PREPARATION OF 4,6-DIAMINORESORCINOL THROUGH A BISAZOARYLRESORCINOL INTERMEDIATE

Abstract: The present invention is a method of preparing a 4,6-bisarylazoresorcinol comprising reacting an aryldiazonium salt and resorcinol in the presence of a base and a reaction medium containing water and a water-miscible solvent at a temperature in the range of -5 DEG C to -60 DEG C. The present invention is also a method of preparing a 2-substituted 4,6-bisarylazoresorcinol comprising reacting an aryldiazonium salt with a 2-substituted resorcinol. The 4,6-bisarylazoresorcinol or 2-substituted 4,6-bisarylazoresorcinol can then be hydrogenated to a 4,6-diaminoresorcinol, which is a precursor to polybisbenzoxazoles (PBOs), polymers which are useful as insulators, solar arrays, and tear-resistant gloves.

Description: PREPARATION OF 4,6-DIAMINORESORCINOL THROUGH A BISAZOARYLRESORCINOL INTERMEDIATE This invention relates to a process for preparing 4,6-diamino-1 ,3-benzenediols (4,6-diamino-resorcinols). More specifically, it relates to the preparation of 4,6-diaminoresorcinols starting with 1,3-benzenediols (resorcinols). Diaminoresorcinols are used to prepare polybenzoxazoles (PBOs), the utility of which is discussed by, for example, Wolfe in Mark et al., The Encyclopedia of Polymer Science and Engineering, Volume 1 1, pp. 601-635, Wiley-lnterScience Publication, New York, 1988. One of the more efficient and economical methods of preparing 4,6-diaminoresorcinol is described by Lysenko (U.S. Patent No. 4,766,244), which reports the synthesis of the desired product in high purities and yields in three steps from 1 ,2,3-trichlorobenzene. Halogenated aromatic compounds have become the subject of close scrutiny in recent years. Thus, the once inexpensive and plentiful 1,2,3-trichloro-benzene is becoming expensive and hard to obtain. The questionable long-term availability of 1 ,2,3-trichloro- benzene requires that an inexpensive commodity starting material be found to prepare 4,6- diaminoresorcinol. Lysenko et al. addresses this problem somewhat in U.S. Patent No. 4,982,001 by preparing 4,6-diaminoresorcinol from the inexpensive and readily available resorcinol through a 1,3-bis(methylcarbonato)benzene intermediate. The steric hindrance of this intermediate causes nitration to take place mostly at the 4- and 6-positions, so that the desired 4,6-diaminoresorcinol can be prepared upon hydrolysis and hydrogenation. Unfortunately, a significant degree of undesirable nitration occurs at the 2-position of the intermediate, and there is the danger of forming the potentially adversely reactive styphnic acid. Zollinoer et al. (Helvetica Chimica Acta. Volume XLI. pp. 1816-1823 (1958) reports that 4,6-bisphenylazoresorcinol can be prepared from resorcinol and benzenediazonium chloride under basic conditions, using 0.1 weight percent resorcinol based on the weight of a buffered aqueous solution. This4,6-bisphenylazoresorcinol can be reduced to the corresponding 4,6-diaminoresorcinol, as shown over 100 years ago by Liebermann and Kostanecki (Berichte der Deutschen Chemischen Gesellschaft, Volume XX, pp. 3114-3119 (1888). Because the reaction between resorcinol and phenyl diazonium salts is so rapid, it is difficult to avoid making the undesirable side-product, 2,4,6-trisphenylazoresorcinol. Zollinger avoids this problem somewhat, though not entirely, by keeping the initial concentration of resorcinol at about 0.1 weight percent based on the weight of solvent. Though this approach may be practical for preparing 4,6-bisphenylazo-resorcinols on a laboratory scale, process scale preparations require higher reagent concentrations than Zollinger contemplates. The challenge, then, becomes maintaining or improving upon, at concentrations above about 0.5 weight percent loading of resorcinol, the yield and selectivity of 4,6-bisphenylazoresorcinol achieved at lower concentrations. The present invention is a method of preparing a 4,6-bisarylazoresorcinol comprising reacting an aryldiazonium salt and resorcinol in the presence of a base and a reaction medium containing water and a water-miscible solvent at a temperature in the range of -5°C to -60°C. Another aspect of the present invention is a method of preparing a 2-substituted 4,6-bisarylazoresorcinol comprising reacting an aryldiazonium salt and a 2-substituted resorcinol. A further aspect of the present invention is a compound of the general formula: where X is chloro, bromo, or n-alkyl; and Ar is an aryl group. The present invention addresses the deficiencies of the art by preparing 4,6-diaminoresorcinol not only in high yields (greater than 60 percent overall yield) and with high selectivity, but using initial concentrations of resorcinol substantially higher than contemplated by Zollinger et al., supra. In one aspect of the present invention, a 4,6-bisarylazoresorcinol is prepared by reacting an aryldiazonium salt and resorcinol in the presence of a base and a reaction medium at a temperature in the range of -5°C to -60°C. Surprisingly, it has been discovered that high yields of the desired product can be obtained, starting with high concentrations of resorcinol, when the reaction is carried out in the specified temperature range. Any aryldiazonium salt that will react with resorcinol to form the corresponding 4,6-bisarylazo-resorcinol may be used. Preferred aryldiazonium salts include phenyldiazonium salts, naphthyldiazonium salts, anthryldiazonium salts, and phenanthryidiazonium salts. More preferred aryldiazonium salts are benzenediazonium salts, such as benzenediazonium chloride, benzenediazonium bromide, benzenediazonium chloride sulfonic acid, benzenediazonium bromide sulfonic acid, carboxybenzenediazonium chloride, carboxybenzenediazonium bromide, toluenediazonium chloride, and toluenediazonium bromide; the most preferred benzenediazonium salt is benzenediazonium chloride. The aryldiazonium salt and resorcinol are advantageously dissolved together in sufficient quantities of a first solvent containing water to effect dissolution, then added to the base and a second solvent containing a water-miscible organic solvent at such a rate to control the resulting exotherm. The first solvent is advantageously maintained at a temperature of about 0°C, and the temperature of the second solvent is maintained at a temperature in the range of -5°C to -60°C. The rate of addition of the first solvent to the second solvent is such that the temperature of the reaction medium is maintained in the range of -5°C to -60°C. Though the first solvent is preferably water, it may also contain one or more water-miscible organic solvents, preferably a water-miscible organic solvent having a boiling point less than 100°C. More preferred water-miscible organic solvents include ethanol, methanol, and acetone or a combination thereof. The second solvent comprises a water-miscible organic solvent, preferably having a boiling point less than 100°C, more preferably methanol, ethanol, acetone, or a combination thereof. Most preferably, the second solvent comprises methanol and preferably not more than 60 weight percent water; more preferably not more than 30 weight percent water; and most preferably, methanol that is substantially water-free. Preferably, the w/w ratio of the first solvent to the second solvent is not more than 1 : 1 , more preferably, not more than 1 :5, most preferably, not more than 1 : 10. In combination, the first and second solvent form the reaction medium. The reaction medium preferably comprises methanol and not more than 80 weight percent water, more preferably methanol and not more than 50 weight percent water, most preferably methanol and not more than 20 weight percent water. The reaction medium is further characterized by having a freezing point below about -10°C, more preferably below -30°C, most preferably below about -60°C. The reagents and the base are essentially completely soluble in the reaction medium at the reaction temperatures (discussed herein). The mole ratio of the aryldiazonium salt to resorcinol is preferably in the range of 1.8: 1 to 2.2: 1, more preferably in the range of 1.9: 1 to 2.1 : 1, most preferably in the range of 1.95: 1 to 2.05: 1. The initial concentration of resorcinol in the reaction medium is preferably at least about 0.5 weight percent, more preferably at least about 1 weight percent, most preferably at least about 1.7 weight percent based on the weight of the medium. The base is a reagent that maintains the reaction at a pH of greater than 7. More preferably, the base is of such a strength, and used in such a concentration to maintain the reaction at a pH in the range of 10 to 14; most preferably from 11 to 13. The base is preferably sodium hydroxide, lithium hydroxide, tetrabutylammonium hydroxide, or potassium hydroxide, with sodium hydroxide being more preferred. The reaction between the aryldiazonium salt and resorcinol is carried out at a temperature in the range of about -5°C, more preferably from about -10°C, most preferably from -15°C; to -60°C, more preferably to -40°C, and most preferably to -30°C. The reaction is quite rapid, and tends to go to completion in the order of minutes. Any 2,4,6-trisarylazoresorcinol that may form preferably precipitates out of solution and can be filtered away from the desired product which remains dissolved in the reaction medium. The filtrate can then be acidified to precipitate the 4,6-bisarylazoresorcinol and the 4-arylazoresorcinol by-product. The 4,6-bisarylazoresorcinol can be purified by recrystallization in a suitable solvent such as a mixture of chloroform and ethanol, thereby removing the 4-arylazoresorcinol. The process of this aspect of the present invention reduces the levels of the 2,4,6- -trisarylazoresorcinols compared to the processes of the prior art, thereby providing greater yields of the desired 4,6-bisarylazoresorcinol, and at higher concentrations than demonstrated by Zollinger et al.. supra. The 4,6-bisarylazoresorcinol, preferably 4,6-bisphenylazoresorcinol, is useful as an intermediate to 4,6-diaminoresorcinol, as discussed below. Reaction of an Aryldiazonium Salt With a 2-Substituted Resorcinol A further aspect of the present invention is a method of preparing a 2-substituted 4,6-bisarylazoresorcinol comprising reacting an aryldiazonium salt and a 2-substituted resorcinol. The term 2-substituted refers to a substituent at the 2-position of resorcinol, specifically one that does not adversely react with the aryldiazonium salt. The preferred 2-substituted resorcinols are 2-haloresorcinols and 2-n-alkyiresorcinols; more preferred are 2-chlororesorcinol, 2-bromoresorcinol, and 2-methyl resorcinol. ' n this aspect of the invention, the undesirable by-product, trisarylazoresorcinol, cannot form due to the protecting group on the 2-position of resorcinol. Thus, the reaction conditions, including the mode of addition, the nature of solvents used, the concentration of reagents, and the pH and temperature of the reaction are not critical in this aspect of the invention. The reaction is preferably carried out in water, preferably at a temperature ranging from ambient temperature to 0°C. The preferred molar ratio of aryldiazonium salt to 2-substituted resorcinol is 2: 1, but a ratio in excess of 2: 1 is acceptable. The reaction can be carried out under acidic, basic, or neutral conditions, with basic conditions being preferred. The reaction times will vary depending primarily on the pH. Generally, the lower the pH, the slower the reaction. Hydrogenation of 4,6-Bisarylazoresorcinol or a 2-Substituted 4,6-Bisarylazoresorcinol to 4,6-Diaminoresorcinol or a 2-Substituted 4,6-Diaminoresorcinol The 4,6-bisarylazoresorcinol or 2-chloro-4,6-bisarylazoresorcinol can be hydrogenated to 4,6-diaminoresorcinol. Similarly, the 2-alkyl-4,6-bisarylazoresorcinol can be hydrogenated to a 2-alkyl-4,6-diaminoresorcinol. The hydrogenating agent can be any agent which will supply hydrogen to the reaction. Suitable hydrogenating agents include borane; metal reducing agents in acids, such as zinc and HCI; Na S 2 0 4 ; and hydrogen over a catalyst. (See March, Advanced Organic Chemistry, 4tn Edition, John Wiley and Sons, (1992) page 1224.) Hydrogen over a catalyst is preferred. Preferred catalysts include platinum, palladium over carbon, and Raney nickel; more preferred are palladium over carbon and Raney nickel. In the preferred process using hydrogen over a catalyst, the catalyst is used in an amount sufficient to catalyze the conversion of 4,6-bisarylazoresorcinol in the presence of hydrogen to the corresponding diaminoresorcinol. Preferably, 0.001 to 1 molar equivalents, more preferably from 0.01 to 0.5 molar equivalents, and most preferably from 0.01 to 0.1 molar equivalents of catalyst per equivalent of the initial concentration of the 4,6-bisarylazoresorcinol is used. The catalyst does not appear to lose activity over the course of several reactions. Thus, the catalyst may be recycled. The hydrogenation reaction can be carried out over a large pressure range, though hydrogenation of the 4,6-bisarylazoresorcinol or the 2-alkyl-4,6- -bisarylazoresorcinol is preferably carried out at low pressures, more preferably in the range of 1 to 4 atmospheres of hydrogen, most preferably at 1 atmosphere; in contrast, hydrogenation of the 2-halo-4,6-bisarylazoresorcinoi is preferably carried out at pressures in the range of 100 to 400 psi in accordance with Lysenko, supra. In general, the hydrogenation reaction is carried out at a sufficiently high temperature to promote hydrogenation, yet sufficiently low enough to inhibit the decomposition of the desired product. The temperature is preferably maintained in the range of ambient temperature to 100°C, more preferably from 40°C to 75°C. The hydrogenation reaction is advantageously carried out in the presence of a solvent, preferably an aqueous solvent that optionally contains a cosolvent, such as ethanol or methanol. The reaction can be carried out under basic, neutral or acidic conditions (provided the catalyst is stable at the pH of the reaction) and for a time sufficient to reduce substantially all of the azo groups to amino groups. The reaction is preferably carried out under approximately neutral conditions and in the substantial absence of air. The products of hydrogenation include 4,6-diaminoresorcinol or 2-alkyl-4,6- -diaminoresorcinol (hereinafter referred to as the diaminoresorcinol) and a primary aromatic amine. (In the reduction of the 2-halo-4,6-diarylazoresorcinol, the halo group is replaced with hydrogen, whereas in the reduction of the 2-alkyl-4,6-diarylazoresorcinol, the alkyl group is not replaced.) Upon the completion of the reaction and before the product is exposed to air, the product mixture is advantageously acidified to form a quaternary ammonium salt, which is more stable to oxidation than the free base. Hydrochloric acid is suitable for such purpose. The consequent quaternary ammonium salt of the diaminoresorcinol may be separated from the quaternary ammonium salt of the primary aromatic amine in a number of ways. One method of separating the aromatic amine from the diaminoresorcinol is to add sufficient acid to selectively form the monoquaternary ammonium salt of diaminoresorcinol, yet insufficient to form the quaternary ammonium salt of the primary aromatic amine. This is possible because the pk a of the primary aromatic amine is about 2 pk a units higher than the first pk a of the diaminoresorcinol. A preferred way of carrying out this selective quatemization is to add under an inert atmosphere sufficient acid, preferably hydrochloric acid, to form the monoquaternary ammonium salt of the diaminoresorcinol, yet insufficient to form the diquaternary salt. During this addition, some quaternary ammonium salt of the primary aromatic amine may form. The solvent can then be removed, preferably in vacuo and in the substantial absence of air, after which sufficient base, preferably sodium hydroxide, can be added to convert any quaternary ammonium salt of the primary aromatic amine to the corresponding free base. This free base can then be removed, for example, by steam distillation. Another method of separating the aromatic amine from the diaminoresorcinol is to add sufficient acid to the product mixture to form the diquaternary ammonium salt of diaminoresorcinol and the quaternary ammonium salt of the primary aromatic amine; remove the solvent, preferably in vacuo and in the substantial absence of air; then recrystallize the diquaternary ammonium salt of diaminoresorcinol in a solvent in which the quaternary ammonium salt of the primary aromatic amine is soluble at ambient temperatures. The recrystallizing solvent is preferably a concentrated inorganic protic acid, and more preferably from 3 N to 12 N hydrochloric acid. In each of the above methods of isolating the desired diaminoresorcinol, a small amount of an antioxidant, such as SnCI 2 can be added along with the acid to inhibit oxidation of the diaminoresorcinol. The products of this invention are useful as precursors to polybisbenzoxazoles (PBOs), polymers which are useful as insulators, solar arrays, and tear-resistant gloves. PBOs can be prepared by reacting 4,6-diaminoresorcinol with bisacids, bisacid halides, bisesters, or bisnitriles. (See Wolfe, supra.) The following examples are provided to illustrate the invention, but are not intended to limit the scope thereof. All parts and percentages are by weight unless otherwise indicated. Example 1 - Preparation of 4,6-Bisphenylazoresorcinol Concentrated aqueous HCI (5 mL) was added to a slurry of aniline (1.88 g, 0.02 mol) in water (15 mL). The resultant anilinium hydrochloride was cooled to 0°C and an aqueous solution of sodium nitrite (1.38 g, 0.02 mol in 5 mL water) was added thereto. The resultant phenyldiazonium chloride was combined with resorcinol (1.1 g, 0.01 mol), diluted to approximately 40 mL total volume with methanol, and slowly added to a -25°C solution of sodium hydroxide (3 g) in methanol (120 mL). The total volume of the reaction medium was 160 mL, which also contained 12 percent water, a 2 percent load of theoretical product, and a 0.7 percent load of resorcinol. When the addition was completed, the methanol was removed by rotary evaporation, about 100 mL of water was added, and the remaining aqueous slurry was filtered through a celite plug. Concentrated HCI was added to the filtrate (to below pH 3) and the precipitate was filtered to give crude 4,6-bisphenylazoresorcinol (3 g) as a red solid. The material was recrystallized from chloroform/ethanol (40 mL/10 mL) to give pure 4,6-bisphenylazoresorcinol as red needles (2.35 g, 73 percent). Example 2 - Preparation of 4,6-Bis(phenylazo)-2-methylresorcinol A 0.5 L 3-necked flask (flask 1), equipped with a magnetic stirring bar and a thermometer protruding to the bottom, was charged with 2-methyl resorcinol (1.24 g, 10 mmol), H 2 O (300 mL), and NaOH (4.5 g, 1 12.5 mmol). The mixture was stirred vigorously until a homogeneous solution resulted, then was cooled in an ice-water bath to 0°C to 2°C. Meanwhile, a 50 mL 3-necked flask (flask 2), equipped with a magnetic stirring bar and a thermometer protruding to the bottom, was charged with aniline (1.88 g, 20.2 mmol) and H 2 0 (6 mL), and the mixture was stirred rapidly and cooled in an ice-water bath while concentrated HCI (6 mL, 59 mmol) was added dropwise. Then, an ice-cold solution of NaN0 2 (1.38 g, 20 mmol) in H 2 0 (5 mL) was added slowly dropwise while maintaining the temperature at < 5°C, and the solution was diluted with ice-cold water (25 mL). The resulting solution in flask 2 was added dropwise to the vigorously stirred solution in flask 1 at such a rate that the temperature was maintained at <5°C. After 15 minutes, the cooling bath was removed and stirring continued at ambient temperature for 1 hour. The resultant dark mixture was filtered under suction, and the solid that collected on the filter was washed with water (50 mL). The solid was dissolved in CH 2 CI 2 (100 mL), and filtered to remove any undissolved solids. The filtrate was diluted with MeOH (0.5 L) with stirring, resulting in the separation of a solid. The solid was collected by filtration and air-dried for 16 hours to give 2.6 g (78 percent yield) of product. The sample was greater than 99 percent pure 4,6-bis(phenylazo)-2-methylresorcinol as determined by HPLC, proton and carbon NMR spectroscopy. Example 3 - Preparation of 4,6-Diaminoresorcinol Dihydrochloride 4,6-Bisphenylazoresorcinol (2.5 g, 7.85 mmol), ethanol (100 percent, 70 mL), distilled water (30 mL), concentrated hydrochloric acid (36 percent to 38 percent, 2.6 mL) and palladium (10 percent on carbon, 0.15 g) were placed in a 250 mL round-bottom flask, equipped with a magnetic stirrer and an oil bath. The temperature of the oil bath rose to 55°C and was maintained at that temperature. The reaction system was evacuated and filled with hydrogen three times, and then filled with hydrogen (1 L, STP). The stirring was started, and the hydrogenation proceeded until hydrogen uptake stopped. At the end of the reaction, the original brown slurry had turned into a colorless aqueous suspension of the catalyst. The time required for hydrogenation was approximately 3 hours, during whicn time about 0.75 L of hydrogen (STP) was consumed. The reaction flask was disconnected from the hydrogenation apparatus and the mixture flushed with nitrogen for 2 minutes. A solution of stannous chloride dihydrate (0.2 g) in hydrochloric acid (5 mL) was added in one portion. The mixture was stirred for 1 minute and then filtered to remove the catalyst. The filtrate was transferred to a flask and solvent was removed by rotary evaporation. The ethanol was azeotroped and collected for recycling, and the remaining aqueous solution was dried under reduced pressure. The residual white solid was redissolved in hydrochloric acid (5 N, 45 mL) and the resultant solution was heated at reflux for 10 minutes. The solution was then allowed to stand at ambient temperature overnight for crystallization. The product was collected by filtration on a fritted funnel, dried first under a stream of nitrogen and then in a vacuum oven at reduced pressure and 45°C for 8 hours affording 4,6-diaminoresorcinol dihydrochloride as white flakes, 1.51 g, in 90 percent yield. Example 4 - Preparation of 2-Methyl-4,6-diaminoresorcinol Dihydrochloride The desired product was prepared using the same procedure as used in Example 3. In this example, 4,6-bis(phenylazo)-2-methylresorcinol (2.6 g, 7.82 mmol), ethanol (100 percent, 70 mL), distilled water (30 mL), concentrated hydrochloric acid (36 to 38 percent, 2.6 mL) and palladium on carbon (l O percent, 0.15 g) were used. The yield of desired 2-methyl- -4,6-diaminoresorcinol dihydrochloride was 1.44 g (81 percent yield).

Claims: CLAIMS: 1. A method of preparing a 4,6-bisarylazoresorcinol comprising reacting an aryldiazonium salt and resorcinol in the presence of a base and a reaction medium containing water and a water-miscible solvent at a temperature in the range of -5°C to -60°C. 2. The method of Claim 1 wherein the reaction medium contains not more than 80 weight percent water based on the weight of the reaction medium. 3. The method of Claim 2 wherein the reaction medium comprises not more than 50 weight percent water. 4. The method of Claim 3 wherein the initial concentration of resorcinol is at least 0.7 weight percent based on the weight of the solvent. 5. The method of Claim 4 wherein the contacting temperature is maintained in the range of - 10°C to -30°C. 6. The method of Claim 5 wherein the aryldiazonium salt and resorcinol are dissolved together in water, then added to the base and the water-miscible solvent. 7. The method of Claim 6 wherein the water-miscible solvent is methanol. 8. The method of Claim 7 wherein the base is sodium hydroxide. 9. The method of Claim 8 wherein the aryldiazonium salt is benzenediazonium chloride. 10. The method of Claim 1 further comprising the step of reacting the 4,6-bisarylazoresorcinol with a hydrogenating agent to form a 4,6-diaminoresorcinol. 1 1 • The method of Claim 10 wherein the hydrogenating agent is hydrogen over a catalyst. 12. The method of Claim 11 wherein the catalyst is Raney nickel or palladium. 13. A method comprising reacting an aryldiazonium salt with a 2-substituted resorcinol to form a 2-substituted-4,6-bisarylazoresorcinol. 14. The method of Claim 13 wherein the 2-substituted resorcinol is 2-methyl resorcinol, 2-chlororesorcinol, or 2-bromoresorcinol. 15. The method of Claim 14 wherein the 2-substituted resorcinol is 2-methyl resorcinol, and the 2-substituted-4,6-bisarylazoresorcinol is 2-methyl-4,6- -bisphenylazoresorcinol. 16. The method of Claim 15 further comprising the step of reacting the 2-methyl- -4,6-bisphenylazoresorcinol with a hydrogenating agent to form 2-methyl- -4,6-diaminoresorcinol. 17. The method of Claim 16 wherein the hydrogenating reagent is hydrogen over a catalyst. where X is chloro, bromo, or n-alkyl; and Ar is an aryl group. 19. The compound of Claim 18 wherein X is methyl; and Ar is phenyl. 20. The compound of Claim 18 wherein X is chloro or bromo; and Ar is phenyl.

Inventors: KENDE ANDREW S, MORGAN TED A, NADER BASSAM S, VOSEJPKA PAUL, WU WESHI, KENDE, ANDREW, S., MORGAN, TED, A., NADER, BASSAM, S., VOSEJPKA, PAUL, WU, WESHI
Applicants: DOW CHEMICAL CO, THE DOW CHEMICAL COMPANY
Application year: 1995
Main classification: C07C245
IPC codes: B01J23, C07B61, C07C213, C07C215, C07C245, C09B41