Title of Invention | A PROCESS FOR THE PREPARATION OF AN ORGANOMETALLIC COMPOSITION |
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Abstract | A PROCESS FOR THE PREPARATION OF AN ORGANOMETALLIC |
Full Text | FORM 2 THE PATENTS ACT, 1970 [39 OF 1970] COMPLETE SPECIFICATION [See Section 10; Rule 13] "A PROCESS FOR THE PREPARATION OF AN ORGANOMETALLIC COMPOSITION" JOHNSON MATTHEY PLC, a British company of 2-4 Cockspur Street, Trafalgar Square, London SW1Y 5BQ, United Kingdom, The following specification particularly describes the nature of the invention and the manner in which it is to be performed:- GRANTED -6 MAY 2005 7-10-2004 This invention relates to a process for the preparation of an organometailic composition and more particularly to organometailic composition based on Group IVB metals and which are useful in polyisocyanate compositions especially compositions for binding lignocellulosic material. The use of organic polyisocyanates as binders for lignocellulosic material in the manufacture of sheets or moulded bodies such as waferboard. chipboard, fibreboard and plywood is well known. In a typical process the organic polyisocyanate, optionally in the form of a solution, dispersion or aqueous emulsion, is applied to the lignocellulosic material which is then subjected to heat and pressure. One suitable polyisocyanate composition is disclosed in PCT Application WO 97/17388. This composition comprises a Group IVB metal compound, preferably a titanium chelate, optionally in combination with a compatibilising compound and/or conventional release agents. Although these compositions perform well as binders for lignocellulosic material and provide good release performance, it is desirable to develop a more economical composition which provides improved stability on storage before use. together with good curing properties and excellent bonding strength wnen applied to the lignocellulosic material. It has now been surprisingly found that certain compounds of Group IVB metals and acetoacetate esters can be used to cure poiyisocyanate compositions and these compositions are very stable on prolonged storage and economical when used for binding lignocellulosic material. According to the invention, an organometailic composition comprises a complex of at least one metal selected from the group consisting of titanium, zirconium and hafnium and an acetoacetate ester in which the molar ratio of Ti or Hf to acetoacetate ester is in the range 1 : 2.5 to 1:10 or the molar ratio of Zr WO 00/02885 PCT/CB99/0I982 to acetoacetate ester is in the range 1 : 4.5 to 1 : 10 and said acetoacetate ester is an ester of an alcohol containing 1 to 6 carbon atoms. The titanium, zirconium or hafnium composition of the invention is described herein as a "complex". It is believed that some of the acetoacetate ester will be chemically bound to the metal (Ti, Zr or Hf) but some can be described as "free" ester. The exact proportions which are bound and free will depend partly upon the exact molar ratios present in the complex and which metal, or metals, are used, but it has been shown that the "free" ester does influence the properties, particularly the stability on storage of polyisocyanate compositions containing the complexes. The molar ratio of titanium or hafnium to acetoacetate ester in the complex is in the range 1 : 2.5 to 1 : 10. When the metal is titanium, the molar ratio is preferably in the range 1 : 2.5 to 1 : 8 and more preferably in the range 1 : 3 to 1 : 6. Particularly preferred compounds have a molar ration in the range 1 : 4 to 1 : 6. In agreement with conventional theories about the co-ordination chemistry of titanium, it is believed that two molecules of acetoacetate ester will be chemically bound to a titanium atom and the remainder will be "free". When the metal is hafnium, the molar ratio is preferably 1 : 4.5 to 1 : 10 and more preferably 1 : 4.5 to 1 : 8, hafnium to acetoacetate ester. When the metal is zirconium, the molar ratio is from 1 : 4.5 to 1 : 10 and preferably from 1 : 4.5 to 1 : 8, zirconium to acetoacetate ester. For hafnium or zirconium, again in accordance with conventional theory, it is believed that, for complexes which contain 4 or more moles of acetoacetate ester. 4 molecules of acetoacetate ester are chemically bound to each atom of zirconium or hafnium and the remainder are "free". Preferably, the complex is a complex of at least one of titanium and zirconium. The preferred acetoacetate ester for preparing the complex is ethyl acetoacetate The complex can be prepared from more than one acetoacetate ester Put preferably only one acetoacetate ester is present in the complex. Typically, the complexes of titanium, zirconium or hafnium are prepared from titanium, zirconium or hafnium alkoxides having the general formula M(OR)4 in which M is Ti, Zr or Hf and R is a substituted or unsubstituted, cyclic or linear, aikyl, alkenyl, aryl or alkyl-aryl group or mixtures thereof. Preferably, R contains up to 8 carbon atoms and, more preferably, up to 6 carbon atoms. Generally, all four OR groups will be identical but alkoxides derived from a mixture of alcohols can be used and mixtures of alkoxides can be employed when more than one metal is present in the complex. Suitable alkoxides include tetramethoxytitanium, tetra-ethoxytitanium, tetra-isopropoxytitanium, tetra-n-propoxytitanium, tetrabutoxytitanium, tetrakis(2-ethylhexoxy)titanium, tetrakis(2-ethoxyethoxy)titanium, tetracyclohexyloxytitanium, tetraphenoxy- titanium, tetrapropoxyzirconium, tetrabutoxyzirconium, tetra-n-propoxyhafnium and tetra-n-butoxyhafnium. Alternatively, the complex can be prepared from condensed alkoxides of titanium, zirconium or hafnium. These compounds can be represented by the general formula RO[M(OR)20],R, wherein M and R have the same meaning as discussed above and x is an integer. Generally, these condensed alkoxides consist of a mixture containing compounds of the above formula with x having a range of values. Preferably, x has an average value in the range 2 to 16 and. more preferably, in the range 2 to 8 A condensed alkoxide is usually prepared by the controlled addition of water to an alkoxide. followed by removal of alcohol which is displaced. Suitable condensed alkoxides include the compounds known as potybutyl titanate, polybutyt zrrconate and polyisopropyl titanate. Complexes of condensed alkoxides can also be prepared by forming a complex WO 00/02885 PCT/GB99/01982 of an acetoacetate ester with an alkoxide. adding water to the complex and removing any by-product alcohol. Other titanium, zirconium or hafnium compounds, such as titanium, zirconium or hafnium tetrachloride or alkoxides which have been substituted with, for example, glycol or phosphorus substituents can be usea as raw materials for the formation of the complex used in the invention. The complex can be readily prepared by mixing, for example, an alkoxide or condensed alkoxide with an appropriate amount of acetoacetate ester. Alcohol from the alkoxide will be displaced by the acetoacetate ester and, preferably, the displaced alcohol is removed by, for example, distillation. In a preferred method, 2 moles of acetoacetate ester per atom of Ti or 4 moles of acetoacetate ester per atom of Zr or Hf are added to an alkoxide or condensed alkoxide and the displaced alcohol is removed by distillation. Any additional acetoacetate ester required is then added to the stripped product. This method is advantageous because it provides a consistent product of known stoichiometry. It is possible to add all the acetoacetate ester in one charge and subsequently remove all the displaced alcohol but some of the "free" acetoacetate ester is usually accidentally removed during this process, leading to inconsistent products and contamination of the displaced alcohol. Alternatively, when an organometallic composition according to the invention is used in a polyisocyanate composition, a product containing, for example, 2 moles of acetoacetate ester per Ti atom or 4 moles of acetoacetate ester per Zr or Hf atom can be prepared according to the method outlined above and this can be mixed with a polyisocyanate. Any additional acetoacetate ester required to produce the organometallic composition of the invention can be added to the polyisocyanate before or after the titanium, zirconium or hafnium compound has been added. This effectively results in the preparation of an - WO 00/02885 PCT/GB99/01982 organometallic composition according to this invention in situ in the poiyisocyanate composition. Other methods of preparing the composition of the invention will be apparent to a person skilled in this art The organometallic complexes of the invention are particularly useful as curing agents in poiyisocyanate compositions and compositions suitable for use with the organometallic compositions of the present invention may be any organic poiyisocyanate compound or mixture of organic poiyisocyanate compounds, provided said compounds have at least 2 isocyanate groups. Organic polyisocyanates include diisocyanates, particularly aromatic diisocyanates, and isocyanates of higher functionality. Examples of organic polyisocyanates for which the organometallic complexes of the present invention are useful curing agents include aliphatic isocyanates such as hexamethyiene diisocyanate; and aromatic isocyanates such as m- and p-phenylene diisocyanate, tolylene-2,4- and tolylene- 2,6-diisocyanate, diphenylmethane-4,4"-diisocyanate, chlorophenylene- 2,4-diisocyanate, naphthylene-1,5-diisocyanate, diphenyiene-4,4"-diisocyanate, 4,4"-diisocyanate-3.3"-dimethyl-diphenyl, 3-methyldiphenylmethane-4,4"-di- isocyanate and diphenyl ether diisocyanate; and cycloaliphatic diisocyanates such as cyclohexane-2.4- and -2,3-diisocyanate. 1-methyicyclohexyl-2,4- and -2,6-diisocyanate and mixtures thereof and bis-(isocyanatocyclohexyl)methane and triisocyanates such as 2,4,6-triisocyanatotoluene and 2,4,4-tri-isocyanatodiphenylether. Modified polyisocyanates containing isocyanurate. carbodiimide or uretonimine groups may be employed tn conjunction with the organometallic complexes of the invention as well. Further blocked polyisocyanates, like the reaction product of a phenol or an oxime and a poiyisocyanate, may be used. having a deblocking temperature below the temperature applied when using a polyisocyanate composition. The organic polyisocyanate useful with the organometallic composition of the invention may also be an isocyanate-ended prepolymer made by reacting an excess of a diisocyanate or higher functionality polyisocyanate with a polyol. Water-emulsifiable organic polyisocyanates like those described in UK patent no. 1 444 933, in European patent publication no. 516 361 and in PCT patent publication no. 91/03082 can also be used. Mixtures of isocyanates may be used in conjunction with the organometallic composition of the invention, for example a mixture of tolylene diisocyanate isomers such as the commercially available mixtures of 2,4- and 2,6-isomers and also the mixture of di- and higher polyisocyanates. Polyisocyanate mixtures may optionally contain monofunctional isocyanates such as p-ethyl phenyiisocyanate. Such mixtures are well-known in the art and include the crude phosgenation products containing methylene bridged poiyphenyl polyisocyanates, including diisocyanate, triisocyanate and higher polyisocyanates together with any phosgenation by-products. Preferred isocyanates to be used in conjunction with the organometallic complexes of the present invention are those wherein the isocyanate is an aromatic diisocyanate or polyisocyanate of higher functionality such as a pure diphenylmethane diisocyanate or a mixture of methylene bridged poiyphenyl polyisocyanates containing diisocyanates, triisocyanates and higher functionality polyisocyanates. Methylene bridged poiyphenyl polyisocyanates are well known in the art. They are prepared by phosgenation of corresponding mixtures of polyamines. For convenience, polymeric mixtures of methylene bridged poiyphenyl WO 00/02885 PCT/GB99/01982 poiyisocyanates containing diisocyanate, triisocyanate and higher functionality polyisocyanates are referred to hereinafter as polymeric MD1. Poiyisocyanates suitable for use with the organometaliic complexes of the invention include SUPRASEC™ DNR. SUPRASEC™ 2185, RUBINATE™ M and RUBINATE™ 1840, all available from Imperial Chemical Industries Preferably the polyisocyanate is liquid at room temperature. Conventional release agents can be added to or used in combination with a polyisocyanate composition containing a titanium, zirconium or hafnium complex of an acetoacetate ester according to the present invention. In such compositions the conventional release agent is present in an amount varying between 0.2 and 10 %, preferably between 0.5 and 6 % and most preferably between 1 and 3 % by weight based on the polyisocyanate whereas the titanium, zirconium or hafnium complex of an acetoacetate ester is preferably present in an amount varying between 0.2 and 4 %, most preferably between 0.2 and 2 % by weight based on the polyisocyanate. Examples of conventional release agents inciude polysiloxanes, saturated or unsaturated fatty acids (such as oleic acid) or fatty acid amides or fatty acid esters and polyolefin waxes. Preferred conventional release agents to be used in polyisocyanate compositions containing the organometaliic complexes according to the present invention are polyolefin waxes or mixtures of polyolefin waxes, especially functionalised polyolefin waxes, which are dispersible in an aqueous medium to form an aqueous emulsion. More preferably, the poiyolefin waxes are selected from oxidised polyethylene waxes and oxidised polypropylene waxes. A preferred method for using the release agent is to apply the emulsion to the surface of the polyisocyanate treated lignocellulosic material or to the press metal surface prior to hot pressing the combination. WO 00/02885 PCT/GB99/01982 When used, an aqueous emulsion of the polyoiefin wax should normally contain a sufficient amount of the poiyolefin wax to provide a coverage of about 0.01 to about 1, and preferably about 0.02 to about 0 5 mg of the polyoiefin wax per cm: of lignocellulosic matenal or press metal surface. Generally, iower levels of poiyolefin wax are preferred as they are more cost effective. When taking the emulsifiers into account, the aqueous emulsions will usually contain about 0.2 to about 10 %, preferably about 0.3 to about 5 % by weight of total solids. The emulsions are usually prepared at 30 to 40 % total solids, transported to the point of use and then diluted with water to the desired concentration. It has been found that the poiyolefin wax emulsion, when used in combination with polyisocyanate compositions containing organometallic compositions of the present invention, may be usefully applied to the lignocellulosic material or press metal surface in an amount equivalent to 8 to 14 mg per cm". A particularly preferred polyethylene wax emulsion which can be used in a process in combination with an organometallic composition of the present invention in combination with a poiyisocyanate is Rubilon™ 603 or Rubilon™ 605, both available from Imperial Chemical Industries. A particularly preferred polypropylene wax emulsion which can be used in a process in combination with an organometallic composition of the present invention in combination with a polyisocyanate is ME 42040 available from Michelman Inc. of Cincinnati, Ohio. In order to further improve the storage stability of a polyisocyanate composition containing an organometallic composition of the present invention a diluent may be added to the composition. Suitable diluents include plasticizers of the type mentioned in Taschenbuch der Kunststoff-Additive", Ed. by R. WO 00/02885 PCT/GB99/0I982 Gachter and H. Muller, Carl Hanser Verlag Munchen, third edition. 1989. Preferred diluents are phthalates, aliphatic carboxylates. fatty acid esters, linseed oil and soybean oil A particularly preferred diluent is Priolube 1403 available from Unichema being methyloleate. These diluents are added in amounts of from 1 to 40 parts by weight per 100 parts by weight of polyisocyanate and preferably in amounts of from 1 to 15 parts by weight per 100 parts by weight of polyisocyanate. A composition containing an organometallic composition of the present invention and a polyisocyanate may further comprise conventional additives like flame retardants, lignocellulosic preserving agents, fungicides, waxes, sizing agents, fillers, surfactants, thixotropic agents and other binders like formaldehyde condensate adhesive resins and lignin (optionally in combination with a iignin solvent such as described in PCT Patent Application No. EP96/00924). A particularly preferred additive to be used in a polyisocyanate composition containing an organometallic composition of the present invention is a coupling agent such as an organofunctional silane (for example, Dynasylan AMEO. available from Huels). Adding such a coupling agent to the polyisocyanate composition leads to improved board properties. The organofunctional silane coupling agents are used in amounts ranging from 0.01 to 3 %, preferably from 0.1 to 2 % by weight based on the polyisocyanate. The organometallic composition of present invention can be used in a process for preparing lignocellulosic bodies by bringing lignocellulosic parts into contact with a polyisocyanate composition containing the organometallic composition of the present invention and pressing this combination. WO 00/02885 PCT/GB99/01982 A typical process comprises the steps of a) bringing said lignoceiiulosic material in contact with a poiyisocyanate composition containing an organometallic composition of the present invention and, b) subsequently allowing said material to bind. The lignoceiiulosic bodies are prepared by bringing the lignoceiiulosic parts into contact with a poiyisocyanate composition by means such as mixing, spraying and/or spreading the composition with/onto the lignoceiiulosic parts and by pressing the combination of the poiyisocyanate composition and the lignoceiiulosic parts, preferably by hot-pressing, normally at 150° C to 250°C and 2 to 6 MPa specific pressure. Such binding processes are commonly known in the art. In waferboard manufacture the lignoceiiulosic material and the poiyisocyanate composition may be conveniently mixed by spraying the present poiyisocyanate composition on the lignoceiiulosic material while it is being agitated. As described hereinbefore, in a preferred process, a release agent, which is preferably an aqueous emulsion of a polyolefin wax, is applied to the surface of the poiyisocyanate treated lignoceiiulosic material or to the press metal surface prior to hot pressing the combination. The iignocelluiosic material after treatment with the poiyisocyanate composition containing an organometallic composition according to the invention is placed on caul plates made of aluminium or steel which serve to carry the furnish into the press where it is compressed to the desired extent usually at a temperature between 150° C and 250° C. While the process is particularly suitable for the manufacture of waferboard known extensively as oriented strand board and will be largely used WO 00/02885 PCT/GB99/0I982 for such manufacture, the process may not be regarded as limited in this respect and can also be used in the manufacture of medium density fibreboard, particle board (also known as chipboard) and plywood. Thus the lignocellulosic material used can include wood strands, woodchips, wood fibres, shavings, veneers, wood wool, cork, bark, sawdust and like waste products of the wood working industry as well as other materials having a lignocellulosic basis such as paper, bagasse, straw, flax, sisal, hemp, rushes, reeds, rice hulls, husks, grass, nutshells and the iike. Additionally, there may be mixed with the lignocellulosic materials other particulate or fibrous materials such as ground foam waste (for example, ground potyurethane foam waste), mineral fillers, glass fibre, mica, rubber, textile waste such as plastic fibres and fabrics. When the polyisocyanate composition containing the organometallic composition of the invention is applied to the lignocellulosic material, the weight ratio of polyisocyanate/iignoceilulosic material will vary depending on the bulk density of the lignocellulosic material employed. Therefore, the polyisocyanate compositions may be applied in such amounts to give a weight ratio of polyisocyanate/iignoceilulosic material in the range of 0.1 : 99.9 to 20 : 80 and preferably in the range of 0.5 : 99.5 to 10 : 90. If desired, other conventional binding agents, such as formaldehyde condensate adhesive resins, may be used in conjunction with the polyisocyanate composition containing the organometallic composition. More detailed descriptions of methods of manufacturing waferboard and similar products based on lignocellulosic material are available in the prior art. The tecnniques and equipment conventionally used can be adapted for use with polyisocyanate compositions containing organometallic compositions of the present invention. WO 00/02885 PCT/GB99/01982 Poiyisocyanate compositions containing organometaliic compositions of the present invention are extremely effective in minimising unwanted adhesion to caul plates, press plates and other surfaces with which the treated lignocellulosic material may come into contact. Their storage stability and release performance is improved compared to poiyisocyanate compositions of the prior art, as well as the obtained board properties. The sheets and moulded bodies produced from the poiyisocyanate compositions containing organometaliic compositions of the present invention have excellent mechanical properties and they may be used in any of the situations where such articles are customarily used. The invention is illustrated but not limited by the following examples. EXAMPLE 1 Preparation of Product A A reactor was charged with tetraisopropyl titanate (1400 kg, Tilcom* TIPT from ICI Vertec). Ethylacetoacetate (1282 kg) was then added with stirring. The resulting product was a pale red liquid. The displaced alcohol (580 kg, isopropanol) was then removed by evaporation to leave a red liquid, PRODUCT A (2090 kg). Product A was then diluted by addition of various amounts of methylacetoacetate. ethylacetoacetate and cetylacetoacetate in the following molar ratios. WO 00/02885 PCT/GB99/01982 TABLE 1 Sample Moles Product A Moles i Methylacetoacetate Test 1 1.1 i | Test 2 i 1 2.2 I ! Test 3 4.4 Test 4 6.6 Test5 8.8 Test 6 1 I 11 I TABLE 2 Sample Moles Product A Moles Ethylacetoacetate Test 7 1-1 Test 8 2.2 Test 9 4.4 Test 10 6.6 Test 11 8.8 Test 12 11 WO 00/02885 PCT/GB99/01982 TABLE 3 Sample Moles Product A Moles Cetylacetoacetate Comparison 1 1 1.1 Comparison 2 1 2.2 Comparison 3 1 4.4 Comparison 4 1 6.6 Comparison 5 1 8.8 Comparison 6 1 11 The products were evaluated by preparing a number of compositions comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR. available from Imperial Chemical Industries) and various amounts of the samples designated Test 1 to 12 (see Table 4 below). Each composition contained the same concentration of Product A. The compositions were then stored at 45° C and the viscosity tested by means of a Brookfield viscometer at various intervals. WO 00/02885 PCT/GB99/01982 TABLE 4 Sample Parts by weight Parts by weight Suprasec DNR Test 1 0.78 100 i Test 2 0.96 100 i Test 3 1.32 100 Test 4 1.67 j 100 Test 5 i 2.03 ! 100 Test 6 i 2.38 ! 100 I Test 7 0.80 100 Test 8 1.00 100 Test 9 1.40 100 Test 10 1.80 100 Test 11 2.20 100 Test 12 2.60 100 As a comparison a number of compositions comprising 100 parts by weight of polyisocyanate (polymeric MDl. SUPRASEC DNR, available from Imperial Chemical Industries) and various amounts of the samples designated Comparison 1 to 6 (see Table 5 below) were made up. All these compositions contained the same amount of Product A, this amount being the same as the amount of Product A in each of the compositions designated Test 1 to Test 12. These compositions were then stored at 45s C and the viscosity tested using a Brookfieid viscometer at the same intervals. WO 00/02885 PCT/GB99/0I982 TABLE 5 Sample Parts by weight Parts by weight Suprasec DNR Comparison 1 1.1 100 Comparison 2 1.6 100 Comparison 3 2.6 100 Comparison 4 3.6 100 Comparison 5 4.6 100 Comparison 6 5.6 100 The following results were obtained for the systems based on Product A with various added amounts of methylacetoacetate and ethyiacetoacetate [all results are reported in Pa sj. TABLE 6 Product A + Methylacetoacetate Time (Days) Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 0 0.292 0.288 0.274 0.272 0.267 i 0.267 14 0.828 0.548 0.632 0.678 0.746 0.806 25 1.208 0.734 0.840 1.007 1.078 1.153 30 n.m. 1.050 1.139 i 1.330 1.526 I 1.756 46 2.568 1.207 j 1.239 i 1.546 1.767 2.125 67 n.m. t 1.917 i 1.707 i i 2.209 2.579 3.392 n.m. = not measured WO 00"02885 PCT/GB99/0I982 TABLE 7 Product A + Ethylacetoacetate Time (Days) Test 7 Test 8 Test 9 Test 10 Test 11 Test 12 0 0.305 0.293 0.280 ! 0.270 I 0.263 0.263 14 0.787 . 0.600 ... j 0.645 0.717 0.806 0.814 25 i 1.136 | 0.879 0.911 1.078 1.197 1.251 30 n.m. | 1.137 1.225 1.538 1.734 1.811 46 2.486 j 1.310 i 1.410 1.735 2.240 2.018 67 n.m. ! 2.028 1.943 2.440 3.275 3.192 n.m. = not measured The foUowing results were obtained for the systems based on Product A with various added amounts of cetylacetoacetate [all results reported in Pa s]. TABLE 8 Product A + Cetylacetoacetate Time (Days) Comparison 1 Comparison 2 Companson Comparison 3 i 4 i Comparison 5 Comparison 6 0 0.324 0.296 0.296 0.277 0.279 0.264 14 1.195 0.599 0.627 0.630 0.667 0.626 25 1.995 0.797 0.839 I 0.851 I 1.014 0.989 30 n.m. | 1.145 1.168 | 1.049 j 1.430 1.427 46 4.620 ! 1.396 i 1.281 | 1.162 j 1.608 1.620 67 n.m. 2.443 1.853 1.610 2.260 2.309 n. m. = not measured WO 00/02885 PCT/GB99/01982 Generally, the most relevant period for storage stability at room temperature is the period 14 to 46 days after production of a poiyisocyanate composition. From Tables 6 to 8 above, it can be seen that the optimum (generally, lowest) viscosity after 46 days at 45° C (an accelerated test) is achieved in Test 2 (2.2 moles methylacetoacetate), Test 8 (2.2 moles ethylacetoacetate) and Comparison 4 (6.6 moles cetyiacetoacetate). The results demonstrate that the titanium complexes used in the composition of the invention provide a more economical means of stabilising the poiyisocyanate composition. EXAMPLE 2 Preparation of Product B A flask was charged with tetra-n-propyl zirconate (43.7g, Tilcom* NPZ [75% solution of Zr(On-C3H7)4 in n-propanol] from IGI Vertec) and placed in a cold water bath. Methylacetoacetate (46.5g) was added over a period of one hour whilst the mixture was stirred. The resulting product was a pale yellow liquid. The displaced alcohol (35.3g, n-propanol) was then removed on a rotary evaporator to leave a yellow oil (54.8g). The oil was then mixed with additional methylacetoacetate (11.6g) to yield PRODUCT B. To evaluate the product a composition comprising 100 parts by weight of poiyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 2.09 parts by weight Product B was prepared in duplicate. The compositions were then stored at 45o C and the viscosity tested at various intervals using a Brookfield viscometer Results are reported in Table 9 below in Pa s. WO 00/02885 TABLE 9 Time (Days) Product B(i) | Product B(ii) 0 0.220 | 0.220 20 I 0.440 ! ! 0.400 41 0.580 j 0.520 62 0.660 i 0.640 84 1.020 j 1.340 Preparation of Product C A flask was charged with tetra-n-propyl zirconate (43.7g, Tilcom* NPZ [75% solution of Zr(On-C3H7), in n-propanol] from ICI Vertec) and placed in a cold water bath. Methylacetoacetate (46.5g) was added over a period of one hour whilst the mixture was stirred. The resulting product was a pale yellow liquid. The displaced alcohol (34.3g, n-propanol) was then removed on a rotary evaporator to leave a yellow oil (55.8g). The oil was then mixed with additional methylacetoacetate (23.2g) to yield PRODUCT C. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 2.48 parts by weight Product C was prepared in duplicate. The compositions were then stored at 45° C and the viscosity tested at various intervals using a Brookfield viscometer. Results are reported in Table 10 below in Pa s. WO 00/02885 TABLE 10 Time (Days) Product C(i) Product C(ii) 0 0.220 0.220 20 0.460 i 0.500 I 41 0.500 i 0.500 62 0.720 0.620 84 1.280 0.980 Preparation of Product D A flask was charged with tetra-n-propyl zirconate (87.3g, Tiicom* NPZ [75% solution of Zr(On-C3H7)4 in n-propanol] from ICI Vertec) and placed in a cold water bath. Ethyiacetoacetate (104g) was added over a period of one hour whilst the mixture was stirred. The resulting product was a pale yellow liquid. The displaced alcohol (67.1g, n-propanol) was then removed on a rotary evaporator to leave a yellow oil (124.3g). The oil was then mixed with additional ethyl acetoacetate (26g) to yield PRODUCT D. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 2.21 parts by weight Product D was prepared in duplicate. The compositions were then stored at 45° C and the viscosity of the compositions tested at various intervals using a Brookfield viscometer. Results are reported in Table 11 below in Pa s. WO 00/02885 PCT/GB99/01982 TABLE 11 Time (Days) \ Product D(i) Product D(ii) i 0 j 0.220 0.220 20 0.480 0.460 41 0.540 0.560 62 0.700 0.920 84 1.140 1.040 Preparation of Product E A flask was charged with tetra-n-propyl zirconate (87.3g, Tilcom* NPZ [75% solution of Zr(On-C3H7)6 in n-propanol] from ICI Vertec) and placed in a cold water bath. Ethylacetoacetate (104g) was added over a period of one hour whilst the mixture was stirred. The resulting product was a paie yellow liquid. The displaced alcohol (70.0g, n-propanol) was then removed on a rotary evaporator to leave a yellow oil (121,4g). The oil was then mixed with additional ethylacetoacetate (52g) to yield PRODUCT E. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 2.56 parts by weight Product E was prepared in duplicate. The compositions were then stored at 45° C and the viscosity of the compositions tested at various intervals using a Brookfield viscometer. Results are reported in Table 12 below in Pa s. WO 00/02885 PCT/G B99/01982 TABLE 12 Time (Days) i Product E(i) j Product E(ii) i 0 0.220 0.220 20 0.560 0.580 41 0.620 0.600 62 0.860 0.780 84 1.060 0.960 The zirconium complexes (Products B, C, D E) show improved stability over a longer period of time than the titanium complexes of Comparison 1 to 6 (Table 8). EXAMPLE 3 Preparation of Product F A flask was charged with tetraisopropyl titanate (71 g, Tilcom* TIPT from ICI Vertec) and placed in a cold water bath. Ethylacetoacetate (65g) was added over a period of one hour whilst the mixture was stirred. Following addition of ethylacetoacetate, distilled water (1.1g, 0.25 moles per mole Ti) was added to the mixture with thorough stirring. The resulting product was a pale red liquid. The displaced alcohol (43.4g, isopropanoi) was then removed on a rotary evaporator to leave a red liquid (94.5g). This liquid was then mixed with additional ethyl acetoacetate (65g) to yield PRODUCT F To evaluate the product a composition comprising 100 parts by weight of poiyisocyanate (polymeric MDl. SUPRASEC DNR, available from Imperial Chemical Industries) and 0.88 parts by weight Product F was prepared. The WO 00/02885 PCT/GB99/01982 composition was then stored at 45" C and the viscosity of the composition tested at various intervals using a Brookfield viscometer. Preparation of Product G A flask was charged with tetraisopropyl titanate (71 g, Tilcom* TIPT from ICI Vertec) and placed in a cold water bath. Ethylacetoacetate (65g) was added over a period of one hour whilst the mixture was stirred. Following addition of ethylacetoacetate. distilled water (2.3g, 0.5 moles per moie of Ti) was added to the mixture with thorough stirring. The resulting product was a pale red liquid. The displaced alcohol (48.4g, isopropanol) was then removed on a rotary evaporator to leave a red liquid (93.3g). This liquid was then mixed with additional ethyl acetoacetate (65g) to yield PRODUCT G. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 0.88 parts by weight Product G was prepared. The composition was then stored at 45° C and the viscosity of the composition tested at various intervals using a Brookfield viscometer. Results are reported for Product F and Product G in Table 13 below in Pa s. TABLE 13 Time (Days) Product F Product G 0 0.220 0.220 10 0.485 0.520 40 0.760 0.760 60 1.100 1.200 80 1.140 1.220 WO 00/02885 PCT/GB99/01982 EXAMPLE 4 A flask was charged with tetraisopropyl titanate (71g, Tilcom* TIPT from ICI Vertec) and placed in a cold water bath. tert-Butylacetoacetate (79.1g) was added over a period of one hour whilst the mixture was stirred. The resulting product was a pale yellow liquid. The displaced alcohol (30.0g, isopropanol) was then removed on a rotary evaporator to leave a red liquid (120.0g). This liquid was then mixed with additional ethyl acetoacetate (65g) to yield PRODUCT H. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 1.02 parts by weight Product H was prepared. The composition was then stored at 45° C and the viscosity of the composition tested at various intervals using a Brookfield viscometer. Results are reported in Table 14 below in Pa s. TABLE 14 Time (Days) Viscosity o - 0.220 10 0.480 40 1.160 60 1.800 80 2.160 00/02885 EXAMPLE 5 Preparation of Product I A flask was charged with tetraisopropyl titanate (71g, Tilcom* TIPT from ICI Vertec) and placed in a cold water bath. Ethyiacetoacetate (65g) was added over a period of one hour whilst the mixture was stirred. Foilowing addition of ethyiacetoacetate, butyl acid phosphate (11.4g, 0.25 moles) was added to the mixture with thorough stirring. The resulting product was a pale red liquid. The displaced alcohol (38.2g, isopropanol) was then removed on a rotary evaporator to leave a red liquid (109.2g). This liquid was then mixed with additional ethyl acetoacetate (65g) to yield PRODUCT I. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial Chemical Industries) and 0.97 parts by weight Product I was prepared in duplicate. The compositions were then stored at 45° C and the viscosity of the compositions tested at various intervals using a Brookfield viscometer (see Table 15). Preparation of Product J A flask was charged with tetraisopropyl titanate (71g, Tilcom* TIPT from ICI Vertec) and placed in a cold water bath. Ethyiacetoacetate (65g) was added over a period of one hour whilst the mixture was stirred. Following addition of ethyiacetoacetate. butyl acid phosphate (22.8g, 0.5 moies) was added to the mixture with thorough stirring. The resulting product was a pale red liquid. The displaced alcohol (40.8g, isopropanol) was then removed on a rotary evaporator to leave a red liquid (118.0g). This liquid was then mixed with additional ethyl acetoacetate (65g) to yield PRODUCT J. To evaluate the product a composition comprising 100 parts by weight of polyisocyanate (polymeric MDI, SUPRASEC DNR, available from Imperial WO 00/02885 PCT/GB99/0I982 Chemical Industries) and 1.02 parts by weight Product J was prepared. The composition was then stored at 45° C and the viscosity of the composition tested at various intervals using a Brookfield viscometer. Results are reported for Product I and Product J in Table 15 below in Pa s. TABLE 15 Time (Days) Product I J Product J 0 0.220 0.220 10 0.440 0.389 40 0.880 0.580 60 1.320 0.960 80 1.360 1.040 WE CLAIM:- 1. A process for the preparation of an organometallic composition comprising a complex of at least one metal selected from the group consisting of titanium, zirconium and hafnium and an acetoacetate ester in which the molar ratio of Ti or Hf to acetoacetate ester is in the range 1 : 2.5 to 1:10 or the molar ratio of Zr to acetoacetate ester is in the range 1 : 4.5 to 1 : 10 and said acetoacetate ester is an ester of an alcohol containing 1 to 6 carbon atoms, said process comprising mixing a compound of titanium, zirconium or hafnium with an acetoatetate ester. 2. A process as claimed in claim 1, wherein the compound of titanium, zirconium or hafnium is selected from an alkoxide, condensed alkoxide, substituted alkoxide or tetrachloride. 3. A process as claimed in claim 2 wherein the compound of titanium, zirconium or hafnium is a titanium, zirconium or hafnium alkoxide having the general formula M(OR)4 in which M is Ti, Zr or Hf and R is a substituted or unsubstituted, cyclic or linear, alky}, alkenyl, aryl or alkyl-aryl group. 4. A process as claimed in claim 3 in which R contains up to 6 carbon atoms. 5. A process as claimed in claim 1 or claim 2 wherein the compound of titanium, zirconium or hafnium is a condensed titanium, zirconium or hafnium alkoxide having the general formula RO[M(OR)20]xR in which M is Ti, Zr or Hf, x is an integer and R is a substituted or unsubstituted, cyclic or linear, alkyl, alkenyl, aryl or alkyl-aryl group. 6. A process as claimed in claim 5 wherein the average value of x is in the range 2 to 16. 7. A process as claimed in any one of claims 2 - 6, further comprising the step of removing an alcohol from the mixture. 8. A process as claimed in claim 7, wherein said alcohol is removed by distillation. 9. A process as claimed in any of the preceding claims, wherein a further quantity of acetoacetate ester is added to said mixture. 10. A process as claimed in any of the preceding claims, in which the complex is a complex of titanium having a molar ratio of Ti to acetoacetate ester in the range 1 : 2.5 to 1 :8. 11. A process as claimed in claim 10, in which the molar ratio of Ti to acetoacetate ester is in the range 1 : 3 to 1 : 6. 12. A process as claimed in any of the preceding claims, in which the complex is a complex of hafnium having a molar ratio of Hf to acetoacetate ester in the range 1 : 4.5 to 1 :10. 13. A process as claimed in any of the preceding claims, in which the molar ratio of Zr or Hf to acetoacetate ester is in the range 1 : 4.5 to 1 : 8. 14. A process as claimed in any of the preceding claims, in which the acetoacetate ester is ethyl acetoacetate. 15. A process for the preparation of an organometallic composition as claimed in any of the preceding claims wherein a product containing 2 moles of acetoacetate ester per Ti atom or 4 moles of acetoacetate ester per Zr or Hf atom is prepared by mixing a compound of titanium, zirconium or hafnium with an acetoacetate ester, then said product is mixed with a polyisocyanate containing any additional acetoacetate ester required to produce the organometallic composition. 16. A process for the preparation of an organometallic composition as claimed in any of the preceding claims wherein a product containing 2 moles of acetoacetate ester per Ti atom or 4 moles of acetoacetate ester per Zr or Hf atom is prepared by mixing a compound of titanium, zirconium or hafnium with an acetoacetate ester, then such additional acetoacetate ester required to produce the organometallic composition is added to the polyisocyanate mixture after the titanium, zirconium or hafnium compound has been added thereto. Dated this 5th day of January, 2001. [SANJAY KUMAR] OF REMFRY & SAGAR ATTORNEY FOR THE APPLICANTS |
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in-pct-2001-00030-mum-assignment(28-4-2003).pdf
in-pct-2001-00030-mum-assignment(7-10-2004).pdf
in-pct-2001-00030-mum-assignment-(7-10-2004).pdf
in-pct-2001-00030-mum-cancelled pages(5-1-2001).pdf
in-pct-2001-00030-mum-cancelled pages(6-5-2005).pdf
in-pct-2001-00030-mum-claims(complete)-(5-1-2001).pdf
in-pct-2001-00030-mum-claims(granted)-(07-10-2004).doc
in-pct-2001-00030-mum-claims(granted)-(31-10-2006).pdf
in-pct-2001-00030-mum-claims(granted)-(7-10-2004).pdf
IN-PCT-2001-00030-MUM-CORRESPONDENCE (23-7-2012).pdf
IN-PCT-2001-00030-MUM-CORRESPONDENCE(23-7-2012).pdf
in-pct-2001-00030-mum-correspondence(5-12-2005).pdf
in-pct-2001-00030-mum-correspondence(7-5-2005).pdf
in-pct-2001-00030-mum-correspondence(ipo)-(27-12-2006).pdf
in-pct-2001-00030-mum-correspondence(ipo)-(31-10-2006).pdf
in-pct-2001-00030-mum-description(granted)-(31-10-2006).pdf
in-pct-2001-00030-mum-descripton(complete)-(5-1-2001).pdf
in-pct-2001-00030-mum-form 1(5-1-2001).pdf
in-pct-2001-00030-mum-form 1(7-10-2004).pdf
in-pct-2001-00030-mum-form 1(7-4-2003).pdf
in-pct-2001-00030-mum-form 13(7-4-2003).pdf
IN-PCT-2001-00030-MUM-FORM 16(23-7-2012).pdf
in-pct-2001-00030-mum-form 19(29-3-2004).pdf
in-pct-2001-00030-mum-form 1a(7-10-2004).pdf
in-pct-2001-00030-mum-form 2(complete)-(5-1-2001).pdf
in-pct-2001-00030-mum-form 2(granted)-(31-10-2006).pdf
in-pct-2001-00030-mum-form 2(granted)-(7-10-2004).doc
in-pct-2001-00030-mum-form 2(granted)-(7-10-2004).pdf
in-pct-2001-00030-mum-form 2(title page)-(complete)-(5-1-2001).pdf
in-pct-2001-00030-mum-form 2(title page)-(granted)-(31-10-2006).pdf
in-pct-2001-00030-mum-form 3(29-3-2004).pdf
in-pct-2001-00030-mum-form 3(5-1-2001).pdf
in-pct-2001-00030-mum-form 3(7-10-2004).pdf
in-pct-2001-00030-mum-form 5(7-10-2004).pdf
in-pct-2001-00030-mum-form 6(28-4-2003).pdf
in-pct-2001-00030-mum-form-pct-ipea-409(5-1-2001).pdf
in-pct-2001-00030-mum-form-pct-isa-210(5-1-2001).pdf
in-pct-2001-00030-mum-general power of authority(9-5-2001).pdf
in-pct-2001-00030-mum-petition under rule 137(7-10-2004).pdf
in-pct-2001-00030-mum-petition under rule 138(7-10-2004).pdf
in-pct-2001-00030-mum-power of authority(28-4-2003).pdf
in-pct-2001-00030-mum-power of authority(5-1-2001).pdf
in-pct-2001-00030-mum-power of authority(9-5-2001).pdf
in-pct-2001-00030-mum-specification(amended)-(6-5-2005).pdf
in-pct-2001-00030-mum-wo international publication report (5-1-2001).pdf
Patent Number | 203444 | ||||||||
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Indian Patent Application Number | IN/PCT/2001/00030/MUM | ||||||||
PG Journal Number | 19/2007 | ||||||||
Publication Date | 11-May-2007 | ||||||||
Grant Date | 31-Oct-2006 | ||||||||
Date of Filing | 05-Jan-2001 | ||||||||
Name of Patentee | JOHNSON MATTHEY PLC | ||||||||
Applicant Address | A BRITISH COMANY, OF 2-4 COCKSPUR STREET, TRAFALGAR SQUARE, LONDON SW1Y 5BQ, UNITED KINGDOM. | ||||||||
Inventors:
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PCT International Classification Number | N/A | ||||||||
PCT International Application Number | N/A | ||||||||
PCT International Filing date | 1999-06-24 | ||||||||
PCT Conventions:
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