I am wondering if you're having some confusion about RAW, edited, and exported file. If you edit a RAW file, unless you do something, your catalog will maintain those edits. The RAW file "appears" to be edited, but really, it is untouched and Lightroom shows it to you with the edites applied. So if I am reading you right, you would want to create a new export from your same edited RAW in a different size. Upsizing edited jpg files would likely produce unsatisfactory results - you always lose quality upsizing. It might also be that you are unnecessarily creating many catalogs for many jobs, when one would suffice. I would put my exported files into a separate directory/folder structure to keep things tidy and separate your RAW/Lightroom images from your exported images. I know I'm assuming a lot here and some or all my assumptions may be wrong!
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