of organic cyclic ethers using represented by the formula where n is an integer from l to 5 inclusive. R individually is a hydrogen. alkyl. haloalkyl. alkoxy. aryl. or haloaryl. the total number of carbon atoms being from 2 to 20. inclusive. and at least one R attached to the car- R-e c dibenzlhydroxylammonium bon atom attached to the oxygen of the cyclic ether ring is a hydrogen catalytic amounts of salts of hexafluoroantimonic acid as catalyst and optionally organic polyols as initiators, the improvement which comprises using as the catalyst a hydroxylamonium hexafluoroantimonate having the formula;  
  o a [SbF6] based on propylene oxide.