Preparation of alkyl silanes

Abstract: Olefins and metal aluminum tetralkyls react with alkylhalosilanes to yield mixtures of tetralkyl silanes which may be employed as functional fluids. For example, decene-1 and sodium aluminum tetraoctyl, NaAl(C₈H₁₇)₄, react with trichlorosilane. The mole ratio of sodium aluminum tetralkyl to halosilane is from 0.75:1.0, to 1:1, and the ratio of olefin to the metal aluminate is selected to confer in the product mixture, the desired concentra­ tion of alkyl radicals derived from the olefin.

Description: This invention relates to the reaction of olefins and alkali metal aluminum tetralkyls (also known as alkali metal aluminates) with alkyl halosilanes. This invention is particularly directed to the preparation of mixtures of tetralkylsilanes produced by this reaction. Such mixtures are useful as functional fluids. Methods for the synthesis of tetraalkyl silanes include the reaction of alkyl magnesium halides or alkyl lithiums with halosilicon compounds; Tamborski et al U.S.-A 4,367,343, and Tamborski et al , "Synthesis and Properties of Silahydrocarbons, A Class of Thermally Stable, Wide Liquid Range Fluids", Ind . Eng . Chem . Prod . Res . Dev . 22 , 172-178 (1983). GB-A-825,987 to Kali-Chemie AG discloses the reaction of trialkyl aluminums with alkyl- or arylchlorosilanes. Jenkner, GB-A-900,132 (also to Kali-Chemie) pertains to the reaction of sodium aluminum tetraethyl with halosilanes, such as silicon tetrachloride, where the reactants are used in a ratio of 4 to 1. Bakshi et al , U.S.-A-4,595,777 pertains to the process of reacting an alkylchlorosilane with a trialkylaluminum. Giraitis et al , U.S.-A-3,398,171, relates to the reaction of organosilanes and mixed metal compounds AMR n wherein A is an alkali metal and M can be aluminum. The process is conducted at a reaction temperature of -20°C. to +50°C. and uses a higher mole ratio of reactants than utilized in this invention (compare the paragraph bridging Columns 5 and 6 of the reference patent with the description of this invention given below). This invention pertains to the preparation of tetraalkylsilanes, wherein one alkyl group is comparatively small and the other three are comparatively large. The small alkyl group preferably has from one to four carbon atoms, while the larger three groups preferably have from 8 to 14 carbon atoms each. These products are prepared by a process which comprises reacting an alkali metal aluminum tetraalkyl, MAlR'₄, and an olefin R'H, with an alkyl trihalosilane, RSiX₃. In the above formulas, each X is a halide radical, R is the smaller alkyl group (preferably one to four carbons), and R' is the larger alkyl group. The process is conducted such that 3 to 4 moles of metal tetraalkyl are reacted with each 4 mole portion of alkyl trihalosilane employed. More particularly, in the process of this invention three moles of MAlR'₄ reactant combine with four moles of alkyltrihalosilane reactant. In order to assist the reaction through the effect of mass action, an excess of up to about one additional mole of MAlR'₄ can be utilized in the reaction mixture. For the process of this invention, one does not use a very large excess of MAlR'₄ reactant, since such excesses can cause the reaction to take a different course, which for the purpose of this invention is not desired; confer, Jenkner, and Giraitis et al, supra . As indicated above, an olefin reactant R'H, is used in the process of this invention, in order to provide a portion of the larger alkyl radicals in the product produced. In a highly preferred embodiment, the alkyl radical R' within the olefin differs from any of the alkyl radicals in the alkali metal aluminum tetralkyl. By use of this preferred embodiment, a product mixture can be obtained which contains alkyl groups from the aluminum compound, as well as a dissimilar alkyl group produced from the olefin. Product mixtures produced in this way can have a composition selected to have one or more desired properties. In other words, the product composition can be 'tailor made' by selecting (a) the type and concentration of the alkyl groups within the aluminum tetralkyl, (b) and the olefin reactant. Although the mechanism of the process of this invention is not known in detail, it is believed that the olefin reactant does not react directly with the alkyl trihalosilane. More particularly, it appears that the olefin first forms an unidentified reaction intermediate containing aluminum, which reacts with the alkyl trihalosilane. U. S.-A-4,711,965 describes a reaction in which a mixture of sodium aluminum tetralkyls are reacted with an alkyl halosilane to produce a mixture of tetrahydrocarbylsilane products. More particularly, a process for the preparation of tetraalkylsilanes is described, wherein one alkyl group is comparatively small and the other three are comparatively large. The small alkyl group has from 1 to about 4 carbon atoms, while the larger three groups have from about 8 to about 14 carbon atoms each. The process comprises reacting an alkali metal aluminumtetraalkyl, MAlR'₄, with an alkyl trihalosilane, RSiX₃, wherein X is a halide group and R is the smaller alkyl group, the process being conducted such about 3 to about 4 moles of metal tetraalkyl are reacted with each 4 moles within of alkyl trihalosilane employed. In the process of the invention described in this application, it is not necessary to use a mixture of sodium aluminum tetralkyls in order to prepare a mixed tetrahydrocarbylsilane product. Instead, one may use just one sodium aluminum tetralkyl, and employ an olefin in place of the second aluminum tetralkyl. The ability to replace one alkali metal aluminum tetralkyl with an olefin in the process of U.S.-A-4711965 is entirely unexpected. The process of this invention is simple, and has decided advantages. For example, with the process of the instant invention, it is unnecessary to make a second aluminum tetralkyl compound. Secondly, storage of metal aluminum tetralkyl reactants is simplified, since only one aluminum tetralkyl needs to be stored for subsequent reaction, rather than two. Furthermore, with the process of this invention, a whole family of different products can be made from one alkali metal aluminum tetralkyl. More specifically, a family of products can be made by reacting the selected tetralkyl with different, selected olefins. Although a preferred embodiment of this invention comprises the reaction of an alkyl trihalosilane with one alkali metal aluminum tetralkyl and one olefin, it is to be understood that this invention comprises processes in which more than one metal aluminate and/or olefin are employed as reactants. Products of this invention are useful as functional fluids, with such diverse suggested uses as engine lubrication, electrical insulation, and as heat transfer media. They can also be used as hydraulic fluids. The products of this invention are particularly useful under high temperature conditions where petroleum-based or synthetic hydrocarbon-based fluids cannot meet specifications. Product mixtures can be made to achieve desired rheological properties. In a highly preferred embodiment, this invention comprises a process for the preparation of a mixture of tetralkylsilanes having the formula RSiR'₃ by reacting (a) at least one metal aluminate having the formula MAlR'₄ or M'(AlR'₄)₂ with (b) at least one alkyl trihalosilane having the formula RSiX₃ in amounts such as to provide an Al/Si mol ratio of 0.75-1/1, in which formulas: R is an alkyl of 1-4 carbons, each R' is an alkyl of 8-14 carbons, M is lithium, sodium, or potassium, M' is magnesium, calcium, or barium, and each X is fluoro, chloro, or bromo; characterized in that the reaction is conducted in the presence of at least one olefin that enters into the reaction to provide an R' alkyl in the traalkylsilanes which is different from the R' alkyls provided by the metal aluminate. As stated above, the process of this invention comprises a reaction of an alkali metal aluminate, MAlR'₄. Lithium, sodium and potassium aluminates can be used, with the lithium and sodium compounds being preferred. The sodium aluminates are highly preferred for reasons of economics and availability. Preferably, each radical indicated by R' in the formula MAlR'₄ is a hydrocarbyl, straight chain alkyl radical of 8 to 14 carbon atoms; however, it is to be understood that the radicals need not be limited to this structural configuration, and the size of the radicals can be larger or smaller than those within the preferred range. The radicals of the preferred configuration and size appear to yield the more useful products, and they are preferred for that reason. However, any metal aluminate MAlR'₄ can be used for the process of this invention, so long as the radicals depicted by R' are stable under the reaction conditions employed, do not form an untoward amount of undesirable co-product when subjected to the reaction conditions employed, or unduly retard the reaction because of steric hindrance. As mentioned above, the metal aluminate reactant may contain one or more groups indicated by R'. The metal aluminate need not be pure; for example, an aluminate can be used in the reaction mixture in which it is formed. Thus for example, Na, Al, and H₂ can be reacted in a hydrocarbon to form NaAlH₄, and the unisolated NaAlH₄ can be reacted with an olefin, such as octene-1, or a mixture of olefins, such as octene-1 and decene-1 in a mole ratio of 2 to 1, and the resultant reaction mixture used as a reactant in the process of this invention. When the reactant is formed in this way, the olefin is generally used in excess. Consequently, the metal aluminate reactant used in the instant process can frequently be admixed with an olefin, or mixture of olefins from which the metal aluminate is prepared. Accordingly, the number of moles of olefin available for reaction in the metal aluminate reactant is the sum of moles of olefin in the metal aluminate plus moles of unreacted olefin admixed with the metal aluminate. An olefin is intentionally added as a reactant to the reaction mixture employed in the process of this invention. In a highly preferred embodiment, the olefin(s) added are different from the olefin(s) employed to make the metal aluminate. The amount of olefin added as a reactant is selected to confer in the product mixture, the desired concentration of R' radicals derived from the olefin. For example, one may use a mixture of 1.5 moles of olefin and 0.75 mole of sodium aluminum tetralkyl reactant. When this mole ratio is employed, the mole ratio of alkyl groups in the mixture of hydrocarbylsilanes produced will have the ratio of 2:1. In other words, there will be twice as many moles of R' radicals conferred by the metal aluminate reactant as contributed by the olefin. In general, one may use a mole ratio of olefin to metal aluminate reactant within the range of 2:1 to 20:1. Greater or lesser amounts may be used, if desired for there is no real upper or lower limit to the amount of olefin which can be employed. However, a large excess of olefin reactant may not be feasible since it takes up a considerable portion of the reactor space. If a product distribution is desired which requires an undesirable amount of olefin reactant, the process disclosed in U.S. 4,711,965, is preferred. Thus, the process of this invention can be considered to have a significant, advantageous relationship with the process of U. S. 4,711,965, infra. As discussed above, in some instances the process of the instant invention is advantageous since it obviates the need to employ a mixture of alkali metal aluminate reactants. On the other hand, in some instances the process of U.S.-A-4711965 is advantageous, since it obviates the need to employ an undesirably large amount of olefin reactant. Of course, instead of using two metal aluminates and the process of the aforementioned patent, one may employ the process of this invention using a different olefin/metal aluminate mixture, and thereby keeping the mol ratio of olefin to metal aluminate in the desired range. For example, instead of using sodium aluminum tetraoctyl and an undesirably large amount of decene-1 involving a mol ratio of olefin/metal alumitate above the desired ones, one may use the process of this invention and 'switch' the reactants, i.e. react sodium aluminum tetradecyl and octene-1 (with the alkyl trihalosilane). By changing the reactants in this way, the mol ratio is kept in the desired range of 2·20/1. The process described herein can be used to make product mixtures which are the same as or related to the product mixtures produced by the methods disclosed in U.S. 4,711,965 and 4,711,966. Examples of olefins which can be employed in the process of this invention are mentioned in the paragraph below. Most olefins available in large commercial quantities are made from natural products or by chain growth of ethylene. In either case, the olefin usually has an even number of carbon atoms. However, it is to be understood that an even number of carbon atoms is not critical, and the olefin and MAlR'₄ reactants can have R' radicals with an odd number of carbon atoms. Nevertheless, because of the more ready availability of even numbered olefins, the preferred MAlR'₄ reactants for this invention have alkyl radicals (depicted by R') that are derived from one or more of the following olefins: octene-1 decene-1 dodecene-1 tetradecene-1 Such olefins are also preferred reactants for this invention. The other reactant employed in the process of this invention is an alkyl trihalosilane, RSiX₃. In this reactant, R is a lower alkyl radical such as methyl, ethyl, propyl, butyl, isopropyl, sec -butyl or the like. Preferably, R is unbranched. More preferably, R is methyl. The three groups indicated by X are halide radicals; preferably all three are the same; however, reactants with two or three halo groups per molecule can be used. More preferably, the halide groups are chloro or bromo radicals, most preferably they are all chloro groups. Although alkyl trihalosilanes in which the alkyl group has from 1 to 4 carbon atoms, it is to be understood that one may use as a reactant a compound having the formula R''SiX₃ wherein R'' is an alkyl group that has 5 or more carbon atoms. The process of this invention is conducted using a reaction temperature that is high enough to cause the reaction to take place at a reasonable rate, but not so high that it causes an undesirable amount of side reaction or decomposition to occur. Generally speaking, a temperature above 150°C. and below 230°C. is used. Preferably, the temperature is from 180°C. to 230°C. The reaction time is not a truly independent variable but depends at least to some extent on the other reaction conditions employed such as the reaction temperature. Generally speaking, reaction is essentially complete in from 3 to 10 hours with 5 to 6 hours being typical. The reaction pressure does not have a large effect on the course of the reaction. Atmospheric, sub-atmospheric and super atmospheric pressure can be used. Atmospheric pressure or the autogenous pressure of the system are preferred. Although the process of this invention is preferably conducted using alkali metal aluminates, MAlR'₄, such as described above, it is to be borne in mind that similar reactants, e.g. alkaline earth aluminates, can also be used in this invention in substantially the same way, to produce substantially the same results. Example 1 To a 1 liter autoclave was charged 172.4 grams of a sodium aluminum tetradecyl [NaAl(C₁₀H₂₁)₄] solution consisting essentially of 167.2 millimoles of sodium aluminum tetradecyl and 334.5 millimoles of decene. The total moles of C₁₀ alkyl groups available for bonding was equal to [(4 X 167.2) + 334.5] or 1003.3 millimoles. There was also charged 74.98 grams of octene-1 (668.9 millimoles). The mole fraction of octene-1 was equal to 0.40. The autoclave was also charged with 29.4 grams of methyl trichlorosilane (196.7 millimoles). The reaction mixture was heated at 190°C. for 5 hours. It was then cooled, and hydrolyzed by slow addition to 750 milliliters of 15 percent caustic solution. The hydrolysis was conducted using rapid agitation. After hydrolysis, the organic phase was washed with caustic, and then several times with water. The organic phase was stripped under vacuum to remove excess olefin reactant and vinylidene olefin produced as a by-product. There was obtained a 94 percent yield of a silahydrocarbon mixture having the following composition: Component Mole Fraction Calculated Mole Fraction 1. CH₃Si(C₈H₁₇)₃ 0.069 0.064 2. CH₃Si(C₈H₁₇)₂(C₁₀H₂₁) 0.281 0.288 3. CH₃Si(C₈H₁₇)(C₁₀H₂₁)₂ 0.420 0.432 4. CH₃Si(C₁₀H₂₁)₃ 0.230 0.216 The calculated mole fraction set forth above is derived from the relationship (a + b)³, i.e.: a³ + 3a²b + 3ab² + b³ wherein a is the mole fraction of one alkyl component, and b is the mole fraction of the other alkyl component. The mole fraction of one component is equal to the number of moles of that component divided by the sum of the number of moles of both alkyl components available for bonding. As indicated above, the moles of alkyl component in one case is equal to the number of moles of alkyl groups present in the sodium tetralkyl aluminate reactant, plus the number of moles of excess olefin admixed with that reactant. For the other component, the moles of alkyl groups available for bonding is equal to the moles of olefin employed as reactant (c). Example 2 A 160 gram portion of metal aluminate solution used in the preceding example was stripped at a temperature below 75°C. and at a pressure of 3 mm Hg. The stripped solution contained 94.7 grams of NaAl(C₁₀H₂₁)₄ and 10.9 grams of decene-1. This mixture was charged to a 1 liter reactor with 156.4 grams of octene-1, 40 grams of heptane, and 27.3 grams of methyl trichlorosilane (182 millimoles). The total C₁₀ alkyl available was 699 millimoles, and the total C₈ alkyl available was 1396.4 millimoles. The mole fraction of C₈ alkyl was 0.666. The reaction mixture was heated and then worked up as in Example 1. Gas chromatographic analysis indicated that a 91.5 percent yield of a mixture of products was obtained. The product mixture was as follows: Component Mole Fraction Calculated Mole Fraction 1. CH₃Si(C₈H₁₇)₃ 0.22 0.30 2. CH₃Si(C₈H₁₇)₂(C₁₀H₂₁) 0.41 0.44 3. CH₃Si(C₈H₁₇)(C₁₀H₂₁)₂ 0.28 0.22 4. CH₃Si(C₁₀H₂₁)₃ 0.09 0.04 The process of this example can be extended to the use of lithium and potassium aluminum tetraalkyls in which the alkyl groups are octyl, decyl, dodecyl or tetradecyl. Such substances may be reacted with methyl, ethyl, n -propyl, isopropyl, or n -butyl trichlorosilane or the trifluoro or tribromo analogs of these substances in the presence of an olefin selected from octene-1, decene-1, dodecene-1, and tetradecene-1. The reaction can be conducted at exogenous pressure or at pressures of up to 500 psi or higher. Such elevated pressures may be imposed by use of an inert gas atmosphere, e.g. nitrogen or argon. The reactions can be conducted at 180°C. to 230°C. for 3 to 10 hours. The mole ratio of metal aluminate to trihalosilane may be in the range of (0.75:1.0) to (1.0:1.0). The mole ratio of added olefin (i.e., the olefin added as a reactant and not including any olefin present with the sodium tetralkyl aluminate) can be in the range of from (1:2) to (1:20). Example 3 To a 1 liter autoclave was charged 163 grams of a solution containing 214.3 millimoles of sodium tetraoctyl aluminate, NaAl(C₈H₁₇)₄, and 495 millimoles of octene-1. The autoclave was also charged with 113.5 grams of decene-1 (811 millimoles) and 37.7 grams of methyl trichlorosilane. The total C₈ alkyl available was equal to [(4 X 214.3) + 495], and the mole fraction of C₈ alkyl was 0.625. Reaction and workup, as in the previous examples, resulted in an 84.1 percent yield of product having the following composition: Component Mole Fraction Calculated Mole Fraction 1. CH₃Si(C₈H₁₇)₃ 0.40 0.24 2. CH₃Si(C₈H₁₇)₂(C₁₀H₂₁) 0.41 0.44 3. CH₃Si(C₈H₁₇)(C₁₀H₂₁)₂ 0.17 0.26 4. CH₃Si(C₁₀H₂₁)₃ 0.03 0.05 The sodium aluminum tetraoctyl in this and the following example was prepared using tri n -octyl aluminum as a catalyst, while the aluminate used in Examples 1 and 2 was prepared using lithium aluminum hydride as a catalyst. It will be noted that the mole fractions found in Examples 1 and 2 more closely conform to the calculated mole fractions, than the mole fractions in Examples 3 and 4. The reason for the disparity in activity between the two types of metal aluminates is unknown. The disparity in activity is also unexpected. With regard to the preparation of the tetralkyl aluminate reactant, it is known in the art that lithium aluminum hydride reacts with olefins at 110°-120°C. forming complexes with the structure LiAlR₄. Sodium aluminum hydride is not added to olefins even at 180°C. without the presence of catalytic amounts of a material selected from trialkyl aluminums, dialkyl aluminum hydrides, lithium aluminum hydride, or aluminum, zinc or lithium halide. The first three hydrogens are readily replaced at 80°-130°C., but the fourth requires a temperature of 170°-230°C. or thereabouts, for 3 to 6 hours. The process is preferentially conducted in the presence of an excess of olefin, e.g., a 1:8 mole ratio of NaAlH₄ to olefin, and 5-15 mole % (based on NaAlH₄) of the catalyst. A paraffin diluent can be used in the reaction mixture. As an illustration of the preparation of NaAlR'₄, a reactor is charged with NaAlH₄, catalyst, and olefin, and heated for 1-2 hours at 125°C., followed by 3-4 hours at 175°C. (It is believed the duration of the heating cycle can be reduced somewhat.) The product is discharged after cooling. The final product typically contains 30-65% of NaAlR₄, and is suitable for most reactions. It is not necessary that the aluminate be employed in the product mix; if desired it can be isolated from some or all of the other substances present in the resultant reaction mixture. Example 4 To a 1 liter autoclave was charged 290.8 grams of an octene-1 solution containing 382 millimoles sodium aluminum tetraoctyl. The total C₈ alkyl available from the metal aluminate and the octene-1 solvent was 2,412 millimoles. There was also added to the autoclave, 169 grams of decene-1, i.e., 1,206 millimoles. The mole fraction of C₈ alkyl was 0.666. Methyl trichlorosilane, 67.2 grams (450 millimoles) was also charged to the reaction vessel. Reaction and workup, as before, resulted in an 89.8 percent yield of a product which was shown to have the following composition: Component Mole Fraction Calculated Mole Fraction 1. CH₃Si(C₈H₁₇)₃ 0.40 0.30 2. CH₃Si(C₈H₁₇)₂(C₁₀H₂₁) 0.43 0.44 3. CH₃Si(C₈H₁₇)(C₁₀H₂₁)₂ 0.15 0.22 4. CH₃Si(C₁₀H₂₁)₃ 0.02 0.04 Example 5 In this example, a solution of sodium aluminum tetraoctyl prepared using lithium aluminum hydride as a catalyst was employed. The total solution was 131 grams. Each milliliter contained 1,303.6 millimoles of sodium aluminum tetraoctyl and 3.085 millimoles of octene-1. The total C₈ alkyl available was equal to [4 X 1.3036) + 3.085] X 131, or 1,087.2 millimoles. The reaction vessel was also charged with 76.1 grams (543.7 millimoles) of decene-1 and 30 grams (200.9 millimoles) of methyl trichlorosilane. The mole fraction of C₈ alkyl available was 0.667. Reaction and workup, as before, resulted in an 92.1 percent yield of product which, as in the previous examples, was shown by gas chromatography to have the following distribution: Component Mole Fraction Calculated Mole Fraction 1. CH₃Si(C₈H₁₇)₃ 0.36 0.30 2. CH₃Si(C₈H₁₇)₂(C₁₀H₂₁) 0.42 0.44 3. CH₃Si(C₈H₁₇)(C₁₀H₂₁)₂ 0.19 0.22 4. CH₃Si(C₁₀H₂₁)₃ 0.03 0.04 Products of this invention are useful as functional fluids, e.g. hydraulic fluids for military or other applications. Hydraulic fluids are used in hydraulic systems to transmit pressure or energy. They also serve to reduce friction in bearings and between sliding surfaces in pumps and similar articles. Hydraulic and other functional fluids also protect surfaces from rusting, and can remove undesirable particulate matter away from surfaces. Like other functional fluid base stocks, the silahydrocarbons produced by the process of this invention can be admixed with additives such as rust inhibitors, antiwear agents, corrosion inhibitors and the like.

Claims: A process for preparing a mixture of tetraalkylsilanes having the formula RSiR'₃ by reacting (a) at least one metal aluminate having the formula MAlR'₄ or M'(AlR'₄)₂ with (b) at least one alkyl trihalosilane having the formula RSiX₃ in amounts such as to provide an Al/Si mol ratio of 0.75-1/1, in which formulas: R is an alkyl of 1-4 carbons, each R' is an alkyl of 8-14 carbons, M is lithium, sodium, or potassium, M' is magnesium, calcium, or barium, and each X is fluoro, chloro, or bromo; characterized in that the reaction is conducted in the presence of at least one olefin that enters into the reaction to provide an R' alkyl in the traalkylsilanes which is different from the R' alkyls provided by the metal aluminate. The process of claim 1 conducted at a temperature in the range of 150-230°C. The process of claim 2 wherein the temperature is in the range of 180-230°C. The process of claim 1 wherein the metal aluminate reactant has the formula MAlR'₄ and the olefin/metal aluminate mol ratio in the reaction mixture is 2-20/1. The process of claim 4 wherein the metal aluminate has the formula NaAlR'₄ in which all of the R' alkyls are the same. The process of claim 5 wherein the metal aluminate is sodium tetraoctylaluminum. The process of claim 6 wherein the alkyl trihalosilane reactant is methyl trichlorosilane and the olefin reactant is decene-1. The process of claim 1 wherein the metal aluminate/alkyl trihalosilane/olefin mol ratio is 0.75/1/1.5.

Inventors: NELSON GUNNER ELWOOD, NELSON, GUNNER ELWOOD
Applicants: ALBEMARLE CORP, ALBEMARLE CORPORATION
Application year: 1989
Main classification: C07F7
IPC codes: C07F7