Abstract:
A process has been developed for preparing 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof, all of which may be used as primary intermediates in compositions for dyeing keratin fibers.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a process for preparing primary intermediates for dyeing keratin fibers. More particularly, the invention relates to a process for preparing 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof. 
     BACKGROUND OF THE INVENTION 
     Primary intermediates are used in compositions for dyeing keratin fibers. Known primary intermediates include 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof. 
     Known processes of preparing 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof have yield and cost deficiencies. Therefore, there is a need for an industrially applicable, less expensive, and higher yielding process to synthesize 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof. 
     SUMMARY OF THE INVENTION 
     According to one embodiment of the invention, there is provided a process for the preparation of 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof comprising (a) performing a reduction of a compound of formula (I) to prepare a compound of formula (II); (b) performing an etherification of the compound of formula (II) to prepare a compound of formula (III); and (c) performing a hydrogenation of the compound of formula (III) to prepare a compound of formula (IV): 
                                
wherein R 1 , R 2 , and R 3  are substituents selected from the group consisting of:
         a) C-linked substituents selected from the group consisting of:
           i. alkyl groups;   ii. aryl groups; and   iii. substituents selected from the group consisting of COOA 1 , CONA 1 , CONA 1 COA 2 , C(═NA 1 )NA 1 A 2 , and CN;
               wherein the C-linked substituents comprise from 1 to about 10 carbon atoms and from 0 to about 5 heteroatoms selected from the group consisting of O, F, Cl, N, P, Si, and mixtures thereof;   
               
           b) S-linked substituents selected from the group consisting of SA 1 , SO 2 A 1 , SO 3 A 1 , SSA 1 , SOA 1 , SO 2 NA 1 A 2 , SNA 1 A 2 , and SONA 1 A 2 ;   c) O-linked substituents selected from the group consisting of OA 1 , ONA 1 A 2 ;   d) N-linked substituents selected from the group consisting of NA 1 A 2 ; (NA 1 A 2 A 3 ) + , NA 1 SA 2 , NO 2 ;   e) halogens selected from the group consisting of F, Cl, Br, and I;   f) hydrogen; and   g) mixtures thereof;
           wherein A 1 , A 2 , and A 3  are alkyl groups comprising from 1 to about 10 carbon atoms and from 0 to about 5 heteroatoms selected from the group consisting of O, F, Cl, N, P, Si, and mixtures thereof;
 
wherein R 5  is an alkyl group; and
 
wherein R 6  and R 7  are selected from the group consisting of hydrogen, alkyl groups, aminoalkyl groups, hydroxyalkyl groups, and mixtures thereof.
   
               

     This and other features, aspects, and advantages of the present invention will become evident to those skilled in the art from a reading of the present disclosure. 
     DETAILED DESCRIPTION OF THE INVENTION 
     In all embodiments of the present invention, all percentages are by weight of the total composition, unless specifically stated otherwise. All ratios are weight ratios, unless specifically stated otherwise. All ranges are inclusive and combinable. The number of significant digits conveys neither a limitation on the indicated amounts nor on the accuracy of the measurements. All numerical amounts are understood to be modified by the word “about” unless otherwise specifically indicated. Unless otherwise indicated, all measurements are understood to be made at about 25° C. and at ambient conditions, where “ambient conditions” means conditions under about one atmosphere of pressure and at about 50% relative humidity. All such weights as they pertain to listed ingredients are based on the active level and do not include carriers or by-products that may be included in commercially available materials, unless otherwise specified. 
     The term “comprising,” as used herein, means that other steps and other ingredients which do not affect the end result can be added. This term encompasses the terms “consisting of” and “consisting essentially of.” Compositions and methods/processes of the present invention can comprise, consist of, and consist essentially of the elements and limitations of the invention described herein, as well as any of the additional or optional ingredients, components, steps, or limitations described herein. 
     The terms “include,” “includes,” and “including,” as used herein, are meant to be non-limiting and are understood to mean “comprise,” “comprises,” and “comprising,” respectively. It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein. 
     The process for the preparation of 2-methoxymethyl-1,4-benzenediamine (IV-a), other compounds of formula (IV), and the salts thereof comprises (a) performing a reduction of a compound of formula (I) to prepare a compound of formula (II); (b) performing an etherification of the compound of formula (II) to prepare a compound of formula (III); and (c) performing a hydrogenation of the compound of formula (III) to prepare a compound of formula (IV). 
     In an embodiment, the reduction, then etherification, and then hydrogenation may be performed successively. In another embodiment, the reduction, then hydrogenation, and then etherification may be performed successively. 
     I. Reduction 
     Reduction may be performed on a compound of formula (I) to prepare a compound of formula (II). R 1 , R 2 , R 3 , R 6 , and R 7  are as defined previously, may be independently selected, and may be identical or different. Reduction may be performed in the presence of a reducing agent, a reduction catalyst, and/or a solvent. 
     The reducing agent may be selected from the group consisting of hydrazine, hydrazine hydrate, H 2 , LiAlH 4 , LiBH 4 , DIBAL-H, NaBH 4 , NaCNBH 3 , B 2 H 6 , BH 3 /THF, sodium hydrosulfite, sodium sulfide, and mixtures thereof. 
     The reduction catalyst may be selected from the group consisting of Raney nickel, nickel, palladium, Lindlar&#39;s catalyst, cobalt, copper chromite, platinum, platinum oxide, rhenium, tin(II) chloride, titanium(III) chloride, zinc, samarium, iron, ruthenium, iridium, rhodium, and mixtures thereof. 
     The solvent may be selected from the group consisting of water, petroleum ether, pentane, acetic acid, cyclopentane, hexane, cyclohexane, benzene, toluene, 1,4-dioxane, chloroform, diethyl ether, dichloromethane, tetrahydrofuran, methyl-tetrahydrofuran, dimethylformamide, acetonitrile, dimethyl sulfoxide, n-butanol, isopropanol, n-propanol, ethanol, methanol, and mixtures thereof. 
     Reduction may be carried out at a temperature of from about 0° C. to about 100° C., alternatively from about 50° C. to about 80° C., alternatively at about 70° C. 
     In an embodiment, the formula indicated by formula (I) may be prepared by inserting a nitro function into isatoic anhydride or compounds thereof in the presence of a nitrating agent and/or a solvent. The nitrating agent may be selected from the group consisting of nitric acid, fuming nitric acid, red fuming nitric acid, salts of nitric acid (i.e. potassium nitrate), and mixtures thereof. 
                                
II. Etherification
 
     Etherification may be performed on the compound of formula (II) to prepare a compound of formula (III). R 1 , R 2 , R 3 , R 5 , R 6 , and R 7  are as defined previously, may be independently selected, and may be identical or different. 
     Alkylation Reaction 
     Etherification may be performed by an alkylation reaction in the presence of an alkylating agent, a phase transfer catalyst, a solvent, and/or a base. The reaction mixture may be homogeneous or heterogeneous, may have two or more liquid phases, and/or may have any combination of liquid and solid phases. 
     The alkylating agent may be selected from the group consisting of alcohols, derivatives of alcohols (i.e. methyl methanesulfonate), (C 1 -C 4 )—I, (C 1 -C 4 )—Br, (C 1 -C 4 )—Cl, Me 2 SO 4 , and mixtures thereof. In one embodiment, the alkylating agent may be dimethyl sulfate. 
     The phase transfer catalyst may be selected from the group consisting of ammonium salts that include tetrapentylammonium bromide, tetraoctylammonium chloride, tetraoctylammonium bromide, tetrahexylammonium iodide, tetrahexylammonium chloride, tetrahexylammonium bromide, tetraheptylammonium bromide, tetraethylammonium tetrafluoroborate, tetraethylammonium chloride, tetraethylammonium bromide, tetradodecylammonium tetrafluoroborate, tetradodecylammonium chloride, tetradodecylammonium bromide, tetradecyl-trimethylammonium chloride, benzyltriethyl ammonium chloride, phenyl-trimethylammonium bromide, octyl-trimethylammonium bromide, octadecyl-trimethylammonium chloride, octadecyl-trimethylammonium bromide, methyl-trioctylammonium iodide, and mixtures thereof. In one embodiment, the phase transfer catalyst may be benzyltriethyl ammonium chloride. 
     The solvent may be selected from the group consisting of water, petroleum ether, pentane, cyclopentane, hexane, cyclohexane, benzene, toluene, 1,4-dioxane, chloroform, diethyl ether, dichloromethane, tetrahydrofuran, methyl-tetrahydrofuran, ethyl acetate, acetone, dimethylformamide, acetonitrile, dimethyl sulfoxide, n-butanol, isopropanol, n-propanol, ethanol, methanol, and mixtures thereof. 
     The base may be selected from the group consisting of sodium hydroxide, potassium hydroxide, ammonium hydroxide, calcium hydroxide, magnesium hydroxide, barium hydroxide, aluminum hydroxide, ferrous hydroxide, ferric hydroxide, zinc hydroxide, lithium hydroxide, sodium bicarbonate, sodium carbonate, and mixtures thereof. In one embodiment, the base may be sodium hydroxide. 
     Condensation Reaction 
     Etherification may also be performed by a condensation reaction in the presence of a condensation catalyst and/or a solvent. 
     The condensation catalyst may be selected from the group consisting of mineral acids, Lewis Acids, aluminum chloride, titanium tetra-isopropoxide, and mixtures thereof. 
     The solvent may be selected from the group consisting of petroleum ether, pentane, cyclopentane, hexane, cyclohexane, benzene, toluene, 1,4-dioxane, chloroform, diethyl ether, dichloromethane, tetrahydrofuran, methyl-tetrahydrofuran, ethyl acetate, acetone, dimethylformamide, acetonitrile, dimethyl sulfoxide, n-butanol, isopropanol, n-propanol, ethanol, methanol, and mixtures thereof. In one embodiment, the solvent may be methanol. 
     The condensation reaction may be carried out with an inert solvent diluent and/or with heating. The inert solvent diluent may be chosen to aid in the removal of water if it is capable of forming a low boiling azeotrope. In this case, the condensation reaction may be carried out at reflux using a Dean Stark trap to drain off the water as it is formed and distilled off with the azeotrope. The condensation reaction may also be carried out in the presence of one or more dehydrating agents which may either react with or physically bind with the water, thereby removing the water from equilibria. The dehydrating agent may be selected from the group consisting of dicyclohexylcarbodiimide, molecular sieves, magnesium sulphate, and mixtures thereof. 
     III. Hydrogenation 
     Hydrogenation may be performed on the compound of formula (III) to prepare a compound of formula (IV). R 1 , R 2 , R 3 , R 5 , R 6 , and R 7  are as defined previously, may be independently selected, and may be identical or different. 
     Hydrogenation may be performed in the presence of hydrogen, a hydrogenation catalyst, and/or a solvent. The hydrogenation catalyst may be selected from the group consisting of Raney nickel, nickel, palladium, Lindlar&#39;s catalyst, cobalt, copper chromite, platinum, platinum oxide, rhenium, tin(II) chloride, titanium(III) chloride, zinc, samarium, iron and mixtures thereof. The hydrogen pressure may be in a range from about atmospheric pressure to about 2,000 psig, alternatively from about 50 psig to about 60 psig. 
     The solvent may be selected from the group consisting of water, petroleum ether, pentane, acetic acid, cyclopentane, hexane, cyclohexane, benzene, toluene, 1,4-dioxane, chloroform, diethyl ether, dichloromethane, tetrahydrofuran, methyl-tetrahydrofuran, ethyl acetate, acetone, dimethylformamide, acetonitrile, dimethyl sulfoxide, n-butanol, isopropanol, n-propanol, ethanol, methanol. and mixtures thereof. In an embodiment, the solvent may be ethyl acetate. 
     In an embodiment, the compound of formula (IV) may be transformed into the salt of formula (V) in the presence of mHZ and a solvent. R 1 , R 2 , R 3 , R 5 , R 6 , and R 7  are as defined previously, may be independently selected, and may be identical or different. 
     
       
                 
         
             
             
         
      
     
     HZ is an acid having an acid proton “H.” “Z” represents the rest of the molecule. For example if HZ=HCl, then Z=Cl. The symbol “m” is the number of moles of the acid. HZ may be selected from the group consisting of D,L-malic acid, L-malic acid, D-malic acid, hydrochloric acid, hydrobromic acid, citric acid, acetic acid, lactic acid, succinic acid, tartaric acid, sulfuric acid, and mixtures thereof; and m may be ½, 1, 3/2, or 2. 
     Protecting Groups 
     In an embodiment, a protecting group may be used when performing the above process. Protecting groups are widely used in chemistry and one skilled in the art would determine the appropriate step during the process to remove the protecting group in order to reach compounds of formula (IV). General explanations and uses of protecting groups are described in “Greene&#39;s Protective Groups in Organic Synthesis” by Peter G. M. Wuts, Theodora W. Greene, Wiley-Interscience; 4th edition (Oct. 30, 2006) and in “Protecting Groups” by Philip J. Kocienski, Thieme, Stuttgart; Auflage: 3rd Revised edition (Feb. 14, 2005). 
     IV. Synthesis of 2-Methoxymethyl-1,4-Benzenediamine 
     Compounds of formula (IV) include 2-methoxymethyl-1,4-benzenediamine (IV-a). The process described above can be utilized to synthesize 2-methoxymethyl-1,4-benzenediamine (IV-a). The process may comprise: 
     a) reducing 5-nitroisatoic anhydride (I-a) to prepare 2-amino-5-nitrobenzyl alcohol (II-a); 
     b) performing the etherification of 2-amino-5-nitrobenzyl alcohol (II-a) to prepare 2-methoxymethyl-4-nitro aniline (III-a); and 
     c) hydrogenating 2-methoxymethyl-4-nitroaniline (III-a) to prepare 2-methoxymethyl-1,4-benzenediamine (IV-a). 
    
    
     
       
                 
         
             
             
         
      
     
     EXAMPLES 
     The following examples illustrate the present invention: 
     Example 1 
     1. Synthesis of 5-Nitroisatoic Anhydride (I-a) 
     Isatoic Anhydride (25.0 g, 153.25 mmol) is suspended in acetic acid (50 mL) with efficient stirring. The reaction vessel is placed in a pre-heated oil bath at 40° C. and red fuming nitric acid (99.5%, 75 mL, 1.67 mol) is added over 35 minutes (Caution: Exothermic). The reaction mixture is stirred for an additional 4 hours at 38-44° C., then cooled to 20° C. using an ice bath. The reaction mixture is poured on ice (400 mL). After the ice melts, the yellow solid is isolated by vacuum filtration and washed with cold water (5×100 mL). The yellow solid is dried under high vacuum to constant weight at 60-70° C. affording 27.92 g (87%) of product;  1 H-NMR (300 MHz, DMSO-d 6 ); δ12.33 (s, 1H), 8.58 (d, J=2.5 Hz, 1H), 8.53 (dd, J=2.6 Hz, 9.0 Hz, 1H), 7.31 (d, J=8.9 Hz, 1H). 
     2. Synthesis of 2-Hydroxymethyl-4-Nitroaniline (II-a) 
     5-Nitroisatoic anhydride (4.0 g, 19.22 mmol) is suspended in ethanol (32 mL) and cooled to 0° C. using an ice bath under a nitrogen atmosphere. A solution of 2.18 g (57.66 mmol) of sodium borohydride in 16 mL of 0.1 M NaOH is added dropwise over 25 minutes while keeping the temperature at 0-18° C. using an ice bath. The reaction mixture is stirred at room temperature for 3 hours, cooled in an ice bath, and carefully quenched by the addition of 6N sulfuric acid (6.5 mL) over a period of 20 minutes (0-37° C.), followed by stirring for an additional 20 minutes at 0° C. After neutralization with 6N NaOH (10 mL), the reaction mixture is poured onto 30 mL of ice water and 10 mL of 0.1 M NaOH. The orange-yellow solid is isolated by vacuum filtration and washed with water (70 mL). The resulting solid is stirred in 0.1 N NaOH (30 mL) for 95 minutes, isolated by vacuum filtration, and washed with water (3×25 mL). The yellow solid is dried under vacuum at 60° C. to constant weight, affording 2.75 g (80%) of product;  1 H-NMR (300 MHz, DMSO-d 6 ); δ 8.05 (s, 1H), 7.90 (d, J=8.6 Hz, 1H), 6.65 (d, J=8.9 Hz, 1H), 6.45 (s, 2H), 5.32 (br s, 1H), 4.39 (d, J=4.65 Hz, 2H). 
     3. Synthesis of 2-Methoxymethyl-4-Nitroaniline (III-a) 
     2-Hydroxymethyl-4-nitroaniline (1.0 g, 5.75 mmol) is suspended in petroleum ether (10 mL). Sodium hydroxide solution (50%, 618 mg, 15.46 mmol) and benzyltriethylammonium chloride (20 mg) are added with stirring. Dimethyl sulfate (728 uL, 7.7 mmol) is added and the reaction mixture is stirred at room temperature for 16 h. Dichloromethane (50 mL) and water (25 mL) are added and the layers are separated. The organic layer is washed with saturated NaHCO 3  and evaporated affording 440 mg of 2-methoxymethyl-4-nitroaniline (Ma) in 82% purity. 
     4. Synthesis of 2-Methoxymethyl-1,4-Benzenediamine (IV-a) 
     Into a Parr hydrogenation bottle previously purged with argon, are placed a solution of 2-methoxymethyl-4-nitroaniline (5.0 g, 27.5 mmol) in ethyl acetate (50 mL) and 0.25 g of 10% palladium on carbon. The bottle is mounted on a Parr shaker and hydrogenation is carried out under 50-60 psig (64.7-74.7 psi or 446-515 kPa) of hydrogen pressure. The pressure is carefully monitored for hydrogen uptake and additional hydrogen is introduced to keep the pressure above 50 psig. The hydrogenation is carried out for 3.5 hours after which the catalyst is removed by vacuum filtration. The filtrate is concentrated to about 25 mL and toluene (25 mL) is added to precipitate the product, which is collected by vacuum filtration and dried at 60° C. under vacuum. The product yield is 4.5 g.  1 H-NMR (500 MHz, DMSO-d 6 ) δ 3.23 (s, 3H), 4.11 (s, 2H), 4.21 (s, 2H), 4.24 (s, 2H), 6.33 (dd, 1H), 6.37 (d, 1H), 6.41 (d, 1H). 
     The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.” 
     Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover all such changes and modifications that are within the scope of this invention.