HIGH YIELD METHOD FOR PREPARATION OF DIALKYL ESTERS OF POLYHALOAROMATIC ACIDS

Abstract: An improved process is provided for the preparation of esters of polyhalophthalic acids, polyhalobenzoic acids, and polyhalophthalic anhydride useful as flame retardants for thermoplastic and thermosetting resins, which comprises the reaction of the above acids or anhydride with alcohols in the presence of certain metal and metallorganic compounds as catalysts. Also provided are certain esters per se .

Description: This invention relates to methods for preparing polyhaloaromatic carboxylic esters, and the use of some esters as flame retardants and/or processing aids. A number of processes have been developed for the preparation of diesters of the phthalic acids and phthalic anhydride from alcohols Using traditional strong acid esterification catalysts, such as sulfuric acid, p-toluenesulfonic acid, hydrochloric acid, etc. However, when the aromatic rings are polyhalogenated, complete esterification becomes slow and difficult, resulting in low yields and poor product quality which make these processes commercially unattractive. Pape, Sanger and Nametz (J. of Cellular Plastics, November, 1968, p. 438) discloses that diesters of tetrabromophthalic anhydride can be prepared only with great difficulty and in low yields. Pape, et al., used epoxides to convert the free-carboxyl group of the intermediate monoester to a hydroxy-substituted ester. Spatz, et al., (I & EC Product Res. and Dev., 8 , 391, 1969) used phosphoric acid as a catalyst to prepare the di-2-ethylhexyl ester of tetrabromophthalic acid with only 60% yield. Substantial decarboxylation of the intermediate half-ester was also observed. Baldino and Feltzin in U.S. Patent 3,929,866 reported the preparation of diesters from alcohols containing at least 3 hydroxyl groups; however, no products were isolated and no yield details are given. Finley in U.S. Patent 4,375,551 prepared allylic esters of tetrabromophthalic anhydride by first preparing the half-ester and then converting the half-ester to the sodium salt which was then treated with allyl chloride in the presence of phase transfer catalysts. The use of metallic salts of tetrachlorophthalic anhydride to prepare diesters has been documented by several workers. Nordlander and Cass (J. A. Chem. Soc., 69 , 2670 (1974) used metallic salts of tetrachlorophthalic acid or tetrachlorophthaloyl chloride in the presence of a base to prepare diesters. Yields ranged from poor to fair (10 to 71%). Lawlor (I. & EC, 39 , 1419 (1947) reported low yields of diesters could be obtained from either the sodium or silver salts of the intermediate half-ester of tetrachlorophthalic anhydride or from the acid chloride, tetrachlorophthaloyl chloride. Nomura, et al., in Japan published Patent Application 75-05701 discloses the use of alkyl titanates together with alkali or alkaline earth metal salts (hydroxide, carbonate, bicarbonate, or salt of organic acid) for the esterification of tetrabromophthalic acid or anhydride with alcohols to produce the corresponding diesters. These alkali or alkaline earth materials are an essential part of the Nomura, et al., catalyst system, whether added together with the alkyl titanate or at different times during the process in order to obtain products having low acid numbers. EP-A-0 235 266 discloses the use of stannous oxalate as catalyst in the esterification of tetrabromophthalic anhydride with 2-[2-methoxyethoxy]-ethanol. However, the yield obtained in this process is very low. The method of the invention is a process for preparing esters of polyhaloaromatic carboxylic acids and anhydrides of the general formula: wherein (a) the aromatic rings can have all possible isomeric arrangements; (b) A is Br or Cl; (c) m is 3, 4, or 5; (d) q is an integer of 1 to 6; (e) R⁷ is (i) a substituted or unsubstituted C₁₋₃₀ alkyl or an aryl having up to 30 carbon atoms, and with a valence (v) which is an integer of 1 to 4; (ii) where: R³ is H or a substituted or unsubstituted C₁₋₃₀ alkyl, or an aryl having up to 30 carbon atoms, R⁴ is independently H or CH₃, p is an integer of 1 to 50, and t is an integer of 1 to 49; or (iii) where R⁵ is a substituted or unsubstituted C₁₋₃₀ alkyl or an aryl having up to 30 carbon atoms; and (f) s is q, m and v being as above defined, which comprises reacting: (I) at least one polyhaloaromatic carboxylic acid or anhydride (A) of the general formulae: wherein A and m are as defined above and n is 3 or 4; with (II) at least a stoichiometric quantity of alcohol or polyol (B) of the general formula: R⁷(OH) v wherein R⁷ and v are as defined above; and (III) a catalytically effective amount of at least one organometallic catalyst compound (C) selected from titanium tetraisopropoxide, titanium bis(ethyl acetate)diisopropoxyl isopropanol, titanium tetrabutoxide, and titanium tetrakis(2-ethyl-1-hexylanol); the molar ratio of (A):(B):(C) being 1:1 to 10:0.0005 to 0.1. Another embodiment of this invention is that a novel process for the esterification of difficult to esterify polyhaloaromatic carboxylic acids and anhydrides is provided. The esters obtained by this process are useful as flame retardants and processing aids. These esters have the general formula II: wherein: (a) A is as defined for general formula I; (b) j is 3 or 4; (c) k is an integer of 1 to 50; (d) R⁹ is H or CH₃; and (e) R¹⁰ is H, a C₁-₃₀ alkyl, or a substituted or unsubstituted aryl having up to 30 carbon atoms. The reaction conditions are such that a complete esterification of the acid or anhydride is achieved, producing a full (as contrasted with half- or semi-)ester. To achieve this, the mol ratio of reactants (polyhaloaromatic carboxylic acid or anhydride):(alcohol or polyol) is 1:1-10.0, preferably 1:1-5.0; and the mol ratio (polyhalocarboxylic acid or anhydride):(metallic or organometallic catalyst) is 1:.0005-.1, preferably 1:.001-.05. The reaction is completed by the removal of the water by-product of the esterification. To accomplish this the reactants preferably are heated to reflux, with continual water by-product removal until no further water is produced. A similar result could be achieved by reacting at lower temperatures, with water by-product removal in any known manner. The temperature will vary with the reactants and the pressure and, while reflux temperatures are generally satisfactory, it may be advantageous with some reactants to use a partial vacuum and thus lower the reflux temperature. The excess alcohol or polyol usually will act as a solvent for the reaction. Where this is inadequate, or where the alcohol or polyol is water-miscible, an organic solvent which forms an azeotrope with water and which is inert to the reaction may be added. Such a solvent may also act favorably to adjust the effective reaction temperature. Useful solvents include, but are not limited to, toluene, xylene, heptane, tetrahydronaphthalene, and the like. It also is advantageous to conduct the reaction under agitation, since this not only promotes contact of the reactants with each other, but also frees water by-product from the reaction mass, facilitating its removal. Generally, if the water by-product is not removed, the esterification will not go to completion. It may be noted that auxiliary co-catalysts such as the alkaline salts described by Nomura, et al., supra , are neither required nor desirable in this invention. Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about". It has been found that certain organometallic compounds are excellent catalysts for the difficult to achieve complete esterification of polyhaloaromatic carboxylic acids and anhydrides. These catalysts permit the esterification to proceed in high yields with high purity, thus making this process commercially attractive. The inventive process for preparing esters of polyhaloaromatic carboxylic acids and anhydrides comprises reacting at least one polyhaloaromatic carboxylic acid or anhydride with at least one alcohol or polyol in the presence of at least one organometallic catalyst compound. The process described above may be represented in general terms by one of the following reaction sequences (1 and 2). ArCO₂H + R₁OH → ArCO₂R₁ + H₂O (1) where Ar is a polyhaloaromatic group and R₁OH is an alcohol or polyol. The time of the reaction is indefinite, since it is allowed to proceed until the reactant present in a lesser amount is substantially reacted. typically, in laboratory preparations, the time was 2 to 22 hours, although a time as long as 73 hours was efficacious in one instance. Examples of representative organometallic catalysts are as follows: Preferred catalysts are the following: The amount of catalyst employed in the preparation of the polyhaloaromatic carboxylic esters of this invention alternatively may be given as 0.0001 to 5.0 (preferably 0.01 to 2.0) parts per part of polyhaloaromatic carboxylic acid or anhydride, where the alcohol or polyol is present in greater than a stoichiometric amount to the acid or anhydride. The aromatic acids and anhydrides that are operable in this invention have the formulas: wherein: m is an integer of 3 to 5, n is an integer of 3 to 4, and A is Cl or Br. Examples of representative polyhaloaromatic carboxylic acids and anhydrides are as follows: The alcohols that can be used in this invention have the formula: R⁷(OH) v wherein R⁷ and v are as defined for general formula I. Examples of representative alcohols and polyols are as follows: Examples of representative esters that can be prepared in high yields by using the catalysts of this invention are as follows (where A is Br or Cl): The diesters obtained by the process of this invention are useful as flame retardants and/or flameproofing agents when incorporated in and/or applied to a variety of inflammable thermoplastic and thermosetting polymers. Such polymers comprise hydrocarbon polymers including saturated, unsaturated, linear, atactic, crystalline or non-linear amorphous polymers, copolymers, terpolymers, and the like, such as polyethylene, polypropylene, poly(4-methyl pentene-1), polybutene-1, polystyrene, styrene-butadiene rubber, butyl rubber, natural rubber, polyisobutylene, ethylene-propylene-copolymer, cis-1-4-polyisoprene, ethlene-propylene-dicyclopentadiene terpolymer, and blends of these polymers with each other. Also useful in this invention are nonhydrocarbon polymers such as the unsaturated polyesters; drying and non-drying alkyd resins; linear-saturated polyesters such as poly(ethylene terephthalate), poly(1,4-cyclohexanedimethylene terephthalate) and poly(1,4-butylene terephthalate); polyurethanes; poly(alkylene oxides) such as poly(ethylene oxide) and poly(propylene oxide), and the like; poly(arylene oxides) such as poly(phenylene oxide); polyamides such as nylon; poly(vinyl alkyl ethers) such as poly(vinyl methyl ether), ethylene-vinyl acetate copolymers; poly(ethyl acrylate), poly(ethyl methacrylate); polysulfones; epoxy resins; butadiene-terpolymers; plasticized poly(vinyl chloride); and the like. The following examples are illustrative of the invention. Reference Example 1 Into a one liter three-necked flask, equipped with an overhead mechanical stirrer, a Dean Stark trap, a water condenser with a nitrogen inlet and a thermometer were charged 231.86 gm (0.50 mol) of tetrabromophthalic anhydride 390.7gm (3.0 mols) of 2-ethyl-1-hexanol, and 2.32 gm of stannous oxalate. The flask and contents were stirred and heated to reflux (195°C) and 9 ml of water (100% of theory) were obtained in 22 hours. The contents were cooled to room, temperature, filtered to remove the catalyst, and the excess of alcohol was removed by vacuum distillation to give 350 gm of a light yellow oil. The yield was 97%. Calculated % Br 45.3, Found % Br, 44.9. Analytical data was consistent with the assigned structure. High pressure liquid chromatography (HPLC) of the product showed it to be 96.2% pure with only a minor amount of by-product (3.3%) due to decarboxylation of the intermediate half-ester which contrasts with the results obtained by Spatz, et al., (I & EC Products Res. and Des., 8 391 (1969). Reference Example 2 Following the procedure outlined in Reference Example 1 using 6955.8 gm (15.0 mols) of tetrabromophthalic anhydride 11.72 kg (90.15 mols) 2-ethyl-1-hexanol, and 69.55 gm of stannous oxalate, resulted in 10.5 kg (99% yield) of di-2-ethylhexyl tetrabromophthalate. Calculated % Br. 45.3, Found % Br 43.5. Analytical data was consistent with the assigned structure. High pressure liquid chromatography (HPLC) of the product showed it to be 97.1% pure with only a minor amount of by-product (2.8%) due to decarboxylation of the intermediate half-ester. Example 1 Into a two liter three-necked flask, equipped with an overhead mechanical stirrer, Dean Stark trap, a water condenser with a nitrogen inlet tube and a thermometer were charged 463.72 gm (1.0 mol) of tetrabromophthalic anhydride, 442.78 gm (3.4 mols) of 2-ethyl-1-hexanol and 6.50 gm (0.022 mols) of titanium tetraisopropoxide. The flask and contents were heated to reflux (198°C) and 23.2 gm of a water phase were collected in 5 hours. (Note: The aqueous phase contained isopropyl alcohol which was derived from the catalyst. If all of the isopropyl groups were converted to isopropyl alcohol, this would amount to 5.3 gm which plus the expected water (18 gm) totals 23.3 gm). The excess 2-ethyl-1-hexanol was removed by vacuum distillation to give 703.7 gm of a light yellow oil. The yield was 99.6%. Calculated % Br, 45.3, Found % Br, 45.0. Analytical data was consistent with the assigned structure. High pressure liquid chromatography showed it to be 98.5% pure with only a minor amount of by-product (1.3%) due to decarboxylation of the intermediate half-ester. Example 2 This compound can be prepared by the procedure outlined in Example 1 except using isodecyl alcohol in place of 2-(methoxyethoxy)-ethanol. Example 3 Into a one liter three-necked flash, equipped with an overhead mechanical stirrer, Dean Stark trap, a water condenser with a nitrogen inlet tube and a thermometer, were charged 285.9gm (1.0 mol) of tetrachlorophthalic anhydride, 442.7gm (3.4 mol) of 2-ethyl-1-hexanol and 6.5gm of titanium tetrakisisopropoxide. The flask and contents were heated to reflux (200°C) and 23gm of a water phase were collected in 2 hours. The excess 2-ethyl-1-hexanol was removed on a rotary evaporator to give 528gm of an oil. The yield was 100%. Example 4 This compound can be prepared following the procedure outlined in Example 1 except using cyclohexanol instead of 2-ethyl-1-hexanol. Example 5 Into a two liter three-necked flask, equipped with an overhead mechanical stirrer, Dean Stark trap, a water condenser with a nitrogen inlet tube and a thermometer, were charged 927.5gm (2 mol) of tetrabromphthalic anhydride, 780gm (6 mols) of 2-ethyl-1-hexanol and 9.27gm of titanium tetrabutoxide. The flask and contents were heated to reflux 185°C at 560mm pressure and 73gm of a water phase were collected in 10 hours. The excess 2-ethyl-1-hexanol was removed on a rotary evaporator to give 1350gm of oil. The yield was 96%. Analytical data was consistent with the assigned structure. Example 6 This compound can be prepared following the procedure outlined in Reference Example 2 except using 1-octanol instead of 2-ethyl-1-hexanol and using titanium tetrabutoxide as a catalyst instead of stannous oxalate. Example 7 This compound can be prepared following the procedure outlined in Example 1 except using 2,3,5,6,-tetrabromoterephthalic acid instead of tetrabromophthalic anhydride. Example 8 This compound can be prepared following the procedure outlined in Example 1 except using 2,4,5,6,-tetrabromoisophthalic acid instead of tetrabromophthalic anhydride. Example 9 This compound can be prepared following the procedure outlined in Example 1 except replacing three-fourths of the 2-ethyl-1-hexanol by an equimolar quantity of 1-butanol and refluxing the 2-ethyl-1-hexanol for 2-3 hours prior to the addition of the remaining alcohol. Example 10 This compound can be prepared following the procedure outlined in Example 9 except using 1-hexanol instead of 2-ethyl-1-hexanol and using 2-ethoxyethoxyethanol instead of 1-butanol. Example 11 This compound can be prepared following the procedure outlined in Example 9 except using cyclohexanol instead of 1-butanol. Example 12 Into a 500ml three-necked flask, equipped with an overhead mechanical stirrer, Dean Stark trap, a water condenser with a nitrogen inlet tube and a thermometer, were charged 185.5gm (0.4 mol) of tetrabromophthalic anhydride, 177gm (1.36 mols) of 2-ethyl-1-hexanol and 1.85gm of titanium bis(ethyl acetate)diisopropoxyl isopropanol. The flask and contents were heated to reflux (194°C) and the water phase were collected in 3 hours. The excess 2-ethyl-1-hexanol was removed on a rotary evaporator to give 248gm of an oil. The yield was 88%. Analytical data was consistent with the assigned structure. Example 13 Into a 500ml three-necked flask, equipped with an overhead mechanical stirrer, Dean Stark trap, a water condenser with a nitrogen inlet tube and a thermometer, were charged 185.5gm (0.4 mol) of tetrabromophthalic anhydride, 177gm (1.36 mols) of 2-ethyl-1-hexanol and 1.85gm of titanium tetrakis(2-ethyl-1-hexanol). The flask and contents were heated to reflux (195°C) and 7.9gm of a water phase were collected in 6 hours. The excess 2-ethyl-1-hexanol was removed on a rotary evaporator to give 254gm of an oil. The yield was 90%. Analytical data was consistent with the assigned structure. Examples 14 to 16 and Comparison Example C-1 The following examples and comparison example were prepared to demonstrate the excellent flame retardant characteristic of diesters according to this invention. A resin blend to be used in examples 14 to 16 and comparison example C-1 was prepared as follows. The following ingredients were mixed, in the indicated order, in a high speed mixer for 5 minutes. ingredient amount in parts by weight (pbw) (a) polyvinyl chloride [sold under the trademark "Geon" by B.F. Goodrich Co., U.S.A.] 600. (b) dibasic lead phthalate [sold under the trademark "Dythal" by Anzon, Inc., U.S.A.] 42. (c) clay [sold under the trademark "Satintone" SP 33 by Englehard Corp., U.S.A.] 60. (d) bisphenol A 1.8 (e) wax - m.p. 165°F (about 79°C) [sold under the trademark "Hostalube" XL165 by Hoechst-Celanese Corp., U.S.A.] 1.8 (f) antimony oxide 18.0 In each of examples 14 to 16 and in comparison example C-1, 120.6 pbw of the above resin blend were blended with 60 pbw of the ester, and then tested in the following manner. [120.6 pbw of blend is equivalent to 100 pbw of polyvinyl chloride, 7 pbw of dibasic lead phthalate, 10 pbw of clay, .3 pbw of bisphenol A, .3 pbw of 165°F wax, and 3 pbw of antimony oxide.] The resin blend and ester were hand stirred for about 1 minute, and then milled into sheets on a two-roll mill at 356°F (180°C) for about 4 minutes. The sheets were then compression molded into strips 1/8 in (about .32 cm) thick, 1/4 in (about 6.4 cm) wide, and 5 in (about 12.7 cm) long, on which the Limited Oxygen Index values were obtained using ASTM (American Society for Testing Materials) Test Procedure D2863-77. The esters tested and the test results are shown in the following table. Example Ester LOI value 14 di[2-(2-methoxyethoxy)-ethyl] tetrabromophthalate 56.5 15 di[2-(2-ethoxyethoxy)-ethyl-tetrabromophthalate 53.5 16 di(2-butoxyethyl)tetrabromophthalate 50.5 C-1 dioctyl phthalate 28.0 As can easily be seen, dioctyl phthalate, an alkyl phthalate ester containing neither bromine nor chlorine, known in the art, produced unacceptable flame retardancy. The minimally acceptable LOI value is 40, over 45 being preferred, over 50 most preferred.

Claims: Claims for the following Contracting States : AT, CH, LI, SE A process for preparing esters of polyhaloaromatic carboxylic acids and anhydrides of the general formula: wherein (a) the aromatic rings can have all possible isomeric arrangements; (b) A is Br or Cl; (c) m is 3, 4, or 5; (d) q is an integer of 1 to 6; (e) R⁷ is (i) a substituted or unsubstituted C₁₋₃₀ alkyl or an aryl having up to 30 carbon atoms, and with a valence (v) which is an integer of 1 to 4; (ii) where: R³ is H or a substituted or unsubstituted C₁₋₃₀ alkyl, or an aryl having up to 30 carbon atoms, R⁴ is independently H or CH₃, p is an integer of 1 to 50, and t is an integer of 1 to 49; or (iii) where R⁵ is a substituted or unsubstituted C₁₋₃₀ alkyl or an aryl having up to 30 carbon atoms; and (f) s is q, m and v being as above defined, which comprises reacting: (I) at least one polyhaloaromatic carboxylic acid or anhydride (A) of the general formulae: wherein A and m are as defined above and n is 3 or 4; with (II) at least a stoichiometric quantity of alcohol or polyol (B) of the general formula: R⁷(OH) v wherein R⁷ and v are as defined above; and (III) a catalytically effective amount of at least one organometallic catalyst compound (C) selected from titanium tetraisopropoxide, titanium bis(ethyl acetate)diisopropoxyl isopropanol, titanium tetrabutoxide, and titanium tetrakis(2-ethyl-1-hexylanol); the molar ratio of (A):(B):(C) being 1:1 to 10:0.0005 to 0.1. The process of claim 1 characterized in that (A) is tetrabromophthalic anhydride or tetrachlorophthalic anhydride; and (B) is 2-ethyl-1-hexanol. The process of claim 1 or 2 characterized in that the ester produced has the general formula (II): wherein: (a) A is as defined for general formula (I) in claim 1; (b) j is 3 or 4; (c) k is an integer of 1 to 50; (d) R⁹ is H or CH₃; and (e) R¹⁰ is H, a C₁₋₃₀ alkyl, or a substituted or unsubstituted aryl having up to 30 carbon atoms. The process of claims 1 to 3 characterized in that an organic solvent which is inert to the reactants and capable of forming an azeotrope with the water by-product is added, and then removed together with said water by-product. Claims for the following Contacting States : BE, DE, FR, GB, IT, NL A process for preparing esters of polyhaloaromatic carboxylic acids and anhydrides of the general formula: wherein (a) the aromatic rings can have all possible isomeric arrangements; (b) A is Br or Cl; (c) m is 3, 4, or 5; (d) q is an integer of 1 to 6; (e) R⁷ is (i) a substituted or unsubstituted C₁₋₃₀ alkyl or an aryl having up to 30 carbon atoms, and with a valence (v) which is an integer of 1 to 4; (ii) where: R³ is H or a substituted or unsubstituted C₁₋₃₀ alkyl, or an aryl having up to 30 carbon atoms, R⁴ is independently H or CH₃, p is an integer of 1 to 50, and t is an integer of 1 to 49; or (iii) where R⁵ is a substituted or unsubstituted C₁₋₃₀ alkyl or an aryl having up to 30 carbon atoms; and (f) s is q, m and v being as above defined, which comprises reacting: (I) at least one polyhaloaromatic carboxylic acid or anhydride (A) of the general formulae: wherein A and m are as defined above and n is 3 or 4; with (II) at least a stoichiometric quantity of alcohol or polyol (B) of the general formula: R⁷(OH) v wherein R⁷ and v are as defined above; and (III) a catalytically effective amount of at least one organometallic catalyst compound (C) selected from titanium tetraisopropoxide, titanium bis(ethyl acetate)diisopropoxyl isopropanol, titanium tetrabutoxide, and titanium tetrakis(2-ethyl-1-hexylanol); in an organic solvent which is inert to the reactants and capable of forming an azeotrope with the water-by-product, the molar ratio of (A):(B):(C) being 1:1 to 10:0.0005 to 0.1. The process of claim 1 characterized in that (A) is tetrabromophthalic anhydride or tetrachlorophthalic anhydride; and (B) is 2-ethyl-1-hexanol. The process of claim 1 or 2 characterized in that the ester produced has the general formula (II): wherein: (a) A is as defined for general formula (I) in claim 1; (b) j is 3 or 4; (c) k is an integer of 1 to 50; (d) R⁹ is H or CH₃; and (e) R¹⁰ is H, a C₁₋₃₀ alkyl, or a substituted or unsubstituted aryl having up to 30 carbon atoms.

Inventors: BOHEN JOSEPH MICHAEL, MANCUSO ANTHONY JOHN, BOHEN, JOSEPH, MICHAEL, MANCUSO, ANTHONY, JOHN
Applicants: PENNWALT CORP, PENNWALT CORPORATION
Application year: 1988
Main classification: C07C69
IPC codes: B01J31, C07B61, C07C69, C07C67