Carboxy-modified aluminum-based catalyst compositions

Abstract

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

1 . A carboxy-modified aluminum-based catalyst composition of the general formula P(O)(OAlR′R″) 3  or RP(O)(OAlR′R″) 2  wherein; 
 O represents oxygen,    P represents pentavalent phosphorous,    Al represents aluminum,    R comprises hydrogen, an alkyl group, or an aryl group, and    R′ and R″ independently comprise a halide, an alkyl group, a haloalkyl group, an alkoxy group, an aryl group, an aryloxy group, or a carboxy group,    so long as at least one of R′ and R″ is a carboxy group.    
     
     
         2 . A catalyst composition as set forth in  claim 1  wherein said carboxy group comprises acetate, trifluoracetate, or dichloroacetate.  
     
     
         3 . A catalyst composition as set forth in  claim 1  wherein said catalyst composition is a carboxy-modified aluminum phosphate catalyst of the general formula P(O)(OAlR′R″) 3 .  
     
     
         4 . A catalyst composition as set forth in  claim 3  wherein said carboxy-modified aluminum phosphate catalyst comprises a tris[bis(carboxy)aluminum]phosphate catalyst.  
     
     
         5 . A catalyst composition as set forth in  claim 4  wherein said tris[bis(carboxy)aluminum]phosphate catalyst is selected from the group of tris(diacetoxyaluminum) phosphate, tris(dibenzoyloxyaluminum) phosphate, tris[bis(chloroacetoxy)aluminum]phosphate, tris[bis(dichloroacetoxy)aluminum]phosphate, tris[bis(trichloroacetoxy)aluminum]phosphate, tris[bis(trifluoroacetoxy)aluminum]phosphate, and mixtures thereof.  
     
     
         6 . A catalyst composition as set forth in  claim 1  wherein said catalyst composition is a carboxy-modified aluminum phosphonate catalyst of the general formula RP(O)(OAlR′R″) 2 .  
     
     
         7 . A catalyst composition as set forth in  claim 6  wherein said carboxy-modified aluminum phosphonate catalyst comprises a bis[bis(carboxy)aluminum]phosphonate catalyst.  
     
     
         8 . A catalyst composition as set forth in  claim 7  wherein said bis[bis(carboxy)aluminum]phosphonate catalyst is selected from the group of bis(diacetoxyaluminum) methylphosphonate, bis(dibenzoyloxyaluminum) methylphosphonate, bis[bis(chloroacetoxy)aluminum]methylphosphonate, bis[bis(dichloroacetoxy)aluminum]methylphosphonate, bis[bis(trichloroacetoxy)aluminum]methylphosphonate, bis[bis(trifluoroacetoxy)aluminum]methylphosphonate, bis(diacetoxyaluminum) phenylphosphonate, bis(dibenzoyloxyaluminum) phenylphosphonate, bis[bis(chloroacetoxy)aluminum]phenylphosphonate, bis[bis(dichloroacetoxy)aluminum]phenylphosphonate, bis[bis(trichloroacetoxy)aluminum]phenylphosphonate, bis[bis(trifluoroacetoxy)aluminum]phenylphosphonate, and mixtures thereof.  
     
     
         9 . Use of said catalyst composition of  claim 1  in forming a polyether polyol.  
     
     
         10 . A polyether polyol comprising said catalyst composition of  claim 1 .  
     
     
         11 . A polyurethane product comprising said catalyst composition of  claim 1 .  
     
     
         12 . A carboxy-modified aluminum-based catalyst composition comprising the reaction product of: 
 phosphoric acid or a pentavalent phosphonic acid;    a tri-substituted aluminum compound; and    a carboxylic acid.    
     
     
         13 . A catalyst composition as set forth in  claim 12  wherein said pentavalent phosphonic acid is of the general formula RPO(OH) 2  wherein; 
 R comprises hydrogen, an alkyl group, or an aryl group,    O represents oxygen,    P represents pentavalent phosphorous, and    H represents hydrogen.    
     
     
         14 . A catalyst composition as set forth in  claim 13  wherein said pentavalent phosphonic acid is selected from the group of phosphonic acid, methylphosphonic acid, ethylphosphonic acid, propylphosphonic acid, iso-, tert-, or sec-butylphosphonic acids, phenylphosphonic acid, and mixtures thereof.  
     
     
         15 . A catalyst composition as set forth in  claim 12  wherein said tri-substituted aluminum compound is of the general formula AlR′″ 3  wherein; 
 R′″ comprises a halide, an alkyl group, a haloalkyl group, an alkoxy group, an aryl group, or an aryloxy group; and    Al represents aluminum.    
     
     
         16 . A catalyst composition as set forth in  claim 15  wherein said tri-substituted aluminum compound is selected from the group of trimethylaluminum, triethylaluminum, triethoxyaluminum, tri-n-propylaluminum, tri-n-propoxyaluminum, tri-iso-propoxyaluminum, tri-iso-butylaluminum, tri-sec-butylaluminum, tri-iso-butoxyaluminum, tri-sec-butoxyaluminum, tri-tert-butoxyaluminum, triphenylaluminum, tri-phenoxyaluminum, and mixtures thereof.  
     
     
         17 . A catalyst composition as set forth in  claim 12  wherein said carboxylic acid is selected from the group of acetic acid, dichloroacetic acid, trifluoracetic acid, and mixtures thereof.  
     
     
         18 . A catalyst composition as set forth in  claim 12  wherein said catalyst composition is a carboxy-modified aluminum phosphate catalyst.  
     
     
         19 . A catalyst composition as set forth in  claim 12  wherein said catalyst composition is a carboxy-modified aluminum phosphonate catalyst.  
     
     
         20 . Use of said catalyst composition of  claim 12  in forming a polyether polyol.  
     
     
         21 . A polyether polyol comprising said catalyst composition of  claim 12 .  
     
     
         22 . A polyurethane product comprising said catalyst composition of  claim 12.