Production of dioxazine compound

Abstract: Dioxazine compounds of the formula (I) which are useful for dyes or pigments are prepared by heating a compound of formula (II) in the presence of inorganic acid with or without an oxidizing agent in an inert organic solvent: wherein R is a C 1-4 alkyl group, and each of X₁ and X₂ is a hydrogen atom or a chlorine atom.

Description: This invention relates to an improvement in production of a dioxazine compound which is useful for dyes, pigments or functional colorants. There are many processes for preparing a dioxazine compound from a compound of the formula wherein R is an alkyl group having 1 - 4 carbon atoms. One of the processes is conducted in the presence of benzenesulfonyl chloride (PB Report 65657). Another process is carried out in the presence of organic acid such as p-toluenesulfonic acid. (Japanese Kokai 58-84857). Difficulties encountered in the known processes are that a long period of time is necessary for filtration and isolation of the desired compound and that a large amount of an organic solvent is needed to wash the filtered compound. When only a small amount of the organic solvent is used for washing, the hue and other properties of a dye or pigment obtained with a dioxazine compound are not so stable that after-treatment is hardly affected. An excess of the oxidizing agent or organic acid, e.g., more than one mole thereof per mole of the compound (II) is necessary in order to effect cyclization, in these known processes. For a higher yield even more oxidizing agent or organic acid is necessary. The dioxazine compound produced is usually contaminated with a considerable amount of various reaction products of the oxidizing agent employed or the organic acid left unchanged. After a long study to solve difficulties encountered above, i.e., contamination of a dioxazine product with an oxidizing agent and the like, the use of a small amount of inorganic acid such as hydrochloric acid with or without an oxidizing agent in place of the oxidizing agent mentioned above was found to be very effective. According to the present invention, a dioxazine compound of the formula wherein R is an alkyl group having 1 - 4 carbon atoms; and each of X 1 and X 2 is a hydrogen atom or a chlorine atom, is prepared by heating a compound of the formula wherein R is the same as defined above, in an inert organic solvent in the presence of inorganic acid with or without an oxidizing agent. The inert organic solvent may be chlorobenzene, dichlorobenzene, trichlorobenzene or a mixture thereof, nitrobenzene or alkyl benzene or alkyl naphthalene whose boiling point is not lower than 110°C, preferably chlorobenzenes, nitrobenzene and alkylbenzenes. The inorganic acid may be hydrochloric acid, sulfuric acid, hydrobromic acid and phosphoric acid, preferably hydrochloric acid and sulfuric acid, and most preferably hydrochloric acid. The acid is used at least in a catalytic amount but usually at least 0.0l mole, preferably 0.01 - 1.0 mole per mole of the compound (II). The oxidizing agent may be p-benzoquinone or derivatives thereof, o-benzoquinone or derivatives thereof, benzenesulfonyl chloride or derivatives thereof and esters of benzenesulfonic acid, preferably p-benzoquinone, p-chloranil, tetracyanobenzoquinone, dicyanodichlorobenzoquinone, o-chloranil, p-toluenesulfonyl chloride or benzenesulfonyl chloride. The oxidizing agent is used in an amount of 0.0001 - 1.0 mole, preferably 0.01 - 0.5 mole per mole of the compound (II). Reaction is usually carried out at a temperature of 100°C or higher, industrially 110° - 200°C, preferably 130° - 180°C, for 3 - 12 hours, preferably 4.0 - 8.0 hours. After the reaction is over, filtration may be effected to obtain crystals which are then washed with enough solvent. Pressing and then drying gives the dioxazine compound (I) with high yield. The process may be economical in cost, because the amounts of reagents necessary are small. The process may also be economical, from view points of energy conservation and saving resources. Labour and energy necessary for recovery of solvents and for after-treatment of waste materials may be greatly reduced because the period of time for filtration is shortened and the amount of solvents necessary is lowered. A dioxazine compound obtained by the present process may be superior in tinting strength, gloss and transparency as pigments. In the following examples, parts and % are calculated by weight. Example 1 To o-dichlorobenzene (400 parts) were added 2,5-dichlor-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 36 % HCl (1.0 part). The mixture was heated to 155° - 160°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the reaction mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (l50 parts) and water (300 parts) in this order and was subjected to pressing. The cake produced was dried to obtain dioxazine compound wherein R of the formula (I) is -C 2 H 5 (51.0 parts). Elemental analysis: C: 71.0 %, H: 4.1 %, N: 9.7%, Cl: 9.0 %. The filtration and washing were completed in shorter period of time and the amount of the solvent used for washing was smaller than for the conventional process. Example 2 To o-dichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-l,4-benzoquinone (60 parts) and then 36 % HCl (2.5 parts). The mixture was heated up to 165° - 170°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound in which R of the formula (I) is C 2 H 5 (50.5 parts). Elemental analysis: C: 70.5 %, H: 4.0 %, N: 9.6 %, Cl: 10.0 %. The filtration and washing were completed in a shorter period of time and the amount of the solvent used for washing was smaller than for the conventional process. Example 3 To o-dichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 78 % sulfuric acid (2.0 parts) and tetracyanobenzoquinone (3.0 parts). The mixture was heated up to 155° - 160°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake produced was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (50.0 parts). Elemental analysis: C: 69.8 %, H: 4.1 %, N: 9.5 %, Cl: 11.3 %. The filtration and washing were completed in a shorter period of time and the amount of the solvent used for washing was smaller than for the conventional process. Example 4 Example 3 was repeated except that 78 % sulfuric acid (6.0 parts) was used in place of 78 % sulfuric acid and tetracyanobenzoquinone. The same results were obtained. Example 5 To o-dichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts), and then 36 % hydrochloric acid (0.5 part). The mixture was heated up to 145° - 150°C under stirring and was kept at this temperature for 12 hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake produced was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (51.0 parts). Elemental analysis: C: 72.0 %, H: 4.1 %, N: 9.8 %, Cl: 8.5 %. The filtration and washing were very easy and the amount of the solvent used for washing was smaller than that required for the conventional process. Example 6 To o-dichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 36 % hydrochloric acid (1.0 part) and p-chloranil (4 parts). The mixture was heated up to 165° - 170°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (51.5 parts). Elemental analysis: C: 70.6 %, H: 4.1 %, N: 9.7 %, Cl: 11.4 %. The filtration and washing were very easy and the amount of the solvent used for washing was smaller than that required for the conventional process. Example 7 Example 6 was repeated except that 36 % hydrochloric acid (1.0 part) was used in place of 36 % hydrochloric acid and p-chloranil to obtain a similar dioxadizine compound. Elemental analysis: C: 70.6 %, H: 4.1 %, N: 9.7 %, Cl: 10.0 %. Example 8 To trichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 70 % sulfuric acid (1.0 part). The mixture was heated up to 190° - 200°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with trichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (49.0 parts). Elemental analysis: C: 71.0 %, H: 4.1 %, N: 10.0 %, Cl: 8.5 %. The filtration and washing were very easy and the amount of the solvent used for washing was smaller than that for the conventional process. Example 9 Example 8 was repeated except that 36 % hydrochloric acid (1.0 part) was used in place of 70 % sulfuric acid. The same result as above was obtained. Example 10 To o-dichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 70 % sulfuric acid (1.0 part) and p-benzensulfonyl chloride (5.0 parts). The mixture was heated up to 165° - 170°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (51.0 parts). Elemental analysis: C: 71.0 %, H: 4.1 %, N: 9.7 %, Cl: 10.8 %. The filtration and washing were completed in a shorter period of time and the amount of the solvent used for washing was smaller than required for the conventional process. Example 11 To o-dichlorobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 98 % sulfuric acid (0.5 part) and o-chloranil (2 parts). The mixture was heated up to 165° - 170°C and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (51.0 parts). Elemental analysis: C: 71.0 %, H: 4.1 %, N: 9.7 %, Cl: 10.5 %. The filtration and washing were able to effect in a shorter period of time and the amount of the solvent used for washing was smaller than for the conventional process. Example 12 To nitrobenzene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 36 % hydrochloric acid (1 part) and benzoquinone (2.0 parts). The mixture was heated up to 155° - 160°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (51.0 parts). Elemental analysis: C: 71.0 %, H: 4.1 %, N: 9.5 %, Cl: 10.5 %. The filtration and washing were completed in a shorter period of time and the amount of the solvent for washing was smaller than those for the conventional process, respectively. Example 13 To mesitylene (400 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then 36 % hydrochloric acid (1.0 part). The mixture was heated up to 155° - 160°C under stirring and was kept at this temperature for five hours. After being cooled to 120°C, the mixture was filtered at this temperature. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C), methanol (150 parts) and water (300 parts) in this order and was subjected to pressing. The cake was dried to obtain a dioxazine compound wherein R of the formula (I) is C 2 H 5 (51.0 parts). Elemental analysis: C: 71.0 %, H: 4.1 %, N: 9.7 %, Cl: 9.0 %. The filtration and washing were completed in a shorter period of time and the amount of the solvent used for washing was smaller than for the conventional process. Comparison example 1 (conventional process) To o-dichlorobenzene (400 parts) was added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts). The mixture was heated up to 115°C and benzenesulfonyl chloride (19 parts) was added thereto. The mixture was further heated up to 175° - 180°C and was kept at this temperature for six hours. After being cooled to 120°C, the mixture was filtered. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C) and then with similar o-dichlorobenzene to the former (400 parts), methanol (150 parts) and water (800 parts) in this order, before being subjected to pressing. The cake was dried to obtain a dioxazine compound (47.6 parts). Elemental analysis: C: 70.0 %, H: 3.8 %, N: 9.6 %, Cl: 11.5 %, S: 0.3 %. The filtration and washing with o-dichlorobenzene took a long time (about one hour). Elemental analysis of a dioxazine compound obtained without the second washing with o-dichlorobenzene, i.e., when the washing with the o-dichlorobenzene (100°C) was followed by the washing with methanol and with water, gave the following: C: 70.0 %, H: 4.0 %, N: 9.0 %, Cl: 11.3 %, S: 1.5 %. A large amount of S was contained and washing was not sufficient. Comparison example 2 (conventional process) To o-dichlorobenzene (300 parts) were added 2,5-dichloro-3,6-bis(9-ethyl-3-carbazolylamino)-1,4-benzoquinone (60 parts) and then p-toluene sulfonic acid (26 parts). The mixture was kept at 80° - 85°C and then added under stirring to o-dichlorobenzene (l00 parts, 175° - 180°C) over three hours. The mixture was kept at 175° - 180°C for six hours after the addition was over. The mixture was cooled to 120°C and then filtered. The precipitate was washed with o-dichlorobenzene (400 parts, 100°C) and then the same washing was repeated three times, followed by washing with methanol (150 parts) and then with water (300 parts), before being subjected to pressing. The cake was dried to obtain a dioxazine compound (38.7 parts). Elemental analysis: C: 66.0 %, H: 4.0 %, N: 7.8 %, Cl: 6.5 %, S: 3.3 %. A large amount of S was contained. The filtration and washing with o-dichlorobenzene took a long time (about 2 hours). Reference example (use example) Mixtures each containing a respective dioxazine compound (100 parts each) obtained in Example 1 or 6 or Comparison Example 1, wherein washing with o-dichlorobenzene was effected two times, were added to table salt (300 mesh size, 700 parts) and ethylene glycol (150 parts) and ground in a kneader having two pestles for seven hours while holding the temperature at 70° - 75°C. Each mass was added to hot water (80°C, 2000 parts) and stirred before filtering. Each precipitate was washed with water (4000 parts) and dried. Nitrocellulose or polyamide gravure ink in which pigment was made from the dried cake above was prepared. The dioxazine compound obtained in the comparison example 1 was taken as standard. Specific surface Tinting strength Gloss Transparency Example 1 93 m 2 /g 120 % + 2 + 1 to 2 Example 6 90 m 2 /g 115 % + 2 + 1 to 2 Comparison example 1 80 m 2 /g 100 % Standard Standard

Claims: A process for preparing a dioxazine compound of the formula (I) wherein R is an alkyl group of 1 to 4 carbon atoms; and each of X 1 and X 2 is a hydrogen atom or a chlorine atom, which comprises heating a compound having the formula (II) wherein R is the same as defined above, in an inert organic solvent in the presence of inorganic acid with or without an oxidizing agent. A process according to claim 1 wherein the inorganic acid is hydrochloric or sulphuric acid. A process according to any one of claims 1 or 2 wherein the oxidizing agent is p-benzoquinone or a derivative thereof, o-benzoquinone or a derivative thereof, benzenesulphonyl chloride or a derivative thereof, or an ester of benzenesulphonic acid. A process according to any one of claims 1 to 3 wherein heating is conducted at a temperature of from 110° to 200°C. A process according to any one of claims 1 to 4 wherein the inert organic solvent is chlorobenzene, dichlorobenzene, trichlorobenzene, or a mixture thereof, nitrobenzene or alkyl benzene having a boiling ponit of not lower than 110°C. A process according to any one of claims 1 to 5 wherein the inorganic acid is provided at least 0.01 mole per mole of the compound (II). A process according to any one of claims 1 to 6 wherein the inorganic acid is provided at from 0.01 to 1.0 mole per mole of the compound (II). A process according to any one of claims 1 to 7 wherein the oxidizing agent is provided at from 0.0001 to 1.0 mole per mole of the compound (II). A process according to any one of claims 1 to 8 wherein the oxidizing agent is provided at from 0.01 to 0.5 mole per mole of the compound (II).

Inventors: FUJITA TAIRA, KAYANE YUTAKA, FUJITA, TAIRA, KAYANE, YUTAKA
Applicants: SUMITOMO CHEMICAL CO, SUMITOMO CHEMICAL COMPANY, LIMITED
Application year: 1987
Main classification: C07D498
IPC codes: C09B19, C07D498