PREPARATION OF 4-(ALPHA-ALKYL-ALPHA-CYANO-METHYL)-2,6-DI-SUBSTITUTED PHENOLS

Abstract: The invention deals with a process of preparation of 4-(α-alkyl-α-cyano-methyl)2,6-di-substituted phenols having the formula wherein R is hydrogen, methyl, ethyl, n-propyl or isopropyl and R₁ and R₂ are the same or different monovalent substituent selected from the group consisting of alkyl, aralkyl and cyclic alkyl radicals. These phenols are prepared by reacting a di-substituted phenol having the formula wherein R₁ and R₂ are as defined above with an aliphatic aldehyde having a single aldehyde radical selected from formaldehyde, acetaldehyde, propionaldehyde or butryal­ dehyde and an alkali metal cyanide or an alkaline earth metal cyanide in a suitable solvent. The phenols in question are useful for preparing α-alkyl-­ 4-hydroxyoxyphenyl-acetic acids.

Description: PREPARATION OF 4- (-ALKYL-oc-CYANO-METHYL ) - 2,6-DI-SUBSTITUTED PHENOLS This invention relates to a novel process for the preparation of 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenols. Further, this invention relates to 4-(-alkyl-ac-cyano- methyl)2,6-di-substituted phenols which are produced in a novel synthesis reaction and are used as intermediates in a reaction sequence in which &alpha;-alkyl-4-hydroxyphenylacetic acids are produced which in turn are used as reaction intermediates in the preparation of insecticides of m-phenoxybenzyl and ^cyano-m- phenoxybenzyl esters. Meta-phenoxybenzyl esters and r-cyano-m-phenozybenzyl esters of 2-haloalkyl (oxy-, thio-, sulfinyl-, or sulfonyl) phenyl-alkanoic acids are known insecticidal and acaricidal agents. These compounds and methods for their preparation are disclosed in Berkeihammer et. al., U.S. Pat. Nos. 4,178,460 and 4,199, 595. In both Berkeihammer et. al. U.S. Pat. Nos. 4,178,460 and 4,199,595, there is disclosed the conversion of certain &alpha;-alkyl-3(or4)-hydroxyphenylacetic acids having the formula EMI1.1 wherein R is ethyl, n-propyl or isopropyl to the corresponding < -alkyl-3(or 4)-difluoromethoxyphenylacetic acids having the formula EMI2.1 wherein R is as defined above by treatment with chlorodifluoromethane in aqueous alkali and dioxane. The ,alkyl-3(or 4)-difluoromethoxyphenylacetic acids thus formed are then treated with thionyl chloride, thionyl bromide, or the like, preferably in the presence of an aromatic solvent such as benzene or toluene, to yieldoc-alkyl(substituted phenyl)acetyl halide which is reacted with m-phenoxybenzyl alcohol or r-cyano-m-phenoxy- benzyl alcohol to yield the desired m-phenoxybenzyl ester or &alpha;-cyano-m-phenoxybenzyl ester of the 2-haloalkyl(oxy-, thio-, sulfinyl- or sulfonyl)phenylalkanoic acids which are useful insecticides. In Berkelhammer et. al., U.S. Pat. Nos. 4,178,460 and 4,199,595, the < -alkyl-3(or 4)-hydroxyphenylacetic acid intermediate is prepared by reacting the appropriate &alpha;-alkyl- 3(or 4)-methoxyphenylacetonitrile with hydrobromic acid. A new process for the synthesis of oc-alkyl-4-hydroxyphenylacetic acids now has been discovered in which these materials can be prepared in a simple and straightforward manner. In this new process, 4-(&alpha;-alkyl-&alpha;-cyano-methyl)-2,6-di-substituted phenols are produced in a novel synthesis reaction and are used as intermediates in a reaction sequence in which < -alkyl-4- hydroxyphenylacetic acids are likewise produced and used as reaction intermediates. Methods are known for preparing 4- W-alkyl-Z-cyano- methyl)2,6-di-substituted phenols. For example, the preparation of 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenol by reacting &alpha;-alkyl-4-hydroxy-3,5-di-tertiary-butylbenzyl halides with sodium cyanide is reported by A.A. Volod'kin et. al., Iz. Akad. Nauk. SSSR. Ser. Khim, 1966, 1031. Also, the preparation of 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenol by the electrochemical reduction of the corresponding 2,6-di-substituted methylenequinones is reported by L.I. Kudinova, et. al., Iz. Akad. Nauk. SSSR. Ser. Khim., 1978, 1313. The synthesis of o- and p-hydroxy substituted phenylacetonitriles also is known and is reported in the literature. See, for example, Journal of Organic Chemistry, Vol. 41, No. 14, 2502 (1976). This invention thus involves in one embodiment the discovery that 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenol can be readily prepared in good yield with high selectivity by reacting a 2-6-di-substituted phenol with an aliphatic aldehyde selected from formaldehyde, acetaldehyde, propionaldehyde or butyraldehyde and an alkali metal cyanide or an alkaline earth metal cyanide in a suitable reaction solvent to form the corresponding 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenol. In another embodiment of this invention,oc-alkyl-4- hydroxyphenylacetic acid is produced by (1) forming a 4-(Qc-alkyl- oC-cyano-methyl)2,6-di-substituted phenol in the above manner, (2) dealkylating the substituent groups ortho to the hydroxyl group from the 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenol to produce a reaction product containing a substantial amount of the corresponding 4- -alkyl-r-cyano-methyl)- phenol and (3) thereafter converting the 4-(X-alkyl-X-cyano-methyl)-phenol to the corresponding -alkyl-4-hydroxyphenylacetic acid by hydrolysis. The phenols which may be used as starting materials in the process of the invention are phenols having the general formula EMI4.1 wherein each R is the same or different monovalent substituent selected from the group consisting of alkyl, aralkyl and cyclic alkyl radicals. These phenols are reacted in a liquid phase with an aldehyde selected from formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde or isobutyraldehyde and an alkali metal or an alkaline earth metal cyanide. Typical examples of alkyl, aralkyl and cyclic alkyl radicals which R1 and R2 may be include any of the above radicals having any number of carbon atoms as long as these substituents do not interfere either with the formation of the desired 4-C- alkyl-Z-cyano-methyl)2,6-di-substituted phenol or with the subsequent dealkylation of the 4-( < -alkyl- < -cyano-methyl)2,6-disubstituted phenol to produce the corresponding 4-(Z-alkyl-Z- cyano-methyl) phenol. These may include, for example, from 1 to 40 or more carbon atoms and the alkyl radicals may include primary, secondary or tertiary alkyl groups and cycloalkyl groups. Since the most readily available of the substituted phenols are those phenols having substituents of from 1 to about 8 carbon atoms they are preferred, but the invention is not limited thereto. Examples of typical substituents include methyl, ethyl, propyl, isopropyl, the isomeric butyl radicals (i.e., n-butyl, isobutyl, cyclobutyl, t-butyl, etc.), the isomeric amyl radicals, the isomeric hexyl radicals, the isomeric decyl radicals, the isomeric hexadecyl radicals, the isomeric eicosyl radicals, the isomeric tricosyl radicals, the isomeric triacontyl radicals, etc. The alkyl radicals may be substituted with aryl, preferably monocyclic aryl radicals, or cycloalkyl radicals, for example, benzyl, phenylethyl, cyclohexylethyl, naphthylethyl, etc, Examples of aryl radicals are phenyl, tolyl, xylyl, biphenylyl, naphthyl, methylnaphthyl, ethylphenyl, cyclohexophenyl, etc. Because the phenols in which the R substituents are methyl, ethyl, propyl, butyl, sec-butyl, isopropyl, t-butyl, amyl, secamyl, t-amyl, hexyl, heptyl, octyl, etc., or phenyl are either readily available commercially or easily made and are ideally suited for the process, the most preferred substituents are where R1 and R2 are a lower alkyl group (i.e., from 1 to about 8 carbon atoms) or phenyl. Examples of phenols having the R substituents groups noted above which are preferred starting materials include 2,6-di- methylphenol, 2,6-di-sec-butylphenol, 2,6-diisopropylphenol, 2,6-di-sec-octylphenol, 2,6-di-(ocmethylbenzyl)phenol, 2-amyl-6methyl phenol, 2,6-dibenzylphenol, 2-methyl-6-benzylphenol and the like. A particularly preferred phenol reactant for use in the practice of the process is 2,6-di-tert-butylphenol. Substituent R groups other than those previously listed such as aryl, chlorine, bromine, fluorine, nitro groups, and the like may be present at the 2- and 6- positions in the aromatic phenol compound providing they do not adversely affect the formation of the 4-( -alkyl-e-cyano-methyl)2,6-di-substituted phenol or the subsequent dealkylation of the condensation reaction product to the corresponding 4-(Z-alkyl-Z-cyano-methyl)phenol. The aldehyde reactant used in the process is an aldehyde having a single aldehyde radical and is selected from either formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde or iso-butyraldehyde. The alkali earth and alkaline earth metal cyanide reactants used in the present process may include sodium cyanide, potassium cyanide, lithium cyanide, magnesium cyanide and calcium cyanide. Ammonium cyanide also may be used in the practice of the process as well as hydrogen cyanide. Sodium cyanide is a preferred cyanide reactant. The reaction is carried out in the liquid phase which is provided by using a solvent which is inert under the reaction conditions. That is, the reaction is carried out in the presence of a solvent which does not enter into the reaction. Preferred solvents are aprotic solvents which include ethers such as di-ethyl ether, dibutyl ether, l-ethoxyhexane, tetrahydrofuran, 1,4-dioxane, 1,3-dioxolane, diglyme, 1,2-diethoxyethane and tertiary amines such as pyridine, N-ethylpiperidine, triethylamine, tributylamine, N,N-diphenyl-N-methyl amine, N,N-dimethylalanine, etc. Especially preferred solvents are dipolar aprotic solvents such as dimethyl sulfoxide, N,N-dimethylformamide, N,N-dimethylacetamide, dimethyl sulfone, tetramethylene sulfone, N-methylpyrrolidinone, acetonitrile and like materials. Other solvents which are inert under the reaction conditions may be used: for example, low boiling hydrocarbons, halogenated hydrocarbons, examples of which are benzene, toluene, tetrachloroethane, the chlorinated benzenes, the chlorinated toluenes, etc. Additionally, lower alkanols having up to about 6 carbon atoms also may be used. These include methanol, ethanol, n-propanol, isopropyl alcohol, n-butanol, sec-butyl alcohol, tert-butyl alcohol, n-pentanol, isopentyl alcohol, n-hexanol and isohexyl alcohol. In addition, a small amount of water may be added to the reaction mixture to facilitate the solubilization of the cyanide-containing reactant in the mixture. The reaction is readily conducted by placing the 2,6-disubstituted phenol and the other reaction mixture components in a reaction vessel having agitation means. The process is preferably conducted in a substantially anhydrous reaction system, and accordingly, the components of the reaction system should be brought together and maintained under a substantially dry, inert atmosphere. Thus, while it is possible to conduct this process in the presence of air or moisture, as when water is added to the reaction mixture, it is desirable to maintain the reaction system under an atmosphere of dry nitrogen or the like. The mode of addition is not particularly critical. Accordingly, it is convenient to add the phenol reactant to a mixture of the other materials, add the aldehyde reactant to a mixture of the other materials, add the cyanide reactant to a mixture of the other materials, introduce all ingredients simultaneously into the reaction zone or the like. The process should be carried out for a time sufficient to convert substantially all of the phenol reactant to the corresponding 4-(Z-alkyl-g-cyano-methyl)2,6-di-substituted phenol intermediate. In general, the length of time for optimum yield depends primarily on the reaction temperature and the particular solvent used in the reaction. However, reaction ordinarily proceeds very rapidly and thus, long reaction times are not required. The reaction can be completed in the matter of minutes or at most a few hours at the reaction conditions. Although the reaction will proceed at a very slow rate at ambient temperatures, it is convenient to conduct the reaction at an elevated temperature of at least about 50to. up to the decomposition temperature of any of the reactants or the products. Ambient atmospheric pressure can be used or pressures lower or higher than ambient pressure can be used. However, there is no advantage to using less than ambient pressure. Higher than ambient pressure conditions are usually used if temperatures higher than the boiling point at atmospheric conditions of the reaction mixture are being used. However, by proper choice of the solvent to form the liquid phase desired, temperatures can be reached within the range of about 50"C. up to the reflux temperature of the reaction mixture at ambient atmospheric conditions which give a suitable reaction rate. Conversion of the 2,6-di-substituted phenol reactant to the corresponding 4-(4-alkyl- rcyano-methyl)2,6-di-substituted phenol in accordance with the practice of the invention results in substantially very little by-product formation, such as unreacted phenol, 4-(Z-alkenyl-Z-methyl)2,6-di-substituted phenol and bis-(3,5-di-t-butyl-4-hydroxyphenyl )alkylmethane. Recovery of the product is achieved by conventional means such as evaporation and water wash or extraction with a suitable organic solvent. For best results, it is desirable to employ an excess of both the aldehyde and cyanide reactants relative to the 2,6-disubstituted phenol reactant. Normally, the reaction system will contain at least one molar equivalent of aldehyde and one molar equivalent of cyanide per mole of phenol reactant and preferably the molar ratio of the aldehyde and the cyanide to the phenol is 2 or more. In general, any of the various dealkylation procedures using conditions and catalysts known in the art for causing dealkylation may be used in removing the substituent groups ortho to the hydroxyl group from the 4-( -alkyl-Z-cyano-methyl)- 2,6-di-substituted phenol to produce a reaction product containing a substantial amount of the corresponding 4-(4-alkyl-Krcyano- methyl)phenol intermediate providing they do not interfere with the course of the reaction. Preferably, dealkylation is achieved in high yield at elevated temperatures using an aluminum phenoxide or a Lewis acid catalyst in the presence of an aromatic or substituted aromatic compound. The conditions used for such dealkylations are well known and are reported in the literature. See, for example, Journal of Organic Chemistry, Vol. 34, 1160 (1969) and references cited therein, all disclosures of which are incorporated herein by reference. The dealkylation process most conveniently employed comprises heating the 2,6-di-substituted phenol at an elevated temperature below the decomposition temperature of the desired 4-(Z-alkyl-X-cyano-methyl)phenol intermediate product, such as from about 60"C. to 2500C. in the presence of a dealkylation catalyst and an aromatic hydrocarbon or a substituted aromatic hydrocarbon, such as, for example, benzene, toluene, xylene and the like. Although it is not a requirement of the dealkylation process, the reaction can be carried out under an inert, nonreactive atmosphere, such as nitrogen, if desired. In the reaction, the aromatic compound serves both as a solvent for the reaction and as an acceptor for the sbstituent groups ortho to the hydroxyl group in the 4-(-alkyl-cyano- methyl)2,6-di-substituted phenol reactants which are dealkylated in a transalkylation process. Dealkylation results in the formation of substituted aromatic by-products, such as, for example, a mixture of ortho- and para- tertiary-butyl toluene when toluene is employed as the aromatic compound in the reaction from which the desired 4-(s-alkyl-r-cyano-methyl)phenol intermediate product can be separate and recovered using well-known techniques such as distillation, fractional distillation, crystallization or extraction techniques, etc. It is not necessary, however, to first recover the desired intermediate phenol product from the reaction mixture prior to subsequent hydrolysis of the intermediate to the corresponding acid. For best results, it is desirable to employ an excess of aromatic or substituted aromatic compound relative to the di-substituted phenol reactant. Normally, the reaction system will contain at least 2 molar equivalents of aromatic reactant per mole of alkylated phenol reactant and preferably the molar ratio of the aromatic reactant to the alkylated phenol reactant is more than 2. Aromatic hydrocarbons or substituted aromatic hydrocarbons which may be used in the dealkylation reaction include benzene, toluene, ethylbenzene, xylene, trimethylbenzene, tetrahydronaphthylene isobutylbenzene, phenols (e.g., phenol, cresol, o-isopropylphenol, 4-hydroxyanisole (mono-, di-, and tribromophenol, etc.), halobenzenes (e.g., mono-, di-, and triflurobenzenes, chlorobenzenes, bromobenzenes, chlorobromobenzenes), aromatic ethers (e.g., anisole, diphenylether, etc.), and the like. Dealkylation of the substituted phenol in accordance with the invention is conducted, for example, by charging to a suitable reaction vessel the substituted phenol of choice, the solvent and the dealkylation catalyst, optionally under a blanket of nitrogen, and then heating to a temperature below the decomposition temperature of the desired 4-( < -alkyl-Z-cyano-methyl)- phenol intermediate product, but high enough to effect dealkylation of the substituted phenol. As pointed out hereinabove, the dealkylation reaction can be conducted over a wide temperature range below the decomposition temperature of the desired dealkylated product. While the reaction will proceed at ambient temperatures at a very slow rate, in general, dealkylation is carried out at a temperature range of from about 60"C. to about 2500C. and will vary within this range depending upon the solvent of choice. In general, dealkylation is carried out at atmospheric pressure although pressures above atmospheric pressure can be used if desired. The dealkylation reaction should be carried out for a time sufficient to convert substantially all of the substituted phenol starting material to the desired dealkylated phenol intermediate product. The length of time required to obtain substantially complete dealkylation of the substituted phenol will depend primarily upon the operating temperature and the particular substituted phenol used in the reaction. A wide variety of catalysts known in the art for causing dealkylation may be used in the practice of the process. For example, dealkylation catalysts such as phenoxy derivatives of such elements as aluminum, magnesium, iron, zinc, phosphorus, zirconium, titanium, bismuth, tin, etc., where the phenoxy moiety may be the phenoxy radical itself, the cresoxy radical, the xyloxy radical, etc. Also, Lewis acids, preferably aluminum chloride, zinc chloride, etc., which are predominantly paradirecting catalysts when used as alkylation catalysts may be used for the dealkylation reaction. A most preferred dealkylation catalyst is aluminum chloride. The amount of catalyst used is an amount sufficient to promote dealkylation of the substituted phenol reactant. While an amount as little as 0.1 mole percent up to amounts of about 20 mole percent based on the weight of the di-substituted phenol reactant can be used, for best results it is desirable to employ an even greater amount of catalyst up to, for example, 120 mole percent. A variety of well-known hydrolysis procedures can be used for converting the 4-( -alkyl-z-cyano-methyl)phenol to the corresponding < -alkyl-4-hydroxyphenylacetic acid. The hydrolysis can be performed in the presence of water and a suitable polar organic solvent such as low-molecular weight alcohols (e.g., methanol or ethanol), 1,4-dioxane, acetone, low-molecular weight carboxylic acids (e.g., acetic acid or propionic acid), N-methyl pyrrolidinone, dimethylsulfoxide or the like. While hydrolysis may be performed in a neutral system or an acidic system, basic hydrolysis is preferred. The reagent of choice is aqueous sodium hydroxide. Reaction temperatures will usually fall between 0 C. and the boiling point of the reaction medium. However, temperatures above the boiling point of the reaction medium can be utilized at elevated pressures to increase the rate of hydrolysis, if desired. These and other details of the hydrolysis reaction can be found in the literature - see, for example, March, Advanced Organic Chemistry, (McGraw-Hill, New York, 1977), pp. 809-10 and references cited therein, all disclosures of which are incorporated herein by reference. The practice of this invention will be still further apparent by the following illustrative examples. EXAMPLE 1 Preparation of (a-Cyano-Methyl )2,6-Di- Tertiary-Butyl Phenol 2,6-di-tertiary-butyl phenol (2.06 g.; 10 mmoles), sodium cyanide (1.47 g; 30 mmoles), paraformaldehyde (0.72 g.; 24 mmoles) and dimethylformamide (8 ml.) were charged to à 180 ml. Fischer Porter tube and pressurized to 8.61 x 105 Pa of manometric pressure (125 psig) with nitrogen and heated to 1400C. (oil bath temperature) for 9 hours. The resultant reaction mixture was allowed to cool to ambient temperature and the mixture was added to water, extracted with diethyl ether, the ether layer was dried (MgSO4), filtered and the ether removed in a rotary evaporator to give a 56.4% yield of 4-(Z-cyano-methyl)2,6-di-tertiary-butyl phenol as characterized by VPC. EXAMPLE 2 Preparation of 4-(4-Isopropyl-t-Cyano- Methyl)2,6-Di-Tertiary-Butyl Phenol. 2,6-di-tertiary-butyl phenol (21.42 g.; 103.8 mmoles), sodium cyanide (15.29 g.; 312 mmoles), isobutyraldehyde (17.99 g.; 250 mmoles) and dimethyl formamide (83 ml.) were charged to a 180 ml. Fischer-Porter tube and pressurized to 8.61 x 105 Pa of manometric pressure (125 psig) with nitrogen and heated to 140 C. (oil bath temperature) for 9 hours. The resultant reaction mixture was allowed to cool to ambient temperature and the mixture was poured into 450 ml. of water, and extracted with diethyl ether. The ether layer was dried (MgSO4), filtered and the ether removed in a rotary evaporator. The residue was dissolved in #30 ml. of ethanol and precipitated by the slow addition of ice to yield 27.05 g. (90.7%) of 4-(&alpha;-isopropyl-&alpha;- cyano-methyl)2,6-di-tertiary-butyl phenol. In a manner similar to Example 2 above, a number of experiments were carried out varying the temperature, reaction time, pressure, and ratio of reactants. The results were analyzed by vapor phase chromotography with internal standards and are shown in Table 1. TABLE I Preparation of 4-(&alpha;-Isopropyl-&alpha;-Cyano-Methyl)2,6-Di-Tertiary-Butyl Phenol 2,6-di-tert- Isobutyr- Manometric Experiment butyl phenol aldehyde NaCN Solvent Temp. Pressure Time No. (mmoles) (mmoles) (mmoles) (ml.) ( C.) (105 Pa) (hr.) % Yield 3 10 24 30 DMF-8 ml. 95 8.61 7 58.5 4 10 24 30 EtOH-8 ml. 140 8.61 7 47.0 5 10 24 30 DMF-8 ml. 135 8.61 7 78 6 80 192 240 DMF-64ml. 140 8.61 9 86 7 10 24 30 toluene- 135 8.61 5 trace 8 ml. 8 103.8 207.6 207.6 DMF-83 ml. 140 8.61 9 94.5 9 103.8 250 114.1 DMF-83 ml. 140 8.61 9 54.0 10 103.8 200 119.4 DMF-83 ml. 140 8.61 9 84.0 11 10 24 30 isopropyl 95 8.61 7 14.2 alc.-8 ml. 12 10 12 30 EtOH-8 ml. 95 8.61 2.5 66.4 TABLE I (Continued) Preparation of 4-(&alpha;-Isopropyl-&alpha;-Cyano-Methyl)2,6-Di-Tertiary-Butyl Phenol 2,6-di-tert- Isobutyr- Manometric Experiment butyl phenol aldehyde NaCN Solvent Temp. Pressure Time No. (mmoles) (mmoles) (mmoles) (ml.) ( C.) (105 Pa) (hr.) % Yield 13 103 250 207 DMF-83 ml. 140 6.89 9 92 14 103 250 207 DMF-83 ml./ 140 6.89 4 75 5% H2O 15 100 200 125 DMF-83 ml./ 140 6.89 9 71 5% H2O 16 103.8 250 207 DMF-83 ml./ 140 5.51 9 83.1 5% H2O 17 103.8 250 207.6 MeOH-83 ml. 140 7.24 5.5 91.7 18 103.8 175 155.7 MeOH-83 ml. 140 6.89 3 87 19 100 175 150 MeOH-85 ml. 140 5.51 3 95 20 100 150 125 MeOH-85 ml. 140 5.51 3 82.4 EXAMPLE 21 Preparation of 4-( -Isopropyl-t- Cyano-Methyl) Phenol A solution of 4-(&alpha;-isopropyl-&alpha; ;-cyano-methyl)2,6-di- tertiary-butyl phenol (30.37 g.; 106.2 mmoles) and 150 ml. toluene was charged to a reactor equipped with a stirrer, thermometer and reflux condenser. Aluminum chloride (17 g.; 127.5 mmoles) was added to the reactor vessel in 3 or 4 increments while vigorous agitation was maintained. An exotherm was observed which raised the reaction temperature by ¯2C C. After the aluminum chloride addition was complete, the solution was heated to 950C. for 5 hours under nitrogen. The reaction mixture was then cooled to ambient temperature, washed twice with water to remove aluminum salts formed during the reaction and the solvent and tertiary-butyl-toluene by-product was removed under reduced pressure to yield 20.1 g. (95.3%) of product determined by VPC (internal standard) as 4-(Z-isopropyl-$-cyano-methyl)phenol. In a manner similar to Example 21 above, a number of experiments were carried out varying the temperature, reaction time, ratio of reactants and catalysts. The results were analyzed by vapor phase chromotography with internal standards (unless otherwise indicated) and are shown in Table II. TABLE II Preparation of 4-(&alpha;-Isopropyl-&alpha;-Cyano-Methyl)Phenol 4-(&alpha;-isopropyl &alpha;-cyano-2,6 di-tertiary Experiment butyl)phenol Catalyst Solvent Temp. Time No. (g.) (g.) (ml.) ( C.) (hr.) % Yield 22 4.80 DEAC* - 0.22 - 160 3 175 2 36.3 - External Standard 23 4.80 DEAC - 0.22 - 180-185 6 56.4 - External Standard 24 5.92 DEAC - 0.24 - 195-200 6 82.5 - External Standard 25 6.5 AlCl3 - 0.48 - 175-180 4 64.8 - External Standard 26 6.5 AlCl3 - 0.47 - 195-200 5 67.6 - External Standard 27 7.0 DEAC - 0.20 - 195-200 5 50.4 - External Standard 28 6.8 DEAC - 0.48 - 200 5 55.0 - External Standard 29 4.0 TEA** - 0.29 - 180 5 trace in toluene 30 4.26 DEAC - 0.29 - 180 5 63.2 31 3.75 AlCl3 - 0.30 - 180 5 68.0 TABLE II (Continued) Preparation of 4-(&alpha;-Isopropyl-&alpha;-Cyano-Methyl)Phenol 4-(&alpha; ;-isopropyl &alpha;-cyano-2,6 di-tertiary Experiment butyl)phenol Catalyst Solvent Temp. Time No. (g.) (g.) (ml.) ( C.) (hr.) % Yield 32 5.04 DEAC - 0.30 - 195-200 5 mostly in phenol starting material 33 7.65 AlCl3 - 1.50 - 170 5 55.9 34 6.01 AlCl3 - 0.69 - 170 5 63.8 35 6.01 AlCl3 - 0.69 toluene - 4.5 140 5 14.7 36 4.54 DEAC - 0.20 - 170 5 38.4 37 7.67 AlCl3 - 0.60 - 170-175 5 45.4 38 6.86 AlCl3 - 4.00 toluene - 50 80-85 5 91.2 39 6.86 AlCl3 - 4.00 toluene - 50 100-105 5 94.2 40 8.11 AlCl3 - 4.45 toluene - 60 90 5 92.3*** 41 24 AlCl3 - 11.40 toluene - 100 95-100 4 93.8 TABLE II (Continued) Preparation of 4-(&alpha;-Isopropyl-&alpha;-Cyano-Methyl)Phenol 4-(&alpha;-isopropyl &alpha;-cyano-2,6 di-tertiary Experiment butyl)phenol Catalyst Solvent Temp. Time No. (g.) (g.) (ml.) ( C.) (hr.) % Yield 42 10 AlCl3 - 5.60 toluene - 50 95 5 88.1 43 10 AlCl3 - 5.60 toluene - 50 + 95 5 81.8 H2O (.03 g.) 44 8.9 AlCl3 - 4.96 toluene - 45 90 5 100 45 9.3 AlCl3 - 5.20 + toluene - 50 90 6 85.1 CH3NO2**** - 2.38 46 12.87 AlCl3 - 7.20 toluene - 65 90-95 4 90.9 47 28.6 AlCl3 - 19.34 toluene - 117 95 4 84.6 * DEAC = diethyl aluminium chloride ** triethyl aluminium *** isolated yield **** p-nitromethane EXAMPLE 48 Preparation of -I sopropyl -4-Hydroxyphenyl acetic Acid 4-(&alpha;-isopropyl-&alpha;-cyano-methyl)phenol (12.88 g.; 74 mmoles) was charged to a 30 ml. stainless steel autoclave along with 17.76 g. NaOH and 120 ml. water. The solution was heated at 1300C. for 6 hours with vigorous stirring while maintaining a 5 pressure of between about 2.41 x 10 and 2.76 x 105 Pa of manometric pressure (35 and 40 psig). After 6 hours, the reaction vessel was cooled to ambient temperature, the reaction mixture was discharged into a separatory funnel, and the pressure vessel was washed with 30 ml. of water which was added to the reaction mixture. The resultant mixture was washed with methylene chloride to remove residual tert-butyl toluene, cooled to 100C. and acidified to a pH between 2 and 3 with concentrated hydrochloric acid. The product was separated by filtration, washed with water and dried under pressure (20 mm. Hg/600C.) to give 14.29 g. (96.0% yield) of 4-isopropyl-4-hydroxyphenyl acetic acid as characterized by gas chromotography. In a manner similar to Example 48 above, a number of experiments were carried out varying the temperature, reaction time, pressure and ratio of reactants. The results were analyzed by HPLC using external standards and are shown in Table III. TABLE III Preparation of &alpha;-Isopropyl-4-Hydroxyphenylacetic Acid 4-(&alpha;-isopropyl &alpha;-cyano-methyl)- Manometric Experiment phenol Catalyst Solvent Temp. Pressure Time No. (g.) (g.) (ml.) ( C.) (105 Pa) (hr.) % Yield 49 1.152 NaOH - 1.39 H2O - 10 reflux ambient 17 82.3 50 1.29 NaOH - 1.48 H2O - 10 reflux ambient 17 100 51 9.77 NaOH - 13.48 H2O - 100 130 2.41 6 85 52 10.89 NaOH - 15.6 H2O - 100 130 2.41 6 86.6 53 14.27 NaOH - 19.7 H2O - 110 130 2.41 5 87.5 Having disclosed the process of the present invention, one skilled in the art can readily envision various modifications and changes which are nevertheless within the scope of the invention. Therefore, it is desired that the process of this invention be limited only by the lawful scope of the appended claims.

Claims: CLAIMS: 1. A process for the prepaThation of 4-( < -alkyl-oc-cyano methyl)2,6-di-substituted phenol having the formula EMI23.1 wherein R is hydrogen, methyl, ethyl, n-propyl or isopropyl and Rl and R2 are the same or different monovalent substituent selected from the group consisting of alkyl, aralkyl and cyclic alkyl radicals which comprises reacting a di-substituted phenol having the formula EMI23.2 wherein Rl and R2 are as defined above with an aliphatic aldehyde selected from formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde or isobutyraldehyde and an alkali metal or an alkaline earth metal cyanide in a suitable reaction solvent to form said 4-(&alpha;-alkyl-&alpha;-cyano-methyl)2,6-di-substituted phenol. 2. The process of Claim 1 wherein R1 and R2 are the same or different monovalent substituent selected from the group consisting of alkyl, aralkyl and cyclic alkyl radicals containing from 1 to about 40 carbon atoms. 3. The process of Claim 1 wherein the alkali metal cyanide is sodium cyanide. 4. The process of Claim 1 wherein the solvent is a do polar aprotic solvent. 5. The process of Claim 4 wherein the solvent is selected from the group consisting of dimethyl sulfoxide, N,Ndimethylformamide, N,N-dimethylacetamide, dimethyl sulfone, tetramethylene sulfone, N-methylpyrrolidinone and acetonitrile. 6. The process of Claim 4 wherein the solvent is selected from the group consisting of a lower alkanol having from 1 to about 6 carbon atoms. 7. The process of Claim 1 wherein the reaction is carried out at an elevated temperature. 8. The process of Claim 7 wherein the process is carried out at a temperature of at least 500C. 9. The use of the 4-(-alkyl-oc-cyano-methyl)2,6-di- substituted phenols as defined in Claim 1 for preparing s-alkyl- 4-hydroxyphenyl-acetic acid having the formula EMI24.1 (i) dealkylating the substituent groups ortho to the hydroxyl group from said 4-(4-alkyl- < -cyano-methyl)2,6-di-substituted phenol to form the corresponding 4(ocralkyl--cyano-methyl)- phenol, and (ii) converting said 4-(X-alkyl-Z-cyano-methyl)- phenol by hydrolysis to the corresponding o(-alkyl-4-hydroxyphenylacetic acid. 10. The use in Claim 9 wherein dealkylation is effected by heating said 4-(i-alkyl-z -cyano-methyl)2,6-di-substituted phenol at an elevated temperature in the presence of a dealkylation catalyst and an aromatic hydrocarbon, preferably said dealkylation catalyst being selected from a phenoxy derivative of aluminum, magnesium, iron, zinc, phosphorus, zirconium, titanium, bismuth or tin and said aromatic hydrocarbon being selected from the group consisting of benzene, toluene, ethylbenzene, xylene, trimethyl benzene, tetrahydronaphthylene, isobutylbenzene, phenol, cresol, o-isopropylphenol, 4-hydroxyanisole, halobenzenes and aromatic ethers.

Inventors: EVERLY, CHARLES R., ROBINSON, GENE C.
Applicants: ETHYL CORPORATION
Application year: 1983
Main classification: C07C120
IPC codes: C07C255, C07C67, C07C253, C07C51