Abstract: A process of forming a polyol includes the steps of providing an alkylene oxide, providing an initiator composition having an average functionality of at least four, and providing an alkaline earth metal hydroxide and an amine. The process also includes the step of reacting the initiator composition and the alkylene oxide in the presence of the alkaline earth metal hydroxide and the amine to form the polyol. This allows the polyol to have consistent chain length and be formed with increased speed and in high yield, while reducing costs and maximizing efficiency. The polyol is reacted with an isocyanate and used to form a polyurethane article.

Abstract: A process of forming a polyol includes the step of providing an initiator composition. The initiator composition includes sucrose as a first initiator and glycerin as a second initiator. The process also includes the steps of providing a dimethylalkanolamine and providing an alkylene oxide. The process further includes the step of reacting the initiator composition, the dimethylalkanolamine, and the alkylene oxide at a pressure of at least 60 psig to form the polyol. After formation, the polyol is utilized in a process of forming a polyurethane article. The process of forming the polyurethane article includes the steps of providing an isocyanate component and providing the polyol. The process of forming the polyurethane articles also includes the step of reacting the isocyanate component and the polyol to form the polyurethane article. The polyurethane article includes the reaction product of the isocyanate component and the polyol.

Abstract: A carboxy-modified aluminum-based catalyst composition is of the general formula P(O)(OAlR?R?)3 or RP(O)(OAlR?R?)2 wherein O represents oxygen, P represents pentavalent phosphorous, Al represents aluminum, R comprises hydrogen, an alkyl group, or an aryl group, and R? and R? independently comprise a halide, an alkyl group, a haloalkyl group, an alkoxy group, an aryl group, an aryloxy group, or a carboxy group, so long as at least one of R? and R? is a carboxy group. The carboxy-modified aluminum-based catalyst composition is, generally, the reaction product of phosphoric acid or a pentavalent phosphonic acid, a tri-substituted aluminum compound, and a carboxylic acid.

Abstract: A polyurethane product includes an aluminum phosphate catalyst and/or a residue of the aluminum phosphate catalyst. The aluminum phosphate catalyst is originally present from a polyether polyol which is used in conjunction with an organic isocyanate to produce the polyurethane product. The aluminum phosphate catalyst may have the general structure of P(O)(OAlR?R?)3 wherein: O represents oxygen, P represents pentavalent phosphorous, Al represents aluminum, and R? and R? independently include a halide, an alkyl group, a haloalkyl group, an alkoxy group, an aryl group, an aryloxy group, or a carboxy group.

Abstract: A polyether polyol is formed by a method utilizing an aluminum phosphate catalyst. The method includes providing an alkylene oxide, providing an initiator molecule having at least one alkylene oxide reactive hydrogen, and reacting the alkylene oxide with the initiator molecule in the presence of the aluminum phosphate catalyst or a residue of the aluminum phosphate catalyst. The aluminum phosphate catalyst may have the general structure of P(O)(OAlR?R?)3 wherein: O represents oxygen; P represents pentavalent phosphorous; Al represents aluminum; and R? and R? independently comprise a halide, an alkyl group, a haloalkyl group, an alkoxy group, an aryl group, an aryloxy group, or a carboxy group.

Abstract: A method of forming a polyethercarbonate polyol enhances incorporation of CO2 into the polyethercarbonate polyol. The method provides a catalyst including a multimetal cyanide compound. The multimetal cyanide compound has an ordered structure defined by a cationic catalytic center and an anionic backbone with the anionic backbone spatially arranged about the cationic catalytic center. The anionic backbone is modified with a supplemental anionic spacer to affect the spatial arrangement and catalytic activity of the cationic catalytic center. The supplemental anionic spacer is incorporated into the multimetal cyanide compound to establish the general formula, M1a[M2b(CN)cMd3Xe]f, wherein M1, M2, and M3 are various metal ions and X is the supplemental anionic spacer. An H-functional initiator, an alkylene oxide, and CO2 are reacted in the presence of the modified multimetal cyanide compound to form the polyethercarbonate polyol.

Abstract: A polyethercarbonate polyol includes polyethercarbonate segments, polycarbonate segments, and polyether segments. A method of forming the polyethercarbonate polyol provides a catalyst, including a multimetal cyanide compound, and reacts an H-functional initiator, an alkylene oxide, and carbon dioxide in the presence of the multimetal cyanide compound to form the polyethercarbonate polyol. Amounts of each segment in the polyethercarbonate polyol are selectively controlled.

Abstract: A method of forming a polyethercarbonate polyol enhances incorporation of CO2 into the polyethercarbonate polyol. The method provides a catalyst including a multimetal cyanide compound. An H-functional initiator, an alkylene oxide, and CO2 are reacted in the presence of the multimetal cyanide compound in a reactor. The method further provides a CO2-philic compound or a CO2-philic substituent. The CO2-philic compound and substituent enhance incorporation of the CO2 into the polyethercarbonate polyol and reduce formation of cyclic alkylene carbonates, such as cyclic propylene carbonate, which are undesirable byproducts.

Abstract: The invention relates to starting compounds which can be used for the preparation of polyurethanes and can be prepared by reaction of hydroxyl-containing oligomers of formaldehyde.

Abstract: A resin composition includes a polyol and is used to form flexible foams. The resin composition also includes water and an alkoxylate of an active hydrogen containing species. The alkoxylate of the active hydrogen containing species acts in two separate ways. The alkoxylate acts as a blowing reaction modifier, thus maintaining slow-blow behavior of a foaming process that accompanies a reaction of the polyol with an isocyanate. The alkoxylate also acts as a compatibilizer. As the compatibilizer, the alkoxylate stabilizes the resin composition such that no phase separation occurs between the polyol, the water, and the alkoxylate. Stabilizing the resin composition allows for multiple day storage of the resin composition with no phase separation, thus extending useable shelf life and reducing production costs. Stabilizing the resin composition also allows for formation of flexible foams with consistent physical properties such as flexibility.

Abstract: A continuous process for preparation of a polyether polyol in a reactor includes introducing an initial starter/catalyst mixture into the reactor. The initial starter/catalyst mixture comprises an initial starter and a catalyst with the catalyst selected from aluminum phosphate catalysts and/or aluminum phosphonate catalysts and/or residues of these catalysts. In this continuous process, one or more alkylene oxide is continuously introduced into the reactor. Additional amounts of the catalyst and a continuous starter are also continuously introduced into the reactor. The polyether polyol prepared herein is continuously withdrawn from the reactor.

Abstract: A method of removing and reclaiming a double metal cyanide (DMC) catalyst from a polyol is disclosed. A polymeric acid that is soluble in the polyol is introduced into the polyol during or after the polymerization reaction. The polymeric acid reacts with the double metal cyanide catalyst thereby causing the double metal cyanide catalyst and the polymeric acid to form an agglomeration in the polyol. The agglomeration is easily separated from the polyol via filtration, for example. The recovered agglomerated DMC catalyst can then be reconstituted using an acid solution.

Abstract: A polyurethane product includes a carboxy-modified aluminum-based catalyst and/or residue of the catalyst. The catalyst is originally present from a polyether polyol which is used in conjunction with an organic isocyanate to produce the polyurethane product. The ideal carboxy-modified aluminum based catalysts used herein are selected from the group of carboxy-modified aluminum phosphate catalysts, carboxy-modified aluminum phosphonate catalysts, and residues or mixtures thereof.

Abstract: A carboxy-modified aluminum-based catalyst composition is of the general formula P(O)(OAlR?R?)3 or RP(O)(OAlR?R?)2 wherein O represents oxygen, P represents pentavalent phosphorous, Al represents aluminum, R comprises hydrogen, an alkyl group, or an aryl group, and R? and R? independently comprise a halide, an alkyl group, a haloalkyl group, an alkoxy group, an aryl group, an aryloxy group, or a carboxy group, so long as at least one of R? and R? is a carboxy group. The carboxy-modified aluminum-based catalyst composition is, generally, the reaction product of phosphoric acid or a pentavalent phosphonic acid, a tri-substituted aluminum compound, and a carboxylic acid.

Abstract: Catalyst suspensions for the ring-opening polymerization of alkylene oxides comprise a) at least one multimetal cyanide compound having a crystalline structure and a content of platelet-shaped particles of at least 30% by weight, based on the multimetal cyanide compound, and b) at least one organic complexing agent c) water and/or d) at least one polyether and/or e) at least one surface-active substance, with the proviso that at least component a) and at least two of the components b) to e) have to be present.