METHOD OF PREPARATION OF A POLYOL BLOCK COPOLYMER

Abstract

A processfor producing a (poly)ol block copolymer comprising the reaction of a DMC catalyst with a polycarbonate or polyester (poly)ol (co)polymer and ethylene oxide, and optionally one or more other alkylene oxides, to produce a (poly)ol block copolymer wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups, and the copolymers and products incorporating such copolymers.

Claims

1. A process for producing a (poly)ol block copolymer comprising the reaction of a DMC catalyst with a polycarbonate or polyester (poly)ol (co)polymer and ethylene oxide and optionally one or more other alkylene oxides to produce a (poly)ol block copolymer wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.

2-99. (canceled)

100. A process for producing a (poly)ol block copolymer comprising a first reaction in a first reactor and a second reaction in a second reactor; wherein the first reaction is the reaction of a carbonate catalyst with CO.sub.2 and alkylene oxide, in the presence of a starter and optionally a solvent to produce a polycarbonate (poly)ol copolymer and the second reaction is the reaction of a DMC catalyst with the polycarbonate (poly)ol copolymer of the first reaction, ethylene oxide and optionally one or more other alkylene oxides to produce a (poly)ol block copolymer, wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.

101. The process according to claim 1, wherein the polycarbonate or polyester (poly)ol (co)polymer is fed into the reaction with the DMC catalyst continuously or semi-continuously, as a crude reaction mixture, wherein said reaction contains a pre-activated DMC catalyst.

102. The process according to claim 101, wherein the crude reaction mixture fed into the reaction with the DMC catalyst includes an amount of unreacted ethylene oxide and/or other alkylene oxide and/or starter.

103. The process according to claim 1, wherein the alkylene oxides are selected from cyclohexene oxide, styrene oxide, ethylene oxide, propylene oxide, butylene oxide, substituted cyclohexene oxides (such as limonene oxide, C.sub.10H.sub.16O or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, C.sub.11H.sub.22O), alkylene oxides (such as ethylene oxide and substituted ethylene oxides), unsubstituted or substituted oxiranes (such as oxirane, epichlorohydrin, 2-(2-methoxyethoxy)methyl oxirane (MEMO), 2-(2-(2-methoxyethoxy)ethoxy)methyl oxirane (ME2MO), 2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)methyl oxirane (ME3MO), 1,2-epoxybutane, glycidyl ethers, glycidyl esters, glycidyl carbonates, vinyl-cyclohexene oxide, 3-phenyl-1,2-epoxypropane, 2,3-epoxybutane, isobutylene oxide, cyclopentene oxide, 2,3-epoxy-1,2,3,4-tetrahydronaphthalene, indene oxide, and functionalized 3,5-dioxaepoxides.

104. The process according to claim 1, wherein when one or more other alkylene oxides are added to the reaction with the DMC catalyst in addition to ethylene oxide, the ethylene oxide addition is increased mol/mol relative to the other alkylene oxide(s) at the end part of the reaction.

105. The process according to claim 1, wherein the reaction with the DMC catalyst is carried out substantially in the absence of CO.sub.2.

106. The process according to claim 1, wherein the alkylene oxide residues in the polycarbonate or polyester (poly)ol are ethylene oxide and/or propylene oxide residues and optionally, in addition, other alkylene oxide residues.

107. The process according to claim 106, wherein the other alkylene oxide residues are selected from cyclohexene oxide, styrene oxide, ethylene oxide, propylene oxide, butylene oxide, substituted cyclohexene oxides (such as limonene oxide, C10H16O or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, C11H22O), alkylene oxides (such as ethylene oxide and substituted ethylene oxides), unsubstituted or substituted oxiranes (such as oxirane, epichlorohydrin, 2-(2-methoxyethoxy)methyl oxirane (MEMO), 2-(2-(2-methoxyethoxy)ethoxy)methyl oxirane (ME2MO), 2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)methyl oxirane (ME3MO), 1,2-epoxybutane, glycidyl ethers, glycidyl esters, glycidyl carbonates, vinyl-cyclohexene oxide, 3-phenyl-1,2-epoxypropane, 2,3-epoxybutane, isobutylene oxide, cyclopentene oxide, 2,3-epoxy-1,2,3,4-tetrahydronaphthalene, indene oxide, and functionalized 3,5-dioxaepoxides.

108. The process according to claim 1, wherein the reaction temperature of the reaction with the DMC catalyst is in the range from about 50 to about 160° C.

109. The process according to claim 1, wherein the polycarbonate or polyester (poly)ol (co)polymer further comprises ether linkages.

110. The process according to claim 1, wherein the DMC catalyst is based upon Zn.sub.3[Co(CN).sub.6].sub.2 (zinc hexacyanocobaltate).

111. The process according to claim 1, wherein the polycarbonate (poly)ol copolymer is a low molecular weight polycarbonate (poly)ol product having a molecular weight (Mn) in the range 200 to 4000 Daltons as measured by Gel Permeation Chromatography (GPC).

112. The process for producing a (poly)ol block copolymer according to claim 2, wherein the starter compound has the formula (III): ##STR00024## . wherein Z can be any group which can have 1 or more, typically, 2 or more -R.sup.Z groups attached to it and may be selected from optionally substituted alkylene, alkenylene, alkynylene, heteroalkylene, heteroalkenylene, heteroalkynylene, cycloalkylene, cycloalkenylene, hererocycloalkylene, heterocycloalkenylene, arylene, heteroarylene, or Z may be a combination of any of these groups, for example Z may be an alkylarylene, heteroalkylarylene, heteroalkylheteroarylene or alkylheteroarylene group; a is an integer which is at least 1, typically, at least 2, optionally a is in the range of between 1 or 2 and 8, optionally a is in the range of between 2 and 6; wherein each R.sup.Z may be —OH, —NHR′, —SH, —C(O)OH, —P(O)(OR′)(OH), —PR′(O)(OH).sub.2 or —PR′(O)OH, optionally R.sup.Z is selected from —OH, —NHR′ or —C(O)OH, optionally each R.sup.z is —OH, —C(O)OH or a combination thereof (e.g. each R.sup.z is -OH); wherein R′ may be H, or optionally substituted alkyl, heteroalkyl, aryl, heteroaryl, cycloalkyl or heterocycloalkyl, optionally R′ is H or optionally substituted alkyl; and wherein Z′ corresponds to R.sup.z, except that a bond replaces the labile hydrogen atom.

113. The process according to claim 2, wherein the first reaction is carried out under CO.sub.2 pressure of less than 20 bar.

114. The process according to claim 2, wherein the first reaction is a batch, semi-batch, or continuous process.

115. The process according to claim 2, wherein the reactors are located in series.

116. The process according to claim 2, wherein the first and second reactors are effective to provide different reaction conditions, such as temperature and/or pressure, to each other simultaneously.

117. The process according to claim 101, wherein the carbonate catalyst is present in the crude reaction mixture.

118. The process according to claim 101, wherein the carbonate catalyst has been removed from the crude reaction mixture prior to the addition to the reactor or second reactor.

119. The process according to claim 2, wherein the temperature of reaction in the first reactor is in the range about 0° C. to 250° C.

120. The process according to claim 2 wherein the carbonate catalyst is a catalyst capable of producing polycarbonate chains with greater than 76% carbonate linkages.

121. The process according to claim 2, wherein the carbonate catalyst is a metal catalyst comprising phenol or phenolate ligands.

122. The process according to claim 2, wherein the product of the first reaction is used to pre-activate the DMC catalyst in the second reaction, prior to addition of ethylene oxide and optionally, alkylene oxide.

123. The process according to claim 2, wherein the same or different alkylene oxides are used in the first or second reactions.

124. The process according to claim 1, further comprising a reaction comprising the reaction of the (poly)ol block copolymer with a monomer or further polymer to produce a higher polymer.

125. A (poly)ol block copolymer obtainable by the process according to claim 1, comprising a general structure B—A—(B)n wherein block A is a polycarbonate or polyester block, wherein n=t-1 and t = the number of reactive end residues on block A, wherein block B is a polyether block and wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.

126. A polyurethane comprising a block copolymer residue according to claim 125.

127. An isocyanate terminated polyurethane prepolymer comprising a block copolymer residue according to claim 27.

128. A lubricant composition comprising a (poly)ol block copolymer of claim 125.

129. A surfactant composition comprising a (poly)ol block copolymer of claim 125.

Description

[0074] The starter compound if polymeric may have a molecular weight (Mn) of at least about 200 Da or of at most about 1000 Da.

[0075] For example, having a molecular weight of about 200 to 1000 Da, optionally about 300 to 700 Da, optionally about 400 Da.

[0076] The or each starter compound typically has one or more R.sup.z groups, optionally two or more, optionally three or more, optionally four or more, optionally five or more, optionally six or more, optionally seven or more, optionally eight or more R.sup.z groups, particularly wherein R.sup.z is hydroxyl.

[0077] It will be appreciated that any of the above features may be combined. For example, a may be between 1 or 2 and 8, each R.sup.z may be —OH, —C(O)OH or a combination thereof, and Z may be selected from alkylene, heteroalkylene, arylene, or heteroarylene. Exemplary starter compounds for either reaction include monofunctional starter substances such as alcohols, phenols, amines, thiols and carboxylic acids; for example, alcohols such as methanol, ethanol, 1- and 2-propanol, 1- and 2-butanol, linear or branched C.sub.3-C.sub.20-monoalcohol such as tert-butanol, 3-buten-1-ol, 3-butyn-1-ol, 2-methyl-3-buten-2-ol, 2-methyl-3-butyn-2-ol, propargyl alcohol, 2-methyl-2-propanol, 1-tert-butoxy-2-propanol, 1-pentanol, 2-pentanol, 3-pentanol, 1-hexanol, 2-hexanol, 3-hexanol, 1-heptanol, 2-heptanol, 3-heptanol, 1-octanol, 2-octanol, 3-octanol, 4-octanol, 1-decanol, 1-dodecanol, phenol, 2-hydroxybiphenyl, 3-hydroxybiphenyl, 4-hydroxybiphenyl, 2-hydroxypyridine, 3-hydroxypyridine, and 4-hydroxypyridine, monoethers or esters of ethylene, propylene, polyethylene; polypropylene glycols such as ethylene glycol mono-methyl ether and propylene glycol mono-methyl ether, phenols such as linear or branched C.sub.3-C.sub.20 alkyl substituted phenols, for example nonyl-phenols or octyl phenols monofunctional carboxylic acids such as formic acid, acetic acid, propionic acid and butyric acid, fatty acids, such as stearic acid, palmitic acid, oleic acid, linoleic acid, linolenic acid, benzoic acid and acrylic acid, and monofunctional thiols such as ethanethiol, propane-1-thiol, propane-2-thiol, butane-1-thiol, 3-methylbutane-1-thiol, 2-butene-1-thiol, and thiophenol, or amines such as butylamine, tert-butylamine, pentylamine, hexylamine, aniline, aziridine, pyrrolidine, piperidine, and morpholine; and/or selected from diols such as 1,2-ethanediol (ethylene glycol), 1-2-propanediol, 1,3-propanediol (propylene glycol), 1,2-butanediol, 1-3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,4-cyclohexanediol, 1,2-diphenol, 1,3-diphenol, 1,4-diphenol, neopentyl glycol, catechol, cyclohexenediol, 1,4-cyclohexanedimethanol, dipropylene glycol, diethylene glycol, tripropylene glycol, triethylene glycol, tetraethylene glycol, polypropylene glycols (PPGs) or polyethylene glycols (PEGs) having an Mn of up to about 1500 g/mol, such as PPG 425, PPG 725, PPG 1000 and the like, triols such as glycerol, benzenetriol, 1,2,4-butanetriol, 1,2,6-hexanetriol, tris(methylalcohol)propane, tris(methylalcohol)ethane, tris(methylalcohol)nitropropane, trimethylol propane, polyethylene oxide triols, polypropylene oxide triols and polyester triols, tetraols such as calix[4]arene, 2,2-bis(methylalcohol)-1,3-propanediol, erythritol, pentaerythritol or polyalkylene glycols (PEGs or PPGs) having 4-OH groups, polyols, such as sorbitol or polyalkylene glycols (PEGs or PPGs) having 5 or more —OH groups, or compounds having mixed functional groups including ethanolamine, diethanolamine, methyldiethanolamine, and phenyidiethanolamine.

[0078] For example, the starter compound may be a monofunctional alcohol such as ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, 1-hexanol, 1-octanol, 1-decanol, 1-dodecanol, a phenol such as nonyl-phenol or octyl phenol or a mono-functional carboxylic acid such as formic acid, acetic acid, propionic acid, butyric acid, fatty acids, such as stearic acid, palmitic acid, oleic acid, linoleic acid, linolenic acid, benzoic acid, acrylic acid.

[0079] For example, the starter compound may be a diol such as 1,2-ethanediol (ethylene glycol), 1-2-propanediol, 1,3-propanediol (propylene glycol), 1,2-butanediol, 1-3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,4-cyclohexanediol, 1,2-diphenol, 1,3-diphenol, 1,4-diphenol, neopentyl glycol, catechol, cyclohexenediol, 1,4-cyclohexanedimethanol, poly(caprolactone) diol, dipropylene glycol, diethylene glycol, tripropylene glycol, triethylene glycol, tetraethylene glycol, polypropylene glycols (PPGs) or polyethylene glycols (PEGs) having an Mn of up to about 1500 g/mol, such as PPG 425, PPG 725, PPG 1000 and the like. It will be appreciated that the starter compound may be 1,6-hexanediol, 1,4-cyclohexanedimethanol, 1,12-dodecanediol, poly(caprolactone) diol, PPG 425, PPG 725, or PPG 1000. Preferably the the starter compound may be a diol such as 1,2-ethanediol (ethylene glycol), 1,3-propanediol (propylene glycol), 1,2-butanediol, 1-3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, 1,4-cyclohexanediol, 1,2-diphenol, 1,3-diphenol, 1,4-diphenol, neopentyl glycol, catechol, cyclohexenediol, 1,4-cyclohexanedimethanol, poly(caprolactone) diol, dipropylene glycol, diethylene glycol, tripropylene glycol, triethylene glycol, tetraethylene glycol, polypropylene glycols (PPGs) or polyethylene glycols (PEGs) having an Mn of up to about 1500 g/mol, such as PPG 425, PPG 725, PPG 1000 and the like. It will be appreciated that the starter compound may be 1,6-hexanediol, 1,4-cyclohexanedimethanol, 1,12-dodecanediol, poly(caprolactone) diol, PPG 425, PPG 725, or PPG 1000.

[0080] Further exemplary starter compounds may include diacids such as oxalic acid, malonic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecanedioic acid or other compounds having mixed functional groups such as lactic acid, glycolic acid, 3-hydroxypropanoic acid, 4-hydroxybutanoic acid, 5-hydroxypentanoic acid.

[0081] The ratio of the starter compound, if present, to the carbonate catalyst may be in amounts of from about 1000:1 to about 1:1, for example, from about 750:1 to about 5:1, such as from about 500:1 to about 10:1, e.g. from about 250:1 to about 20:1, or from about 125:1 to about 30:1, or from about 50:1 to about 20:1. These ratios are molar ratios. These ratios are the ratios of the total amount of starter to the total amount of the carbonate catalyst used in the processes. These ratios may be maintained during the course of addition of materials.

[0082] By a crude reaction mixture is meant that the product of the reaction is typically not isolated prior to addition of the reaction mixture ot the second reaction. Preferably, the reaction mixture undergoes no further processing steps prior to its addition to the second reaction.

[0083] The product of the first reaction may be a low molecular weight polycarbonate (poly)ol. The preferred molecular weight (Mn) of the polycarbonate (poly)ol depends on the preferred overall molecular weight of the (poly)ol block copolymer. The molecular weight (Mn) of the polycarbonate (poly)ol may be in the range from about 200 to about 4000 Da, from about 200 to about 2000 Da, from about 200 to about 1000 Da, or from about 400 to about 800 Da, as measured by Gel Permeation Chromatography.

[0084] The first reaction may produce a generally alternating polycarbonate (poly)ol product. The product of the first reaction may be fed into the separate reactor containing a pre-activated DMC catalyst. The first product may be fed into the separate reactor as a crude reaction mixture.

[0085] The first reaction of the second aspect of the present invention may be carried out under CO.sub.2 pressure of less than 20 bar, preferably less than 10 bar, more preferably less than 8 bar of CO.sub.2 pressure. The second reaction of the present invention may be carried out under CO.sub.2 pressure of less than 60 bar, preferably less than 20 bar, more preferably less than 10 bar, most preferably less than 5 bar of CO.sub.2 pressure.

[0086] The CO.sub.2 may be added continuously in the first reaction of the second aspect of the present invention, preferably in the presence of a starter.

[0087] The first reaction may be carried out at a pressure of between about 1 bar and about 60 bar carbon dioxide, optionally about 1 bar and about 40 bar, optionally about 1 bar and about 20 bar, optionally between about 1 bar and about 15 bar, optionally about 1 bar and about 10 bar, optionally about 1 bar and about 5 bar.

[0088] The second reaction may be carried out under reduced pressure or an inert gas such as N.sub.2 or Ar. Any residual CO.sub.2 remaining from the first reaction may be stripped by gas stripping the reaction mixture or by applying a vacuum to the reaction mixture. As discussed above, residual amounts of CO.sub.2 may be present in the reaction mixture from the first reaction but will be less than less than 5 wt.% CO.sub.2 by weight of the reaction mixture prior to addition to the second reaction, preferably less than 2.5 wt.%, less than 1.0 wt.%, less than 0.5 wt.% or less than 0.1 wt.%. No additional CO.sub.2 is added during the second reaction. The product of the first reaction may be transferred to the second reaction under the pressure of unused CO.sub.2 from the first reaction, but no further CO.sub.2 is added in the second reactor.

[0089] The first reaction process being carried out under these relatively low CO.sub.2 pressures and the CO.sub.2 added continuously can produce a (poly)ol with high CO.sub.2 content, under low pressure. The CO.sub.2 may be introduced into the first reactor via standard methods, such as directly into the headspace or directly into the reaction liquid via standard methods such as a inlet tube, gassing ring or a hollow shaft stirrer. The mixing may be optimised by using different configurations of stirrer, such as single agitators or agitators configured in multiple stages.

[0090] The first reaction may be carried out in a batch, semi-batch or continuous process. In a batch process, all the carbonate catalyst, alkylene oxide, CO.sub.2, starter and optionally solvent are present at the beginning of the reaction. In a semi-batch or continuous reaction, one or more of the carbonate catalyst, alkylene oxide, CO.sub.2, starter and/or solvent are added into the reactor in a continuous or discontinuous manner.

[0091] The reaction or second reaction comprising DMC is carried out as a continuous process. In a continuous process one or more of the DMC catalyst, alkylene oxide, starter and/or solvent is added into the reaction in a continuous manner.

[0092] Optionally, the crude reaction mixture feed may include an amount of carbonate catalyst. Optionally, the carbonate catalyst may have been removed prior to the addition to the second reactor.

[0093] The polycarbonate product of the first reaction may be referred to as the crude product. The polycarbonate product of the first reaction may be fed into the second reaction in a continuous or semi-continuous manner. Preferably, the product of the first reaction is fed into the second reactor continuously. The product of the first reaction is fed into the second reactor optionally containing unreacted ethylene oxide and/or other alkylene oxide and/or carbonate catalyst. This is advantageous as the continuous addition of the product of reaction 1 as a starter for the DMC catalyst allows the DMC catalyst in reactor 2 to operate in a more controlled manner. This may prevent deactivation of the DMC catalyst in reactor 2. The polycarbonate of reaction 1 may be fed into the second reactor prior to DMC activation and may be used during the DMC activation. The DMC catalyst may also be pre-activated with the (poly)ol block copolymer which may be added into the reactor, or may be the remaining product from a previous reaction, the so-called ‘reaction heel’.

[0094] The temperature of the reaction in the first reactor may be in the range of from about 0° C. to 250° C., preferably from about 40° C. to about 160° C., more preferably from about 50° C. to 120° C.

[0095] The temperature of the reaction in the second reactor may be in the range from about 50 to about 160° C., preferably in the range from about 70 to about 140° C., more preferably from about 80 to about 130° C.

[0096] The two reactors may be located in a series, or the reactors may be nested. Each reactor may individually be a stirred tank reactor, a loop reactor, a tube reactor or other standard reactor design.

[0097] The first reaction may be carried in more than one reactor that feeds the crude reaction mixture into the second reaction, and reactor, continuously. Preferably, reaction 2 is run in a continuous mode.

[0098] The product of the first reaction may be stored for subsequent later use in the second reactor.

[0099] Advantageously, the two reactions can be run independently to get optimum conditions for each. If the two reactors are nested they may be effective to provide different reaction conditions to each other simultaneously.

[0100] Optionally, the polycarbonate (poly)ol may not have been stabilised by an acid prior to addition to the second reactor.

[0101] If the polycarbonate (poly)ol is stabilised by an acid prior to addition to the second reactor, the acid may be an inorganic or an organic acid. Such acids include, but are not limited to, phosphoric acid derivatives, sulfonic acid derivatives (e.g. methanesulfonic acid, p-toluenesulfonic acid), carboxylic acids (e.g. acetic acid, formic acid, oxalic acid, salicylic acid), mineral acids (e.g. hydrochloric acid, hydrobromic acid, hydroiodic acid), nitric acid or carbonic acid. The acid may be part of an acidic resin, such as an ion exchange resin. Acidic ion exchange resins may be in the form of a polymeric matrix (such as polystyrene or polymethacrylic acid) featuring acidic sites such as strong acidic sites (e.g. sulfonic acid sites) or weak acid sites (e.g. carboxylic acid sites). Example ionic exchange resins include Amberlyst 15, Dowex Marathon MSC and Amberlite IRC 748.

[0102] The first and second reactions of the present invention may be carried out in the presence of a solvent, however it will also be appreciated that the processes may also be carried out in the absence of a solvent. When a solvent is present, it may be toluene, hexane, t-butyl acetate, diethyl carbonate, dimethyl carbonate, dioxane, dichlorobenzene, methylene chloride, propylene carbonate, ethylene carbonate, acetone, ethyl acetate, propyl acetate, n-butyl acetate, tetrahydrofuran (THF), etc. The solvent may be toluene, hexane, acetone, ethyl acetate and n-butyl acetate.

[0103] The solvent may act to dissolve one or more of the materials. However, the solvent may also act as a carrier, and be used to suspend one or more of the materials in a suspension. Solvent may be required to aid addition of one or more of the materials during the steps of the processes of the present invention.

[0104] The process may employ a total amount of solvent, and wherein about 1 to 100% of the total amount of solvent may be mixed in the first reaction, with the remainder added in the second reaction; optionally with about 1 to 75% being mixed in the first reaction, optionally with about 1 to 50%, optionally with about 1 to 40%, optionally with about 1 to 30%, optionally with about 1 to 20%, optionally with about 5 to 20%.

[0105] The total amount of the carbonate catalyst may be low, such that the first reaction of the invention may be carried out at low catalytic loading. For example, the catalytic loading of the carbonate catalyst may be in the range of about 1:500-100,000 [total carbonate catalyst]:[total epoxide], such as about 1:750-50,000 [total carbonate catalyst]:[ total epoxide], e.g. in the region of about 1:1,000-20,000 [total carbonate catalyst]:[ total epoxide], for example in the region of about 1:10,000 [total carbonate catalyst]:[ total epoxide]. The ratios above are molar ratios. These ratios are the ratios of the total amount of carbonate catalyst to the total amount of epoxide used in the first reaction.

[0106] The process may employ a total amount of alkylene oxide, and about 1 to 95% of the total amount of alkylene oxide may be mixed in the first reaction. The remainder of alkylene oxide may be added in the second reaction; with optionally about 5 to 90% being mixed in the first reaction, optionally with about 10 to 90%, optionally with about 20 to 90%, optionally with about 40 to 90%, optionally with about 40 to 80%, optionally with about 5 to 50% being mixed in the first reaction.

[0107] In addition to the ethylene oxide in the second reaction, ethylene oxide may also be present in the first reaction and further alkylene oxides may optionally be present in either the first or second reactions. Exemplary further alkylene oxides for the first reaction in addition to ethylene oxide and for the second reaction include propylene oxide, butylene oxide, cyclohexene oxide, glycidyl ether, glycidyl ester and glycidyl carbonates. The alkylene oxide(s) used for the second reaction may be the same or different from the alkylene oxide(s) used for the first reaction. Accordingly, a mixture of one or more alkylene oxides may be present in one or both of the reactions. For example, the first reaction may comprise propylene oxide and the second reaction may comprise ethylene oxide, or both reactions may comprise ethylene oxide, or one or both reactions may use a mixture of alkylene oxides such as a mixture of ethylene oxide with propylene oxide. Preferably, propylene oxide is used in one or both reactions.

[0108] Examples of alkylene oxides which may be used in the present invention include, but are not limited to, cyclohexene oxide, styrene oxide, ethylene oxide, propylene oxide, butylene oxide, substituted cyclohexene oxides (such as limonene oxide, C.sub.10H.sub.16O or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, C.sub.11H.sub.22O), alkylene oxides (such as ethylene oxide and substituted ethylene oxides), unsubstituted or substituted oxiranes (such as oxirane, epichlorohydrin, 2-(2-methoxyethoxy)methyl oxirane (MEMO), 2-(2-(2-methoxyethoxy)ethoxy)methyl oxirane (ME2MO), 2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)methyl oxirane (ME3MO), 1,2-epoxybutane, glycidyl ethers, glycidyl ester, glycidyl carbonates, vinyl-cyclohexene oxide, 3-phenyl-1,2-epoxypropane, 2,3-epoxybutane, isobutylene oxide, cyclopentene oxide, 2,3-epoxy-1,2,3,4-tetrahydronaphthalene, indene oxide, and functionalized 3,5-dioxaepoxides. Examples of functionalized 3,5-dioxaepoxides include:

##STR00004##

##STR00005##

##STR00006##

##STR00007##

[0109] The epoxide moiety may be a glycidyl ether, glycidyl ester or glycidyl carbonate. Examples of glycidyl ethers, glycidyl esters glycidyl carbonates include:

##STR00008##

##STR00009##

##STR00010##

##STR00011##

##STR00012##

##STR00013##

##STR00014##

##STR00015##

##STR00016##

[0110] As noted above, the epoxide substrate may contain more than one epoxide moiety, i.e. it may be a bis-epoxide, a tris-epoxide, or a multi-epoxide containing moiety. Examples of compounds including more than one epoxide moiety include, bis-epoxybutane, bis-epoxyoctane, bis-epoxydecane, bisphenol A diglycidyl ether and 3,4-epoxycyclohexylmethyl-3′,4′-epoxycyclohexanecarboxylate, It will be understood that reactions carried out in the presence of one or more compounds having more than one epoxide moiety may lead to cross-linking in the resulting polymer.

[0111] Optionally, between 0.1 and 20% of the total alkylene oxide in the first reaction may be an alkylene oxide substrate containing more than one epoxide moiety. Preferably, the multi-epoxide substrate is a bis-epoxide.

[0112] The skilled person will appreciate that the alkylene oxide can be obtained from “green” or renewable resources. The alkylene oxide may be obtained from a (poly)unsaturated compound, such as those deriving from a fatty acid and/or terpene, obtained using standard oxidation chemistries.

[0113] The alkylene oxide moiety may contain —OH moieties, or protected —OH moieties. The —OH moieties may be protected by any suitable protecting group. Suitable protecting groups include methyl or other alkyl groups, benzyl, allyl, tert-butyl, tetrahydropyranyl (THP), methoxymethyl (MOM), acetyl (C(O)alkyl), benzolyl (C(O)Ph), dimethoxytrityl (DMT), methoxyethoxymethyl (MEM), p-methoxybenzyl (PMB), trityl, silyl (such as trimethylsilyl (TMS), t-butyldimethylsilyl (TBDMS), t-butyldiphenylsilyl (TBDPS), tri-iso-propylsilyloxymethyl (TOM), and triisopropylsiiyl (TIPS)), (4-methoxyphenyl)diphenylmethyl (MMT), tetrahydrofuranyl (THF), and tetrahydropyranyl (THP).

[0114] The alkylene oxide optionally has a purity of at least 98%, optionally >99. The carbonate catalyst of the present invention may be a catalyst that produces a polycarbonate (poly)ol with greater than 76% carbonate linkages, preferably greater than 80% carbonate linkages, more preferably greater than 85% carbonate linkages, most preferably greater than 90% carbonate linkages.

[0115] If the alkylene oxide used is asymmetric (e.g. propylene oxide), the catalyst may produce polycarbonate (poly)ols with a high proportion of head to tail linkages, such as greater than 70%, greater than 80% or greater than 90% head to tail linkages. Alternatively, the catalyst may produce polycarbonate (poly)ols with no stereoselectivity, producing (poly)ols with approximately 50% head to tail linkages.

[0116] The carbonate catalyst may be heterogeneous or homogeneous.

[0117] The carbonate catalyst may be a mono-metallic, bimetallic or multi-metallic homogeneous complex.

[0118] The carbonate catalyst may comprise phenol or phenolate ligands.

[0119] Typically, the carbonate catalyst may be a bimetallic complex comprising phenol or phenolate ligands. The two metals may be the same or different.

[0120] The carbonate catalyst may be a catalyst of formula (IV):

##STR00017##

wherein: [0121] M is a metal cation represented by M-(L).sub.v; [0122] x is an integer from 1 to 4, preferably x is 1 or 2; is a multidentate ligand or plurality of multidentate ligands; [0124] L is a coordinating ligand, for example, L may be a neutral ligand, or an anionic ligand that is capable of ring-opening an epoxide; [0125] v is an integer that independently satisfies the valency of each M, and/or the preferred coordination geometry of each M or is such that the complex represented by formula (IV) above has an overall neutral charge. For example, each v may independently be 0, 1, 2 or 3, e.g. v may be 1 or 2. When v > 1, each L may be different.

[0126] The term multidentate ligand includes bidentate, tridentate, tetradentate and higher dentate ligands. Each multidentate ligand may be a macrocyclic ligand or an open ligand.

[0127] Such catalysts include those in WO2010022388 (metal salens and derivatives, metal porphyrins, corroles and derivatives, metal tetraaza annulenes and derivatives), W02010028362 (metal salens and derivatives, metal porphyrins, corroles and derivatives, metal tetraaza annulenes and derivatives), WO2008136591 (metal salens), WO2011105846 (metal salens), WO2014148825 (metal salens), WO2013012895 (metal salens), EP2258745A1 (metal porphyrins and derivatives), JP2008081518A (metal porphyrins and derivatives), CN101412809 (metal salens and derivatives), WO2019126221 (metal aminotriphenol complexes), US9018318 (metal beta-diiminate complexes), US6133402A (metal beta-diiminate complexes) and US8278239 (metal salens and derivatives), the entire contents of which, especially, insofar as they relate to suitable carbonate catalysts for the reaction of CO.sub.2 and alkylene oxide, in the presence of a starter and optionally a solvent to produce a polycarbonate polyol copolymer as defined herein are incorporated herein by reference.

[0128] Such catalysts also include those in WO2009/130470, WO2013/034750, WO2016/012786, WO2016/012785, WO2012037282 and WO2019048878A1 (all bimetallic phenolate complexes), the entire contents of which, especially, insofar as they relate to suitable carbonate catalysts for the reaction of CO.sub.2 and alkylene oxide, in the presence of a starter and optionally a solvent to produce a polycarbonate polyol copolymer as defined herein are incorporated herein by reference.

[0129] The carbonate catalyst may have the following structure:

##STR00019##

wherein: [0130] M, and M.sub.2 are independently selected from Zn(II), Cr(II), Co(II), Cu(II), Mn(II), Mg(II), Ni(II), Fe(II), Ti(II), V(II), Cr(III)-X, Co(III)-X, Mn(III)-X, Ni(III)-X, Fe(III)-X, Ca(II), Ge(II), Al(III)-X, Ti(III)-X, V(III)-X, Ge(IV)-(X).sub.2, Y(III)-X, Sc(III)-X or Ti(IV)-(X).sub.2; [0131] R.sub.1 and R.sub.2 are independently selected from hydrogen, halide, a nitro group, a nitrile group, an imine, an amine, an ether, a silyl group, a silyl ether group, a sulfoxide group, a sulfonyl group, a sulfinate group or an acetylide group or an optionally substituted alkyl, alkenyl, alkynyl, haloalkyl, aryl, heteroaryl, alkoxy, aryloxy, alkylthio, arylthio, alicyclic or heteroalicyclic group; [0132] R.sub.3 is independently selected from optionally substituted alkylene, alkenylene, alkynylene, heteroalkylene, heteroalkenylene, heteroalkynylene, arylene, heteroarylene or cycloalkylene, wherein alkylene, alkenylene, alkynylene, heteroalkylene, heteroalkenylene and heteroalkynylene, may optionally be interrupted by aryl, heteroaryl, alicyclic or heteroalicyclic; [0133] R.sub.5 is independently selected from H, or optionally substituted aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl, heteroaryl, alkylheteroaryl or alkylaryl; E.sub.1 is C, E.sub.2 is O, S or NH or E.sub.1 is N and E.sub.2 is O; [0134] E.sub.3, E.sub.4, E.sub.5 and E.sub.6 are selected from N, NR.sub.4, 4 and S, wherein when E.sub.3, E.sub.4, E.sub.5 or E.sub.6 are N, is and wherein when E.sub.3, E.sub.4, E.sub.5 or E.sub.6 are NR.sub.4, O or S, is ; [0135] R.sub.4 is independently selected from H, or optionally substituted aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl, heteroaryl, alkylheteroaryl, -alkyiC(O)OR.sub.19 or -alkylC≡N or alkylaryl; [0136] X is independently selected from OC(O)R.sub.x, OSO.sub.2R.sub.x, OSOR.sub.x, OSO(R.sub.x).sub.2, S(O)R.sub.x, OR.sub.x, phosphinate, phosphonate, halide, nitrate, hydroxyl, carbonate, amino, nitro, amido or optionally substituted aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl, wherein each X may be the same or different and wherein X may form a bridge between M.sub.1 and M.sub.2; [0137] R.sub.x is independently hydrogen, or optionally substituted aliphatic, haloaliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl, alkylaryl or heteroaryl; and G is absent or independently selected from a neutral or anionic donor ligand which is a Lewis base.

[0138] Each of the occurrences of the groups R.sub.1 and R.sub.2 may be the same or different, and R.sub.1 and R.sub.2 can be the same or different.

[0139] The rate at which the materials are added may be selected such that the temperature of the (exothermic) reactions does not exceed a selected temperature (i.e. that the materials are added slowly enough to allow any excess heat to dissipate such that the temperature of the remains approximately constant). The rate at which the materials are added may be selected such that the epoxide concentration does not exceed a selected epoxide concentration.

[0140] The process may produce a (poly)ol with a polydispersity between 1.0 and 2.0, preferably between 1.0 and 1.8, more preferably between 1.0 and 1.5, most preferably between 1.0 and 1.3.

[0141] The process may further comprise a third reaction comprising the reaction of the block copolymer of the first aspect of the invention with a monomer or further to produce a higher polymer.

[0142] The monomer or further polymer may be a (poly)isocyanate and the product of the third reaction may be a polyurethane.

[0143] The process may comprise mixing double metal cyanide (DMC) catalyst, epoxide, starter and optionally solvent to form a pre-activated mixture and adding the pre-activated mixture to the second reactor either before or after the crude reaction mixture of the first reaction, to form the second reaction mixture. However, this may take place continuously so that the pre-activated mixture is added at the same time as the crude reaction mixture. The pre-activated mixture may also be formed in the second reactor by mixing the DMC catalyst, epoxide, starter and optionally solvent. The pre-activation may occur at a temperature of about 50° C. to 160° C., preferably between about 70° C. to 140° C., more preferably about 90° C. to 140° C.The pre-activated mixture may be mixed at a temperature of between about 50 to 160° C. prior to contact with the crude reaction mixture, optionally between about 70 to 140° C.

[0144] In the overall reaction process, the amount of said carbonate catalyst and the amount of said double metal cyanide (DMC) catalyst may be at a predetermined weight ratio of from about 300:1 to about 1:100 to one another, for example, from about 120:1 to about 1:75, such as from about 40:1 to about 1:50, e.g. from about 30:1 to about 1:30 such as from about 20:1 to about 1:1, for example from about 10:1 to about 2:1, e.g. from about 5:1 to about 1:5. The processes of the present invention can be carried out on any scale. The process may be carried out on an industrial scale. As will be understood by the skilled person, catalytic reactions are generally exothermic. The generation of heat during a small-scale reaction is unlikely to be problematic, as any increase in temperature can be controlled relatively easily by, for example, the use of an ice bath. With larger scale reactions, and particularly industrial scale reactions, the generation of heat during a reaction can be problematic and potentially dangerous. Thus, the gradual addition of materials may allow the rate of the catalytic reaction to be controlled and can minimise the build-up of excess heat. The rate of the reaction may be controlled, for example, by adjusting the flow rate of the materials during addition. Thus, the processes of the present invention have particular advantages if applied to large, industrial scale catalytic reactions.

[0145] The temperature may increase or decrease during the course of the processes of the invention.

[0146] The amount of said carbonate catalyst and the amount of said double metal cyanide (DMC) catalyst will vary depending on which carbonate catalyst and DMC catalyst is used.

[0147] The product of the process of the first aspect of the invention is a (poly)ol block copolymer.

[0148] According to the third aspect of the invention, there is provided a (poly)ol block copolymer obtainable by the process of the first or second aspect of the present invention of general structure B—A—(B)n wherein block A is a polycarbonate or polyester, wherein n=t-1 and t = the number of reactive end residues on block A, wherein block B is a polyether block and wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.

[0149] According to the fourth aspect of the invention, there is provided a (poly)ol block copolymer obtained by the process of the first or second aspect of the present invention of general structure B—A—(B)n wherein block A is a polycarbonate or polyester block, wherein n=t-1 and t = the number of reactive end residues on block A, wherein block B is a polyether block and wherein > 70% of the copolymer chain ends are terminated by primary hydroxyl groups.

[0150] Preferably, wherein > 75%, more preferably, >80% of the copolymer chain ends are terminated by primary hydroxyl groups.

[0151] The mol/mol ratio of block A to block B may be in the range 25:1 to 1:250. Typically the weight ratio of block A to block B is in the range 50:1 to 1:100.

[0152] The carbonates present in block A may be derived from CO.sub.2. Typically, block A is derived from alkylene oxides and CO.sub.2.

[0153] Block A may partly derived from alkylene oxides and wherein optionally the alkylene oxides are selected from cyclohexene oxide, styrene oxide, ethylene oxide, propylene oxide, butylene oxide, substituted cyclohexene oxides (such as limonene oxide, C10H16O or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, C.sub.11H.sub.22O), alkylene oxides (such as ethylene oxide and substituted ethylene oxides), unsubstituted or substituted oxiranes (such as oxirane, epichlorohydrin, 2-(2-methoxyethoxy)methyl oxirane (MEMO), 2-(2-(2-methoxyethoxy)ethoxy)methyl oxirane (ME2MO), 2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)methyl oxirane (ME3MO), 1,2-epoxybutane, glycidyl ethers, vinyl-cyclohexene oxide, 3-phenyl-1,2-epoxypropane, 1,2- and 2,3-epoxybutane, isobutylene oxide, cyclopentene oxide, 2,3-epoxy-1,2,3,4-tetrahydronaphthalene, indene oxide, and functionalized 3,5-dioxaepoxides.

[0154] Typically, block A is a polyalkylenecarbonate block, more typically derived from alkylene oxides and CO.sub.2. The alkylene oxides and CO.sub.2 may provide at least 90% of the residues in the block not including any starter, especially, at least 95% of the residues in the block, more especially, at least 99% of the residues in the block, most especially, about 100% of the residues in the block not including any starter are residues of alkylene oxide and CO.sub.2. Most typically, block A includes ethylene oxide and/or propylene oxide residues and optionally other alkylene oxide residues, such as butylene oxide, gycidyl ethers, glycidyl esters and glycidyl carbonates. Typically, at least 50% of the alkylene oxide residues of block A are ethylene oxide or propylene oxide residues, more typically, at least 70% of the alkylene oxide residues of block A are ethylene oxide or propylene oxide residues, most typically, at least 90% of the alkylene oxide residues of block A are ethylene oxide or propylene oxide residues, especially, ethylene oxide at these levels.

[0155] Typically, the carbonate of block A is derived from CO.sub.2 i.e. the carbonates incorporate CO.sub.2 residues. Typically, block A has between 70-100% carbonate linkages, more typically, 80-100%, most typically, 90-100%. The polycarbonate block, A, of the (poly)ol block copolymer may have at least 76% carbonate linkages, preferably at least 80% carbonate linkages, more preferably at least 85% carbonate linkages. Block A may have less than 98% carbonate linkages, preferably less than 97% carbonate linkages, more preferably less than 95% carbonate linkages. Optionally, block A has between 75% and 99% carbonate linkages, preferably between 77% and 95% carbonate linkages, more preferably between 80% and 90% carbonate linkages.

[0156] Surprisingly, block A of the present invention has been found to facilitate the incorporation of more primary hydroxyl terminal ends in the B block. The block A connected to the respective B block is therefore surprisingly adapted to react with alkylene oxide so that the (poly)ol block copolymer has > 70% primary hydroxyl ends, typically, > 75%, more preferably, >80% primary hydroxyl ends.

[0157] Typically, block B includes ethylene oxide and optionally other alkylene oxide residues. Typically, ethylene oxide residues form 5-100% of the epoxide residues in block B, more typically, 10-100%, most typically 10-50% of the epoxide residues. Typically, block B is a mixture of at least ethylene and propylene oxide residues. Typically, at least 50% of the alkylene oxide residues of block B are ethylene oxide or propylene oxide residues, more typically, at least 70% of the alkylene oxide residues of block B are ethylene oxide or propylene oxide residues, most typically, at least 90% of the alkylene oxide residues of block B are ethylene oxide or propylene oxide residues, especially, ethylene oxide at these levels. Generally, to form a primary hydroxyl end, at least the terminal epoxide residue is an ethylene oxide residue. Typically, at least 70% of the terminal epoxide residues are ethylene oxide residues, more typically, at least 75%, most typically, at least 80% of the terminal epoxide residues are ethylene oxide residues. It is also possible for a small proportion of other epoxides to form a primary hydroxyl end but such primary hydroxyl arrangements are unusual due to the selective ring-opening at the unhindered methylene carbon.

[0158] Generally, where more than one alkylene oxide is used >50% of the ethylene oxide residues in block B are incorporated into the copolymer chain nearer to the copolymer terminal end than the A block terminal end, more typically, > 60% of the ethylene oxide residues, most typically, at least 70% are so incorporated.

[0159] Optionally, block B comprises only ether linkages. Typically, block B is at least 90% derived, typically, at least 95% derived, more typically, at least 99%, most typically, 100% derived from alkylene oxides and wherein optionally the alkylene oxides are selected from cyclohexene oxide, styrene oxide, ethylene oxide, propylene oxide, butylene oxide, substituted cyclohexene oxides (such as limonene oxide, C10H16O or 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, C11H22O), alkylene oxides (such as ethylene oxide and substituted ethylene oxides), unsubstituted or substituted oxiranes (such as oxirane, epichlorohydrin, 2-(2-methoxyethoxy)methyl oxirane (MEMO), 2-(2-(2-methoxyethoxy)ethoxy)methyl oxirane (ME2MO), 2-(2-(2-(2-methoxyethoxy)ethoxy)ethoxy)methyl oxirane (ME3MO), 1,2-epoxybutane, glycidyl ethers, vinyl-cyclohexene oxide, 3-phenyl-1,2-epoxypropane, 1,2- and 2,3-epoxybutane, isobutylene oxide, cyclopentene oxide, 2,3-epoxy-1,2,3,4-tetrahydronaphthalene, indene oxide, and functionalized 3,5-dioxaepoxides.

[0160] Typically, block B has less than 10% carbonate linkages, typically, less than 5% carbonate linkages, more typically, less than 1% carbonate linkages, most typically, 0% carbonate linkages.

[0161] The polycarbonate block, A, of the (poly)ol block copolymer may also comprise ether linkages. Block A may have less than 24% ether linkages, preferably less than 20% ether linkages, more preferably less than 15% ether linkages such as less than 10%, for example less than 5% ether linkages. Block A may have at least 1% ether linkages, such as at least 2% ether linkagesor even at least 5% ether linkages. Optionally, block A may have between 0% and 25% ether linkages, preferably between 1% and 20% ether linkages, more preferably between 1% and 15% ether linkages.

[0162] The A block may have a high carbonate content and the B block a low carbonate content, for example, the A block may have greater than 70% carbonate linkages and/or, for example, the B block may have less than 10% carbonate linkages, typically, less than 5% carbonate linkages, more typically, less than 1% carbonate linkages, most typically, 0% carbonate linkages.

[0163] Optionally, block A of the present invention may be a generally alternating polycarbonate (poly)ol residue.

[0164] If the alkylene oxide is asymmetric, then the polycarbonate may have between 0-100% head to tail linkages, preferably between 40-100% head to tail linkages, more preferably between 50-100%. The polycarbonate may have a statistical distribution of head to head, tail to tail and head to tail linkages in the order 1:2:1, indicating a non-stereoselective ring opening of the epoxide, or it may preferentially make head to tail linkages in the order of more than 50%, optionally more than 60%, more than 70%, more than 80%, or more than 90%.

[0165] Typically, ethylene oxide residues form 0-100% of the alkylene oxide residues in the (poly)ol block copolymer, typically 5-70%, more typically, 10-60% of the alkylene oxide residues in the (poly)ol block copolymer, most typically, 10-40% of the alkylene oxide residues in the (poly)ol block copolymer and/or, at least 5%, 10%, 15%, 20%, 25% or 30% of the alkylene oxide residues in the (poly)ol block copolymer are ethylene oxide residues.

[0166] The A block of the third aspect of the present invention with a starter may be defined as

##STR00020##

Accordingly, the (poly)ol block structure of the copolymer may be defined as:

##STR00021##

wherein n= t-1 and wherein t= the number of terminal OH group residues on the block A; and wherein each A′ is independently a polycarbonate chain having at least 70% carbonate linkages, and wherein each B is independently a polyether chain and wherein Z′-Z-(Z′).sub.n is a starter residue. The (poly)ol has at least 70% primary hydroxyl end groups. For the avoidance of doubt, when t=1 then n=0 and the polyblock structure is:—B—A′—Z′—Z, the “% of the copolymer chain ends terminated by primary hydroxyl groups” as claimed refers to the percentage of OH functional chain ends that are so terminated.

[0167] The polycarbonate block comprises —A′— which may have the following structure:

##STR00022##

wherein the ratio of p:q is at least 7:3; and R.sup.e1 and R.sup.e2 depend on the nature of the epoxide used to prepare block A.

[0168] The polyether block B may have the following structure:

##STR00023##

wherein R.sup.e3 and R.sup.e4 depend on the nature of the epoxide used to prepare blocks B.

[0169] Each R.sup.e1, R.sup.e2, R.sup.e3, or R.sup.e4 may be independently selected from H, halogen, hydroxyl,), or optionally substituted alkyl (such as methyl, ethyl, propyl, butyl, —CH.sub.2Cl, —CH.sub.2—OR.sub.20, —CH.sub.2—OC(O)R.sub.12, or —CH.sub.2—OC(O)OR.sub.18), alkenyl, alkynyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl, heteroalkyl or heteroalkenyl, preferably selected from H or optionally substituted alkyl.

[0170] R.sup.e1 and R.sup.e2 or R.sup.e3 and R.sup.e4 may together form a saturated, partially unsaturated or unsaturated ring containing carbon and hydrogen atoms, and optionally one or more heteroatoms.

[0171] As set out above, the nature of R.sup.e1, R.sup.e2, R.sup.e3 and R.sup.e4 will depend on the alkylene oxide used in the reaction. For example, if the alkylene oxide is cyclohexene oxide (CHO), then R.sup.e1 and R.sup.e2 (or R.sup.e3 and R.sup.e4) will together form a six membered alkyl ring (e.g. a cyclohexyl ring). If the alkylene oxide is ethylene oxide, then R.sup.e1 and R.sup.e2 (or R.sup.e3 and R.sup.e4) will be H. If the alkylene oxide is propylene oxide, then R.sup.e1 (or R.sup.e3) will be H and R.sup.e2 (or R.sup.e4) will be methyl (or R.sup.e1 (or R.sup.e3) will be methyl and R.sup.e2 (or R.sup.e4) will be H, depending on how the alkylene oxide is added into the polymer backbone). If the alkylene oxide is butylene oxide, then R.sup.e1 (or R.sup.e3) will be H and R.sup.e2 (or R.sup.e4) will be ethyl (or vice versa). If the alkylene oxide is styrene oxide, then R.sup.e1 (or R.sup.e3) may be hydrogen, and R.sup.e2 (or R.sup.e4) may be phenyl (or vice versa). If the alkylene oxide is a glycidyl ether, then R.sup.e1 (or R.sup.e3) will be the ether group (—CH.sub.2—OR.sub.20) and R.sup.e2 (or R.sup.e4) will be H (or vice versa). If the alkylene oxide is a glycidyl ester, then R.sup.e1 (or R.sup.e3) will be the ester group (—CH.sub.2—OC(O)R.sub.12) and

[0172] R.sup.e2 (or R.sup.e4) will be H (or vice versa). If the alkylene oxide is a glycidyl carbonate, then R.sup.e1 (or R.sup.e3) will be the carbonate group (CH.sub.2—OC(O)OR18) and R.sup.e2 (or R.sup.e4) will be H (or vice versa).

[0173] It will also be appreciated that if a mixture of alkylene oxides are used, then each occurrence of R.sup.e1 and/or R.sup.e2 (or R.sup.e3 and/or R.sup.e4) may not be the same, for example if a mixture of ethylene oxide and propylene oxide are used, R.sup.e1 (or R.sup.e3) may be independently hydrogen or methyl, and R.sup.e2 (or R.sup.e4) may be independently hydrogen or methyl.

[0174] Thus, R.sup.e1 and R.sup.e2 (or R.sup.e3 and R.sup.e4 ) may be independently selected from hydrogen, alkyl or aryl, or R.sup.e1 and R.sup.e2 (or R.sup.e3 and R.sup.e4 ) may together form a cyclohexyl ring, preferably R.sup.e1 and R.sup.e2 (or R.sup.e3 and R.sup.e4 ) may be independently selected from hydrogen, methyl, ethyl, phenyl, or R.sup.e1 and R.sup.e2 (or R.sup.e3 and R.sup.e4 ) may together form a cyclohexyl ring.

[0175] The identity of Z and Z′ will depend on the nature of the starter compound.

[0176] The starter compound may be of the formula (III) as defined above.

[0177] Preferably, the (poly)ol block copolymer has a molecular weight (Mn) in the range of from about 300 to 20,000 Da, more preferably in the range of from about 400 to 8000 Da, most preferably from about 500-6000 Da.

[0178] The polycarbonate block, A, of the (poly)ol block copolymer preferably has a molecular weight (Mn) in the range of from about 200 to 4000 Da, more preferably in the range of from about 200 to 2000 Da, most preferably from about 200 to 1000 Da, especially from about 400 to 800 Da.

[0179] The polyether blocks, B, of the (poly)ol block copolymer preferably have a molecular weight (Mn) in the range of from about 100 to 20,000 Da, more preferably of from about 200 to 10,000 Da, most preferably from about 200 to 5000 Da.

[0180] Alternatively, the polyether blocks B and hence also the (poly)ol block copolymer may have a high molecular weight. The polyether blocks B may have a molecular weight (Mn) of at least about 25,000 Daltons, such as at least about 40,000 Daltons, e.g. at least about 50,000 Daltons, or at least about 100,000 Daltons. High molecular weight (poly)ol block copolymers formed by the method of the present invention may have molecular weights above about 100,000 Daltons.

[0181] The Mn and hence the PDI of the polymers produced by the processes of the invention may be measured using Gel Permeation Chromatography (GPC). For example, the GPC may be measured using an Agilent 1260 Infinity GPC machine with two Agilent PLgel .Math.m mixed-D columns in series. The samples may be measured at room temperature (293 K) in THF with a flow rate of 1ml/min against narrow polystyrene standards (e.g. polystyrene low EasiVials supplied by Agilent Technologies with a range of Mn from 405 to 49,450 g/mol). Optionally, the samples may be measured against polyethylene glycol) standards, such as polyethylene glycol easivials supplied by Agilent Technologies.

[0182] According to the fifth aspect of the invention, there is also provided a composition comprising the (poly)ol block copolymer according to the first aspect of the present invention. The composition may also comprise of one or more additives from those known in the art. The additives may include, but are not limited to, catalysts, blowing agents, stabilizers, plasticisers, fillers, flame retardants, defoamers, and antioxidants.

[0183] Fillers may be selected from mineral fillers or polymer fillers, for example, styreneacrylonitrile (SAN) dispersion fillers.

[0184] The blowing agents may be selected from chemical blowing agents or physical blowing agents. Chemical blowing agents typically react with (poly)isocyanates and liberate volatile compounds such as CO.sub.2. Physical blowing agents typically vaporize during the formation of the foam due to their low boiling points. Suitable blowing agents will be known to those skilled in the art, and the amounts of blowing agent added can be a matter of routine experimentation. One or more physical blowing agents may be used or one or more chemical blowing agents may be used, in addition one or more physical blowing agents may be used in conjunction with one or more chemical blowing agents. Chemical blowing agents include water and formic acid. Both react with a portion of the (poly)isocyanate producing carbon dioxide which can function as the blowing agent. Alternatively, carbon dioxide may be used directly as a blowing agent, this has the advantage of avoiding side reactions and lowering urea crosslink formation, if desired water may be used in conjunction with other blowing agents or on its own.

[0185] Typically, physical blowing agents for use in the current invention may be selected from acetone, carbon dioxide, optionally substituted hydrocarbons, and chloro/fluorocarbons. Chloro/fluorocarbons include hydrochlorofluorocarbons, chlorofluorocarbons, fluorocarbons and chlorocarbons. Fluorocarbon blowing agents are typically selected from the group consisting of: difluoromethane, trifluoromethane, fluoroethane, 1,1-difluoroethane, 1,1,1-trifluoroethane, tetrafluoroethanes difluorochloroethane, dichloromono-fluoromethane, 1,1-dichloro-1-fluoroethane, 1,1-difluoro-1,2,2-trichloroethane, chloropentafluoroethane, tetrafluoropropanes, pentafluoropropanes, hexafluoropropanes, heptafluoropropanes, pentafluorobutanes.

[0186] Olefin blowing agents may be incorporated, namely trans-1-chloro-3.3.3-trifluoropropene (LBA), trans-1,3,3,3-tetrafluoro-prop-1-ene (HFO-1234ze), 2,3,3,3-tetrafluoro-propene (HFO-1234yf), cis-1,1,1,4,4,4-hexafluoro-2-butene (HFO-1336mzz).

[0187] Typically, non-halogenated hydrocarbons for use as physical blowing agents may be selected from butane, isobutane, 2,3-dimethylbutane, n- and i-pentane isomers, hexane isomers, heptane isomers and cycloalkanes including cyclopentane, cyclohexane and cycloheptane. More typically, non-halogenated hydrocarbons for use as physical blowing agents may be selected from cyclopentane, iso-pentane and n-pentane.

[0188] Typically, where one or more blowing agents are present, they are used in an amount of from about 0 to about 10 parts, more typically 2-6 parts of the total formulation. Where water is used in conjunction with another blowing agent the ratio of the two blowing agents can vary widely, e.g. from 1 to 99 parts by weight of water in total blowing agent, preferably, 25 to 99+ parts by weight water

[0189] Preferably, the blowing agent is selected from cyclopentane, iso-pentane, n-pentane. More preferably the blowing agent is n-pentane.

[0190] Typical plasticisers may be selected from succinate esters, adipate esters, phthalate esters, diisooctylphthalate (DIOP), benzoate esters and N,N-bis(2-hydroxyethyl)-2-aminoethane sulfonic acid (BES).

[0191] Typical flame retardants will be known to those skilled in the art, and may be selected from phosphonamidates, 9,10-dihydro-9-oxa-phosphaphenanthrene-10-oxide (DOPO), chlorinated phosphate esters, Tris(2-chloroisopropyl)phosphate (TCPP), Triethyl phosphate (TEP), tris(chloroethyl) phosphate, tris(2,3-dibromopropyl) phosphate, 2,2-bis(chloromethyl)-1,3-propylene bis(di(2-chloroethyl) phosphate), tris(1,3-dichloropropyl) phosphate, tetrakis(2-chloroethyl) ethylene diphosphate, tricresyl phosphate, cresyl diphenyl phosphate, diammonium phosphate, melamine, melamine pyrophosphate, urea phosphate, alumina, boric acid, various halogenated compounds, antimony oxide, chlorendic acid derivatives, phosphorus containing polyols, bromine containing polyols, nitrogen containing polyols, and chlorinated paraffins. Flame retardants may be present in amounts from 0-60 parts of the total mixture.

[0192] The compositions of the invention can also further comprise a (poly)isocyanate. Typically, the (poly)isocyanate comprises two or more isocyanate groups per molecule. Preferably, the (poly)isocyanates are diisocyanates. However, the (poly)isocyanates may be higher (poly)isocyanates such as triisocyanates, tetraisocyanates, isocyanate polymers or oligomers, and the like. The (poly)isocyanates may be aliphatic (poly)isocyanates or derivatives or oligomers of aliphatic (poly)isocyanates or may be aromatic (poly)isocyanates or derivatives or oligomers of aromatic (poly)isocyanates. Typically, the (poly)isocyanate component has a functionality of 2 or more. In some embodiments, the (poly)isocyanate component comprises a mixture of diisocyanates and higher isocyanates formulated to achieve a particular functionality number for a given application.

[0193] In some embodiments, the (poly)isocyanate employed has a functionality greater than 2. In some embodiments, such (poly)isocyanates have a functionality between 2 to 5, more typically, 2-4, most typically, 2-3.

[0194] Suitable (poly)isocyanates which may be used include aromatic, aliphatic and cycloaliphatic polyisocyanates and combinations thereof. Such polyisocyanates may be selected from the group consisting of: 1,3-Bis(isocyanatomethyl)benzene, 1,3-Bis(isocyanatomethyl)cyclohexane (H6-XDI), 1,4-cyclohexyl diisocyanate, 1,2-cyclohexyl diisocyanate, 1,4-phenylene diisocyanate, 1,3-phenylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 1,6-hexamethylaminediisocyanate (HDI), isophorone diisocyanate (IPDI), 2,4-toluene diisocyanate (TDI), 2,4,4-trimethylhexamethylene diisocyanate (TMDI), 2,6-toluene diisocyanate (TDI), 4,4′methylene-bis(cyclohexyl isocyanate) (H12MDI), naphthalene-1,5-diisocyanate, diphenylmethane-2,4′-diisocyanate (MDI), diphenylmethane-4,4′-diisocyanate (MDI), triphenylmethane-4,4′,4″triisocyanate, isocyanatomethyl-1,8-octane diisocyanate (TIN), m-tetramethylxylylene diisocyanate (TMXDI), p-tetramethylxylylene diisocyanate (TMXDI), Tris(p-isocyanatomethyl)thiosulfate, trimethylhexane diisocyanate, lysine diisocyanate, m-xylylene diisocyanate (XDI), p-xylylene diisocyanate (XDI), 1,3,5-hexamethyl mesitylene triisocyanate, 1-methoxyphenyl-2,4-diisocyanate, toluene-2,4,6-triisocyanate, 4,4′-biphenylene diisocyanate, 3,3′-dimethyl-4,4′-diphenyl diisocyanate, 4,4′-dimethyldiphenyl methane-2,2′,5,5′-tetraisocyanate and mixtures of any two or more of these. In addition, the (poly)isocyanates may be selected from polymeric version of any of these isocyanates, these may have high or low functionality. Preferred polymeric isocyanates may be selected from MDI, TDI, and polymeric MDI.

[0195] According to the sixth aspect of the present invention, there is also provided a polyurethane produced from the reaction of a polyol block copolymer product of the process of the first or second aspect of the present invention and a (poly)isocyanate. A polyurethane can also be produced from the reaction of a composition comprising the product of the first aspect of the invention and a (poly)isocyanate. The polyurethane may be in the form of a soft foam, a flexible foam, an integral skin foam, a high resilience foam, a viscoelastic or memory foam, a semi-rigid foam, a rigid foam (such as a polyurethane (PUR) foam, a polyisocyanurate (PIR) foam and/or a spray foam), an elastomer (such as a cast elastomer, a thermoplastic elastomer (TPU) or a microcellular elastomer), an adhesive (such as a hot melt adhesive, pressure sensitive or a reactive adhesive), a sealant or a coating (such as a waterborne or solvent dispersion (PUD), a two-component coating, a one component coating, a solvent free coating). The polyurethane may be formed via a process that involves extruding, moulding, injection moulding, spraying, foaming, casting and/or curing. The polyurethane may be formed via a ‘one pot’ or ‘pre-polymer’ process.

[0196] The polyurethane of the sixth aspect may also comprise one or more chain extenders, which are typically low molecular weight polyols, polyamines or compounds with both amine and hydroxyl functionality known in the art. Such chain extenders include ethylene glycol, 1,2-propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol, 1,10-decanediol, 1,12-dodecanediol, neopentyl glycol, trimethoxypropane (TMP), diethylene glycol, dipropylene glycol, diamines such as ethylenediamine, 1,2-propylenediamine, 1,3-propylenediamine, N-methylpropylene-1,3-diamine, 2,4-tolylenediamine, 2,6 tolylenediamine and diethanolamine.

[0197] According to the seventh aspect of the present invention, there is also provided a polyurethane comprising a block copolymer residue according to the third aspect of the present invention. The block copolymer residue of the polyurethane of the seventh aspect may include any one or more features as defined above in relation to the product of the third aspect of the invention.

[0198] According to the eighth aspect of the invention, there is also provided an isocyanate terminated polyurethane prepolymer comprising the reaction product of the polyol block copolymer product of the process according to the first or second aspect of the present invention and an excess of (poly)isocyanate such as at least >1 mole of isocyanate groups per mole OH groups. The isocyanate terminated prepolymer may be formed into a polyurethane via reaction with one or more chain extenders (such as water, diols, triols, diamines etc) and/or further polyisocyanates and/or other additives.

[0199] According to the ninth aspect of the invention, there is provided an isocyanate terminated polyurethane prepolymer comprising a block copolymer residue according to the third aspect of the present invention.

[0200] The isocyanate terminated polyurethane prepolymer of the seventh aspect may include any one or more features as defined above in relation to the product of the third aspect of the invention.

[0201] Catalysts that may be added to the polyol block copolymer product of the process of the first aspect of the present invention may be catalysts for the reaction of (poly)isocyanates and a polyol. These catalysts include suitable urethane catalysts such as tertiary amine compounds and/or organometallic compounds.

[0202] Optionally, a trimerisation catalyst may be used. An excess of (poly)isocyanate, or more preferably an excess of polymeric isocyanate relative to polyol may be present so that polyisocyanurate ring formation is possible when in the presence of a trimerisation catalyst. Any of these catalysts may be used in conjunction with one or more other trimerisation catalysts.

[0203] According to the tenth aspect of the invention, there is provided a lubricant composition comprising a (poly)ol block copolymer according to the third aspect of the present invention.

[0204] According to the eleventh aspect of the invention, there is provided a surfactant composition comprising a (poly)ol block copolymer according to the third aspect of the present invention.

Definitions

[0205] For the purpose of the present invention, an aliphatic group is a hydrocarbon moiety that may be straight chain (i.e. unbranched) branched, or cyclic and may be completely saturated, or contain one or more units of unsaturation, but which is not aromatic. The term “unsaturated” means a moiety that has one or more double and/or triple bonds. The term “aliphatic” is therefore intended to encompass alkyl, cycloalkyl, alkenyl cycloalkenyl, alkynyl or cycloalkenyl groups, and combinations thereof.

[0206] An aliphatic group is optionally a C.sub.1-30 aliphatic group, that is, an aliphatic group with 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 or 30 carbon atoms. Optionally, an aliphatic group is a C.sub.1-15aliphatic, optionally a C.sub.1-12aliphatic, optionally a C.sub.1-10aliphatic, optionally a C.sub.1-.sub.8aliphatic, such as a C.sub.1-6aliphatic group. Suitable aliphatic groups include linear or branched, alkyl, alkenyl and alkynyl groups, and mixtures thereof such as (cycloalkyl)alkyl groups, (cycloalkenyl)alkyl groups and (cycloalkyl)alkenyl groups.

[0207] The term “alkyl,” as used herein, refers to saturated, straight- or branched-chain hydrocarbon radicals derived by removal of a single hydrogen atom from an aliphatic moiety. An alkyl group is optionally a “C.sub.1-20 alkyl group”, that is an alkyl group that is a straight or branched chain with 1 to 20 carbons. The alkyl group therefore has 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms. Optionally, an alkyl group is a C.sub.1-15 alkyl, optionally a C.sub.1-12 alkyl, optionally a C.sub.1-1O alkyl, optionally a C.sub.1- .sub.8 alkyl, optionally a C.sub.1-6 alkyl group. Specifically, examples of “C.sub.1-20 alkyl group” include methyl group, ethyl group, n-propyl group, iso-propyl group, n-butyl group, iso-butyl group, sec-butyl group, tert-butyl group, sec-pentyl, iso-pentyl, n-pentyl group, neopentyl, n-hexyl group, sec-hexyl, n-heptyl group, n-octyl group, n-nonyl group, n-decyl group, n-undecyl group, n-dodecyl group, n-tridecyl group, n-tetradecyl group, n-pentadecyl group, n-hexadecyl group, n-heptadecyl group, n-octadecyl group, n-nonadecyl group, n-eicosyl group, 1,1-dimethylpropyl group, 1,2-dimethylpropyl group, 2,2-dimethylpropyl group, 1-ethylpropyl group, n-hexyl group, 1-ethyl-2-methylpropyl group, 1,1,2-trimethylpropyl group, 1-ethylbutyl group, 1-methylbutyl group, 2-methylbutyl group, 1,1-dimethylbutyl group, 1,2-dimethylbutyl group, 2,2-dimethylbutyl group, 1,3-dimethylbutyl group, 2,3-dimethylbutyl group, 2-ethylbutyl group, 2-methylpentyl group, 3-methylpentyl group and the like.

[0208] The term “alkenyl,” as used herein, denotes a group derived from the removal of a single hydrogen atom from a straight- or branched-chain aliphatic moiety having at least one carbon-carbon double bond. The term “alkynyl,” as used herein, refers to a group derived from the removal of a single hydrogen atom from a straight- or branched-chain aliphatic moiety having at least one carbon-carbon triple bond. Alkenyl and alkynyl groups are optionally “C.sub.2-20alkenyl” and “C.sub.2-20alkynyl”, optionally “C.sub.2-15 alkenyl” and “C.sub.2-15 alkynyl”, optionally “C.sub.2-12 alkenyl” and “C.sub.2-12 alkynyl”, optionally “C.sub.2-10 alkenyl” and “C.sub.2-10 alkynyl”, optionally “C.sub.2-8 alkenyl” and “C.sub.2-8 alkynyl”, optionally “C.sub.2-6 alkenyl” and “C.sub.2-6 alkynyl” groups, respectively. Examples of alkenyl groups include ethenyl, propenyl, allyl, 1,3-butadienyl, butenyl, 1-methyl-2-buten-1-yl, allyl, 1,3-butadienyland allenyl. Examples of alkynyl groups include ethynyl, 2-propynyl (propargyl) and 1-propynyl.

[0209] The terms “cycloaliphatic”, “carbocycle”, or “carbocyclic” as used herein refer to a saturated or partially unsaturated cyclic aliphatic monocyclic or polycyclic (including fused, bridging and spiro-fused) ring system which has from 3 to 20 carbon atoms, that is an alicyclic group with 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms. Optionally, an alicyclic group has from 3 to 15, optionally from 3 to 12, optionally from 3 to 10, optionally from 3 to 8 carbon atoms, optionally from 3 to 6 carbons atoms. The terms “cycloaliphatic”, “carbocycle” or “carbocyclic” also include aliphatic rings that are fused to one or more aromatic or nonaromatic rings, such as tetrahydronaphthyl rings, where the point of attachment is on the aliphatic ring. A carbocyclic group may be polycyclic, e.g. bicyclic or tricyclic. It will be appreciated that the alicyclic group may comprise an alicyclic ring bearing one or more linking or non-linking alkyl substituents, such as —CH.sub.2—cyclohexyl. Specifically, examples of carbocycles include cyclopropane, cyclobutane, cyclopentane, cyclohexane, bicycle[2,2,1]heptane, norborene, phenyl, cyclohexene, naphthalene, spiro[4.5]decane, cycloheptane, adamantane and cyclooctane.

[0210] A heteroaliphatic group (including heteroalkyl, heteroalkenyl and heteroalkynyl) is an aliphatic group as described above, which additionally contains one or more heteroatoms. Heteroaliphatic groups therefore optionally contain from 2 to 21 atoms, optionally from 2 to 16 atoms, optionally from 2 to 13 atoms, optionally from 2 to 11 atoms, optionally from 2 to 9 atoms, optionally from 2 to 7 atoms, wherein at least one atom is a carbon atom. Optional heteroatoms are selected from O, S, N, P and Si. When heteroaliphatic groups have two or more heteroatoms, the heteroatoms may be the same or different. Heteroaliphatic groups may be substituted or unsubstituted, branched or unbranched, cyclic or acyclic, and include saturated, unsaturated or partially unsaturated groups.

[0211] An alicyclic group is a saturated or partially unsaturated cyclic aliphatic monocyclic or polycyclic (including fused, bridging and spiro-fused) ring system which has from 3 to 20 carbon atoms, that is an alicyclic group with 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms. Optionally, an alicyclic group has from 3 to 15, optionally from 3 to 12, optionally from 3 to 10, optionally from 3 to 8 carbon atoms, optionally from 3 to 6 carbons atoms. The term “alicyclic” encompasses cycloalkyl, cycloalkenyl and cycloalkynyl groups. It will be appreciated that the alicyclic group may comprise an alicyclic ring bearing one or more linking or non-linking alkyl substituents, such as —CH.sub.2cyclohexyl. Specifically, examples of the C.sub.3-20 cycloalkyl group include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, adamantyl and cyclooctyl.

[0212] A heteroalicyclic group is an alicyclic group as defined above which has, in addition to carbon atoms, one or more ring heteroatoms, which are optionally selected from O, S, N, P and Si. Heteroalicyclic groups optionally contain from one to four heteroatoms, which may be the same or different. Heteroalicyclic groups optionally contain from 5 to 20 atoms, optionally from 5 to 14 atoms, optionally from 5 to 12 atoms.

[0213] An aryl group or aryl ring is a monocyclic or polycyclic ring system having from 5 to 20 carbon atoms, wherein at least one ring in the system is aromatic and wherein each ring in the system contains three to twelve ring members. The term “aryl” can be used alone or as part of a larger moiety as in “aralkyl”, “aralkoxy”, or “aryloxyalkyl”. An aryl group is optionally a “C.sub.6-12 aryl group” and is an aryl group constituted by 6, 7, 8, 9, 10, 11 or 12 carbon atoms and includes condensed ring groups such as monocyclic ring group, or bicyclic ring group and the like. Specifically, examples of “C.sub.6-10 aryl group” include phenyl group, biphenyl group, indenyl group, anthracyl group, naphthyl group or azulenyl group and the like. It should be noted that condensed rings such as indan, benzofuran, phthalimide, phenanthridine and tetrahydro naphthalene are also included in the aryl group.

[0214] The term “heteroaryl” used alone or as part of another term (such as “heteroaralkyl”, or “heteroaralkoxy”) refers to groups having 5 to 14 ring atoms, optionally 5, 6, or 9 ring atoms; having 6, 10, or 14 π electrons shared in a cyclic array; and having, in addition to carbon atoms, from one to five heteroatoms. The term “heteroatom” refers to nitrogen, oxygen, or sulfur, and includes any oxidized form of nitrogen or sulfur, and any quaternized form of nitrogen. The term “heteroaryl” also includes groups in which a heteroaryl ring is fused to one or more aryl, cycloaliphatic, or heterocyclyl rings, where the radical or point of attachment is on the heteroaromatic ring. Examples include indolyl, isoindolyl, benzothienyl, benzofuranyl, dibenzofuranyl, indazolyl, benzimidazolyl, benzthiazolyl, quinolyl, isoquinolyl, cinnolinyl, phthalazinyl, quinazolinyl, quinoxalinyl, 4H-quinolizinyl, carbazolyl, acridinyl, phenazinyl, phenothiazinyl, phenoxazinyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, and pyrido[2,3-b]-1,4-oxazin-3(4H)-one. Thus, a heteroaryl group may be mono- or polycyclic.

[0215] The term “heteroaralkyl” refers to an alkyl group substituted by a heteroaryl, wherein the alkyl and heteroaryl portions independently are optionally substituted.

[0216] As used herein, the terms “heterocycle”, “heterocyclyl”, “heterocyclic radical”, and “heterocyclic ring” are used interchangeably and refer to a stable 5- to 7-membered monocyclic or 7-14-membered bicyclic heterocyclic moiety that is saturated, partially unsaturated, or aromatic and having, in addition to carbon atoms, one or more, optionally one to four, heteroatoms, as defined above. When used in reference to a ring atom of a heterocycle, the term “nitrogen” includes a substituted nitrogen.

[0217] Examples of alicyclic, heteroalicyclic, aryl and heteroaryl groups include but are not limited to cyclohexyl, phenyl, acridine, benzimidazole, benzofuran, benzothiophene, benzoxazole, benzothiazole, carbazole, cinnoline, dioxin, dioxane, dioxolane, dithiane, dithiazine, dithiazole, dithiolane, furan, imidazole, imidazoline, imidazolidine, indole, indoline, indolizine, indazole, isoindole, isoquinoline, isoxazole, isothiazole, morpholine, napthyridine, oxazole, oxadiazole, oxathiazole, oxathiazolidine, oxazine, oxadiazine, phenazine, phenothiazine, phenoxazine, phthalazine, piperazine, piperidine, pteridine, purine, pyran, pyrazine, pyrazole, pyrazoline, pyrazolidine, pyridazine, pyridine, pyrimidine, pyrrole, pyrrolidine, pyrroline, quinoline, quinoxaline, quinazoline, quinolizine, tetrahydrofuran, tetrazine, tetrazole, thiophene, thiadiazine, thiadiazole, thiatriazole, thiazine, thiazole, thiomorpholine, thianaphthalene, thiopyran, triazine, triazole, and trithiane.

[0218] The term “halide”, “halo” and “halogen” are used interchangeably and, as used herein mean a fluorine atom, a chlorine atom, a bromine atom, an iodine atom and the like, optionally a fluorine atom, a bromine atom or a chlorine atom, and optionally a fluorine atom.

[0219] A haloalkyl group is optionally a “C.sub.1-20 haloalkyl group”, optionally a “C.sub.1-15 haloalkyl group”, optionally a “C.sub.1-12 haloalkyl group”, optionally a “C.sub.1-.sub.10 haloalkyl group”, optionally a “C.sub.1-8 haloalkyl group”, optionally a “C.sub.1-6 haloalkyl group” and is a C.sub.1-20 alkyl, a C.sub.1-15 alkyl, a C.sub.1-12 alkyl, a C.sub.1-10 alkyl, a C.sub.1-8 alkyl, or a C.sub.1-6 alkyl group, respectively, as described above substituted with at least one halogen atom, optionally 1, 2 or 3 halogen atom(s). The term “haloalkyl” encompasses fluorinated or chlorinated groups, including perfluorinated compounds. Specifically, examples of “C.sub.1-20 haloalkyl group” include fluoromethyl group, difluoromethyl group, trifluoromethyl group, fluoroethyl group, difluoroethyl group, trifluoroethyl group, chloromethyl group, bromomethyl group, iodomethyl group and the like.

[0220] The term “acyl” as used herein refers to a group having a formula —C(O)R where R is hydrogen or an optionally substituted aliphatic, aryl, or heterocyclic group.

[0221] An alkoxy group is optionally a “C.sub.1-20 alkoxy group”, optionally a “C.sub.1-15 alkoxy group”, optionally a “C.sub.1-12 alkoxy group”, optionally a “C.sub.1-10 alkoxy group”, optionally a “C.sub.1-8 alkoxy group”, optionally a “C.sub.1-6 alkoxy group” and is an oxy group that is bonded to the previously defined C.sub.1-20 alkyl, C.sub.1-15 alkyl, C.sub.1-12 alkyl, C.sub.1-10 alkyl, C.sub.1-8 alkyl, or C.sub.1-6 alkyl group respectively. Specifically, examples of “C.sub.1-20 alkoxy group” include methoxy group, ethoxy group, n-propoxy group, iso-propoxy group, n-butoxy group, iso-butoxy group, sec-butoxy group, tert-butoxy group, n-pentyloxy group, iso-pentyloxy group, secpentyloxy group, n-hexyloxy group, iso-hexyloxy group, , n-hexyloxy group, n-heptyloxy group, n-octyloxy group, n-nonyloxy group, n-decyloxy group, n-undecyloxy group, n-dodecyloxy group, n-tridecyloxy group, n-tetradecyloxy group, n-pentadecyloxy group, n-hexadecyloxy group, n-heptadecyloxy group, n-octadecyloxy group, n-nonadecyloxy group, n-eicosyloxy group, 1,1-dimethylpropoxy group, 1,2-dimethylpropoxy group, 2,2-dimethylpropoxy group, 2-methylbutoxy group, 1-ethyl-2-methylpropoxy group, 1,1,2-trimethylpropoxy group, 1,1-dimethylbutoxy group, 1,2-dimethylbutoxy group, 2,2-dimethylbutoxy group, 2,3-dimethylbutoxy group, 1,3-dimethylbutoxy group, 2-ethylbutoxy group, 2-methylpentyloxy group, 3-methylpentyloxy group and the like.

[0222] An aryloxy group is optionally a “C.sub.5-20 aryloxy group”, optionally a “C.sub.6-12 aryloxy group”, optionally a “C.sub.6-.sub.10 aryloxy group” and is an oxy group that is bonded to the previously defined C.sub.5-20 aryl, C.sub.6-12 aryl, or C.sub.6-10 aryl group respectively.

[0223] An alkylthio group is optionally a “C.sub.1-20 alkylthio group”, optionally a “C.sub.1-15 alkylthio group”, optionally a “C.sub.1-12 alkylthio group”, optionally a “C.sub.1-10 alkylthio group”, optionally a “C.sub.1-8 alkylthio group”, optionally a “C.sub.1-6 alkylthio group” and is a thio (—S—) group that is bonded to the previously defined C.sub.1-20 alkyl, C.sub.1-15 alkyl, C.sub.1-12 alkyl, C.sub.1-.sub.10 alkyl, C.sub.1-8 alkyl, or C.sub.1-6 alkyl group respectively.

[0224] An arylthio group is optionally a “C.sub.5-20 arylthio group”, optionally a “C.sub.6-12 arylthio group”, optionally a “C.sub.6-10 arylthio group” and is a thio (—S—) group that is bonded to the previously defined C.sub.5-.sub.20 aryl, C.sub.6-12 aryl, or C.sub.6-10 aryl group respectively.

[0225] An alkylaryl group is optionally a “C.sub.6-12 aryl C.sub.1-20 alkyl group”, optionally a a “C.sub.6-12 aryl C.sub.1- .sub.16 alkyl group”, optionally a “C.sub.6-12 aryl C.sub.1-6 alkyl group” and is an aryl group as defined above bonded at any position to an alkyl group as defined above. The point of attachment of the alkylaryl group to a molecule may be via the alkyl portion and thus, optionally, the alkylaryl group is —CH.sub.2—Ph or —CH.sub.2CH.sub.2—Ph. An alkylaryl group can also be referred to as “aralkyl”.

[0226] A silyl group is optionally —Si(R.sub.s).sub.3, wherein each R.sub.5 can be independently an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. Optionally, each R.sub.5 is independently an unsubstituted aliphatic, alicyclic or aryl. Optionally, each R.sub.5 is an alkyl group selected from methyl, ethyl or propyl.

[0227] A silyl ether group is optionally a group OSi(R.sub.6).sub.3 wherein each R.sub.6, can be independently an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. Each R.sub.6 can be independently an unsubstituted aliphatic, alicyclic or aryl. Optionally, each R.sub.6 is an optionally substituted phenyl or optionally substituted alkyl group selected from methyl, ethyl, propyl or butyl (such as n-butyl (nBu) or tert-butyl (tBu)). Exemplary silyl ether groups include OSi(Me).sub.3, OSi(Et).sub.3, OSi(Ph).sub.3, OSi(Me).sub.2(tBu), OSi(tBu).sub.3 and OSi(Ph).sub.2(tBu).A nitrile group (also referred to as a cyano group) is a group CN.

[0228] An imine group is a group -CRNR, optionally —CHNR.sub.7 wherein R.sub.7 is an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.7 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.7 is an alkyl group selected from methyl, ethyl or propyl.

[0229] An acetylide group contains a triple bond —C≡C—R.sub.9, optionally wherein R.sub.9 can be hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. For the purposes of the invention when R.sub.9 is alkyl, the triple bond can be present at any position along the alkyl chain. R.sub.9 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.9 is methyl, ethyl, propyl or phenyl.

[0230] An amino group is optionally —NH.sub.2, —NHR.sub.10 or -N(R.sub.10).sub.2 wherein R.sub.10 can be an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, a silyl group, aryl or heteroaryl group as defined above. It will be appreciated that when the amino group is N(R.sub.10).sub.2, each R.sub.10 group can be the same or different. Each R.sub.10 may independently an unsubstituted aliphatic, alicyclic, silyl or aryl. Optionally R.sub.10 is methyl, ethyl, propyl, SiMe.sub.3 or phenyl.

[0231] An amido group is optionally —NR.sub.11C(O)— or —C(O)—NR.sub.11— wherein R.sub.11 can be hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.11 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.11 is hydrogen, methyl, ethyl, propyl or phenyl. The amido group may be terminated by hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group.

[0232] Unless defined otherwise herein, an ester group is optionally —OC(O)R.sub.12 or —C(O)OR.sub.12 wherein R.sub.12 can be an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.12 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.12 is methyl, ethyl, propyl or phenyl. The ester group may be terminated by an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group. It will be appreciated that if R.sub.12 is hydrogen, then the group defined by —OC(O)R.sub.12 or —C(O)OR.sub.12 will be a carboxylic acid group.

[0233] A sulfoxide is optionally —S(O)R.sub.13 and a sulfonyl group is optionally —S(O).sub.2R.sub.13 wherein R.sub.13 can be an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.13 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.13 is methyl, ethyl, propyl or phenyl.

[0234] A carboxylate group is optionally —OC(O)R.sub.14, wherein R.sub.14 can be hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.14 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.14 is hydrogen, methyl, ethyl, propyl, butyl (for example n-butyl, isobutyl or tert-butyl), phenyl, pentafluorophenyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, trifluoromethyl or adamantyl.

[0235] An acetamide is optionally MeC(O)N(R.sub.15).sub.2 wherein R.sub.15 can be hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.15 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.15 is hydrogen, methyl, ethyl, propyl or phenyl.

[0236] A phosphinate group is optionally-OP(O)(R.sub.16).sub.2 or —P(O)(OR.sub.16)(R.sub.16) wherein each R.sub.16 is independently selected from hydrogen, or an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.16 may be aliphatic, alicyclic or aryl, which are optionally substituted by aliphatic, alicyclic, aryl or C.sub.1-6alkoxy. Optionally R.sub.16 is optionally substituted aryl or C.sub.1-20 alkyl, optionally phenyl optionally substituted by C.sub.1-6alkoxy (optionally methoxy) or unsubstituted C.sub.1-20alkyl (such as hexyl, octyl, decyl, dodecyl, tetradecyl, hexadecyl, stearyl). A phosphonate group is optionally -P(O)(OR.sub.16).sub.2 wherein R.sub.16 is as defined above. It will be appreciated that when either or both of R.sub.16 is hydrogen for the group —P(O)(OR.sub.16).sub.2, then the group defined by -P(O)(OR.sub.16).sub.2will be a phosphonic acid group.

[0237] A sulfinate group is optionally —S(O)OR.sub.17 or —OS(O)R.sub.17 wherein R.sub.17 can be hydrogen, an aliphatic, heteroaliphatic, haloaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.17 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.17 is hydrogen, methyl, ethyl, propyl or phenyl. It will be appreciated that if R.sub.17 is hydrogen, then the group defined by —S(O)OR.sub.17 will be a sulfonic acid group.

[0238] A carbonate group is optionally —OC(O)OR.sub.18, wherein R.sub.18 can be hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.18 may be optionally substituted aliphatic, alicyclic or aryl. Optionally R.sub.18 is hydrogen, methyl, ethyl, propyl, butyl (for example n-butyl, isobutyl or tert-butyl), phenyl, pentafluorophenyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, trifluoromethyl, cyclohexyl, benzyl or adamantyl. It will be appreciated that if R.sub.17 is hydrogen, then the group defined by —OC(O)OR.sub.18 will be a carbonic acid group.

[0239] A carbonate functional group is —OC(O)O— and may be derived from a suitable source. Generally, it is derived from CO.sub.2.

[0240] In an -alkylC(O)OR.sub.19 or -alkylC(O)R.sub.19 group, R.sub.19 can be hydrogen, an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.19 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.19 is hydrogen, methyl, ethyl, propyl, butyl (for example n-butyl, isobutyl or tert-butyl), phenyl, pentafluorophenyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, trifluoromethyl or adamantyl.

[0241] An ether group is optionally —OR.sub.20 wherein R.sub.20 can be an aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. R.sub.20 may be unsubstituted aliphatic, alicyclic or aryl. Optionally R.sub.20 is methyl, ethyl, propyl, butyl (for example n-butyl, isobutyl or tert-butyl), phenyl, pentafluorophenyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, trifluoromethyl or adamantyl.

[0242] It will be appreciated that where any of the above groups are present in a Lewis base G, one or more additional R groups may be present, as appropriate, to complete the valency. For example, in the context of an amino group, an additional R group may be present to give RNHR.sub.10., wherein R is hydrogen, an optionally substituted aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl group as defined above. Optionally, R is hydrogen or aliphatic, alicyclic or aryl.

[0243] As used herein, the term “optionally substituted” means that one or more of the hydrogen atoms in the optionally substituted moiety is replaced by a suitable substituent. Unless otherwise indicated, an “optionally substituted” group may have a suitable substituent at each substitutable position of the group, and when more than one position in any given structure may be substituted with more than one substituent selected from a specified group, the substituent may be either the same or different at every position. Combinations of substituents envisioned by this invention are optionally those that result in the formation of stable compounds. The term “stable”, as used herein, refers to compounds that are chemically feasible and can exist for long enough at room temperature i.e. (16-25° C.) to allow for their detection, isolation and/or use in chemical synthesis.

[0244] Optional substituents for use in the present invention include, but are not limited to, halogen, hydroxy, nitro, carboxylate, carbonate, alkoxy, aryloxy, alkylthio, arylthio, heteroaryloxy, alkylaryl, amino, amido, imine, nitrile, silyl, silyl ether, ester, sulfoxide, sulfonyl, acetylide, phosphinate, sulfonate or optionally substituted aliphatic, heteroaliphatic, alicyclic, heteroalicyclic, aryl or heteroaryl groups (for example, optionally substituted by halogen, hydroxy, nitro, carbonate, alkoxy, aryloxy, alkylthio, arylthio, amino, imine, nitrile, silyl, sulfoxide, sulfonyl, phosphinate, sulfonate or acetylide).

[0245] It will be appreciated that although in formula (V), the groups X and G are illustrated as being associated with a single M.sub.1 or M.sub.2 metal centre, one or more X and G groups may form a bridge between the M.sub.1 and M.sub.2 metal centres.

[0246] For the purposes of the present invention, the alkylene oxide substrate is not limited. The term allkylene oxide therefore relates to any compound comprising an epoxide moiety (i.e. a substituted or unsubstituted oxirane compound). Substituted oxiranes include monosubstituted oxiranes, disubstituted oxiranes, trisubstituted oxiranes, and tetrasubstituted oxiranes. Alkylene oxides may comprise a single oxirane moiety. Alkylene oxides may comprise two or more oxirane moieties.

[0247] It will be understood that the term “an alkylene oxide” is intended to encompass one or more alkylene oxides. In other words, the term “an alkylene oxide” refers to a single alkylene oxide, or a mixture of two or more different alkylene oxides. For example, the alkylene oxide substrate may be a mixture of ethylene oxide and propylene oxide, a mixture of cyclohexene oxide and propylene oxide, a mixture of ethylene oxide and cyclohexene oxide, or a mixture of ethylene oxide, propylene oxide and cyclohexene oxide.

[0248] The term polyethercarbonate block polyether (poly)ol generally refers to polymers which are substantially terminated at one or each end with —OH, —SH, and/or —NHR′ groups (encompassing C—OH, P—OH, —C(O)OH, etc. moieties). R′ may be H, or optionally substituted alkyl, heteroalkyl, aryl, heteroaryl, cycloalkyl or heterocycloalkyl, optionally R′ is H or optionally substituted alkyl.

[0249] By way of example, at least about 90%, at least about 95%, at least about 98% or at least about 99% of polymers may be terminated at each end with —OH groups. The skilled person will appreciate that if the polymer is linear, then it may be capped at both ends with —OH groups. If the polymer is branched, each of the branches may be capped with —OH groups. Such polymers are generally useful in preparing higher polymers such as polyurethanes. The chains may comprise a mixture of functional groups (e.g. —OH and -SH) groups, or may contain the same functional group (e.g. all-OH groups).

[0250] The term “continuous” used herein can be defined as the mode of addition of materials or may refer to the nature of the reaction method as a whole.

[0251] In terms of continuous mode of addition, the relevant materials are continually or constantly added during the course of a reaction. This may be achieved by, for example, adding a stream of material with either a constant flow rate or with a variable flow rate. In other words, the one or more materials are added in an essentially non-stop fashion. It is noted, however, that non-stop addition of the materials may need to be briefly interrupted for practical considerations, for example to refill or replace a container of the materials from which these materials are being added.

[0252] In terms of a whole reaction being continuous, the reaction may be conducted over a long period of time, such as a number of days, weeks, months, etc. In such a continuous reaction, reaction materials may be continually topped-up and/or products of the reaction may be tapped-off. It will be appreciated that although catalysts may not be consumed during a reaction, catalysts may in any case require topping-up, since tapping-off may deplete the amount of catalyst present.

[0253] A continuous reaction may employ continuous addition of materials.

[0254] A continuous reaction may employ a semi-continuous (i.e. batch-wise or semi batch-wise) addition of materials

[0255] The term series used herein refers to when two or more reactors are connected so that the crude reaction mixture can flow from the first reactor to the second reactor.

[0256] The term nested used herein refers to when two or more reactors are configured so that one is located within the other. For example in the present invention, when the second reactor is located inside the first reactor, allowing the conditions of both reactors to influence the other.

[0257] By “end part of the reaction” is meant the total reaction time after 50% of the total monomers to be incorporated into the polymer chain are so incorporated into the growing polymer chain, preferably, after 75% of the total are so incorporated into the growing polymer chain, more preferably, after 90% of the total monomers are so incorporated into the growing polymer chain, most preferably, after 95% of the total monomers are so incorporated into the growing polymer chain.

[0258] By “after the start of the reaction” is meant any time after the reaction has begun.

[0259] The term “(co)polymer” is used with reference to the polycarbonate or polyester (poly)ol. The parentheses are used to indicate that if the compound is a polycarbonate (poly)ol it may be a copolymer due to the presence of both carbon dioxide and epoxide residues, whereas if the compound is a polyester polyol it may be a homopolymer if only one monomer was used (for example via ring-opening polymerisation).

[0260] The term “(poly)ol” used herein means polyol or mono-ol and therefore refers to an organic compound which comprises one or more hydroxyl groups and typically no other functional groups, such as a mono-ol, diol or triol.

METHODS

GelPermeation Chromatography

[0261] GPC measurements were carried out against narrow polydispersity poly(ethylene glycol) or polystyrene standards in THF using an Agilent 1260 Infinity machine equipped with Agilent PLgel Mixed-D columns.

EXAMPLES

Example 1

[0262] Hexanediol (2.9 g), catalyst (1) (0.2 g) and EO (30 mL) is added into a 100 mL reactor. The vessel is heated to 75° C. and pressurised to 20 bar with CO.sub.2 and stirred for 16 hours, after which it is cooled and vented. This results in a ca. 1100 g/mol polyethylene carbonate polyol. The contents of the reactor are transferred into a Schlenk tube, along with the addition of PO (6 mL) and EtOAc (20 mL).

[0263] In a separate 100 mL reactor, 9.2 mg of DMC catalyst and PPG400 (0.4 mL) are added. Ethyl acetate (15 mL) is injected into the vessel. The vessel is heated to 130° C. 2 × 0.5 g of PO are added to confirm activity of the DMC catalyst.

[0264] The reactor is cooled to 85° C. under 1 bar N.sub.2 pressure. The first reaction mixture is then added via a HPLC pump. Addition occurred over 1 hour. The reaction is continued for 3 hours before the addition of EO (9 mL) over 0.5 hours. The reaction is run for a further 16 hours before the reactor is cooled to below 10° C. and any residual pressure released. NMR and GPC were measured immediately.

[0265] The final polyol had an Mn of 1500 g/mol and a CO.sub.2 content of 15 wt%.