METHOD FOR PREPARING STERICALLY HINDERED ARYL PHOSPHITES

Abstract: A new process is disclosed for the manufacture of hindered aryl phosphites using derivatives of mercaptothiazole or dithiocarbamic acid as catalysts. Ortho-tertiary alkyl aryl phosphites are produced by the reaction of a phosphorus trihalide with an ortho-tertiary alkyl phenolic compound in the presence of the aforementioned catalysts.

Description: - - METHOD FOR PREPARING STERICALLY HINDERED ARYL PHOSPHITES BACKGROUND OF THE INVENTION The invention relates to a new process for the manufacture of hindered aryl phosphites using derivatives of mercapto thiazole or dithiocarbamic acid derivatives as catalysts. More particularly, ortho-tertiary alkyl aryl phosphites are produced by the reaction of a phosphorus tri halide with an ortho-tertiary alkyl phenolic compound in the presence of the aforementioned catalysts. BACKGROUND ART Aryl phosphite compounds are of great value as non discoloring stabilizers of polymers. Tris (p-nonyl phenyl) phosphite, as described in U.S. Patent 2,733,226 is widely used as a stabilizer for rubbers and plastics. This compound is manufactured by reacting p-nonyl phenol with phosphorus trichloride. The reaction proceeds very well at moderate temperature and high yields of the liquid phosphite are readily obtained US90/06619 -2- at relatively low cost. Special treatment of the product with certain acid sequestering agents improves the hydrolysis stability of the substance and the commercial material has been considered very satisfactory for many uses. More recently certain εterically hindered aryl phosphites have been developed which exhibit even greater resistance to hydrolysis and are preferred in certain applications where extreme resistance to water and steam is important. Of particular interest are a number of solid aryl phosphite compounds- which contain tertiary alkyl groups ortho to the phosphite linkage. The preparation of ortho tertiary alkyl aryl phosphites is more difficult than is the preparation of phosphites containing less hindering substituents. In fact it has proven impossible to obtain acceptable yields of good quality hindered aryl phosphites in the absence of catalysts. The formation of ortho tertiary alkyl aryl phosphites is represented: (2) (1) ■-Q - OH + PC .-Q -- -P + 3HC The highly hindering effect of the ortho tertiary alkyl group (R ) greatly inhibits the reaction and in the absence of an effective catalyst the reaction remains incomplete even after extended periods of heating and substantial quantities of partially reacted intermediates remain in the product. Such partially unreacted intermediates are very undesirable (particularly in relation to hydrolysis stability) and such preparations are worthless in the intended application. Early work showed that certain basic materials such as triethylamine, used in stoichiometric .quantities as a hydrogen chloride scavenger (U.S. 3,533,989) gave yields as high as 80% of theory of the desired product. Other basic substances such as sodium ethylate, sodium amide and lithium butyrate are proposed as catalysts in the preparation of tris(2,4-di tertiary octyl phenyl) phosphite, preferably in the absence of solvents (U.S. 4,321,218). It is noteworthy, however, that the cited inventor prefers to use a stoichiometric quantity of tri ethyl amine in the preparation of the cited phosphite compound. U.S. Patents 4,312,818 and 4,440,696 disclose a wide variety of catalysts for the preparation of triaryl phosphites. These comprise amines, ammonium salts, amides of carboxylic acids and thiocarboxylic acids and also oxygen acids of phosphorus, non-aromatic nitrogen " containing heterocycles and salts thereof, sulfones, sulfoxides and sulfonium salts, primary, secondary and tertiary phosphines and salts thereof, phosphine oxides, phosphine sulfides or esters of phosphoric acid. The objects of the present invention are to provide catalysts for the preparation of sterically hindered triaryl phosphites which produce high yields of high quality products and which are free of disadvantages and complications associated with catalysts heretofore disclosed. The achievement of these objectives will be made apparent in the description that follows: DETAILED DESCRIPTION OF THE INVENTION The catalysts to be used according to the invention comprise several classes of organic compounds not previously described as catalysts for the production of phosphites. They share the attribute that a central carbon atom is bonded to a sulfur atom and to two other hetro atoms. The following is a " structural representation of the active portion of the catalyst molecules. Z± is 0, S or N. Z 2 is N or S Of course Z and Z 2 may be further bonded to other substituents depending upon the valence as will be illustrated in Structures I-VII below which provide illustrative examples. The first group of the new catalysts are properly described as ercapto thiazole derivatives. These compounds include the molecular arrangement of carbon, • nitrogen and sulfur atoms outlined in (I). The free bonds on nitrogen and the two sulfur atoms may be attached to other atoms or groups as will be made clear in the list of compounds claimed in this invention. For example, the following compounds are included: 2-Mercaptobenzothiazole; Zinc salt of 2-mercaptobenzothiazole; Bis(benzothiazyl) disulfide; N-Tertiary butyl benzothiazole-2-sulfenamide; N-cyclohexyl benzothiazole-2-sulfenamide; N,N-dicyclohexyl benzothiazole-2-sulfenamide; N-morpholyl benzothiazole-2-sulfenamide; and 2-mercapto thiazole. A structural representation (A) describes some of the compounds. R 4 and R 5 individually are hydrogen, C^-C^ alkyl, C 2 -C 8 branched or linear alkylene; R^ and 5 combinedly may be benzo, substituted phenyl, C 2 -C 18 branched or.linear alkylene; when m is 1, Y is hydrogen, alkylamino, cycloalkylamino, a monovalent metal, morpholino, CJ-CJJ alkyl, phenyl, substituted phenyl, or benzyl; and when m is 2, Y is a bond, divalent metal, C 2 -C 8 alkylene, or alkylene diamine. Preferred compounds are those in which R 4 and 5 along with the adjacent carbons of the thiazole ring combinedly are benzo, and m is 1 or 2. Y is a bond when m is 2. Y is hydrogen, alkylamino, cyclohexyl amino, dicyclohexyl amino,- morpholino, zinc, when m=l. More preferred are those in which R 4 and R5 with the adjacent carbons combinedly are benzo, m is 1, Y is hydrogen or cyclohexylam no. The second group of catalysts covered by the invention may be generally classified as derivatives of dithiocarbamic acid possessing the molecular arrangement of carbon, nitrogen and sulfur atoms outlined in struc¬ ture (II). Here again the free bonds attached to nitrogen and sulfur are joined to other atoms or groups as clarified in the following list of compounds: Tetra methyl thiuram disulfide Tetra ethyl thiuram disulfide Tetra propyl thiuram disulfide Tetra butyl thiuram disulfide Tetra benzyl thiuram disulfide Tetra methyl thiuram monosulfide Tetra ethyl thiuram monosulfide Tetra propyl thiuram monosulfide Tetra butyl thiuram monosulfide Tetra benzyl thiuram monosulfide Structural representation B describes others of the foregoing compounds. (B) Z is -S-, -S-S-, S-metal-S; n=0, 1. When n is 1 then Rg, R- j , Rg, Rg are independently selected from hydrogen, C^-Cg branched or linear alkyl, benzo, phenyl,and substituted phenyl. When n is 0, then R g , R 7 , R g , R g are independently selected from C^-C 8 alkyl, alkylene,or alkoxy and wherein Rg and R 7 combined may be oxydialkylene. Most preferably Rg-Rγ and/or Rg-Rg with the adjacent nitrogen forms a morpholino group. The structures (III), (IV), (V) represent various mercaptothiazolines, mercaptobenzimidazoles and mercaptobenzoxadoles respectively: a mercaptothiazoline derivative of structure a mercaptobenzimidazole containing the structure a mercaptobenzoxazole containing structure (V) Various Thiocarbamyl εulfenamides and N-oxydiethylene Thiocarbamyl -N-oxydiethylenesul- fenamide may also be used as catalysts. It will be apparent to rubber chemists that many of the compounds listed are well known as vulcanization accelerators and for the most part are readily available at moderate cost. Such is not the case with many com¬ pounds previously proposed as catalysts for the prepara¬ tion of aryl phosphites. Unique and outstanding characteristics of the catalysts of the invention become apparent as these are applied in the preparation of hindered alkyl aryl phosphites. The hindered alkyl aryl phosphites of this invention are preferably of the triaryl phosphites of the formula (1) . Preferred structures for R j _, R 2 and R3 are t-butyl; t-amyl; t-octyl; t-nonyl; t-dodecyl; dimethyl benzyl; The PCI3 may incrementally be added to reactants. Rl must contain a tertiary carbon atom substituted ortho to the oxygen on the phenyl ring. The preferred substitutes are the tertiary alkyls, most preferably c ~ c i 8 a lkylε. However, it is believed that the tertiary carbon may be substituted with one or more branched alkyl, cycloalkyl or aryl groups, although the hindrance of such bulky groups may limit their commercial availability and reaction rates. Most preferred R j groups would be tertiary butyl, tertiary octyl, and tertiary amyl. R 2 and 3 are independently are selected from hydrogen, hydroxy, C 4 -C^ 8 tertiary alkyl, CJ-C2 Q alkyl; cycloalkyl, aryl, aralkyl, alkoxy. Preferred are hydrogen, tertiary alkyl, and hydroxy. The phosphites of structure (1) are formed by the reaction of a phosphorus trihalide with hydroxy- substituted aromatic compound of the formula (2) in the presence or absence of a solvent. (2) In another embodiment of the invention two different hydroxy-substituted aromatic compounds (i.e. two alkyl ■ phenols) of the structural formula (2) types are sequentially reacted with the phosphorus trihalide with the first one being present in less than stoichemetric amounts (less than 3 mols per mol of phosporous trihalide) . The second reaction completes the trihalide substitution. Thus, a (first alkyl phenol)2 - (second phenol)1 phosphite is formed. The hydroxy-substituted aromatic compound is preferably 2-t-butylphenol, 2, -di-butyl- phenol, 2,6-di-t-butylphenol, 2-(l,1-dimethylpropyl) phenol, 2-t-amylphenol, 2, -di-t-amylphenol,2-t-octyl- phenol, di-t-octylphenol, t-nonylphenol, t-dodecyl- phenol, 2-(dimethylbenzyl)phenol, 2,5-di-tert-butyl hydroquinone 2,5-di-tert-amylhydroquinone. The Reaction For example, it has been clearly demonstrated that the preferred compounds of the invention are nicely compatible with the preparative reaction mixtures consisting of an ortho tertiary alkyl phenol, a suitable solvent and phosphorus trichloride. When warmed to reaction temperature the ingredients dissolve completely to form a clear solution and remain in solution until ' the crystalline product (the alkyl aryl phosphite) is produced at the later stages of the reaction. Indeed, with a sufficient amount of a suitable solvent all will remain in clear solution as hydrogen chloride is eliminated. Upon cooling the completed reaction mixture deposits the desired crystalline reaction product. The crystalline product can be filtered off and the resulting filtrate will retain the catalyst in a reusable condition. One can recharge the catalyst containing filtrate (along with any solveit washings) into the reactor and by adding new charges of alkyl phenol and phosphorus trichloride repeat the preparation with no additional catalyst. This can be repeated numerous times. An additional advantage of the instant invention's soluble catalysts is that they do not separate along with the phosphite product as an unwanted contaminant. In the case of the prior art triethylamine used as a catalyst, the a ine will react with the evolving hydrogen chloride and will form the solvent insoluble amine hydrochloride which will contaminate the crystalline phosphite product and must be subsequently eliminated. Further, the triethylamine will be removed from the solvent and new amine must be added for a subsequent preparation.. The mode of reaction and the work up of solid tertiary alkyl aryl phosphite preparations employing the instant invention's preferred catalysts can be varied to suit the employment of equipment modifications. We have already described a process in which a proper mixture of ortho alkyl phenol, solvent, phosphorus trichloride and catalyst are heated for times sufficient for elimination of all hydrogen chloride and production of hot solvent solution of the product. Simple cooling of the mixture (preferably under agitation) produces the solid crystal- line product which may be filtered off, washed with a proper solvent and dried. The filtrate, as mentioned before, retains the solvent and may be reused for a subsequent preparation. A modification of the above described procedure involves the use of a sufficient amount of a suitable solvent to hold the product in solution even after cooling to ambient temperatures. The solution can then be transported to a different area where the solvent can be removed (usually under diminished pressure) to leave a crude solid product (still containing the catalyst and any unreacted alkyl phenol) . Treatment of the crude product with a suitable solvent ( ethanol, ethanol, isopropanol or a suitable hydrocarbon solvent) produces an insoluble purified product. Filtration will be a necessary step in this method as well as in the procedure previously described. Any of a number of solvents can be used in the preparation of hindered aryl phosphites. Hexane, heptane, octane, nonane, decane, etc. can be used a well as benzene, toluene, xylenes, etc. Other solvents may also be used. Certain alcohols are sometimes advanta¬ geously used in the work up of the products. Methanol, ethanol, isopropanol can wash out any unreacted interme¬ diates along with residual catalysts. Under certain conditions the hindered aryl phosphites can be produced in the absence of solvents. In such cases the applica- tion of alcohols, to the raw product can improve the purity, of the phosphite. The molar percent of catalyst per mole of the alkyl phenol of formula (2) should fall between about .005 to 10 mol %. The more preferred range is .01 to 2 mol percent. The most preferred range is .1 to 1 mol percent per mol of alkyl phenol. The molar ratios of hydroxy substituted aromatic compound of formula (2) to phosphorus trihalide is between 2.5:1 and 4.5:1. Preferred would be 10% above or below the stoichemetric ratio of 3:1. The amounts of solvent (if any) can vary widely and generally will range from 0.1 to 3 times the weight of reactants. The least amount useful will be that amount required to maintain the reaction mass in a liquid state at the reactor temperature. The reaction temperatures are conveniently run at reflux temperature of the reaction mass, but other fixed and variable temperature profiles over the reaction period can be utilized to optimize yield, selectivity, etc. The phosporous trihalide may, of course, be added incrementally to the reactor mass over a period of time to assure good control of reaction rate. The modes of applying the new catalysts in the preparation of sterically hindered aryl phosphite compounds are illustrated in the following examples: SYNTHESIS EXAMPLES 1 - 9 EXAMPLE 1 Preparation of tris(2,4-di-tertiary butyl phenyl)phosphite In a 500 ml 3-necked flask equipped with thermome¬ ter, reflux condenser, and heating mantle was introduced 61.9 g (0.3 mole) of 2,4-di-tertiary butyl phenol, 0.3 g 2-mercaptobenzothiazole and 100 cc of hexane. To this mix (at room temperature) was then added 13.7 g (0.1 mole) of phosphorus trichloride. The mixture was gradually heated to reflux temperature over the course of one hour. Hydrogen chloride gas was rapidly evolved. The heating was continued for a total period of eight hours when the evolution of hydrogen chloride practically ceased. Nitrogen gas was passed through the clear solution to rid th mix of any residual hydrogen chloride. The hexane was then distilled off- (diminished pressure) leaving a solid residue in the reaction flask. To this product was then added 100 cc of isopropanol. The stirred mixture formed a white εuspension of crystalline powder. The product was filtered off, washed with a small amount of isopropanol and dried. Yield = 61.2 g (94% of theory). The material melted at 181-182°C. EXAMPLE 2 In a 500 ml 3-necked flask equipped with thermome¬ ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g 2-mercaptobenzothiazole and 100 cc of heptane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux temperature for eight hours. Nitrogen was passed through the hot solution to sweep out any residual hydrogen chloride. A εtirrer waε attached and the mix was stirred and cooled (finally to 10°C) whereupon. tris(2,4-ditertiary butyl phenyl) phosphite separated as a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 91.28 g (85% of theory). The material melted at 178-184?C. EXAMPLE 3 In a 500 ml 3-necked flask equipped with thermome¬ ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g bis (benzothiazyl) disulfide and 100 cc of hexane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux temperature for eight hours. Nitrogen" was passed through the hot εolution to sweep out any residual hydrogen chloride. A εtirrer was attached and the mix was stirred and cooled (finally to 10°C) whereupon tris(2,4-ditertiary butyl phenyl) phosphite separated as a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 83.87 g (78% of theory). The material melted at 181-184°C. EXAMPLE 4 In a 500 ml 3-necked flask equipped with thermome- ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g of N-cyclohexyl benzothiazole-2-sulfenamide and 100 cc of hexane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux tempera- ture for eight hours. Nitrogen was passed through the hot solution to sweep out any reεidual hydrogen chloride. A εtirrer was attached and the mix was stirred and cooled (finally to 10°C) whereupon tris(2,4-ditertiary butyl phenyl) phosphite separated as a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 96.68 g (90% of theory). The material melted at 178-184°C. EXAMPLE 5 In a 500 ml 3-necked flask equipped with thermome¬ ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g of the zinc εalt of 2-mercaptobenzothiazole and 100 cc of hexane. ' 23.0 g (1/6 mol) of phoεphoruε trichloride waε then added and the mixture waε heated to reflux temperature for eight hourε. Nitrogen waε paεsed through the hot εolution to sweep out any reεidual hydrogen chloride. A εtirrer waε attached and the mix _ waε εtirred and cooled (finally to 10°C) whereupon triε(2,4-ditertiary butyl phenyl) phoεphite εeparated aε a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 78.35 g (73% of theory).. The material melted at 182-186°C. EXAMPLE 6 In a 500 ml 3-necked flask equipped with thermome- ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g morpholyl-benzothiazole-2-sulfenamide and 100 cc of hexane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux tempera- ture for eight hours. Nitrogen was passed through the hot solution to εweep out any residual hydrogen chloride. A stirrer was attached and the mix was stirred and cooled (finally to 10°C) whereupon tris(2,4-ditertiary butyl phenyl) phoεphite separated as a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 76.2 g (71% of theory). The material melted at 179-180°C. EXAMPLE 7 In a 500 ml 3-necked flask equipped with thermome- ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g of 2-mercapto thiazoline and 100 cc of hexane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux temperature for eight hours. Nitrogen was passed through the hot solution to εweep out any reεidual hydrogen chloride. " A εtirrer was attached and the mix was stirred and cooled (finally to 10°C) whereupon tris(2, -ditertiary butyl phenyl) phoεphite separated aε a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 87.6 g (81% of theory).. The material melted at 180-184°C. EXAMPLE 8 In a 500 ml 3-necked flask equipped with thermome- ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g of 2-mercapto benzoxazole and 100 cc of hexane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux temperature for eight hours. Nitrogen was passed through the hot solution to sweep out any residual hydrogen chloride. A stirrer was attached and the mix was stirred and cooled (finally to 10°C) whereupon tris(2,4-ditertiary butyl phenyl) phosphite εeparated aε a white cryεtalline εolid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 87.6 g (81% of theory). The material melted at 180-182°C. EXAMPLE 9 Preparation of tris (2,4-di-tertiary amyl phenyl) phosphite (2-mercapto benzothiazole catalyst) 117 g (1/2 mole) of 2,4-di-tertiary amyl phenol, 0.3 g 2-mercapto benzothiazole and 100 cc of heptane were charged into a 500 ml 3-neck flask. 23.0 g (1/6 mole) of phosphorus trichloride was added. The mixture was heated to reflux for seven hours, after which time the evolution of hydrogen chloride virtually ceased. Nitro- gen gas was pasεed through the solution to carry out any residual hydrogen chloride. The clear solution was placed in a vacuum evaporator and the heptane waε removed. The oily reεidue weighed 129 g. This was treated with 200 cc methyl alcohol whereupon a white crystalline εolid separated. This product was filtered off and washed with 50 cc of methyl alcohol and dried. The resulting tris (2,4-di-tertiary amyl phenyl) phosphite weighed 98.4 g(88%Theory) and melted sharply at 103°C. Carbon, hydrogen and nitrogen analyses gave the following: EXAMPLES 10-22 RECYCLE OF SOLVENT AND CATALYST Several series of experiments were conducted to illustrate the excellent results observed when the solvent filtrate from an initial preparation (containing the catalyst) is recharged into the reaction vessel along with new charges of hindered phenol and phosphorus trichloride. Recycle Series (A) N-cyclohexyl benzothiazole-2 sulfenamide was used as Catalyst in Examples 10-13 EXAMPLE 10 In a 500 ml 3-necked flask equipped with thermome¬ ter, reflux condenser, and heating mantle was introduced 103 g (1/2 mole) 2,4-ditertiary butyl phenol, 0.3 g of N-cyclohexyl benzothiazole-2-sulfenamide and 100 cc of hexane. 23.0 g (1/6 mole) of phosphorus trichloride was then added and the mixture was heated to reflux tempera¬ ture for eight hours. Nitrogen was passed through the hot solution to sweep out any residual hydrogen chloride. A stirrer was attached and the mix was stirred and cooled (finally to 10°C) whereupon tris(2,4-ditertiary butyl phenyl) phosphite separated. as a white crystalline solid. This was filtered off and washed with 50 cc of heptane. The dried product weighed 80.4 g (74% of theory). The material melted at 178-184°C. EXAMPLE 11 The combined filtrate and washings from 10 above (containing the catalyst) was recharged into the reaction flask,' along with 103 g of 2,4-ditertiary butyl phenol and 23.0 g phoεphoruε trichloride. After heating to reflux for eight hourε the solution was stirred and cooled and the filtered product was washed with 50 cc of heptane. The dried crystalline solid weighed 101.67 g and melted at 183-184 β C. EXAMPLE 12 The filtrate from 11 above was recharged into the reaction flask, along with 103 g 2,4-ditertiarybutyl phenol and 23 g phosphorus trichloride. After eight hours reflux, the mixture was cooled to 10 β C, filtered and worked up by washing with 50 cc heptane. The product weighed 95.2g. and melted at 183-185°C. EXAMPLE 13 The filtrate from 12 above was heated with 103 g 2,4- ditertiary butyl phenol and 23 g phosphoruε trichloride for eight hours at reflux. The solution, upon stirring and cooling deposited the crystalline -product, after washing with 50 cc of heptane the product (when dry) , weighed 96.68 g and melted at 182-185 β C. Recycle Series (Bl (N.N-Dicyclohexyl benzothiazole-2-sulfenamide aε catalyεt) EXAMPLE 14 Following the general procedure outlined in Series (A), above, 103 g of 2,4-ditertiary butyl phenol, 0.3 g N,N-dicyclohexyl benzothiazole-2-sulfenamide and 100 cc of heptane were treated with 23 g of phosphorus trichloride and heated to reflux for eight hours. The product, after washing with hexane and drying weighed 81.9 g and melted at 180-186°C. EXAMPLE 15 The filtrate and washings from Example 14 above were heated eight hours to reflux with 103 g of 2,4-ditertiary butyl phenol and 23 g phosphorus trichloride. The filtered, washed (50 cc heptane) and dried product weighed 88.7 g and melted at 183-185°C. EXAMPLE 16 The filtrate and washings from Example 15 above were again heated with 103 g 2,4-ditertiary butyl phenol and 23 g phosphorus trichloride. The product in this case weighed 83.09 g and melted at 183-185°C. Recycle Series (C) (Tetra methyl thiuram disulfide S. catalyst) EXAMPLE 17 Employing the conditions described in the above experiments 103 g of 2,4-di-tertiary butyl phenol, 0.3 g of tetramethyl thiuram disulfide, 100 c of heptane and 23 g of phoεphorus trichloride were reacted to form 78.29 g of product which melted at 179-185°C. EXAMPLE 18 The filtrate and waεhingε of Example 17 above were heated with a new charge of 103 g of 2,4-ditertiary butyl phenol and 23 g of phosphorus trichloride. The product weighed 91.63 g and melted at 182-184°C. EXAMPLE 19 The filtrate and washings of 18 above were heated with 103 g ditertiary butyl phenol and 23.0 g phosphoruε trichloride. Yield 89.3 g m.p. 180-183°C. Recycle Serieε (D) (Tetra methyl thiuram moήoεulfide as catalyst EXAMPLE 20 In the manner described above 103 g of 2,4-ditertiary butyl phenol, 0.3 g tetra methyl thiuram mono εulfide, 100 cc heptane and 23 g phoεphoruε trichloride were reacted to yield 75.1 g of triε (2,4-ditertiary butyl phenyl) phoεphite melting at 181-186°C. EXAMPLE 21 The filtrate and washings of 20 above were refluxed for eight hours with 103 g of 2,4-ditertiary butyl phenol and 23.0 g phosphorus trichloride. The filtered and washed product weighed 96.4 g and melted at 181-184 β C. EXAMPLE 22 The filtrate and washingε of 21 above were heated to reflux for eight hourε with 103 g 2,4-ditertiary butyl phenol and 23 g phoεphorus trichloride. Yield = 88.9 g of product, .p. 180-183°C. EXAMPLES 23-51 Additional preparations of triε(2,4-di-tertiary butyl phenyl)phosphite were carried out using varying amounts of 2-mercaρtobenzothiazole as catalyst and following esεentially the procedureε set forth in Examples.1-9. The yieldε of these preparations along with reaction conditions and melting points of the product appear in Table I. It can be seen from this Table that high yields of tris(2,4-di-tertiary butyl phenyl)phosphite can be obtained under certain reaction conditions using very low levels of catalyst. EXAMPLES 52-63 AND COMPARATIVE EXPERIMENTS A. B. AND C Again following the procedures outlined Examples 1-9, more triε(2,4-ditertiary butyl-phenyl)phosphite was prepared, using various catalysts within the scope of this invention, under differing reaction conditions. Also, Comparative Experiments A and B were run using prior art catalysts. Comparative Experiment C contained no catalyst. Table II clearly shows that high yields can be obtained at very low catalyst levels and that these yields are superior to representative prior art catalysts. EXAMPLE 64 Tris(2,5-ditertiary butyl-4-hydroxy phenyl) phosphite. The following were charged into a 500ml 3-neck flask: lllg(l/2 mole) of 2,5-ditertiarybutyl hydroquinone, 0.3g mercaptobenzothiazole, 200 cc toluene, 23g phosphorus trichloride. The mixture was gradually heated over a period of one hour to 81°C whereupon hydrogen chloride was evolved. The mix was heated to near 120°C for an .additional seven hours. After standing overnight and cooling to room temperature the product crystallized. A stirrer was attached and the mixture was reheated to near 100°C whereupon all had passed into solution. A stream of nitrogen gas waε paεεed through the solution to remove residual traces of hydrogen chloride. The heater was removed and the mix was stirred and cooled to room temperature where upon the product crystallized. The crystals were filtered and washed with 100 cc of toluene and then two 50 cc portions of hexane. The dried product weighed 102 g (88% of theory) and melted at 266-273°C. Ana lyε i s : Calculated Found %C 72.62 72.53 %H 9.08 9.17 %P 4.47 4.66 EXAMPLE 65 Tris(2-tertiary butyl-4-nonyl phenyl) phosphite. Using the same equipment described in Example 64, the following ingredientε were charged into the 500 ml 3-neck flask: 1-38 g (1/2 mole) of 2-tertiary butyl-4-nonyl phenol 0.4 g mercaptobenzothiazole 23.0 g (1/6 mole) of phosphorus trichloride The mixture was gradually heated to 49°C whereupon the mixture foamed quite badly. At this point 100 cc of heptane was added. Heating was continued and the temperature slowly increased to 96°C over a two hour period. Hydrogen chloride was controllably evolved and no problem with foaming was encountered. The mixture was heated between 96° and 110 β C for a further ten hours. Nitrogen gas was passed through the hot reaction mixture to remove residual hydrogen chloride. The heptane was removed by heating the mixture under diminished pressure. The resulting product was a light colored viscous liquid. The yield was 140 grams (98.67% of theory). EXAMPLE 67 Reaction of phoεphoruε trichloride (1/3 mole) with 2,4-di-tertiary amyl phenol (2/3 mole) then with 2,4-ditertiary butyl phenol (1/3 mole). One-third of a mole of phosphorus trichloride (46 g) was charged into a 500 ml 3-neck flaεk. One hundred cubic centimeters of toluene and 0.2 g mercaptobenzothiazole were added. Then 156 g (2/3 mole) of melted 2,4-di-tertiary amyl phenol was dropped in over a period of two hours, the temperature being maintained between 55° and 65°C. The temperature was then increased to 120-123°C for two hours. Nitrogen gas was passed through the hot mix to remove residual hydrogen chloride. The mix stood over the weekend at room temperature. An infrared analysiε showed no hydroxyl. The mixture was warmed to 60°C and 68.3g (1/3 mole) of solid 2,4-di-tertiary butyl phenol was added. The mix was gradually heated to 127°C (over two hours) and then heated near " that temperature for three hours longer. Nitrogen gas was bubbled through the hot mix to remove reεidual hydrogen chloride. The toluene waε removed by heating under diminished pressure. The residual product was a clear liquid that hardened to a clear glassy product on cooling. Three hundred cc of methanol was added and the mixture was stirred and heated to 60°C. • The product gradually crystallized to a white powder. After standing in the methanol at room temperature overnight the εolid product was filtered off and waεhed with 100 cc of methanol. The dried produce weighed 197.8 g (90% of theory). The material melted at 89-93°C. EXAMPLE 68 Tris(2,4-ditertiary amyl phenyl) phosphite 117 g of 2,4-ditertiary amyl phenol (1/2 mole), 0.1 g mercaptobenzothiazole, 50 cc of xylene and 24 g (1/6 mole + 5% excesε) of phosphorus trichloride were charged into a 500 ml 3-neck flask equipped with- a heating mantle, thermometer, reflux condenser and gas evolution tube. The mix was gradually heated to 72° whereupon hydrogen chloride was evolved. The mix was then heated gradually to 157 β C and kept near that temperature for a ' total heating time of eight hours. Nitrogen gaε waε passed through the hot mixture to remove residual hydrogen chloride. The xylene was removed by heating under diminished pressure. The solid product remaining in the flask was then treated with 100 cc methanol. The filtered product weighed 102.4 g. This melted at 97.5-105.5°C. The product was then heated with 200 cc of hot methanol and filtered. The product weighed 101.5 g and melted at 105-107.5 β C. TABLE I A ION f T ( 4- - *Toluene not distilled off TABLE I (Cont'd) PREPARATION of TRIS (2 , 4-dι-ter lary butyl phenyl) PHOSPHITE Yield 10 MP.°C 15 20 *Toluene not distilled off TABLE II PREPARATION of TRIS ( 2.4-di-tertiarv butyl phenyl) PHOSPHITE Example Nρ_, DTBP 52 103 10 53 103 54 103 55 103 56 103 57 103 15 58 103 59 103 60 103 61 103 62 103 20 63 206 Comparative Example A 103 . 0.10 1-0" 50 24 129 9 45.5+1.6 173.0-178.0 25 B 103 0.10 11 50 24 130 9 52.8 175.5-180.0 C 103 None 50 23 136 8 0 1 N-Dicyclohexyl benzothiazole sulfenamide 2 N-Oxydiethylene benzothiazole sulfenamide 3 Tetramethyl thiuram disulfide 30 4 Tetramethyl thiuram monosulfide 5 N-oxydiethylene thiocarbamyl-N-oxydiethylene sulfenamide 6 Zinc salt of 2-mercaptobenzothiazole 7 Zinc dibutyl dithiocarbamate 8 Zinc dibenzyl dithiocarbamate 35 9 N-cyclohexyi-2-benzothiazole sulfenamide 10 Thiόurea 11 Thiocetamide COMPARATIVE EXAMPLE D Example 68 except no catalyst added. Yield - 9.16 g, mp 102.5-107.5°C Various changes and modifications to the examples and description can be made by one skilled in the art without departing from the invention as hereinafter claimed.

Claims: CLAIMS 1. A procesε of making a triarylphosphite of formula (1) wherein R^ is a C^-C-^ tertiary alkyl, R 2 and R 3 are independently selected from hydrogen, hydroxy, C 4 -C j8 tertiary alkyl, C 1 -C 20 straight chain or branched alkyl, cycloalkyl, aryl and aralkyl groups, said process comprising: a) reacting a phosphoruε trihalide with a hydroxy-substituted aromatic compound of the formula (2) in the presence or absence of a solvent, and in the presence of 0.005 to 10 mol %, relative to the hydroxy-εubεtituted aromatic compound, of a catalyst to form a reaction mixture. (b) isolating said triaryl phosphite from said reaction mixture; said catalyst being selected from the group consisting of a mercaptothiazole derivative containing structure (I); a dithiocarbamic acid derivative containing the εtructure (II) ; N-C-S— ) a mercaptothiazoline derivative of εtructure (in); H a mercaptobenzimidazole containing the structure a mercaptobenzoxazole containing structure (V) 2. A procesε according to Claim 1 wherein the reacting εtep (a) is conducted in the presence of a solvent and the step (b) isolating step is conducted so as to leave a filtrate containing εaid εolvent and εubεtantially all of said catalyst. 3. A procesε according to Claim 2 further compriεing the repeating εteps (a) and (b) sequentially for a plurality of iterations using said filtrate to replace εubεtantially all of said εolvent and said catalyst in the reacting step (a). 4. A process according to Claim 1 wherein said iεolating step (b) consists of crystallizing εaid triaryl phosphite. 5. A proceεε according to Claim 2 wherein εaid iεolating step (b) consists of crystallizing said triaryl phosphite. 6. A process according to Claim 1 wherein εaid mercaptothiazole derivative haε the εtructure of formula wherein R 4 and R5 individually are hydrogen, C^-C^ alkyl, C 2 -C 8 branched or linear alkylene; R 4 and R 5 combinedly may be benzo, substituted phenyl, C 2 -C 18 branched or linear alkylene; when m is 1, Y is hydrogen, alkylamino, cycloalkylamino, a monovalent metal, morpholino, C-^-Cg alkyl, phenyl, substituted phenyl, or benzyl; and when m is 2, Y is a bond, divalent metal, C 2 -C 8 alkylene, or alkylene diamine. 7. A procesε according to Claim 1 wherein εaid dithiocarbamic acid derivative haε the εtructure of formula (B) wherein n is 0 or 1 and Z is -S-, -S-S-, S-Metal-S-; when n is 1, then Rg, R 7 , Rg, Rg are independently selected from hydrogen, C^-Cg branched or linear alkyl, benzo, phenyl or substituted phenyl; when n is 0, then Rg, R 7 , Rg, Rg are independently selected from C^-Cg alkyl, alkylene, alkoxy, and Rg and R 7 combinedly are oxydialkylene. 8. A process according to Claim 6 wherein R^ and R5 together with the two adjacent carbon atoms in the ring combinedly are benzo. 9. A proceεε according to Claim 8 wherein when m=2, Y iε a bond and when m=l, Y is hydrogen, alkylamino, cyclohexylamino, dicyclohexyl amino, morpholino, alkylamino, or zinc. 10. A procesε according to Claim 8 wherein m iε 1 and Y iε hydrogen or cyclohexylamino. 11. A proceεε according to Claim 1 wherein εaid catalyεt iε selected from the group consisiting of 2-mercaptobenzothiazole, zinc salt of 2-mercaptobenzo- thiazole, bis(benzothiazyl)diεulfide, N-tertiary butyl benzothiazole-2-sulfenamide, N-cyclohexylbenzothi- azole-2-εulfenamide, N,N-dicyclohexylbenzothiazole-2 -εulfenamide, N-2-morpholyl-benzothiazole-2-εulfen- amide, 2-mercaptothiazole, mercaptobenzoxazole and 2-mercaptothiazoline. 12. A process according to Claim 1 wherein said catalyεt iε^ εelected from the group consisting of tetra methylthiuram disulfide, tetraethylthiuram diεulfide, tetrapropylthiuram disulfide, tetrabutylthiruam disulfide, tetrabenzyl thiuram disulfide, tetramethyl thiuram monosulfide, tetraethylthiuram monosulfide, tetrapropylthiuram monosulfide, tetrabutylthiura monosulfide, and. tetrabenzylthiuram monoεulfide. 13. A procesε according to Claim 1 wherein the hydroxy-substituted aromatic compound is selected from the group consisting of 2-t-butylphenol, 2,4-di-tbutyl- phenol, 2,6-di-t-butylphenol, 2-(l,1-dimethylpropyl) phenol, 2-t-amylphenol, 2,4-di-t-amylphenol, 2-t-octyl- phenol, 2,4 di-t-octylphenol, 2-t-nonylphenol, 2-t-dodecyl- phenol, 2-(dimethylbenzyl)phenol, 2,5-di-tert-butyl hydroquinone, 2,5-di-tert-amylhydroquinone. 14. A process according to Claim 2 wherein said solvent iε used in step (a) and is selected from the group consisting of saturated or unsaturated aliphatics, aromatic and alkyl substituted aromatics, and halogenated aliphatics. 15. A process according to Claim 14 wherein said solvent iε εelected from the group conεisting of hexane, heptane, octane, nonane, decene, benzene, naphtha, toluene, xylene, and mixtures thereof. 16. A proceεs according to Claim 5 wherein εaid crystallizing step includes the addition of an alcohol to εaid reaction mixture. 17. A process according to Claim 1 wherein no solvent is used in said reacting step (a) and said isolating step (b) includes addition of an alcohol to said reaction mixture. 18. A process according to Claim 1 wherein said reacting step (a) uses a first hydroxy-substituted aromatic compound of formula (2) in less than stoichiometric amount and wherein said process further comprises a second reacting step identical to said step (a) except that a second hydroxy-substituted aromatic compound is added to the reaction mixture of step (a) and the reaction is then completed. 19. A procesε for making tris (2,4-ditertiary butyl phenyl) phosphite comprising: a) mixing a subεtantially stoichiometric amount of 2,4-ditertiary butylphenol with a phosphorus trihalide in a solvent in the presence of 0.005 to 10 mol percent relative to said 2,4 ditertiary butylphenol of a catalyεt selected from the group consiεting of 2-mercaptobenzothiazole, N-oxydiethylene benzothiazole εulfenamide, tetra alkylthiuram diεulfide, tetra alkylthiuram onoεulfide, N-oxydiethylene thiocar- bamyl-N-oxydiethylene. εulfenamide, zinc salt of 2-mercaptobenzothiazole, zinc dialkyl dithiocarbamate, zinc dibenzyl dithiocarbamate, N-cycloalkyl-2-benzo- thiazole sulfenamide; t-butyl benzothiazole sulfenamide, and di-cyclohexyl benzothiazole sulfenamide; b) heating to reflux temperature until hydrogen generation has substantially ceased; c) diεtilling off said solvent to leave a reaction mixture; d) adding an alcohol to said reaction mixture; e) crystallizing said- tris (2,4 ditertiary butylphenyl)phosphite; and f) filtering of ..said tris (2,4-ditertiary butylphenyl) phosphite leaving a filtrate containing said catalyst.

Inventors: HUNTER BYRON A, HUNTER, BYRON, A.
Applicants: UNIROYAL CHEM CO INC, UNIROYAL CHEMICAL COMPANY, INC.
Application year: 1990
Main classification: C07F9
IPC codes: B01J31, C07B61, C07F9