U.S. patent application number 14/721418 was filed with the patent office on 2015-12-03 for aqueous monomer compositions and methods of making and using the same.
This patent application is currently assigned to ELEVANCE RENEWABLE SCIENCES, INC.. The applicant listed for this patent is Elevance Renewable Sciences, Inc.. Invention is credited to Kamlesh Mody, Daniel Mubima.
Application Number | 20150344620 14/721418 |
Document ID | / |
Family ID | 54699639 |
Filed Date | 2015-12-03 |
United States Patent
Application |
20150344620 |
Kind Code |
A1 |
Mody; Kamlesh ; et
al. |
December 3, 2015 |
Aqueous Monomer Compositions and Methods of Making and Using the
Same
Abstract
Aqueous compositions of carboxylic acids, carboxylate esters,
and carboxylate salts are generally disclosed, including methods of
using such compounds to make various polymers, including, but not
limited to, polyesters, polyamides, and polycarbamates. In certain
embodiments, the carboxylic acids, carboxylate esters, and
carboxylate salts are derived from a renewable source, such as a
natural oil.
Inventors: |
Mody; Kamlesh; (Woodridge,
IL) ; Mubima; Daniel; (Woodridge, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Elevance Renewable Sciences, Inc. |
Woodridge |
IL |
US |
|
|
Assignee: |
ELEVANCE RENEWABLE SCIENCES,
INC.
Woodridge
IL
|
Family ID: |
54699639 |
Appl. No.: |
14/721418 |
Filed: |
May 26, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62004087 |
May 28, 2014 |
|
|
|
Current U.S.
Class: |
252/182.24 |
Current CPC
Class: |
A61K 2800/10 20130101;
A61Q 19/00 20130101; A61K 8/37 20130101; C09D 177/06 20130101; C08G
69/26 20130101; C08G 63/81 20130101; C08G 63/16 20130101 |
International
Class: |
C08G 63/81 20060101
C08G063/81 |
Claims
1. An aqueous composition, the composition comprising: water; and a
compound of formula (I) ##STR00005## wherein: X.sup.1 is
C.sub.12-36 alkylene, C.sub.12-24 alkenylene, C.sub.12-36
heteroalkylene, or C.sub.12-24 heteroalkenylene, each of which is
optionally substituted one or more times by substituents selected
independently from R.sup.3; R.sup.1 and R.sup.2 are independently
--OH, --O--R.sup.4, or --O.sup.-Z.sup.+; R.sup.3 is a halogen atom,
--OH, --NH.sub.2, oxo, C.sub.1-6 heteroalkyl, or C.sub.2-6
heteroalkenyl; R.sup.4 is C.sub.1-6 alkyl or C.sub.2-24
heteroalkyl, each of which is optionally substituted one or more
times by --OH; and Z.sup.+ is a positively charged counterion;
provided that at least one of R.sup.1 and R.sup.2 is not --OH.
2. (canceled)
3. (canceled)
4. The aqueous composition of claim 1, wherein X.sup.1 is
C.sub.12-36 alkylene, which is optionally substituted one or more
times with substituents selected independently from --OH and
C.sub.1-6 oxyalkyl.
5. (canceled)
6. The aqueous composition of claim 1, wherein X.sup.1 is
--(CH.sub.2).sub.12--, --(CH.sub.2).sub.14--,
--(CH.sub.2).sub.16--, --(CH.sub.2).sub.18--,
--(CH.sub.2).sub.20--, or --(CH.sub.2).sub.22--.
7. The aqueous composition of claim 6, wherein X.sup.1 is
--(CH.sub.2).sub.16--.
8. (canceled)
9. The aqueous composition of claim 8 claim 1, wherein X.sup.1 is
C.sub.12-36 oxyalkylene, which is optionally substituted one or
more times with substituents selected independently from oxo, --OH,
and C.sub.1-6 oxyalkyl.
10. The aqueous composition of claim 9, wherein X.sup.1 is a moiety
of formula (II) ##STR00006## wherein: X.sup.2 and X.sup.4 are
independently C.sub.12-20 alkylene; and X.sup.3 is C.sub.2-10
alkylene; and n is an integer from 1 to 10.
11. The aqueous composition of claim 10, wherein X.sup.2 and
X.sup.4 are independently --(CH.sub.2).sub.12--,
--(CH.sub.2).sub.14--, --(CH.sub.2).sub.16--,
--(CH.sub.2).sub.18--, --(CH.sub.2).sub.20--, or
--(CH.sub.2).sub.22--.
12. The aqueous composition of claim 11, wherein X.sup.2 and
X.sup.4 are --(CH.sub.2).sub.16--.
13. The aqueous composition of claim 10, wherein X.sup.3 is
--(CH.sub.2).sub.2--, --(CH.sub.2).sub.4--, --(CH.sub.2).sub.6--,
--(CH.sub.2).sub.8--, or --(CH.sub.2).sub.10--.
14. (canceled)
15. (canceled)
16. The aqueous composition of claim 10, wherein n is 1, 2, 3, 4,
or 5.
17. (canceled)
18. (canceled)
19. The aqueous composition of claim 1, wherein R.sup.1 is
--OH.
20. The aqueous composition of claim 1, wherein R.sup.1 is
--O.sup.-Z.sup.+.
21. The aqueous composition of claim 1, wherein R.sup.1 is
--O--R.sup.4.
22. The aqueous composition of claim 1, wherein R.sup.2 is
--OH.
23. The aqueous composition of claim 1, wherein R.sup.2 is
--O.sup.-Z.sup.+.
24. The aqueous composition of claim 1, wherein R.sup.2 is
--O--R.sup.4.
25. (canceled)
26. The aqueous composition of claim 1, wherein Z.sup.+ is an
ammonium compound.
27. (canceled)
28. (canceled)
29. The aqueous composition of claim 26, wherein Z+ is selected
from the group consisting of: ammonium cation, triethylammonium
cation, and N,N-dimethylethanolammonium cation.
30. (canceled)
31. The aqueous composition of claim 1, wherein R.sup.4 is
C.sub.2-24 oxyalkyl, which is optionally substituted one or more
times by --OH.
32. The aqueous composition of claim 31, wherein R.sup.4 is
--CH.sub.2CH.sub.2--(O--CH.sub.2--CH.sub.2).sub.p--O--R.sup.9,
wherein p is an integer from 0 to 10, and R.sup.9 is a hydrogen
atom, methyl, or ethyl.
33-48. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of priority of
U.S. Provisional Application No. 62/004,087, filed May 28, 2014,
which is hereby incorporated by reference as though fully set forth
herein in its entirety.
TECHNICAL FIELD
[0002] Aqueous compositions of carboxylic acids, carboxylate
esters, and carboxylate salts are generally disclosed, including
methods of using such compounds to make various polymers,
including, but not limited to, polyesters, polyamides, and
polycarbamates. In certain embodiments, the carboxylic acids,
carboxylate esters, and carboxylate salts are derived from a
renewable source, such as a natural oil.
BACKGROUND
[0003] Long-chain dibasic acids, or derivatives thereof, can be
used for making a wide variety of novel polymers that have improved
properties relative to incumbent polymers made with short-chain
dibasic acids. Such polymers can have a variety of desirable
properties, such as increased toughness, increased solvent
resistance, increased resistance to hydrolysis, and the like. But
because long-chain dibasic acids can be especially hydrophobic, it
can be difficult to use them in applications where the
polymerization may occur in an aqueous environment.
[0004] Therefore, there is a continuing need to develop compounds,
compositions, and methods of employing long-chain dibasic acids, or
their derivatives, to carry out polymerization reactions in aqueous
environments.
SUMMARY
[0005] In a first aspect, the disclosure provides aqueous
compositions, the compositions including: water; and a compound of
formula (I)
##STR00001## [0006] wherein:
[0007] X.sup.1 is C.sub.12-36 alkylene, C.sub.12-24 alkenylene,
C.sub.12-36 heteroalkylene, or C.sub.12-24 hetero-alkenylene, each
of which is optionally substituted one or more times by
substituents selected independently from R.sup.3;
[0008] R.sup.1 and R.sup.2 are independently --OH, --O--R.sup.4, or
--O.sup.-Z.sup.+;
[0009] R.sup.3 is a halogen atom, --OH, --NH.sub.2, oxo, C.sub.1-6
heteroalkyl, or C.sub.2-6 heteroalkenyl;
[0010] R.sup.4 is C.sub.1-6 alkyl or C.sub.2-24 heteroalkyl, each
of which is optionally substituted one or more times by --OH;
and
[0011] Z.sup.+ is a positively charged counterion;
[0012] provided that at least one of R.sup.1 and R.sup.2 is not
--OH.
[0013] In a second aspect, the disclosure provides methods of
forming a polymer, the methods including: providing a composition
of any embodiment of the first aspect; and reacting one or more
compounds of formula (I) with one or more monomers to form a
polymer.
[0014] Further aspects and embodiments are provided in the
foregoing drawings, detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The following drawings are provided for purposes of
illustrating various embodiments of the compositions and methods
disclosed herein. The drawings are provided for illustrative
purposes only, and are not intended to describe any preferred
compositions or preferred methods, or to serve as a source of any
limitations on the scope of the claimed inventions.
[0016] FIG. 1 shows a non-limiting example of a compound of certain
embodiments disclosed herein, wherein: X.sup.1 is C.sub.12-36
alkylene, C.sub.12-24 alkenylene, C.sub.12-36 heteroalkylene, or
C.sub.12-24 hetero-alkenylene, each of which is optionally
substituted one or more times; R.sup.1 and R.sup.2 are
independently --OH, --O--R.sup.4, or --O.sup.-Z.sup.+; R.sup.4 is
C.sub.1-6 alkyl or C.sub.2-24 heteroalkyl, each of which is
optionally substituted one or more times by --OH; and Z.sup.+ is a
positively charged counterion; provided that at least one of
R.sup.1 and R.sup.2 is not --OH.
DETAILED DESCRIPTION
[0017] The following description recites various aspects and
embodiments of the inventions disclosed herein. No particular
embodiment is intended to define the scope of the invention.
Rather, the embodiments provide non-limiting examples of various
compositions, and methods that are included within the scope of the
claimed inventions. The description is to be read from the
perspective of one of ordinary skill in the art. Therefore,
information that is well known to the ordinarily skilled artisan is
not necessarily included.
Definitions
[0018] The following terms and phrases have the meanings indicated
below, unless otherwise provided herein. This disclosure may employ
other terms and phrases not expressly defined herein. Such other
terms and phrases shall have the meanings that they would possess
within the context of this disclosure to those of ordinary skill in
the art. In some instances, a term or phrase may be defined in the
singular or plural. In such instances, it is understood that any
term in the singular may include its plural counterpart and vice
versa, unless expressly indicated to the contrary.
[0019] As used herein, the singular forms "a," "an," and "the"
include plural referents unless the context clearly dictates
otherwise. For example, reference to "a substituent" encompasses a
single substituent as well as two or more substituents, and the
like.
[0020] As used herein, "for example," "for instance," "such as," or
"including" are meant to introduce examples that further clarify
more general subject matter. Unless otherwise expressly indicated,
such examples are provided only as an aid for understanding
embodiments illustrated in the present disclosure, and are not
meant to be limiting in any fashion. Nor do these phrases indicate
any kind of preference for the disclosed embodiment.
[0021] As used herein, "natural oil," "natural feedstock," or
"natural oil feedstock" refer to oils derived from plants or animal
sources. These terms include natural oil derivatives, unless
otherwise indicated. The terms also include modified plant or
animal sources (e.g., genetically modified plant or animal
sources), unless indicated otherwise. Examples of natural oils
include, but are not limited to, vegetable oils, algae oils, fish
oils, animal fats, tall oils, derivatives of these oils,
combinations of any of these oils, and the like. Representative
non-limiting examples of vegetable oils include rapeseed oil
(canola oil), coconut oil, corn oil, cottonseed oil, olive oil,
palm oil, peanut oil, safflower oil, sesame oil, soybean oil,
sunflower oil, linseed oil, palm kernel oil, tung oil, jatropha
oil, mustard seed oil, pennycress oil, camelina oil, hempseed oil,
and castor oil. Representative non-limiting examples of animal fats
include lard, tallow, poultry fat, yellow grease, and fish oil.
Tall oils are by-products of wood pulp manufacture. In some
embodiments, the natural oil or natural oil feedstock comprises one
or more unsaturated glycerides (e.g., unsaturated triglycerides).
In some such embodiments, the natural oil feedstock comprises at
least 50% by weight, or at least 60% by weight, or at least 70% by
weight, or at least 80% by weight, or at least 90% by weight, or at
least 95% by weight, or at least 97% by weight, or at least 99% by
weight of one or more unsaturated triglycerides, based on the total
weight of the natural oil feedstock.
[0022] As used herein, "natural oil derivatives" refers to the
compounds or mixtures of compounds derived from a natural oil using
any one or combination of methods known in the art. Such methods
include but are not limited to saponification, fat splitting,
transesterification, esterification, hydrogenation (partial,
selective, or full), isomerization, oxidation, and reduction.
Representative non-limiting examples of natural oil derivatives
include gums, phospholipids, soapstock, acidulated soapstock,
distillate or distillate sludge, fatty acids and fatty acid alkyl
ester (e.g. non-limiting examples such as 2-ethylhexyl ester),
hydroxy substituted variations thereof of the natural oil. For
example, the natural oil derivative may be a fatty acid methyl
ester ("FAME") derived from the glyceride of the natural oil. In
some embodiments, a feedstock includes canola or soybean oil, as a
non-limiting example, refined, bleached, and deodorized soybean oil
(i.e., RBD soybean oil). Soybean oil typically comprises about 95%
weight or greater (e.g., 99% weight or greater) triglycerides of
fatty acids. Major fatty acids in the polyol esters of soybean oil
include saturated fatty acids, as a non-limiting example, palmitic
acid (hexadecanoic acid) and stearic acid (octadecanoic acid), and
unsaturated fatty acids, as a non-limiting example, oleic acid
(9-octadecenoic acid), linoleic acid (9,12-octadecadienoic acid),
and linolenic acid (9,12,15-octadecatrienoic acid).
[0023] As used herein, "metathesis catalyst" includes any catalyst
or catalyst system that catalyzes an olefin metathesis
reaction.
[0024] As used herein, "metathesize" or "metathesizing" refer to
the reacting of a feedstock in the presence of a metathesis
catalyst to form a "metathesized product" comprising new olefinic
compounds, i.e., "metathesized" compounds. Metathesizing is not
limited to any particular type of olefin metathesis, and may refer
to cross-metathesis (i.e., co-metathesis), self-metathesis,
ring-opening metathesis, ring-opening metathesis polymerizations
("ROMP"), ring-closing metathesis ("RCM"), and acyclic diene
metathesis ("ADMET"). In some embodiments, metathesizing refers to
reacting two triglycerides present in a natural feedstock
(self-metathesis) in the presence of a metathesis catalyst, wherein
each triglyceride has an unsaturated carbon-carbon double bond,
thereby forming a new mixture of olefins and esters which may
include a triglyceride dimer. Such triglyceride dimers may have
more than one olefinic bond, thus higher oligomers also may form.
Additionally, in some other embodiments, metathesizing may refer to
reacting an olefin, such as ethylene, and a triglyceride in a
natural feedstock having at least one unsaturated carbon-carbon
double bond, thereby forming new olefinic molecules as well as new
ester molecules (cross-metathesis).
[0025] As used herein, "hydrocarbon" refers to an organic group
composed of carbon and hydrogen, which can be saturated or
unsaturated, and can include aromatic groups. The term
"hydrocarbyl" refers to a monovalent or polyvalent hydrocarbon
moiety.
[0026] As used herein, "olefin" or "olefins" refer to compounds
having at least one unsaturated carbon-carbon double bond. In
certain embodiments, the term "olefins" refers to a group of
unsaturated carbon-carbon double bond compounds with different
carbon lengths. Unless noted otherwise, the terms "olefin" or
"olefins" encompasses "polyunsaturated olefins" or "poly-olefins,"
which have more than one carbon-carbon double bond. As used herein,
the term "monounsaturated olefins" or "mono-olefins" refers to
compounds having only one carbon-carbon double bond. A compound
having a terminal carbon-carbon double bond can be referred to as a
"terminal olefin" or an "alpha-olefin," while an olefin having a
non-terminal carbon-carbon double bond can be referred to as an
"internal olefin." In some embodiments, the alpha-olefin is a
terminal alkene, which is an alkene (as defined below) having a
terminal carbon-carbon double bond. Additional carbon-carbon double
bonds can be present.
[0027] The number of carbon atoms in any group or compound can be
represented by the terms: "C.sub.z", which refers to a group of
compound having z carbon atoms; and "C.sub.x-y", which refers to a
group or compound containing from x to y, inclusive, carbon atoms.
For example, "C.sub.1-6 alkyl" represents an alkyl chain having
from 1 to 6 carbon atoms and, for example, includes, but is not
limited to, methyl, ethyl, n-propyl, isopropyl, isobutyl, n-butyl,
sec-butyl, tert-butyl, isopentyl, n-pentyl, neopentyl, and n-hexyl.
As a further example, a "C.sub.4-10 alkene" refers to an alkene
molecule having from 4 to 10 carbon atoms, and, for example,
includes, but is not limited to, 1-butene, 2-butene, isobutene,
1-pentene, 1-hexene, 3-hexene, 1-heptene, 3-heptene, 1-octene,
4-octene, 1-nonene, 4-nonene, and 1-decene.
[0028] As used herein, the term "low-molecular-weight olefin" may
refer to any one or combination of unsaturated straight, branched,
or cyclic hydrocarbons in the C.sub.2-14 range.
Low-molecular-weight olefins include alpha-olefins, wherein the
unsaturated carbon-carbon bond is present at one end of the
compound. Low-molecular-weight olefins may also include dienes or
trienes. Low-molecular-weight olefins may also include internal
olefins or "low-molecular-weight internal olefins." In certain
embodiments, the low-molecular-weight internal olefin is in the
C.sub.4-14 range. Examples of low-molecular-weight olefins in the
C.sub.2-6 range include, but are not limited to: ethylene,
propylene, 1-butene, 2-butene, isobutene, 1-pentene, 2-pentene,
3-pentene, 2-methyl-1-butene, 2-methyl-2-butene, 3-methyl-1-butene,
cyclopentene, 1,4-pentadiene, 1-hexene, 2-hexene, 3-hexene,
4-hexene, 2-methyl-1-pentene, 3-methyl-1-pentene,
4-methyl-1-pentene, 2-methyl-2-pentene, 3-methyl-2-pentene,
4-methyl-2-pentene, 2-methyl-3-pentene, and cyclohexene.
Non-limiting examples of low-molecular-weight olefins in the
C.sub.7-9 range include 1,4-heptadiene, 1-heptene, 3,6-nonadiene,
3-nonene, 1,4,7-octatriene. Other possible low-molecular-weight
olefins include styrene and vinyl cyclohexane. In certain
embodiments, it is preferable to use a mixture of olefins, the
mixture comprising linear and branched low-molecular-weight olefins
in the C.sub.4-10 range. Olefins in the C.sub.4-10 range can also
be referred to as "short-chain olefins," which can be either
branched or unbranched. In one embodiments, it may be preferable to
use a mixture of linear and branched C.sub.4 olefins (i.e.,
combinations of: 1-butene, 2-butene, and/or isobutene). In other
embodiments, a higher range of C.sub.11-14 may be used.
[0029] In some instances, the olefin can be an "alkene," which
refers to a straight- or branched-chain non-aromatic hydrocarbon
having 2 to 30 carbon atoms and one or more carbon-carbon double
bonds, which may be optionally substituted, as herein further
described, with multiple degrees of substitution being allowed. A
"monounsaturated alkene" refers to an alkene having one
carbon-carbon double bond, while a "polyunsaturated alkene" refers
to an alkene having two or more carbon-carbon double bonds. A
"lower alkene," as used herein, refers to an alkene having from 2
to 10 carbon atoms.
[0030] As used herein, "ester" or "esters" refer to compounds
having the general formula: R--COO--R', wherein R and R' denote any
organic group (such as alkyl, aryl, or silyl groups) including
those bearing heteroatom-containing substituent groups. In certain
embodiments, R and R' denote alkyl, alkenyl, aryl, or alcohol
groups. In certain embodiments, the term "esters" may refer to a
group of compounds with the general formula described above,
wherein the compounds have different carbon lengths. In certain
embodiments, the esters may be esters of glycerol, which is a
trihydric alcohol. The term "glyceride" can refer to esters where
one, two, or three of the --OH groups of the glycerol have been
esterified.
[0031] It is noted that an olefin may also comprise an ester, and
an ester may also comprise an olefin, if the R or R' group in the
general formula R--COO--R' contains an unsaturated carbon-carbon
double bond. Such compounds can be referred to as "unsaturated
esters" or "olefin ester" or "olefinic ester compounds." Further, a
"terminal olefinic ester compound" may refer to an ester compound
where R has an olefin positioned at the end of the chain. An
"internal olefin ester" may refer to an ester compound where R has
an olefin positioned at an internal location on the chain.
Additionally, the term "terminal olefin" may refer to an ester or
an acid thereof where R' denotes hydrogen or any organic compound
(such as an alkyl, aryl, or silyl group) and R has an olefin
positioned at the end of the chain, and the term "internal olefin"
may refer to an ester or an acid thereof where R' denotes hydrogen
or any organic compound (such as an alkyl, aryl, or silyl group)
and R has an olefin positioned at an internal location on the
chain.
[0032] As used herein, "alkyl" refers to a straight or branched
chain saturated hydrocarbon having 1 to 30 carbon atoms, which may
be optionally substituted, as herein further described, with
multiple degrees of substitution being allowed. Examples of
"alkyl," as used herein, include, but are not limited to, methyl,
ethyl, n-propyl, isopropyl, isobutyl, n-butyl, sec-butyl,
tert-butyl, isopentyl, n-pentyl, neopentyl, n-hexyl, and
2-ethylhexyl. The number of carbon atoms in an alkyl group is
represented by the phrase "C.sub.x-y alkyl," which refers to an
alkyl group, as herein defined, containing from x to y, inclusive,
carbon atoms. Thus, "C.sub.1-6alkyl" represents an alkyl chain
having from 1 to 6 carbon atoms and, for example, includes, but is
not limited to, methyl, ethyl, n-propyl, isopropyl, isobutyl,
n-butyl, sec-butyl, tert-butyl, isopentyl, n-pentyl, neopentyl, and
n-hexyl. In some instances, the "alkyl" group can be divalent, in
which case the group can alternatively be referred to as an
"alkylene" group. Also, in some instances, one or more of the
carbon atoms in the alkyl or alkylene group can be replaced by a
heteroatom (e.g., selected from nitrogen, oxygen, or sulfur,
including N-oxides, sulfur oxides, and sulfur dioxides, where
feasible), and is referred to as a "heteroalkyl" or
"heteroalkylene" group, respectively. Non-limiting examples include
"oxyalkyl" or "oxyalkylene" groups, which include groups such as:
--O-(alkyl), -[-(alkylene)-O--].sub.x-alkyl,
-[-(alkylene)-O--].sub.x-alkylene-,
--O--[-(alkylene)-O--].sub.x-alkyl,
--O--[-(alkylene)-O--].sub.x-alkylene-, and the like, where x is 1
or more, such as 1, 2, 3, 4, 5, 6, 7, or 8.
[0033] As used herein, "alkenyl" refers to a straight or branched
chain non-aromatic hydrocarbon having 2 to 30 carbon atoms and
having one or more carbon-carbon double bonds, which may be
optionally substituted, as herein further described, with multiple
degrees of substitution being allowed. Examples of "alkenyl," as
used herein, include, but are not limited to, ethenyl, 2-propenyl,
2-butenyl, and 3-butenyl. The number of carbon atoms in an alkenyl
group is represented by the phrase "C.sub.x-y alkenyl," which
refers to an alkenyl group, as herein defined, containing from x to
y, inclusive, carbon atoms. Thus, "C.sub.2-6 alkenyl" represents an
alkenyl chain having from 2 to 6 carbon atoms and, for example,
includes, but is not limited to, ethenyl, 2-propenyl, 2-butenyl,
and 3-butenyl. In some instances, the "alkenyl" group can be
divalent, in which case the group can alternatively be referred to
as an "alkenylene" group. Also, in some instances, one or more of
the saturated carbon atoms in the alkenyl or alkenylene group can
be replaced by a heteroatom (e.g., selected from nitrogen, oxygen,
or sulfur, including N-oxides, sulfur oxides, and sulfur dioxides,
where feasible), and is referred to as a "heteroalkenyl" or
"heteroalkenylene" group, respectively. Non-limiting examples
include "oxyalkenyl" or "oxyalkenylene" groups, which include
groups of the following formulas: --O-(alkenyl),
-[--(R.sup.f)--O--].sub.x--R.sup.g,
-[--(R.sup.f)--O--].sub.x--R.sup.h--, and the like, where x is 1 or
more, such as 1, 2, 3, 4, 5, 6, 7, or 8, and R.sup.f, R.sup.g, and
R.sup.h are independently alkyl/alkylene or alkenyl/alkenylene
groups, provided that each such "oxyalkenyl" or "oxyalkenylene"
group contains at least one carbon-carbon double bond.
[0034] As used herein, "halogen" refers to fluorine, chlorine,
bromine, or iodine. In some embodiments, "halogen" can refer to
fluorine or chlorine.
[0035] As used herein, the term "oxo" refers to a .dbd.O moiety.
Thus, a non-limiting example of an oxo-substituted alkyl group is a
group such as --CH.sub.2--(C.dbd.O)--CH.sub.3. A non-limiting
example of an oxo-substituted heteroalkyl group is a group such as
--CH.sub.2--C(.dbd.O)--O--CH.sub.3.
[0036] As used herein, the term "Lewis base" refers to any compound
capable of donating a pair of electrons to form a Lewis acid. The
term is intended to include Bronsted bases, which are compounds
capable of accepting a proton to form a Bronsted acid. Ammonia is a
non-limiting example of a Lewis base, whose conjugate acid is the
NH.sub.4.sup.+ cation. In some embodiemnts, the Lewis base is a
Bronsted base.
[0037] As used herein, "polymer" refers to a substance having a
chemical structure that includes the multiple repetition of
constitutional units formed from substances of comparatively low
relative molecular mass relative to the molecular mass of the
polymer. The term "polymer" includes soluble and/or fusible
molecules having chains of repeat units, and also includes
insoluble and infusible networks. The term "polymer" includes
compounds often referred to as oligomers.
[0038] As used herein, "monomer" refers to a substance that can
undergo a polymerization reaction to contribute constitutional
units to the chemical structure of a polymer.
[0039] As used herein, "polyester" refers to a polymer comprising
two or more ester linkages. Other types of linkages can be
included, however. In some embodiments, at least 80%, or at least
90%, or at least 95% of the linkages in the polyester are ester
linkages. The term can refer to an entire polymer molecule, or can
also refer to a particular polymer sequence, such as a block within
a block copolymer.
[0040] As used herein, "polyamide" refers to a polymer comprising
two or more amide linkages. Other types of linkages can be
included, however. In some embodiments, at least 80%, or at least
90%, or at least 95% of the linkages in the polyamide are amide
linkages. The term can refer to an entire polymer molecule, or can
also refer to a particular polymer sequence, such as a block within
a block copolymer.
[0041] As used herein, "polycarbamate" refers to a polymer
comprising two or more carbamate (urethane) linkages. Other types
of linkages can be included, however. In some embodiments, at least
80%, or at least 90%, or at least 95% of the linkages in the
polycarbamate are carbamate linkages. The term can refer to an
entire polymer molecule, or can also refer to a particular polymer
sequence, such as a block within a block copolymer.
[0042] As used herein, "substituted" refers to substitution of one
or more hydrogen atoms of the designated moiety with the named
substituent or substituents, multiple degrees of substitution being
allowed unless otherwise stated, provided that the substitution
results in a stable or chemically feasible compound. A stable
compound or chemically feasible compound is one in which the
chemical structure is not substantially altered when kept at a
temperature from about -80.degree. C. to about +40.degree. C., in
the absence of moisture or other chemically reactive conditions,
for at least a week, or a compound which maintains its integrity
long enough to be useful for therapeutic or prophylactic
administration to a patient. As used herein, the phrases
"substituted with one or more . . . " or "substituted one or more
times . . . " refer to a number of substituents that equals from
one to the maximum number of substituents possible based on the
number of available bonding sites, provided that the above
conditions of stability and chemical feasibility are met.
[0043] As used herein, "yield" refers to the amount of reaction
product formed in a reaction. When expressed with units of percent
(%), the term yield refers to the amount of reaction product
actually formed, as a percentage of the amount of reaction product
that would be formed if all of the limiting reactant were converted
into the product.
[0044] As used herein, "mix" or "mixed" or "mixture" refers broadly
to any combining of two or more compositions. The two or more
compositions need not have the same physical state; thus, solids
can be "mixed" with liquids, e.g., to form a slurry, suspension, or
solution. Further, these terms do not require any degree of
homogeneity or uniformity of composition. This, such "mixtures" can
be homogeneous or heterogeneous, or can be uniform or non-uniform.
Further, the terms do not require the use of any particular
equipment to carry out the mixing, such as an industrial mixer.
[0045] As used herein, "optionally" means that the subsequently
described event(s) may or may not occur. In some embodiments, the
optional event does not occur. In some other embodiments, the
optional event does occur one or more times.
[0046] As used herein, "comprise" or "comprises" or "comprising" or
"comprised of" refer to groups that are open, meaning that the
group can include additional members in addition to those expressly
recited. For example, the phrase, "comprises A" means that A must
be present, but that other members can be present too. The terms
"include," "have," and "composed of" and their grammatical variants
have the same meaning. In contrast, "consist of" or "consists of"
or "consisting of refer to groups that are closed. For example, the
phrase "consists of A" means that A and only A is present.
[0047] As used herein, "or" is to be given its broadest reasonable
interpretation, and is not to be limited to an either/or
construction. Thus, the phrase "comprising A or B" means that A can
be present and not B, or that B is present and not A, or that A and
B are both present. Further, if A, for example, defines a class
that can have multiple members, e.g., A1 and A2, then one or more
members of the class can be present concurrently.
[0048] As used herein, the various functional groups represented
will be understood to have a point of attachment at the functional
group having the hyphen or dash (-) or an asterisk (*). In other
words, in the case of --CH.sub.2CH.sub.2CH.sub.3, it will be
understood that the point of attachment is the CH.sub.2 group at
the far left. If a group is recited without an asterisk or a dash,
then the attachment point is indicated by the plain and ordinary
meaning of the recited group.
[0049] As used herein, multi-atom bivalent species are to be read
from left to right. For example, if the specification or claims
recite A-D-E and D is defined as --OC(O)--, the resulting group
with D replaced is: A-OC(O)-E and not A-C(O)O-E.
[0050] Other terms are defined in other portions of this
description, even though not included in this subsection.
Aqueous Monomer Compositions
[0051] In a certain aspects, the disclosure provides aqueous
compositions, the compositions including: water; and a compound of
formula (I)
##STR00002##
wherein:
[0052] X.sup.1 is C.sub.12-36 alkylene, C.sub.12-24 alkenylene,
C.sub.12-36 heteroalkylene, or C.sub.12-24 heteroalkenylene, each
of which is optionally substituted one or more times by
substituents selected independently from R.sup.3;
[0053] R.sup.1 and R.sup.2 are independently --OH, --O--R.sup.4, or
--O.sup.-Z.sup.+;
[0054] R.sup.3 is a halogen atom, --OH, --NH.sub.2, oxo, C.sub.1-6
heteroalkyl, or C.sub.2-6 heteroalkenyl;
[0055] R.sup.4 is C.sub.1-6 alkyl or C.sub.2-24 heteroalkyl, each
of which is optionally substituted one or more times by --OH;
and
[0056] Z.sup.+ is a positively charged counterion;
[0057] provided that at least one of R.sup.1 and R.sup.2 is not
--OH.
[0058] Any embodiments of the compound of formula (I) can be
employed. For example in some embodiments, X.sup.1 is C.sub.12-36
alkylene or C.sub.12-36 heteroalkylene, each of which is optionally
substituted one or more times by substituents selected
independently from R.sup.3. In some further embodiments, X.sup.1 is
C.sub.12-36 alkylene, which is optionally substituted one or more
times by substituents selected independently from R.sup.3. In some
further embodiments, X.sup.1 is C.sub.12-36 alkylene, which is
optionally substituted one or more times with substituents selected
independently from --OH and C.sub.1-6 oxyalkyl, e.g., --O(C.sub.1-6
alkyl). In some further embodiments, X.sup.1 is C.sub.12-20
alkylene, optionally substituted one or more times with
substituents selected independently from --OH and C.sub.1-6
oxyalkyl, e.g., --O(C.sub.1-6 alkyl). In some such embodiments,
X.sup.1 is --(CH.sub.2).sub.12--, --(CH.sub.2).sub.14--,
--(CH.sub.2).sub.16--, --(CH.sub.2).sub.18--,
--(CH.sub.2).sub.20--, or --(CH.sub.2).sub.22--. In some further
such embodiments, X.sup.1 is --(CH.sub.2).sub.16--.
[0059] In some other embodiments, X.sup.1 is C.sub.12-36
heteroalkylene, which is optionally substituted one or more times
by substituents selected independently from R.sup.3. In some such
embodiments, X.sup.1 is C.sub.12-36 oxyalkylene, which is
optionally substituted one or more times by substituents selected
independently from R.sup.3. In some further such embodiments,
X.sup.1 is C.sub.12-36 oxyalkylene, which is optionally substituted
one or more times with substituents selected independent from oxo,
--OH, and C.sub.1-6 oxyalkyl. In some further such embodiments,
X.sup.1 is a moiety of formula (II)
##STR00003##
wherein: X.sup.2 and X.sup.4 are independently C.sub.12-20
alkylene; X.sup.3 is C.sub.2-10 alkylene; and n is an integer from
1 to 10. In some such embodiments, X.sup.2 and X.sup.4 are
independently --(CH.sub.2).sub.12--, --(CH.sub.2).sub.14--,
--(CH.sub.2).sub.16--, --(CH.sub.2).sub.18--,
--(CH.sub.2).sub.20--, or --(CH.sub.2).sub.22--. In some further
such embodiments, X.sup.2 and X.sup.4 are --(CH.sub.2).sub.16--. In
some further such embodiments, X.sup.3 is --(CH.sub.2).sub.2--,
--(CH.sub.2).sub.4--, --(CH.sub.2).sub.6--, --(CH.sub.2).sub.8--,
or --(CH.sub.2).sub.10--. In some further such embodiments, X.sup.3
is --(CH.sub.2).sub.2--, --(CH.sub.2).sub.4--, or
--(CH.sub.2).sub.6--. In some further such embodiments, X.sup.3 is
--(CH.sub.2).sub.6--. In some further such embodiments, n is 1, 2,
3, 4, or 5. In some further such embodiments, n is 1, 2, or 3. In
some even further such embodiments, n is 2.
[0060] In some further embodiments of any of the above embodiments,
R.sup.1 is --OH. In some further embodiments of any of the above
embodiments, R.sup.1 is --O.sup.-Z.sup.+. In some further
embodiments of any of the above embodiments, R.sup.1 is
--O--R.sup.4.
[0061] In some further embodiments of any of the above embodiments,
R.sup.2 is --OH. In some further embodiments of any of the above
embodiments, R.sup.2 is --O.sup.-Z.sup.+. In some further
embodiments of any of the above embodiments, R.sup.2 is
--O--R.sup.4.
[0062] In some further embodiments of any of the above embodiments,
Z.sup.+ is the conjugate acid of a Lewis base. In some embodiments,
Z.sup.+ is an ammonium compound, i.e., a quaternary ammonium cation
that can be optionally substituted with 1 to 4 organic moieties. In
some such embodiments, the ammonium compound is a compound of
formula (III):
##STR00004##
wherein R.sup.5, R.sup.6, R.sup.7, and R.sup.8 are independently a
hydrogen atom or a C.sub.1-10 alkyl, where the alkyl group is
optionally substituted one or more times with substituents selected
independently from the group consisting of a halogen atom, --OH,
--NH.sub.2, and C.sub.1-6 heteroalkyl. In some further embodiments,
R.sup.5, R.sup.6, R.sup.7, and R.sup.8 are independently a hydrogen
atom or a C.sub.1-6 alkyl, where the alkyl group is optionally
substituted one or more times with substituents selected
independently from the group consisting of a halogen atom, --OH,
and --O(C.sub.1-6alkyl). In some even further embodiments, Z.sup.+
is selected from the group consisting of: an unsubstituted ammonium
cation (NH.sub.4.sup.+), a triethylammonium cation, and an
N,N-dimethylethanolammonium cation.
[0063] In some embodiments of any of the above embodiments, R.sup.4
is C.sub.2-24 heteroalkyl, which is optionally substituted one or
more times by --OH. In some such embodiments, R.sup.4 is C.sub.2-24
oxyalkyl, which is optionally substituted one or more times by
--OH. In some such embodiments, R.sup.4 is
--CH.sub.2CH.sub.2--(O--CH.sub.2--CH.sub.2).sub.p--O--R.sup.9,
wherein p is an integer from 0 to 10, and R.sup.9 is a hydrogen
atom, methyl, or ethyl.
[0064] The aqueous compositions disclosed herein can contain any
suitable amount of water. In some embodiments, the composition
comprises at least 40% by weight, or at least 50% by weight, or at
least 60% by weight, or at least 70% by weight, or at least 80% by
weight, or at least 90% by weight, or at least 95% by weight, or at
least 97% by weight, water.
[0065] The aqueous compositions disclosed herein can contain any
suitable additional ingredients, whether or not miscible and/or
soluble in water. For example, in some embodiments, the composition
further comprises an additional solvent, a co-solvent, a
surfactant, a co-surfactant, an emulsifier, a natural or synthetic
colorant, a natural or synthetic fragrance, an antioxidant, a
corrosion inhibitor, or an antimicrobial agent. Such solvents or
co-solvents can be miscible in water (e.g., alcohols, etc.) or at
least partially immiscible in water.
[0066] The compounds of formula (I) can exist in the aqueous medium
in any suitable form. In some embodiments, the compounds are at
least partially solubilized by the aqueous medium, meaning that the
composition is a solution. In some embodiments, at least a portion
of the compounds are not solubilized and exist in the medium as
particles, i.e., as dispersed particles, leading to an embodiment
where the composition is a dispersion.
[0067] Any other additional ingredient can be included in the
composition, as long as their inclusion is not inconsistent with
the utility of the composition.
Methods of Making Monomer Compounds
[0068] In the above embodiments, the aqueous composition can
include at least one compound that can serve as a monomer, such as
a compound of formula (I). Such compounds can be made by any
suitable means. For example, in some embodiments, a long-chain
dibasic acid, such as 1,18-octadecanedioic acid, can be converted
to a salt by treating it with base in the presence of suitable
counterions (e.g., ammonium cations). In other embodiments, a
long-chain dibasic acid, such as 1,18-octadecanedioic acid, can be
converted to an ester by transesterification in the presence of an
alcohol.
Derivation from Renewable Sources
[0069] The compounds employed in any of the aspects or embodiments
disclosed herein can, in certain embodiments, be derived from
renewable sources, such as from various natural oils or their
derivatives. Any suitable methods can be used to make these
compounds from such renewable sources. Suitable methods include,
but are not limited to, fermentation, conversion by bioorganisms,
and conversion by metathesis.
[0070] Olefin metathesis provides one possible means to convert
certain natural oil feedstocks into olefins and esters that can be
used in a variety of applications, or that can be further modified
chemically and used in a variety of applications. In some
embodiments, a composition (or components of a composition) may be
formed from a renewable feedstock, such as a renewable feedstock
formed through metathesis reactions of natural oils and/or their
fatty acid or fatty ester derivatives. When compounds containing a
carbon-carbon double bond undergo metathesis reactions in the
presence of a metathesis catalyst, some or all of the original
carbon-carbon double bonds are broken, and new carbon-carbon double
bonds are formed. The products of such metathesis reactions include
carbon-carbon double bonds in different locations, which can
provide unsaturated organic compounds having useful chemical
properties.
[0071] A wide range of natural oils, or derivatives thereof, can be
used in such metathesis reactions. Examples of suitable natural
oils include, but are not limited to, vegetable oils, algae oils,
fish oils, animal fats, tall oils, derivatives of these oils,
combinations of any of these oils, and the like. Representative
non-limiting examples of vegetable oils include rapeseed oil
(canola oil), coconut oil, corn oil, cottonseed oil, olive oil,
palm oil, peanut oil, safflower oil, sesame oil, soybean oil,
sunflower oil, linseed oil, palm kernel oil, tung oil, jatropha
oil, mustard seed oil, pennycress oil, camelina oil, hempseed oil,
and castor oil. Representative non-limiting examples of animal fats
include lard, tallow, poultry fat, yellow grease, and fish oil.
Tall oils are by-products of wood pulp manufacture. In some
embodiments, the natural oil or natural oil feedstock comprises one
or more unsaturated glycerides (e.g., unsaturated triglycerides).
In some such embodiments, the natural oil feedstock comprises at
least 50% by weight, or at least 60% by weight, or at least 70% by
weight, or at least 80% by weight, or at least 90% by weight, or at
least 95% by weight, or at least 97% by weight, or at least 99% by
weight of one or more unsaturated triglycerides, based on the total
weight of the natural oil feedstock.
[0072] The natural oil may include canola or soybean oil, such as
refined, bleached and deodorized soybean oil (i.e., RBD soybean
oil). Soybean oil typically includes about 95 percent by weight (wt
%) or greater (e.g., 99 wt % or greater) triglycerides of fatty
acids. Major fatty acids in the polyol esters of soybean oil
include but are not limited to saturated fatty acids such as
palmitic acid (hexadecanoic acid) and stearic acid (octadecanoic
acid), and unsaturated fatty acids such as oleic acid
(9-octadecenoic acid), linoleic acid (9,12-octadecadienoic acid),
and linolenic acid (9,12,15-octadecatrienoic acid).
[0073] Metathesized natural oils can also be used. Examples of
metathesized natural oils include but are not limited to a
metathesized vegetable oil, a metathesized algal oil, a
metathesized animal fat, a metathesized tall oil, a metathesized
derivatives of these oils, or mixtures thereof. For example, a
metathesized vegetable oil may include metathesized canola oil,
metathesized rapeseed oil, metathesized coconut oil, metathesized
corn oil, metathesized cottonseed oil, metathesized olive oil,
metathesized palm oil, metathesized peanut oil, metathesized
safflower oil, metathesized sesame oil, metathesized soybean oil,
metathesized sunflower oil, metathesized linseed oil, metathesized
palm kernel oil, metathesized tung oil, metathesized jatropha oil,
metathesized mustard oil, metathesized camelina oil, metathesized
pennycress oil, metathesized castor oil, metathesized derivatives
of these oils, or mixtures thereof. In another example, the
metathesized natural oil may include a metathesized animal fat,
such as metathesized lard, metathesized tallow, metathesized
poultry fat, metathesized fish oil, metathesized derivatives of
these oils, or mixtures thereof.
[0074] Such natural oils, or derivatives thereof, can contain
esters, such as triglycerides, of various unsaturated fatty acids.
The identity and concentration of such fatty acids varies depending
on the oil source, and, in some cases, on the variety. In some
embodiments, the natural oil comprises one or more esters of oleic
acid, linoleic acid, linolenic acid, or any combination thereof.
When such fatty acid esters are metathesized, new compounds are
formed. For example, in embodiments where the metathesis uses
certain short-chain olefins, e.g., ethylene, propylene, or
1-butene, and where the natural oil includes esters of oleic acid,
an amount of 1-decene and 1-decenoid acid (or an ester thereof),
among other products, are formed. Following transesterification,
for example, with an alkyl alcohol, an amount of 9-denenoic acid
alkyl ester is formed. In some such embodiments, a separation step
may occur between the metathesis and the transesterification, where
the alkenes are separated from the esters. In some other
embodiments, transesterification can occur before metathesis, and
the metathesis is performed on the transesterified product.
[0075] In some embodiments, the natural oil can be subjected to
various pre-treatment processes, which can facilitate their utility
for use in certain metathesis reactions. Useful pre-treatment
methods are described in United States Patent Application
Publication Nos. 2011/0113679, 2014/0275595, and 2014/0275681, all
three of which are hereby incorporated by reference as though fully
set forth herein.
[0076] In some embodiments, after any optional pre-treatment of the
natural oil feedstock, the natural oil feedstock is reacted in the
presence of a metathesis catalyst in a metathesis reactor. In some
other embodiments, an unsaturated ester (e.g., an unsaturated
glyceride, such as an unsaturated triglyceride) is reacted in the
presence of a metathesis catalyst in a metathesis reactor. These
unsaturated esters may be a component of a natural oil feedstock,
or may be derived from other sources, e.g., from esters generated
in earlier-performed metathesis reactions. In certain embodiments,
in the presence of a metathesis catalyst, the natural oil or
unsaturated ester can undergo a self-metathesis reaction with
itself. In other embodiments, the natural oil or unsaturated ester
undergoes a cross-metathesis reaction with the low-molecular-weight
olefin or mid-weight olefin. The self-metathesis and/or
cross-metathesis reactions form a metathesized product wherein the
metathesized product comprises olefins and esters.
[0077] In some embodiments, the low-molecular-weight olefin (or
short-chain olefin) is in the C.sub.2-6 range. As a non-limiting
example, in one embodiment, the low-molecular-weight olefin may
comprise at least one of: ethylene, propylene, 1-butene, 2-butene,
isobutene, 1-pentene, 2-pentene, 3-pentene, 2-methyl-1-butene,
2-methyl-2-butene, 3-methyl-1-butene, cyclopentene, 1,4-pentadiene,
1-hexene, 2-hexene, 3-hexene, 4-hexene, 2-methyl-1-pentene,
3-methyl-1-pentene, 4-methyl-1-pentene, 2-methyl-2-pentene,
3-methyl-2-pentene, 4-methyl-2-pentene, 2-methyl-3-pentene, and
cyclohexene. In some embodiments, the short-chain olefin is
1-butene. In some instances, a higher-molecular-weight olefin can
also be used.
[0078] In some embodiments, the metathesis comprises reacting a
natural oil feedstock (or another unsaturated ester) in the
presence of a metathesis catalyst. In some such embodiments, the
metathesis comprises reacting one or more unsaturated glycerides
(e.g., unsaturated triglycerides) in the natural oil feedstock in
the presence of a metathesis catalyst. In some embodiments, the
unsaturated glyceride comprises one or more esters of oleic acid,
linoleic acid, linoleic acid, or combinations thereof. In some
other embodiments, the unsaturated glyceride is the product of the
partial hydrogenation and/or the metathesis of another unsaturated
glyceride (as described above). In some such embodiments, the
metathesis is a cross-metathesis of any of the aforementioned
unsaturated triglyceride species with another olefin, e.g., an
alkene. In some such embodiments, the alkene used in the
cross-metathesis is a lower alkene, such as ethylene, propylene,
1-butene, 2-butene, etc. In some embodiments, the alkene is
ethylene. In some other embodiments, the alkene is propylene. In
some further embodiments, the alkene is 1-butene. And in some even
further embodiments, the alkene is 2-butene.
[0079] Metathesis reactions can provide a variety of useful
products, when employed in the methods disclosed herein. For
example, the unsaturated esters may be derived from a natural oil
feedstock, in addition to other valuable compositions. Moreover, in
some embodiments, a number of valuable compositions can be targeted
through the self-metathesis reaction of a natural oil feedstock, or
the cross-metathesis reaction of the natural oil feedstock with a
low-molecular-weight olefin or mid-weight olefin, in the presence
of a metathesis catalyst. Such valuable compositions can include
fuel compositions, detergents, surfactants, and other specialty
chemicals. Additionally, transesterified products (i.e., the
products formed from transesterifying an ester in the presence of
an alcohol) may also be targeted, non-limiting examples of which
include: fatty acid methyl esters ("FAMEs"); biodiesel; 9-decenoic
acid ("9DA") esters, 9-undecenoic acid ("9UDA") esters, and/or
9-dodecenoic acid ("9DDA") esters; 9DA, 9UDA, and/or 9DDA; alkali
metal salts and alkaline earth metal salts of 9DA, 9UDA, and/or
9DDA; dimers of the transesterified products; and mixtures
thereof.
[0080] Further, in some embodiments, multiple metathesis reactions
can also be employed. In some embodiments, the multiple metathesis
reactions occur sequentially in the same reactor. For example, a
glyceride containing linoleic acid can be metathesized with a
terminal lower alkene (e.g., ethylene, propylene, 1-butene, and the
like) to form 1,4-decadiene, which can be metathesized a second
time with a terminal lower alkene to form 1,4-pentadiene. In other
embodiments, however, the multiple metathesis reactions are not
sequential, such that at least one other step (e.g.,
transesterification, hydrogenation, etc.) can be performed between
the first metathesis step and the following metathesis step. These
multiple metathesis procedures can be used to obtain products that
may not be readily obtainable from a single metathesis reaction
using available starting materials. For example, in some
embodiments, multiple metathesis can involve self-metathesis
followed by cross-metathesis to obtain metathesis dimers, trimmers,
and the like. In some other embodiments, multiple metathesis can be
used to obtain olefin and/or ester components that have chain
lengths that may not be achievable from a single metathesis
reaction with a natural oil triglyceride and typical lower alkenes
(e.g., ethylene, propylene, 1-butene, 2-butene, and the like). Such
multiple metathesis can be useful in an industrial-scale reactor,
where it may be easier to perform multiple metathesis than to
modify the reactor to use a different alkene.
[0081] For example, multiple metathesis can be employed to make the
dibasic acid compounds used to make the diesters disclosed herein.
In some embodiments, alkyl (e.g., methyl) esters of 9-decenoic
acid, 9-undecenoic acid, 9-dodecenoic acid, or any combination
thereof, can be reacted in a self-metathesis reaction or a
cross-metathesis to generate various unsaturated dibasic alkyl
esters, such as dimethyl 9-octadecendioate. Such compounds can then
be converted to dibasic acids by hydrolysis or via saponification
followed by acidification. If a saturated dibasic acid is desired,
the compound can be hydrogenated, either before conversion to the
acid or after. Dibasic acids of other chain lengths can be made by
analogous means.
[0082] The conditions for such metathesis reactions, and the
reactor design, and suitable catalysts are as described below with
reference to the metathesis of the olefin esters. That discussion
is incorporated by reference as though fully set forth herein.
Olefin Metathesis
[0083] In some embodiments, one or more of the unsaturated monomers
can be made by metathesizing a natural oil or natural oil
derivative. The terms "metathesis" or "metathesizing" can refer to
a variety of different reactions, including, but not limited to,
cross-metathesis, self-metathesis, ring-opening metathesis,
ring-opening metathesis polymerizations ("ROMP"), ring-closing
metathesis ("RCM"), and acyclic diene metathesis ("ADMET"). Any
suitable metathesis reaction can be used, depending on the desired
product or product mixture.
[0084] In some embodiments, after any optional pre-treatment of the
natural oil feedstock, the natural oil feedstock is reacted in the
presence of a metathesis catalyst in a metathesis reactor. In some
other embodiments, an unsaturated ester (e.g., an unsaturated
glyceride, such as an unsaturated triglyceride) is reacted in the
presence of a metathesis catalyst in a metathesis reactor. These
unsaturated esters may be a component of a natural oil feedstock,
or may be derived from other sources, e.g., from esters generated
in earlier-performed metathesis reactions. In certain embodiments,
in the presence of a metathesis catalyst, the natural oil or
unsaturated ester can undergo a self-metathesis reaction with
itself. In other embodiments, the natural oil or unsaturated ester
undergoes a cross-metathesis reaction with the low-molecular-weight
olefin or mid-weight olefin. The self-metathesis and/or
cross-metathesis reactions form a metathesized product wherein the
metathesized product comprises olefins and esters.
[0085] In some embodiments, the low-molecular-weight olefin is in
the C.sub.2-6 range. As a non-limiting example, in one embodiment,
the low-molecular-weight olefin may comprise at least one of:
ethylene, propylene, 1-butene, 2-butene, isobutene, 1-pentene,
2-pentene, 3-pentene, 2-methyl-1-butene, 2-methyl-2-butene,
3-methyl-1-butene, cyclopentene, 1,4-pentadiene, 1-hexene,
2-hexene, 3-hexene, 4-hexene, 2-methyl-1-pentene,
3-methyl-1-pentene, 4-methyl-1-pentene, 2-methyl-2-pentene,
3-methyl-2-pentene, 4-methyl-2-pentene, 2-methyl-3-pentene, and
cyclohexene. In some instances, a higher-molecular-weight olefin
can also be used.
[0086] In some embodiments, the metathesis comprises reacting a
natural oil feedstock (or another unsaturated ester) in the
presence of a metathesis catalyst. In some such embodiments, the
metathesis comprises reacting one or more unsaturated glycerides
(e.g., unsaturated triglycerides) in the natural oil feedstock in
the presence of a metathesis catalyst. In some embodiments, the
unsaturated glyceride comprises one or more esters of oleic acid,
linoleic acid, linoleic acid, or combinations thereof. In some
other embodiments, the unsaturated glyceride is the product of the
partial hydrogenation and/or the metathesis of another unsaturated
glyceride (as described above). In some such embodiments, the
metathesis is a cross-metathesis of any of the aforementioned
unsaturated triglyceride species with another olefin, e.g., an
alkene. In some such embodiments, the alkene used in the
cross-metathesis is a lower alkene, such as ethylene, propylene,
1-butene, 2-butene, etc. In some embodiments, the alkene is
ethylene. In some other embodiments, the alkene is propylene. In
some further embodiments, the alkene is 1-butene. And in some even
further embodiments, the alkene is 2-butene.
[0087] Metathesis reactions can provide a variety of useful
products, when employed in the methods disclosed herein. For
example, terminal olefins and internal olefins may be derived from
a natural oil feedstock, in addition to other valuable
compositions. Moreover, in some embodiments, a number of valuable
compositions can be targeted through the self-metathesis reaction
of a natural oil feedstock, or the cross-metathesis reaction of the
natural oil feedstock with a low-molecular-weight olefin or
mid-weight olefin, in the presence of a metathesis catalyst. Such
valuable compositions can include fuel compositions, detergents,
surfactants, and other specialty chemicals. Additionally,
transesterified products (i.e., the products formed from
transesterifying an ester in the presence of an alcohol) may also
be targeted, non-limiting examples of which include: fatty acid
methyl esters ("FAMEs"); biodiesel; 9-decenoic acid ("9DA") esters,
9-undecenoic acid ("9UDA") esters, and/or 9-dodecenoic acid
("9DDA") esters; 9DA, 9UDA, and/or 9DDA; alkali metal salts and
alkaline earth metal salts of 9DA, 9UDA, and/or 9DDA; dimers of the
transesterified products; and mixtures thereof.
[0088] Further, in some embodiments, the methods disclosed herein
can employ multiple metathesis reactions. In some embodiments, the
multiple metathesis reactions occur sequentially in the same
reactor. For example, a glyceride containing linoleic acid can be
metathesized with a terminal lower alkene (e.g., ethylene,
propylene, 1-butene, and the like) to form 1,4-decadiene, which can
be metathesized a second time with a terminal lower alkene to form
1,4-pentadiene. In other embodiments, however, the multiple
metathesis reactions are not sequential, such that at least one
other step (e.g., transesterification, hydrogenation, etc.) can be
performed between the first metathesis step and the following
metathesis step. These multiple metathesis procedures can be used
to obtain products that may not be readily obtainable from a single
metathesis reaction using available starting materials. For
example, in some embodiments, multiple metathesis can involve
self-metathesis followed by cross-metathesis to obtain metathesis
dimers, trimmers, and the like. In some other embodiments, multiple
metathesis can be used to obtain olefin and/or ester components
that have chain lengths that may not be achievable from a single
metathesis reaction with a natural oil triglyceride and typical
lower alkenes (e.g., ethylene, propylene, 1-butene, 2-butene, and
the like). Such multiple metathesis can be useful in an
industrial-scale reactor, where it may be easier to perform
multiple metathesis than to modify the reactor to use a different
alkene.
[0089] The metathesis process can be conducted under any conditions
adequate to produce the desired metathesis products. For example,
stoichiometry, atmosphere, solvent, temperature, and pressure can
be selected by one skilled in the art to produce a desired product
and to minimize undesirable byproducts. In some embodiments, the
metathesis process may be conducted under an inert atmosphere.
Similarly, in embodiments where a reagent is supplied as a gas, an
inert gaseous diluent can be used in the gas stream. In such
embodiments, the inert atmosphere or inert gaseous diluent
typically is an inert gas, meaning that the gas does not interact
with the metathesis catalyst to impede catalysis to a substantial
degree. For example, non-limiting examples of inert gases include
helium, neon, argon, and nitrogen, used individually or in with
each other and other inert gases.
[0090] The rector design for the metathesis reaction can vary
depending on a variety of factors, including, but not limited to,
the scale of the reaction, the reaction conditions (heat, pressure,
etc.), the identity of the catalyst, the identity of the materials
being reacted in the reactor, and the nature of the feedstock being
employed. Suitable reactors can be designed by those of skill in
the art, depending on the relevant factors, and incorporated into a
refining process such, such as those disclosed herein.
[0091] The metathesis reactions disclosed herein generally occur in
the presence of one or more metathesis catalysts. Such methods can
employ any suitable metathesis catalyst. The metathesis catalyst in
this reaction may include any catalyst or catalyst system that
catalyzes a metathesis reaction. Any known metathesis catalyst may
be used, alone or in combination with one or more additional
catalysts. Examples of metathesis catalysts and process conditions
are described in US 2011/0160472, incorporated by reference herein
in its entirety, except that in the event of any inconsistent
disclosure or definition from the present specification, the
disclosure or definition herein shall be deemed to prevail. A
number of the metathesis catalysts described in US 2011/0160472 are
presently available from Materia, Inc. (Pasadena, Calif.).
[0092] In some embodiments, the metathesis catalyst includes a
Grubbs-type olefin metathesis catalyst and/or an entity derived
therefrom. In some embodiments, the metathesis catalyst includes a
first-generation Grubbs-type olefin metathesis catalyst and/or an
entity derived therefrom. In some embodiments, the metathesis
catalyst includes a second-generation Grubbs-type olefin metathesis
catalyst and/or an entity derived therefrom. In some embodiments,
the metathesis catalyst includes a first-generation
Hoveyda-Grubbs-type olefin metathesis catalyst and/or an entity
derived therefrom. In some embodiments, the metathesis catalyst
includes a second-generation Hoveyda-Grubbs-type olefin metathesis
catalyst and/or an entity derived therefrom. In some embodiments,
the metathesis catalyst includes one or a plurality of the
ruthenium carbene metathesis catalysts sold by Materia, Inc. of
Pasadena, Calif. and/or one or more entities derived from such
catalysts. Representative metathesis catalysts from Materia, Inc.
for use in accordance with the present teachings include but are
not limited to those sold under the following product numbers as
well as combinations thereof: product no. C823 (CAS no.
172222-30-9), product no. C848 (CAS no. 246047-72-3), product no.
C601 (CAS no. 203714-71-0), product no. C627 (CAS no. 301224-40-8),
product no. C571 (CAS no. 927429-61-6), product no. C598 (CAS no.
802912-44-3), product no. C793 (CAS no. 927429-60-5), product no.
C801 (CAS no. 194659-03-9), product no. C827 (CAS no. 253688-91-4),
product no. C884 (CAS no. 900169-53-1), product no. C833 (CAS no.
1020085-61-3), product no. C859 (CAS no. 832146-68-6), product no.
C711 (CAS no. 635679-24-2), product no. C933 (CAS no.
373640-75-6).
[0093] In some embodiments, the metathesis catalyst includes a
molybdenum and/or tungsten carbene complex and/or an entity derived
from such a complex. In some embodiments, the metathesis catalyst
includes a Schrock-type olefin metathesis catalyst and/or an entity
derived therefrom. In some embodiments, the metathesis catalyst
includes a high-oxidation-state alkylidene complex of molybdenum
and/or an entity derived therefrom. In some embodiments, the
metathesis catalyst includes a high-oxidation-state alkylidene
complex of tungsten and/or an entity derived therefrom. In some
embodiments, the metathesis catalyst includes molybdenum (VI). In
some embodiments, the metathesis catalyst includes tungsten (VI).
In some embodiments, the metathesis catalyst includes a molybdenum-
and/or a tungsten-containing alkylidene complex of a type described
in one or more of (a) Angew. Chem. Int. Ed. Engl., 2003, 42,
4592-4633; (b) Chem. Rev., 2002, 102, 145-179; and/or (c) Chem.
Rev., 2009, 109, 3211-3226, each of which is incorporated by
reference herein in its entirety, except that in the event of any
inconsistent disclosure or definition from the present
specification, the disclosure or definition herein shall be deemed
to prevail.
[0094] In certain embodiments, the metathesis catalyst is dissolved
in a solvent prior to conducting the metathesis reaction. In
certain such embodiments, the solvent chosen may be selected to be
substantially inert with respect to the metathesis catalyst. For
example, substantially inert solvents include, without limitation:
aromatic hydrocarbons, such as benzene, toluene, xylenes, etc.;
halogenated aromatic hydrocarbons, such as chlorobenzene and
dichlorobenzene; aliphatic solvents, including pentane, hexane,
heptane, cyclohexane, etc.; and chlorinated alkanes, such as
dichloromethane, chloroform, dichloroethane, etc. In some
embodiments, the solvent comprises toluene.
[0095] In other embodiments, the metathesis catalyst is not
dissolved in a solvent prior to conducting the metathesis reaction.
The catalyst, instead, for example, can be slurried with the
natural oil or unsaturated ester, where the natural oil or
unsaturated ester is in a liquid state. Under these conditions, it
is possible to eliminate the solvent (e.g., toluene) from the
process and eliminate downstream olefin losses when separating the
solvent. In other embodiments, the metathesis catalyst may be added
in solid state form (and not slurried) to the natural oil or
unsaturated ester (e.g., as an auger feed).
[0096] The metathesis reaction temperature may, in some instances,
be a rate-controlling variable where the temperature is selected to
provide a desired product at an acceptable rate. In certain
embodiments, the metathesis reaction temperature is greater than
-40.degree. C., or greater than -20.degree. C., or greater than
0.degree. C., or greater than 10.degree. C. In certain embodiments,
the metathesis reaction temperature is less than 200.degree. C., or
less than 150.degree. C., or less than 120.degree. C. In some
embodiments, the metathesis reaction temperature is between
0.degree. C. and 150.degree. C., or is between 10.degree. C. and
120.degree. C.
[0097] The metathesis reaction can be run under any desired
pressure. In some instances, it may be desirable to maintain a
total pressure that is high enough to keep the cross-metathesis
reagent in solution. Therefore, as the molecular weight of the
cross-metathesis reagent increases, the lower pressure range
typically decreases since the boiling point of the cross-metathesis
reagent increases. The total pressure may be selected to be greater
than 0.1 atm (10 kPa), or greater than 0.3 atm (30 kPa), or greater
than 1 atm (100 kPa). In some embodiments, the reaction pressure is
no more than about 70 atm (7000 kPa), or no more than about 30 atm
(3000 kPa). In some embodiments, the pressure for the metathesis
reaction ranges from about 1 atm (100 kPa) to about 30 atm (3000
kPa).
Methods of Making Polymers
[0098] In certain aspects, the disclosure provides methods of
forming a polymer, the methods including: providing a composition
(e.g., an aqueous composition) of any of the above embodiments; and
reacting one or more compounds of formula (I) with one or more
additional monomers to form a polymer. In some embodiments, the one
or more additional monomers are polyols, such as diols, and the
formed polymer is a polyester. In some other embodiments, the one
or more monomers are polyamines, such as diamines, and the formed
polymer is a polyamide. In some other embodiments, the one or more
monomers are polyisocyanates, such as diisocyanates, and the formed
polymer is a polycarbamate.
Use in Sizing Compositions
[0099] The aqueous compositions disclosed above, or the polymers
formed therefrom, can be used and/or formed in any suitable
application, such as part of a sizing composition for a cellulosic
fiber (e.g., starch, cellulose, hydroxylated celluloses, such as
hydroxyalkylcelluloses) and other hydroxyl-containing polymers. For
example, in some embodiments, the composition, or polymers formed
therefrom, is used as a coating or sizing for a cellulosic fiber,
e.g., as a coating for paper or other wood and/or products. In some
other embodiments, the composition, or a polymer formed therefrom,
is used as a coating or sizing for a glass fiber.
Use in Personal Care Compositions
[0100] The aqueous compositions disclosed above, or the polymers
formed therefrom, can be used in certain personal care
compositions, e.g., as emulsifiers for various ingredients, such as
fatty acids (e.g., stearic acid) and glycerol.
EXAMPLES
[0101] The following Examples illustrate certain aspects and
embodiments of the compounds, compositions, and methods disclosed
herein. The Examples merely illustrate particular embodiments and
aspects of the disclosed subject matter, and are not intended to
provide substantive limits on the scope of the claimed subject
matter.
Example 1
Aqueous Composition of 1,18-Octadecandioate
[0102] About 60 grams of warm water (68.degree. C.) was added to a
flask fitted with a condenser, followed by the addition of 10 grams
of 1,18-octadecanedioic acid (ODDA) with stirring. In a separate
vial, 5.5 mL of triethylamine was mixed with an equal volume of
water, and was added to the ODDA mixture. The mixture was heated to
90.degree. C., while adding additional water, if necessary. The
composition was cooled to room temperature to obtain an aqueous
composition of 1,18-octadecanedioate.
Example 2
Aqueous Composition of 1,18-Octadecandioic Acid Derivative
[0103] A 150-gram sample of ODDA was added to a flask fitted with a
condenser and a receiver. Then, 38 grams of 1,6-hexanediol and a
small amount of tin catalyst was added. The mixture was heated to
190.degree. C. until all of the reaction water was removed. Then,
30 grams of dimethylethanolamine (DMEA) in 90 grams of water was
added to the mixture. Additional water was added until the contents
of the flask were converted to a dispersion of fine particles
dispersed in the aqueous medium. The dispersion was then cooled to
room temperature.
* * * * *