PREPARATION OF AROMATIC CARBONYL COMPOUNDS

Abstract: Aromatic carbonyl compounds, in particular arylene ether ketones, are prepared by reacting an appropriate reagent sys­ tem in the presence of free Lewis acid and a complex between a Lewis acid; for example, aluminum trichloride, and a Lewis base, for example, N,N-dimethylformamide, and, optionally, a diluent, such as methylene chloride. The process is particularly advantageous for the preparation of substantially or all para­ linked arylene ether ketones as the presence of the Lewis acid/­ Lewis base complex markedly reduces alkylation and ensures the substantial absence of ortho substitution.

Description: This invention relates to the preparation of aryl carbonyl compounds, and in particular to para substituted aryl carbonyl compounds. Aryl carbonyl compounds are useful in the preparation of poly(arylene ether ketones). In the preparation of these polymers it is essential that the monomers used be in a highly pure state to prevent undesirable side reactions. Furthermore, the polymers obtained should be stable enough to survive extrusion without undue deleterious effects on their physical properties. The substitution pattern of the monomers used can control the properties of the polymers synthesised, and it is generally recognised that the highest melting points and glass-rubber transition temperatures are obtained with all para linked polymers. Mixtures of substitution isomers are used when polymers of reduced crystallinity or lowered Tg are required, but the all para substituted polymers are most preferred. When mixtures of monomers are used, known ratios of the different isomers are needed, necessitating the use of pure starting materials. The present invention relates to a process for the preparation of aryl carbonyl compounds that improves outstandingly the degree of purity of the product and/or the degree of para substitution. Aryl carbonyl compounds are also useful as chemicals and chemical intermediates, for example, in the pharmaceutical and agricultural chemicals, dyestuffs and general chemical additives area. Here too it is frequently found that the all para substituted carbonyl compounds are the most useful. Avoidance of concurrent formation of other isomeric by products in the synthesis of such compounds is always beneficial economically and in some instances is essential because some isomeric compounds which are different to remove have been found to be toxic or even carcinogenic. A known method of producing aryl carbonyl compounds by Friedel Crafts condensation using a Lewis acid catalyst is described in GB-A-2103604. In accordance with the present invention, the Friedel-Crafts condensation of appropriate reactants is controlled to suppress side reaction including alkylation and/or ortho acylation by the addition of a controlling agent, such as a Lewis base, to the reaction medium. Thus the invention provides a process for the preparation of a para-substituted aromatic carbonyl compound which is not an oligomer or polymer, by a Friedel Crafts condensation of (1) an aromatic compound containing at least one activated hydrogen atom with (2) phosgene or an acyl compound in the presence of (3) a Lewis acid, characterised in that any aromatic ring which contains an activated hydrogen atom also contains less than 2 alkoxy groups, and the condensation is controlled by the addition of at least 0.1 equivalents of Lewis base per equivalent of acid, ester of acid halide groups in the reactants, plus an additional equivalent of Lewis acid per equivalent of Lewis base. One aspect of this invention provides a process for the preparation of an aromatic carbonyl compound having the formula (R) s ArDCOY, (R) s ArDCOBD(R') t , (R) s ArDCOBDCOArD(R) s or (R) s ArDCODAr(R) s wherein each s and t independently is 1, 2 or 3 and each R, Ar, B, D, Y and R' independently is as defined below, which comprises reacting a first reactant consisting of a substituted or unsubstituted aromatic compound containing at least one activated hydrogen atom of the formula (R) S ArDH with a second reactant consisting of phosgene or a mono-functional acyl compound of the general formula YCOBD(R') t or O(COBD(R') t )₂ or a di-functional acyl compound of the general formula YCOBDCOY in a reaction medium comprising: A) a Lewis acid in an amount of one equivalent per equivalent of carbonyl or other basic species in the reactants plus one equivalent per equivalent of Lewis base plus an amount effective to act as a catalyst for the reaction; B) a Lewis base in an amount of from 0.1 to 4 equivalents per equivalent of acid, ester or acid halide group in the reactants; and C) a non-protic diluent in an amount from about 20 to about 93% by weight, based on the weight of the total reaction mixture, wherein : (a) Ar is a homo or hetero-aromatic mono-, di- or tri- cyclic moiety or a fused homo-aromatic ring system containing less than 20 aromatic carbon atoms or a hetero-aromatic system containing less than 8 nitrogen atoms; (b) D is -(ZAr) n -(ZAr) m -(ZAr) p - wherein n, m, and p are each independently 0, 1, 2 or 3, provided that n + m + p is less than 4, and Z -CO- or -SO₂- when linking two Ar moieties which are both 4-phenoxyphenyl, or Z is -CO-C₆H₄-CO-, -O(CF₂) q O-, or V, provided that when n + m + p > 0 any Ar group comprising an activated hydrogen atom is also linked to a V group, where V Is a divalent radical of the formula -O-, -S-, -N=N-, -(CF₂) q -, -(CH₂) q - or -C(CH₃)₂- wherein q is 1 to 20; (c) B is independently a divalent substituted or unsubstituted aliphatic or cycloaliphatic group or Ar; (d) R and R' which may be the same or different are H, Br, Cl or F atom or a hydroxy, alkoxy, alkyl, aralkyl, unsubstituted or mono- or disubstituted amino, nitro, ester, acid, or acid halide, amide or imide group; and (e) Y represents a Br, Cl or F atom or a hydroxy or alkoxy group; subject to the proviso that any aromatic ring which contains an activated hydrogen atom also contains less than 2 alkoxy groups, and the resulting aromatic carbonyl compound contains less than 2 identical directly linked sequences containing at least one -CO- or -SO₂-group and at least one -V-group. Pendant substitutents which can be present on B or Ar groups include, for example, lower alkyl, cyano, halogen, nitro, benzoyl or any other atom or group which will not interfere with the reaction by virtue of either its chemical nature or its location in the reactant from which the B group is derived. The term "activated hydrogen atom" refers to a hydrogen atom displaceable under the electrophilic (Friedel-Crafts) reaction conditions employed in the reaction. Aromatic compounds suitable for acylation according to the process of the instant invention exhibit carbon-13 nuclear magnetic resonance (C-13 NMR) chemical shifts at the ring site where acylation is desired at least 2.1, preferably at least 2.4 and most preferably at least 2.8 parts per million (ppm) less than that exhibited by benzene. For a listing of C-13 NMR chemical shifts of monosubstituted benzenes see M. Mishima et al (Memoirs of the Faculty of Science, Kyusuu Un., Ser. C, Vol. 11 No. 1, 1978). Table 2 of this reference lists C-13 NMR chemical shifts of a variety of mono-substituted benzenes measured in solution in carbon tetrachloride. Benzene in this solvent is stated to have a chemical shift of 128.04 ppm. The aromatic compounds useful in the instant invention may, but preferably do not, form additional complexes with Lewis acid under the reaction conditions. Those skilled in the art will readily recognize that when an addition complex is formed, it should not substantially deactivate the molecule to acylation. Thus such complexes, for example, should still exhibit C-13 NMR chemical shifts which are at least 2.1 ppm less than that of benzene or sufficient uncomplexed aromatic compound is present to enable the reaction to proceed at the desired rate. Illustrative aromatic compounds of the general formulas (R) s ArDh are: toluene, ethyl benzene, fluorobenzene, anisole, ethoxy benzene, 3-chloroanisole, naphthalene, anthracene, and compounds of the formulas Illustrative mono or di-acyl compounds of the general formula YCOBD(R') t ,O(COBD(R') t )₂ or YCOBDCOY are: acetic anhydride, acetyl chloride, adipoyl dichloride, benzoyl chloride, 4-fluorobenzoyl chloride, 4-chlorobenzoyl chloride, 3-nitrobenzoyl chloride, phthaloyl chloride, pthalic anhydride, naphthoyl chloride, tetrabromophthaloyl chloride, and compounds of the following formulas wherein each V is independently as defined above, a is 0, 1 or 2 and Z is as defined above. Preferred acylating agents are phosgene, and acyl compounds such as 4-fluorobenzoic acid or acid halide, iso- or tere-phthalic acid or acid halide, naphthalene 2,6-dicarboxylic acid or acid chloride and benzophenone 4,4'-dicarboxylic acid or acid chloride. Preferred combinations of substituted aromatic compounds and acyl compounds are fluorobenzene or diplenyl ether with 4-fluorobenzoyl chloride, ethyl 4-fluorobenzoate, acetyl chloride, acetic anhydride, iso- or tere-phthaloyl chloride, 4-hydroxybenzoyl chloride and 4-(4 hydroxyphenoxy)-benzoyl chloride. In carrying out the process of this invention, equivalent amounts of the substituted aromatic compound and the aromatic acyl compound are preferably employed, although it may be advantageous in certain circumstances to use up to about a molar excess of one reactant. The term "Lewis acid" is used herein to refer to a substance which can accept an unshared electron pair from another molecule. Lewis acids which can be used in the practice of this invention include, for example, aluminium trichloride, aluminium tribromide, antimony pentachloride, antimony pentafluoride, indium trichloride, gallium trichloride, boron trichloride, boron trifluoride, zinc chloride, ferric chloride, stannic chloride, titanium tetrachloride, and molybdenum pentachloride. The use of substantially anhydrous aluminium trichloride as the Lewis acid is preferred. The amount of Lewis acid used in the practice of this invention varies depending on the particular starting materials and reaction medium selected. In all instances where the Lewis acid forms a complex with carbonyl groups or other organic species in the reactants forming a complex with Lewis acid (hereinafter called "other basic species") irreversibly under the reaction conditions, at least about one equivalent of Lewis acid per equivalent of carbonyl groups or other basic species present in the starting materials is used plus an amount effective to act as a catalyst for the acylation. Generally the catalytic amount added is from about 0.05 to about 0.3 equivalents of Lewis acid per equivalent of acid, ester or acid halide in the reaction mixture. As is well known to those skilled in the art, acids, esters and many acid anhydrides react with an excess of Lewis acids such as aluminium trichloride to yield the corresponding acid halide which then serves as the actual acylating agent. As indicated above, the Friedel-Crafts acylation reaction is controlled by the addition of a Lewis base controlling agent to achieve the desired compound substantially free of isomeric by-products. The term "Lewis base" is used herein to refer to a substance capable of donating an unshared electron pair to a Lewis acid. Thus, the Lewis base forms a complex with the Lewis acid used in the reaction medium. It has been found that Lewis bases which form a 1:1 complex having a heat of association at least about that of diphenyl ether with the Lewis acid are preferred. For example, where aluminium trichloride is the Lewis acid the Lewis base used should form a 1:1 complex having a heat of association of at least about 15 kcal/mole, preferably at least about 30 kcal/mole. While the heats of association are for a 1:1 Lewis acid/Lewis base complex consisting solely of these two components, the actual complex formed in the reaction medium need not be a 1:1 complex. A discussion on heats of association for Lewis acid/Lewis base complexes is found in J. Chem. Soc. (A), 1971, pages 3132-3135 (D.E.H. Jones et al). The Lewis base used should not be an acylating, alkylating or arylating agent nor should it be acylatable under the reaction conditions. Mixtures of two or more Lewis bases can be used if desired. The Lewis base used as a controlling agent in the practice of this invention is an additional component added to the reaction medium. This does not include basic species formed in situ during the acylation. When a Lewis base is used as a controlling agent, an additional amount of Lewis acid, generally about one equivalent per equivalent of Lewis base, is used. When aluminium chloride is used as the Lewis acid one equivalent is considered to be AlCl₃. Typical Lewis bases which can be employed include, for example, amides, amines, esters, ethers, ketones, nitriles, nitro compounds, phosphines, oxides, phosphoramides, sulfides, sulfones, sulfonamides, sulfoxides and halide salts. Examples of specific organic Lewis bases that can be used in the practice of this invention are acetone, benzophenone, cyclohexanone, methyl acetate, ethylene carbonate, N-methylformamide, acetamide, N,N-dimethylacetamide, N-methylpyrrolidone, urea, tetramethylurea, N-acetylmorpholine, dimethyl sulfoxide, N,N-dimethylformamide, diphenyl sulfone, dimethyl sulfone, N,N-dimethylmethane-sulfonamide, phosphoryl chloride, phenylphosphonyl chloride, pyridine-N-oxide, triphenylphosphine oxide, trioctylphosphine oxide, nitropropane, nitrobenzene, benzonitrile, n-butyronitrile, methyl ether, tetrahydrofuran, dimethyl sulfide, trimethylamine, N,N,N',N'-tetramethylethylenediamine, N,Ndimethyldodecylamine, imidazole, pyridine, quinoline, isoquinoline, benzimidazole, 2,2'-bipyridine, o-phenanthroline, 4-dimethylaminopyridine, and the like, In addition to covalent organic compounds, suitable Lewis bases include inorganic salts which can form complexes with Lewis acids, for example, chlorides, such as trimethylammonium chloride, tetramethylammonium chloride, sodium chloride or lithium chloride, perchlorates, trifluoromethanesulfonates and the like. Preferred Lewis bases for the practice of this invention are N-methylformamide, N,N-dimethylformamide, N,N-dimethylacetamide, 1-methyl-2-pyrrolidone, tetramethylene sulfone (also known as Sulfolane), n-butyronitrile, dimethyl sulfide, imidazole, acetone, benzophenone, trimethylamine, trimethylamine hydrochloride, tetramethylammonium chloride, pyridine-N-oxide, 1-ethylpyridinium chloride, lithium chloride, lithium bromide, sodium chloride, sodium bromide, potassium chloride, potassium bromide and mixtures thereof. The amount of Lewis base present may be up to about 4 equivalents per equivalent of acid halide groups present in the reagent system. Amounts greater than 4 equivalents could be employed, if desired. However, no additional controlling effect is usually achieved by adding larger amounts. Thus, it is preferred to use no more than about 4 equivalents and generally about 2 equivalents. At least about 0.1, preferably at least about 0.2 and most preferably at least about 0.5 equivalents of Lewis base per equivalent of acid halide groups present should be used. The particular amount of Lewis base added depends to a certain extent on the nature of the monomers present. When a Lewis base is used to control the reaction the temperature at which the reaction is conducted can be from about -50 o C to about +150 o C. It is preferred tostart the reaction at lower temperatures, for example at about -50 to about -10 o C, particularly if the reaction mixture contains highly reactive reagents. After acylation has commenced, the temperature can be raised up to about 150 o C or even higher if desired, for example, to increase the rate of reaction. It is generally preferred to carry out the reaction at temperatures in the range of between about -30 o C and +25 o C (room temperature). A non-protic diluent can also be employed, if desired. Advantageously, the diluent should dissolve the Lewis acid/Lewis base complex and the Lewis acid/acyl compound complex. It should also be relatively inert toward Friedel-Crafts reactions. Preferred diluents include, for example, methylene chloride, carbon disulfide, o-dichlorobenzene, 1,2, 4-trichlorobenzene, o-difluorobenzene, 1,2-dichloroethane, 1,1,2-trichloroethene, 1,1,2,2-tetrachloroethane, tetrachloroethene and mixtures thereof. In certain cases it may be advantageous to use an excess of the aromatic reactant, which also serves as a solvent for the reaction. If a diluent such as methylene chloride or dichloromethane is used, although we do not wish to be bound to any particular explanation it is believed that the Lewis acid/Lewis base complex reduces the tendency of the diluent to act as an alkylating agent by competing with the diluent for available Lewis acid and thereby suppressing alkylation of reactant and/or product. Alkylation of the aromatic component in the para or ortho position introduces undesirable impurities which often are difficult to remove by conventional purification methods. The diluent is preferably used in an amount from 20 to about 93% by weight, based on the weight of the total reaction mixture. It has been found that the reagent to diluent molar ratio can contribute to control of the reaction to yield the desired product. Typically the diluent is used in an amount of at least about 20%, preferably at least 30% by weight based on the weight of the reaction mixture. Typically the diluent is also used in an amount of less than 93%, preferably less than 80%, most preferably less than 60%. Use of an alkylating or acylating diluent can lead to undesired side reactions as mentioned above. When such solvents are employed, control of the reaction by techniques taught in this specification suppresses such alkylation or arylation. The result is an aryl carbonyl or sulfonyl compound of outstanding purity and/or degree of para substitution. The compound produced contains catalyst residues complexed to the carbonyl group. Decomplexation can be accomplished by treating the reaction mixture with a decomplexing base after completion of the reaction. The base can be added to the reaction medium or the reaction medium can be added to the base. The decomplexing base must be at least as basic towards the Lewis acid as the basic groups on the polymer chain. Such decomplexation preferably should be effected before isolation of the product from the reaction mixture. The following examples illustrate the process of this invention using a variety of Lewis acids, Lewis bases, diluents and reagents. It is to be understood that other reactants and reaction media within the scope of the teaching of this invention can be employed, if desired. Example 1 To an agitated mixture of lithium chloride (3.18 g., 0.075 mole) and aluminium chloride (20 g., 0.15 mole) in dichloroethane (20 ml) at -15 o C was added dropwise a mixture of 4-fluorobenzoyl chloride (8 g., 0.05 mole) and fluorobenzene (4.8 g., 0.05 mole) in dichloroethane (7 ml). The reaction mixture was removed from the water bath after one hour, stored at 0 o C for three hours then at room temperature overnight. The reaction mixture was then slowly added to 100 mls of a stirred mixture of ice and dilute aqueous hydrochloric acid, the organic phase separated and the aqueous phase was washed with two 50 ml aliquots of ether. The combined organic phases were then washed with 50 ml of dilute sodium hydroxide solution, then water, separated and dried over anhydrous magnesium sulfate. The dried solution was filtered to remove the drying agent and the solvents removed in a rotary evaporator. 4,4'-Difluorobenzophenone (10.3 g., 94.5% yield) was obtained as a white solid of melting point 106.5 -109 o C, whose purity was estimated by differential scanning calorimetry (DSC) by the reference test method described in the United States Pharmacopaeia National Formulary, XIX, pages 980 to 983 (1975) and also R. L. Blaine in the DuPont Company, Analytical Instruments Division Application Brief Number T.A.80, and also by 1H and 19F nuclear magnetic resonance (NMR). The purity by the DSC method was estimated to be 97.2% and the 1H NMR method about 95%. Example 2 (Comparison) In an experiment not using the process of the instant invention but following the teachings of traditional Fridel-Crafts chemistry, that is in the absence of lithium chloride and in the presence of aluminium chloride in an amount of 8 g., (0.06 mole), which is less than 1.5 equivalents per equivalent of 4-fluorobenzoyl chloride, the remaining ingredients being as described in example 1, the addition was commenced at 0°C and the reaction mixture maintained at room temperature overnight. After work up as described in example 1, and orange oil was obtained in low yield. 1H NMR indicated only 50% of the product was the desired 4,4'-difluorobenzophenone, the remainder being isomers, impurities and the starting materials. Example 3 Example 1 was repeated except that 20 g., (0.208 mole) fluorobenzene was used and the reaction mixture was kept at 0°C overnight. The crude yield of 4,4' difluorobenzophenone was 92.3% (m.p. 108-110°C; DSC purity 97.4 mol %, 1H NMR purity >95 mol %). 19F NMR indicated about 0.1% ortho acylation. After recrystallization from hexane the yield was 64%, the DSC purity was 99.75% and 19F NMR showed no evidence of ortho substituted (i.e., isomeric) impurities. Example 4 The procedure and materials of Example 3 were used except that 5.75 g., (0.025 mole) terephthaloyl chloride was used in place of 4 fluorobenzoyl chloride and the reaction mixture was kept at about -5 o C for three days. The crude product 1,4-bis(4-fluorobenzoyl) benzene (6.98 g., 86.7% yield, m.p. 220.5-222 o C) had a purity by 1H NMR greater than 95% and 19F NMR indicated no ortho isomers to be present. Example 5 The procedure and materials of Example 1 were used except that dimethylforamide (5.2 ml.,0.067 mol.) was used in place of lithium chloride, terephthaloyl chloride (5.75 g., 0.028 mol) in place of 4 fluorobenzoyl chloride, and the reaction mixture was left for a further two days at room temperature). After work up the 1,4-bis(4-fluorobenzoyl)benzene obtained (6.91 g., 85.8% yield, m.p. 211.5217 o C) had a DSC purity of 95%. Example 6 The materials and procedure of Example 4 were used except that butyronitrile (6.5 ml, 0.075 mole) was used instead of dimethylformamide and the reaction mixture was kept at 0 o C overnight. The crude 1,4-bis(4-fluorobenzoyl)benzene obtained (9.91 g., 123% yield, m.p. 207.5-212 o C) was 85% pure by 1H NMR (i.e. it contained nearly a quantitative yield of the desired product, the impurities being volatile at its melting point as the DSC purity was over 99%. Example 7 (Comparison) The materials and procedure of Example 6 were used except that the butyronitrile was omitted and the reaction mixture was kept at room temperature overnight. The crude 1,4-bis(4-fluorobenzoyl)benzene obtained (9.1 g., 83% yield) was 80% pure by 1H NMR. Example 8 To an agitated mixture of lithium clhoride (3.18 g., 0,075 mole) and aluminium chloride (20 g., 0.15 mole) in dichloroethane (20 ml) at about -15 o C was added 4-fluorobenzoyl chloride (9.6 g., 0.06 mole) and diphenyl ether (4.25 g., 0.025 mole) in dichloroethane (10 ml). The reaction mixture was maintained at -15 to -17 o C for one hour then 0 o C for three hours then left at about -5 o C for three days. After working up as described in Example 1 the 4,4'-bis(4-fluorobenzoyl)diphenyl ether obtained (9.34 g., 90% yield, m.p. 214.5-215.5 o C) had a 1H NMR purity of over 99% and the DSC purity was 99.5%. Example 9 (Comparison) The materials and procedures of Example 8 were repeated except that the lithium chloride was omitted, only 9.6 g., (0.072 mole) aluminium chloride was present and the reaction mixture was kept at 0 o C overnight then worked up. 3.92 g., (38% yield) of crude 4,4'-bis(fluorobenzoyl) diphenyl ether of only 80% 1H NMR purity was obtained. Example 10 To an agitated mixture of aluminium chloride (20 g., 0.15 mole) and lithium chloride (3.18 g., 0.075 mole) and dichloroethane (20 ml) at -15 o C was slowly added toluene (4.6 g., 0.05 mole) and acetyl chloride (3.93 g., 0.05 mole) in dichloroethane (10 ml). The reaction mixture was left at -15 o C for one hour then allowed to warm up to room temperature overnight. After working up as described in Example 1, the 4-methylacetophenone obtained (7.17 g.), had a 1H NMR estimated purity of about 95%. 1H NMR showed less than 2% ortho isomers. Example 11 The materials and procedures of Example 10 were followed except that benzoyl chloride (7.0 g., 0.05 mole) was used instead of acetyl chloride. The 4-methylbenzophenone obtained (8.62 g., 88% yield) had a 1H NMR purity of 95% and a DSC purity of 97.7%. Gas chromatography (G.C.) indicated the presence of less than 2% ortho isomers. Example 12 To an agitated mixture of lithium chloride (3.18 g., 0.075 mole) and aluminium chloride (20 g., 0.15 mol) in dichloroethane (20 ml) was slowly added diphenyl ether (8.51 g., 0.05 mole) and acetyl chloride (3.93 g., 0.05 mol) in dichloroethane (7 ml) following the procedure of example 12. The 4-phenoxyacetophenone obtained (9.57 g., 90.3% yield, m.p. 43.5-51 o C) had a 1H NMR purity of 90%. Example 13 The materials and procedures of Example 12 were used except that acetic anhydride (5.1 g., 0.05 mole) was used instead of acetyl chloride. The 4-phenoxyacetophenone obtained (9.75 g., 92% yield, m.p. 46-51.5 o C) had a 1H NMR purity of 90%, the major impurity being unreacted diphenyl ether. Example 14 The materials and procedures of Example 12 were used except that benzoyl chloride (7.03 g., 0.05 mole) was used instead of acetyl chloride. The p-phenoxybenzophenone obtained (12.83 g., 93.6% yield) had a 1H NMR purity of 90%, unreacted diphenyl ether being the main impurity. Example 15 The materials and procedures of Example 12 were used except that only 4.20 g., (0.025 mole) of diphenyl ether were used and 4 chlorobenzoyl chloride (10.5 g., 0.06 mole) was used instead of acetyl chloride. The reaction product was poured into dilute hydrochloric acid-ice mixture, separated, suspended in methanol, filtered and dried in vacuum at 80 o C. (This procedure was used because this product is insoluble in common solvents.) The 4,4'-bis(4-chlorobenzoyl)diphenyl ether obtained (10.84 g., 97% yield, m.p. 244-248 o C) had a DSC purity of 98.1%. Example 16 To an agitated mixture of lithium chloride (3.18 g., 0.075 mole) and aluminium chloride (20 g., 0.15 mole) in dichloroethane cooled to below -10 o C was added anisole (5.41 g., 0.05 mole) and benzoyl chloride (7.03 g., 0.05 mole) in dichloroethane (10 ml). The reaction mixture was held below -10 o C for one hour then allowed to come to room temperature overnight. The 4-methoxybenzophenone produced (9.55 g., 90.1% yield) had a gas chromatograph/mass spectrometer estimated purity of over 95% with 2% ortho isomers. Example 17 To a solution of diphenyl ether (3.57 g., 0.021 mole) in dichloroethane (15 ml) at -15 o C was added, by means of a bubbler, phosgene (0.87 g., 0.01 mole). The combined reactants were than added to an agitated mixture of lithium chloride (0.64 g., 0.015 mole) and aluminium trichloride (3.67 g., 0.275 mole) in dichloroethane (20 ml) at -15 o C. The reaction mixture was allowed to warm up to room temperature over 1.25 hours. After 68 hours at room temperature, the reaction mixture was worked up as described in example 1 to yield crude 4,4'-diphenoxy-benzophenone (2.2 g., 60% yield) of DSC purity 96.6%. Example 18 The procedure and materials of Example 8 were used except that the same volumes of carbon disulfide are used as diluent instead of dichloroethane. The crude 4,4'-bis (4-fluorobenzoyl)diphenyl ether obtained (9.25 g., 89.4% yield) had a DSC purity of 95%. 1H and 19F NMR both indicated 95% purity. Example 19 (Comparison) In an experiment not following the teachings of the instant invention, Example 10 was repeated except that no lithium chloride was used and only 8.0 g (0.06 mole) aluminium chloride was present. After working up in the same way as example 11, 4-methylacetophenone was obtained with a 1H NMR purity of 80 to 85%. GC/MS indicated an impurity with a mass of 324 Daltons was present. Example 20 (Comparison) In an experiment not following the teachings of the instant invention, Example 13 was repeated except that no lithium chloride was used and only 8.0 g (0.06 mole) aluminium chloride was present. The 4-phenoxyacetophenone obtained had a 1H NMR purity of 80 to 85%, the main impurities being about 5% unreacted diphenyl ether and about 10% of the diacetylated product. Example 21 (Comparison) In an experiment not following the teachings of the instant invention, Example 15 was repeated except that no lithium chloride was used and only 9.6 g (0.072 mole) aluminium chloride was present. The 4,4'-bis(4-chlorobenzoyl(diphenyl ether was obtained in 86% yield.

Claims: A process for the preparation of a para-substituted aromatic carbonyl compound which is not an oligomer or polymer, by a Friedel Crafts condensation of (1) an aromatic compound containing at least one activated hydrogen atom with (2) phosgene or an acyl compound in the presence of (3) a Lewis acid, characterised in that any aromatic ring which contains an activated hydrogen atom also contains less than 2 alkoxy groups, and the condensation is controlled to suppress alkylation and/or orthoacylation by the addition of at least 0.1 equivalents of Lewis base per equivalent of acid, ester or acid halide group in the reactants, plus an additional equivalent of Lewis acid per equivalent of Lewis base. A process according to claim 1 for the preparation of an aromatic carbonyl compound having the formula (R) s ArDCOY, (R) s ArDCOBD(R') t , (R) s ArDCOBDCOArd(R) s or (R) s ArDCODAr(R) s wherein each s and t independently is 1,2 or 3 and each R, Ar, B, D, Y and R' independently is as defined below, which comprises reacting a first reactant, consisting of a substituted or unsubstituted aromatic compound containing at least one activated hydrogen atom of the formula (R) s ArDH with a second reactant, consisting of phosgene or a monofunctional acyl compound of the general formula YCOBD(R') t or O(COBD(R') t )₂ or a di-functional acyl compound of the general formula YCOBDCOY in a reaction medium comprising: A) a Lewis acid in an amount of about one equivalent per equivalent of carbonyl or other basic species in the reactants plus one equivalent per equivalent of Lewis base plus an amount effective to act as a catalyst for the reaction; B) a Lewis base in an amount of from 0.1 to 4 equivalents per equivalent of acid, ester or acid halide group in the reactants; and C) a non-protic diluent in an amount from 20 to 93% by weight, based on the weight of the total reaction mixture, wherein : (a) Ar is a homo or hetero-aromatic mono-, di- or tri- cyclic moiety or a fused homo-aromatic ring system containing less than 20 aromatic carbon atoms or a hetero-aromatic system containing less than 8 nitrogen atoms: (b) D is -(ZAr) n -(ZAr) m -(ZAr) p - wherein n, m, and p are each independently 0, 1,2 or 3, provided that n + m + p is less than 4, and Z is -CO- or -SO₂- when linking two Ar moieties which are both 4-phenoxyphenyl, or Z is -CO-C₆H₄-CO-, -O(CF₂) q O-, or V, provided that when n + m + p > 0 , any Ar group comprising an activated hydrogen atom is also linked to a V group, where V is a divalent radical of the formula -O-, -S-, -N=N-, -(CF₂) q -, (CH₂) q - or -C(CH₃)₂- wherein q is 1 to 20; (c) B is independently a divalent substituted or unsubstituted aliphatic or cycloaliphatic group or Ar; (d) R and R' which may be the same or different are H, Br, Cl or F atom or a hydroxy, alkoxy, alkyl, aralkyl, unsubstituted or mono-or disubstituted amino, nitro, ester, acid, or acid halide, amide or imide group; and (e) Y represents a Br, Cl or F atom or hydroxy or alkoxy group; subject to the proviso that the resulting aromatic carbonyl compound contains less than 2 identical directly linked sequences containing at least one -CO- or -SO₂- group and at least one -V-group. A process according to claim 2, wherein Y is Cl and neither R nor R' is an acid halide group. A process according to claim 2 or 3 wherein the aromatic carbonyl compound produced has the structure (R') t DBCOArDCOBD(R') t and the first reactant contains 2 activated hydrogen atoms. A process according to claim 2 or 3 wherein the aromatic carbonyl compound produced has the structure ClCOArDCOY. A process according to any of the preceding claims, wherein the aromatic compound is selected from benzene, toluene, ethyl benzene, fluorobenzene, chlorobenzene, bromobenzene, anisole, ethoxy benzene, 3-chloroanisole, naphthalene, anthracene, and compounds of the formulas A process according to any of the preceding claims, wherein the organic mono-or di-acid compound is selected from acetic anhydride, acetyl chloride, oxalyl dichloride, adipoyl dichloride, benzoyl chloride, 3-nitrobenzoyl chloride, terephthaloyl chloride, 4-fluorobenzoyl chloride, 4-chlorobenzoyl chloride, isophthaloyl chloride, phthaloyl chloride, phthalic anhydride, naphthoyl chloride, tetrabromophthaloyl chloride, and compounds of the following formulas A process according to any of the preceding claims wherein the Lewis acid is selected from aluminium trichloride, aluminium tribromide, antimony pentachloride, antimony pentafluoride, indium trichloride, gallium trichloride, boron trichloride, boron trifluoride, zinc chloride, ferric chloride, stannic chloride, titanium tetrachloride, and molybdenum pentachloride. A process according to any of the preceding claims wherein the Lewis base is selected from organic amides, amines, esters, ethers, ketones, nitriles, nitro compounds, phosphines, phosphine oxides, phosphoramides, sulfides, sulfones, sulfonamides, sulfoxides and inorganic or organic halide salts. A process according to claim 9 wherein the Lewis base is selected from acetone, benzophenone, cyclohexanone, methyl acetate, ethylene carbonate, N-methylformamide, acetamide, N,N-dimethylacetamide, N-methylpyrrolidone, 1-methyl-2-pyrrolidone, tetramethylene sulfone, n-butyronitrile, dimethyl sulfide, imidazole, urea, tetramethylurea, N-acetylmorpholine, dimethyl sulfoxide, N,N-dimethylformamide, diphenyl sulfone, dimethyl sulfone, N,N-dimethylmethanesulfonamide, phosphoryl chloride, phenylphosphonyl chloride, pyridine-N-oxide, triphenylphosphine oxide, trioctylphosphine oxide, nitropropane, nitrobenzene, benzonitrile, n-butyronitrile, methyl ether, tetrahydrofuran, dimethyl sulfide, trimethylamine, N,N,N',N'-tetramethylethylenediamine, N,N-dimethyldodecylamine, imidazole, pyridine, quinoline, isoquinoline, benzimidazole, 2,2'-bipyridine, o-phenanthroline, 4-dimethylaminopyridine, tetramethylammonium chloride, pyridine-N-oxide, 1-ethylpyridinium chloride, trimethylammonium chloride, tetramethylammonium chloride, and sodium chloride, lithium chloride, sodium perchlorate, lithium perchlorate, sodium trifluoromethanesulfonate, lithium trifluoromethanesulfonate, lithium bromide, sodium bromide, potassium chloride, potassium bromide and mixtures thereof. A process according to any of the preceding claims wherein the diluent is selected from methylene chloride, carbon disulfide, o-dichlorobenzene, 1,2,4-trichlorobenzene, o-difluorobenzene, 1,2-dichloroethane, 1,1,2,2-tetrachloroethane and mixtures thereof.

Inventors: GORS, HEINRICH CARL, HORNER, PATRICK JAMES, JANSONS, VIKTORS
Applicants: RAYCHEM CORPORATION (A DELAWARE CORPORATION)
Application year: 1985
Main classification: C07C45
IPC codes: C07D521, C07C313, C07C51, C07C49, C07C323, C07C67, C07C319, C07C45, C07C63