U.S. patent application number 16/363607 was filed with the patent office on 2019-09-12 for renewably derived polyesters 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 Paul A. Bertin, Timothy E. Long, Ashley M. Nelson, Keren Zhang.
Application Number | 20190276589 16/363607 |
Document ID | / |
Family ID | 60116338 |
Filed Date | 2019-09-12 |
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United States Patent
Application |
20190276589 |
Kind Code |
A1 |
Nelson; Ashley M. ; et
al. |
September 12, 2019 |
Renewably Derived Polyesters and Methods of Making and Using the
Same
Abstract
Polyester compositions are disclosed herein, as well as methods
of making and using such polyesters. In some embodiments, the
polyesters are formed from monomers derived from natural oils. In
some embodiments, the polyesters are highly branched polymers, such
as highly branched polymers that have low viscosity at higher
molecular weights.
Inventors: |
Nelson; Ashley M.;
(Blacksburg, VA) ; Zhang; Keren; (Blacksburg,
VA) ; Long; Timothy E.; (Blacksburg, VA) ;
Bertin; Paul A.; (Western Springs, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Elevance Renewable Sciences, Inc. |
Woodridge |
IL |
US |
|
|
Assignee: |
Elevance Renewable Sciences,
Inc.
Woodridge
IL
|
Family ID: |
60116338 |
Appl. No.: |
16/363607 |
Filed: |
March 25, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
15487174 |
Apr 13, 2017 |
10280254 |
|
|
16363607 |
|
|
|
|
62325437 |
Apr 20, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C09D 11/00 20130101;
C08G 63/6852 20130101; C08G 63/60 20130101; C09D 167/04 20130101;
C09J 167/04 20130101; C08G 63/664 20130101; C08L 67/00 20130101;
C08G 63/6822 20130101; C08G 63/6882 20130101; C08G 63/06 20130101;
C08L 67/04 20130101; C09D 167/00 20130101; C09D 11/104 20130101;
C09J 167/00 20130101 |
International
Class: |
C08G 63/06 20060101
C08G063/06; C08G 63/688 20060101 C08G063/688; C08G 63/682 20060101
C08G063/682 |
Claims
1-20. (canceled)
31. A block copolymer, which comprises a first block and a second
block, wherein the first block comprises a polyester polymer
comprising constitutional units formed from a reaction mixture
comprising one of more monomers of Formula (I): ##STR00004##
wherein: R.sup.1 is --OH or --OR.sup.2; R.sup.2 is C.sub.1-6 alkyl
or C.sub.1-6 oxyalkyl; and X.sup.1 is C.sub.4-10 alkylene.
32. The block copolymer of claim 31, where the second block
comprises a poly(alkylene oxide).
33. The block copolymer of claim 32, wherein the poly(alkylene
oxide) is selected from the group consisting of poly(ethylene
oxide), poly(1,2-propylene oxide), and poly(1,3-propylene
oxide).
34. The block copolymer of claim 31, wherein the second block
comprises polycaprolactone.
35. The block copolymer of claim 31, wherein the second block
comprises a polycarbamate.
36. The block copolymer of claim 31, wherein the second block
comprises a polyester.
37. The block copolymer of claim 31, wherein the second block
comprises a polyamide.
38. The block copolymer of claim 31, wherein the second block
comprises a polyamide ester.
39. The block copolymer of claim 31, wherein R.sup.1 is --OH.
40. The block copolymer of claim 31, wherein R.sup.1 is
--OR.sup.2.
41. The block copolymer of claim 31, wherein R.sup.2 is methyl.
42. The block copolymer of claim 31, wherein X.sup.1 is
--(CH.sub.2).sub.7--.
43. The block copolymer of claim 31, wherein the reaction mixture
further comprises monomers of Formula (II): ##STR00005## wherein:
X.sup.2 is C.sub.2-12 alkylene or C.sub.2-12 oxyalkylene.
44. The block copolymer of claim 43, wherein X.sup.2 is
--(CH.sub.2).sub.2--, --(CH.sub.2).sub.4--, or
--(CH.sub.2).sub.6--.
45. The block copolymer of any one of claim 31, wherein the
reaction mixture further comprises one or more diacids, or esters
thereof.
46. The block copolymer of claim 45, wherein the one or more
diacids, or esters thereof, are selected from the group consisting
of oxalic acid, malonic acid, succinic acid, glutaric acid, adipic
acid, pimelic acid, suberic acid, azelaic acid, sebacic acid,
1,12-dodecanedioic acid, 1,14-tetradecanedioic acid,
1,16-hexadecanedioic acid, 1,18-octadecanedioic acid,
1,20-eicosanedioic acid, 1,22-docosanedioic acid,
1,18-octadec-9-enedioic acid, and esters of any of the
foregoing.
47. The block copolymer of claim 31, wherein the reaction mixture
further comprises one or more hydroxy acids, or esters thereof.
48. The block copolymer of claim 47, wherein the one or more
hydroxy acids, or esters thereof, are selected from the group
consisting of .alpha.-hydroxy acids, .beta.-hydroxy acids,
.omega.-hydroxy acids, and esters of any of the foregoing.
49. The block copolymer of claim 31, wherein the reaction mixture
further comprises one or more branching agents.
50. The block copolymer of claim 31, wherein the reaction mixture
further comprises one or more cross-linking agents.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of
U.S. patent application Ser. No. 15/487,174, filed Apr. 13, 2017,
which claims the benefit of U.S. Provisional Application No.
62/325,437, filed Apr. 20, 2016, both of which are hereby
incorporated by reference as though set forth herein in their
entireties.
TECHNICAL FIELD
[0002] Polyester compositions are disclosed herein, as well as
methods of making and using such polyesters. In some embodiments,
the polyesters are formed from monomers derived from natural oils.
In some embodiments, the polyesters are highly branched polymers,
such as highly branched polymers having a low viscosity at higher
molecular weights.
BACKGROUND
[0003] Polyesters are polymers that contain a plurality of ester
linkages. Polyesters are one of the most widely used polymers for
commercial applications. In fact, after polyolefins, polyesters are
the most widely used polymers for commercial applications. The most
commonly used polyester is polyethylene terephthalate (PET). Other
commonly used polyesters include polybutylene terephthalate (PBT),
polybutylene succinate (PBS), polyethylene adipate (PEA),
polycaprolactone (PCL), and polylactic acid (PLA).
[0004] In many cases, polyesters are formed from monomers that are
derived from refining petroleum products. Such processes generally
involve cracking and refining crude petroleum to obtain olefin
fragments having a small number of carbon atoms (e.g., two or three
carbons). To form longer-chain compounds, the fragments must be
reacted to with other such fragments and/or other compounds to form
compounds having longer carbon chains. This process is
energy-intensive and time-intensive. Further, such processes
contribute to the further depletion of non-renewable sources of
carbonaceous material.
[0005] There are some exceptions, such as polylactic acid (PLA). In
fact, PLA has the second highest consumption of any renewably
derived polymer in use today. But its use is generally limited to
situations where resistance to degradation is not an issue. For
example, PLA is widely used in making biodegradable materials, such
as medical implants, disposable cups, and the like. But there are a
very limited number of polymers made from renewably derived
monomers that exhibit chemical and physical characteristics closer
to those of more commonly used polyesters.
[0006] Refining processes for natural oils (e.g., employing
metathesis) can lead to compounds having carbon-chain lengths
closer to those generally desired for chemical intermediates of
specialty chemicals (e.g., about 9 to 15 carbon atoms). Thus, the
refining of natural oils may, in many instances, provide a more
chemically efficient and straightforward way to make certain
monomers for use in making polymeric species, such as polyesters.
Further, because such compounds contain a certain degree of
inherent functionality that is otherwise absent from
petroleum-sourced materials, it may often be more desirable, if not
cheaper, to use natural oils or their derivatives as a starting
point for making certain compounds. Additionally, natural oils and
their derivatives are generally sourced from renewable feedstocks.
Thus, by using such starting materials, one can enjoy the
concomitant advantage of developing useful chemical products
without consuming limited supplies of petroleum.
[0007] Thus, there is a continuing need to discover novel
polyesters that are formed using monomers derived from renewable
sources, such as natural oils.
SUMMARY
[0008] In a first aspect, the disclosure provides polyester
polymers, which include constitutional units formed from one of
more monomers of Formula (I):
##STR00001##
wherein R.sup.1 is --OH or --OR.sup.2; R.sup.2 is C.sub.1-6 alkyl
or C.sub.1-6 oxyalkyl; and X.sup.1 is C.sub.4-10 alkylene.
[0009] In a second aspect, the disclosure provides a coating
composition, the composition including polyester polymers of the
first aspect. In some embodiments, the coating composition includes
one or more additional polymers. In some such embodiments, the one
or more additional polymers have a higher glass transition
temperature than the polyester polymers of the first aspect.
[0010] In a third aspect, the disclosure provides a personal care
composition, the composition including polyester polymers of the
first aspect. In some embodiments, the personal care composition
includes one or more additional ingredients. Non-limiting examples
of personal care compositions include shampoos, hair conditioners,
skin moisturizers, hair-styling products, and the like.
[0011] In a fourth aspect, the disclosure provides an ink
composition, the composition including polyester polymers of the
first aspect. In some embodiments, the ink compositions include one
or more additional ingredients.
[0012] In a fifth aspect, the disclosure provides a rheology
modifier composition, the composition including polyester polymers
of the first aspect. In some embodiments, the rheology modifier
compositions include one or more additional ingredients.
[0013] In a sixth aspect, the disclosure provides a polyurethane
block copolymer, wherein at least one of the blocks of the block
copolymer includes a polyester polymer of the first aspect. In some
embodiments, one or more of the other blocks in the block copolymer
include a polycarbamate 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] The FIGURE shows a monomer useful for forming constitutional
units making up the polyesters disclosed herein, wherein R.sup.1 is
a hydroxyl group or an ether or polyether functional group, and
X.sup.1 is an alkylene group.
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, "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. As used herein, the term
"polymer" can include oligomeric materials, which have only a few
(e.g., 5-100) constitutional units
[0022] 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.
[0023] As used herein, "copolymer" refers to a polymer having
constitutional units formed from more than one species of
monomer.
[0024] As used herein, "block copolymer" refers to a copolymer
having two or more different blocks of polymerized monomers, i.e.,
different polymer sequences.
[0025] As used herein, "polyurethane" refers to a polymer
comprising two or more urethane (or carbamate) linkages. Other
types of linkages can be included, however. For example, in some
instances, the polyurethane or polycarbamate can contain urea
linkages, formed, for example, when two isocyanate groups can
react. In some other instances, a urea or urethane group can
further react to form further groups, including, but not limited
to, an allophanate group, a biuret group, or a cyclic isocyanurate
group. In some embodiments, at least 70%, or at least 80%, or at
least 90%, or at least 95% of the linkages in the polyurethane or
polycarbamate are urethane linkages. Further, in the context of a
block copolymer, the term "polyurethane block copolymer" refers to
a block copolymer, where one or more of the blocks are a
polyurethane or a polycarbamate. Other blocks in the "polyurethane
block copolymer" may contain few, if any, urethane linkages. For
example, in some polyurethane block copolymers, at least one of the
blocks is a polyether or a polyester and one or more other blocks
are polyurethanes or polycarbamates.
[0026] 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 between monomers 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.
[0027] As used herein, "copolymer" refers to a polymer having
constitutional units formed from more than one species of
monomer.
[0028] As used herein, "block copolymer" refers to a copolymer
having two or more different blocks of polymerized monomers, i.e.,
different polymer sequences.
[0029] As used herein, "polyurethane" or "polycarbamate" refers to
a polymer comprising two or more urethane (or carbamate) linkages.
Other types of linkages can be included, however. For example, in
some instances, the polyurethane or polycarbamate can contain urea
linkages, formed, for example, when two isocyanate groups can
react. In some other instances, a urea or urethane group can
further react to form further groups, including, but not limited
to, an allophanate group, a biuret group, or a cyclic isocyanurate
group. In some embodiments, at least 70%, or at least 80%, or at
least 90%, or at least 95% of the monomer linkages in the
polyurethane or polycarbamate are urethane linkages. Further, in
the context of a block copolymer, the term "polyurethane block
copolymer" refers to a block copolymer, where one or more of the
blocks are a polyurethane or a polycarbamate. Other blocks in the
"polyurethane block copolymer" may contain few, if any, urethane
linkages. For example, in some polyurethane block copolymers, at
least one of the blocks is a polyether or a polyester and one or
more other blocks are polyurethanes or polycarbamates.
[0030] 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.
[0031] 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).
[0032] As used herein, "metathesis catalyst" includes any catalyst
or catalyst system that catalyzes an olefin metathesis
reaction.
[0033] 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).
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] As used herein, "alcohol" or "alcohols" refer to compounds
having the general formula: R--OH, wherein R denotes any organic
moiety (such as alkyl, aryl, or silyl groups), including those
bearing heteroatom-containing substituent groups. In certain
embodiments, R denotes alkyl, alkenyl, aryl, or alcohol groups. In
certain embodiments, the term "alcohol" or "alcohols" may refer to
a group of compounds with the general formula described above,
wherein the compounds have different carbon lengths. The term
"hydroxyl" refers to a --OH moiety. In some cases, an alcohol can
have two or more hydroxyl groups. As used herein, "diol" refers to
alcohols having two or more hydroxyl groups.
[0041] As used herein, "carboxylic acid" or "carboxylic acids"
refer to compounds having the general formula: R--C(O)--OH, wherein
R denotes any organic moiety (such as alkyl, aryl, or silyl
groups), including those bearing heteroatom-containing substituent
groups. In certain embodiments, R denotes alkyl, alkenyl, aryl, or
alcohol groups. In certain embodiments, the term "carboxylic acid"
or "carboxylic acids" may refer to a group of compounds with the
general formula described above, wherein the compounds have
different carbon lengths. The term "carboxyl" refers to a --C(O)OH
moiety. In some cases, a carboxylic acid can have two or more
hydroxyl groups. As used herein, "dicarboxylic acid" and "diacid"
refer to carboxylic acids having two or more carboxyl groups.
[0042] As used herein, "hydroxy acid" or "hydroxy acids" refer to
compounds having the general formula: HO--R--C(O)--OH, wherein R
denotes any organic moiety (such as alkyl, aryl, or silyl groups),
including those bearing heteroatom-containing substituent groups.
In certain embodiments, R denotes alkyl, alkenyl, aryl, or alcohol
groups. In certain embodiments, the term "hydroxy acid" or "hydroxy
acids" may refer to a group of compounds with the general formula
described above, wherein the compounds have different carbon
lengths.
[0043] 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.1-6 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. 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 of the
following formulas: -[-(alkylene)-O-].sub.x-alkyl,
-[-(alkylene)-O-].sub.x-alkylene-, respectively, where x is 1 or
more, such as 1, 2, 3, 4, 5, 6, 7, or 8.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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., A.sub.1 and A.sub.2, then one
or more members of the class can be present concurrently.
[0049] 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.
[0050] 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.
[0051] Other terms are defined in other portions of this
description, even though not included in this subsection.
Polyester Polymers
[0052] In certain aspects, the disclosure provides polyester
polymers, which include constitutional units formed from one of
more monomers of Formula (I):
##STR00002##
wherein R.sup.1 is --OH or --OR.sup.2; R.sup.2 is C.sub.1-6 alkyl
or C.sub.1-6 oxyalkyl; and X.sup.1 is C.sub.4-10 alkylene.
[0053] In some embodiments of any of the aforementioned
embodiments, R.sup.1 is --OH. In some other embodiments, R.sup.1 is
--OR.sup.2. In some such embodiments, R.sup.2 is methyl, ethyl, or
isopropyl. In some further such embodiments, R.sup.2 is methyl.
[0054] In some embodiments of any of the aforementioned
embodiments, X.sup.1 is --(CH.sub.2).sub.5--, --(CH.sub.2).sub.6--,
or --(CH.sub.2).sub.7--. In some further embodiments, X.sup.1 is
--(CH.sub.2).sub.7--.
[0055] In some embodiments of any of the aforementioned
embodiments, the polyester polymer further comprises constitutional
units formed from monomers of Formula (II):
##STR00003##
wherein X.sup.2 is C.sub.2-12 alkylene or C.sub.2-12
oxyalkylene.
[0056] In some embodiments of any of the aforementioned
embodiments, X.sup.2 is --(CH.sub.2).sub.2--, --(CH.sub.2).sub.4--,
or --(CH.sub.2).sub.6--. In some such embodiments, X.sup.2 is
--(CH.sub.2).sub.4--.
[0057] The polyester polymers disclosed herein can contain
constitutional units formed from compounds of Formula (I) and
constitutional units formed from compounds of Formula (II) in any
suitable ratio. In some embodiments, the molar ratio of
constitutional units formed from monomers of Formula (I) to
constitutional units formed from monomers of Formula (II) is from
1:5 to 20:1.
[0058] The polyester polymers disclosed herein can have any
suitable type. In some embodiments of any of the aforementioned
embodiments, the polyester polymer is an AA'B-type polymer. In some
embodiments, the polyester polymer is a highly branched
polymer.
[0059] The polyester polymers disclosed herein can have any
suitable physical properties. In some embodiments, the polyester
polymer is a thermoplastic polymer. In some embodiments, the
polyester polymer is biodegradable.
[0060] The polyester polymers can include any additional
constitutional units formed from other monomers, such as diols,
dicarboxylic acids (diacids) or esters thereof, and/or hydroxyl
acids or esters thereof. In some embodiments of any of the
aforementioned embodiments, the reaction mixture further comprises
one or more diols. In some embodiments, the one or more diols are
selected from the group consisting of ethylene glycol,
1,2-propylene glycol, 1,3-propylene glycol, 1,4-butanediol,
2,3-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,8-octanediol,
2-methyl-1,3-propanediol, 2-butyl-2-ethyl-1,3-propanediol, and
neopentyl glycol. In some embodiments of any of the aforementioned
embodiments, the reaction mixture further comprises constitutional
units formed from one or more diacids, or esters thereof (such as
C.sub.1-6 alkyl esters, e.g., dimethyl esters). In some
embodiments, the one or more diacids, or esters thereof, are
selected from the group consisting of oxalic acid, malonic acid,
succinic acid, glutaric acid, adipic acid, pimelic acid, suberic
acid, azelaic acid, sebacic acid, 1,12-dodecanedioic acid,
1,14-tetradecanedioic acid, 1,16-hexadecanedioic acid,
1,18-octadecanedioic acid, 1,20-eicosanedioic acid,
1,22-docosanedioic acid, 1,18-octadec-9-enedioic acid, and esters
of any of the foregoing. In some embodiments of any of the
foregoing embodiments, the reaction mixture further comprises one
or more hydroxy acids, or esters thereof. In some embodiments, the
one or more hydroxy acids, or esters thereof, are selected from the
group consisting of .alpha.-hydroxy acids (such as glycolic acid,
lactic acid, malic acid, citric acid, tartaric acid, and the like),
.beta.-hydroxy acids (such as 3-hydroxypropionic acid,
3-hydroxybutanoic acid, 3-hydroxy-3-methylbutanoic acid, and the
like), .omega.-hydroxy acids (such as 16-hydroxypalmitic acid,
18-hydroxystearic acid, and the like), and esters of any of the
foregoing.
[0061] The polyester polymers disclosed herein can include certain
additives that may play a role in tuning the properties. For
example, in some embodiments, the reaction mixture further
comprises one or more branching agents. In some embodiments, the
reaction mixture further comprises one or more cross-linking
agents.
Compositions Including the Polyester Polymers
[0062] The aforementioned polyester polymers can be included in any
suitable compositions, such as coating compositions, personal care
compositions, and adhesive compositions.
[0063] For example, in certain aspects and embodiments, the
disclosure provides coating compositions that include polyester
polymers of any of the foregoing embodiments. Such coating
compositions can include any additional additives and polymers,
such as are commonly included in coating compositions, such as
pigments, coalescents, additional resins, and the like. The coating
compositions can be suitable for coating any suitable surface,
including, but not limited to, plastic, metal, wood, stone,
concrete, glass, and the like.
[0064] In certain other aspects and embodiments, the disclosure
provides personal care compositions that include polyester polymers
of any of the foregoing embodiments. Such personal care
compositions can include any additional additives and polymers,
such as are commonly included in personal care compositions, such
as hydrocarbons, waxes, glyceride esters, surfactants, and the
like.
[0065] In certain other aspects and embodiments, the disclosure
provides ink compositions that include polyester polymers of any of
the foregoing embodiments. Such ink compositions can include any
additional additives and polymers, such as are commonly included in
ink compositions, such as solvents, pigments, dyes, and the
like.
[0066] In certain other aspects and embodiments, the disclosure
provides rheology modifier compositions that include polyester
polymers of any of the foregoing embodiments. Such rheology
modifier compositions can include any additional additives and
polymers, such as are commonly included in rheology modifier
compositions.
[0067] In certain other aspects and embodiments, the disclosure
provides adhesive compositions that include polyester polymers of
any of the foregoing embodiments. Such adhesive compositions can
include any additional additives and polymers, such as are commonly
included in adhesive compositions, such as tackifiers, waxes, rosin
oils, and the like.
[0068] In certain other aspects and embodiments, the disclosure
provides compositions for the delivery of a bioactive agent, which
include: (a) polyester polymers of any of the foregoing embodiments
or block copolymers of any of the embodiments described below; and
(b) one or more bioactive agents. The bioactive agents can be
incorporated into the polymer in any suitable manner, such as by
solution, by suspension, by containment within a capsule or
nanoparticle, and the like. In some embodiments, the one or more
bioactive agents are selected from the group consisting of
small-molecule drug compounds, proteins (such as enzymes, biologic
drug compounds, antibodies, antigens, and the like),
polynucleotides (such as DNA, RNA, and the like), fatty acids,
antioxidants, vitamins, amino acids, hormones, steroids,
polysaccharides, pesticides, herbicides, and any combinations
thereof. In some embodiments, the composition is suitable for
administration to a mammal, such as a human. In some such
embodiments, the composition is a pharmaceutical composition, which
is suitable for administration to or disposition within a mammal,
such as a human (e.g., as a biodegradable coating on an implantable
device). In some embodiments, the composition is suitable for
agricultural use, such as for the delivery of a pesticide or
herbicide.
Block Copolymers
[0069] In certain aspects and embodiments, the disclosure provides
certain block copolymers in which the polyester polymers of any of
the foregoing embodiments can serve as one of the blocks in the
block copolymer. Any suitable block copolymers can be formed,
including, but not limited to, diblock copolymers, triblock
copolymers, and the like. In addition to the polyester block the
other block(s) can include any suitable polymeric chain. For
example, in some embodiments, the block copolymer comprises a
second block that includes polycaprolactone. In some other
embodiments, the block copolymer comprises a second block that
includes a polycarbamate. In some such embodiments, the block
copolymer is a thermoplastic polyurethane (TPU). In some other
embodiments, the block copolymer comprises a second block that
includes another polyester. In some other embodiments, the block
copolymer comprises a second block that includes a polyamide. In
some other embodiments, the block copolymer comprises a second
block that includes a polyamide ester. In some embodiments of any
of the aforementioned embodiments, the block copolymer is
biodegradable. Any of the foregoing block copolymers can also be
used in any of the types of compositions described in the
immediately preceding section.
Derivation from Renewable Sources
[0070] 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.
[0071] 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.
[0072] 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.
[0073] 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).
[0074] 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.
[0075] 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.
[0076] 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.
[0077] 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.
[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).
[0079] 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
[0080] 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.
[0081] 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.
[0082] 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).
[0083] 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.
[0084] The reactor 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.
[0085] 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.).
[0086] 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.
[0087] 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).
[0088] 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.
[0089] 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.
[0090] 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).
[0091] 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.
EXAMPLES
Materials
[0092] Methyl 9-decenoate (9-DAME) was provided from Elevance
Renewable Sciences, Inc. and used as received. Formic acid (FA;
97%) and potassium hydroxide (KOH; 85%) were obtained from Alfa
Aesar and used as received. Dibutyltin oxide (SnOBu.sub.2; 98%),
antimony(III) oxide (Sb.sub.2O.sub.3; 99%; 5 micron powder),
meta-chloroperoxybenzoic acid (m-CPBA, .ltoreq.77%), sodium
hydroxide solution (NaOH, 1.0 M in water), magnesium sulfate
(MgSO.sub.4, 99%) sodium sulfite (NaSO.sub.3, .gtoreq.98%), sodium
bicarbonate (NaHCO.sub.3, .gtoreq.99.7), N-methyl-2-pyrrolidone
(NMP, ACS grade), and sodium chloride (NaCl, .gtoreq.99%) were
obtained from Sigma Aldrich and used as received. A titanium
tetraisopropoxide catalyst solution (Ti(OiPr).sub.4; 0.01 g Ti/mL)
was prepared in anhydrous 1-butanol (99.8%; Sigma Aldrich)
according to the procedure set forth in Bao et al, Polymer
International, vol. 62, p. 1457 (2013). Hydrochloric acid (HCl) and
isopropanol (IPA) were purchased from Spectrum Chemicals and used
as received. Dichloromethane (DCM) was obtained from Fisher
Scientific and used as received. All water used was purified using
a reverse osmosis process.
Example 1--Monomer Synthesis
[0093] In the first step, m-CPBA (33 g, 0.14 mol) and DCM (200 mL)
were added to a 500 mL round-bottomed flask equipped with a
magnetic stir bar. The reaction setup was placed into an ice bath
with constant stirring until m-CPBA dissolved. 9-DAME (20 g, 0.11
mol) was then added into the solution and allowed to stir
overnight. White precipitate was removed from the solution using
vacuum filtration. DCM was then removed using a rotary evaporator.
Additional white precipitate was removed again with vacuum
filtration. The filtrate was washed with saturated NaSO.sub.3
solution 2 times, NaOH 1.0 M solution 3 times, NaHCO.sub.3 2 times,
and brine 2 times. Light yellow oil was obtained and placed at
-20.degree. C. overnight. The oil was filtered through a 5 .mu.m
membrane filter and dried in vacuo. The structure and purity of
obtained 9,10-epoxydecanoate intermediate were confirmed using NMR
spectroscopy and mass spectroscopy. In the second step,
9,10-epoxydecanoate (2.0 g, 10 mmol) was refluxed with 40 mL water
overnight. The organic phase was then collected and dried in vacuo
to obtain a white solid (2.0 g, >90% yield).
Example 2--Polymerization
[0094] Following a polymerization procedure from Bao et al. (see
above), methyl 9,10-dihydroxydecanoate (MDHD) was dried in a vacuum
oven at ca. 50 OC overnight prior to use. Then, 1.14 g of MDHD and
0.0258 g of Sb.sub.2O.sub.3 (0.5 g catalyst/0.1 mol monomer) were
added to a dry 50 mL round bottomed flask equipped with a
mechanical stirrer and distillation apparatus using a t-neck
connector. The reaction was purged with N.sub.2 and evacuated 3
times prior to starting the reaction to ensure oxygen removal. The
reaction was placed in a silicon oil bath heated to
.about.80.degree. C. and allowed to react with stirring and a
constant N.sub.2 purge for 2 h. The temperature was then raised to
120.degree. C. for 2 h and again to 170.degree. C. for ca. 2 h.
Vacuum (<0.15 mmHg) was applied to the reaction and gelation
occurred within 17 min. The gel was removed from the round-bottomed
flask for further characterization.
Example 3--Polymerization
[0095] Following a modified polymerization procedure from Bao et al
(see above), 1.11 g of dry MDHD and .about.0.5 mL Ti(OiPr).sub.4
solution (0.1 g Ti per 0.1 mol monomer) were added to a dry 50 mL
round-bottomed flask equipped with a distillation apparatus and
mechanical stirrer. A N.sub.2 and subsequent vacuum purge was
performed 3 times to ensure complete removal of oxygen prior to
beginning the polymerization. The reaction setup was lowered into
an 80.degree. C. oil bath and allowed to proceed for 2 h with
stirring and a constant N.sub.2 purge. The temperature was then
increased to 120.degree. C. for 2 h and increased again to
170.degree. C. After 5 h at 170.degree. C. a gel had formed which
was removed from the round-bottomed flask for characterization
without any purification.
* * * * *