PROCESS FOR PRODUCING BETA-HYDROXY-GAMMA-BUTYROLACTONE DERIVATIVES AND BETA-(METH)ACRYLOYLOXY-GAMMA-BUTYROLACTONE DERIVATIVES

Abstract: The present invention relates to a process for preparing corresponding β -hydroxy-γ -butyrolactone or β -methyl- β - hydroxy-γ-butyrolactone represented by the formula (1): wherein R 1 represents a hydrogen atom or a methyl group, which comprises cyanating glycidol or 2-methyl-2,3-epoxypropanol, followed by hydrolysis and further lactonization.

Description: TECHNICAL FIELD The present invention relates to a process for preparing β-hydroxy-γ-butyrolactone and β-methyl-β-hydroxy-γ-butyrolactone (hereinafter referred to as "β-hydroxy-γ-butyrolactones"), and a process for preparing β-(meth)acryloyloxy-γ-butyrolactone and β-methyl-β-(meth)acryloyloxy-γ-butyrolactone (hereinafter referred to as "β-(meth)acryloyloxy-γ-butyrolactones") which are useful as a constituent component monomer of paints, adhesives, sticking agents, resins for ink,-and the like. BACKGROUND ART As a process for preparing β-hydroxy-γ-butyrolactones used as a precursor of β-(meth)acryloyloxy-γ-butyrolactones, for example, a process of reacting glycidol with carbon monoxide at high temperature under high pressure using a noble metal catalyst as a catalyst (U.S. Patent No. 4,968,817) and a process of lactonizing an epoxidized product, obtained by reacting 3-butenoic acid with hydrogen peroxide in the presence of a platinum catalyst, after hydrating the epoxidized product (Angew. Chem., Int. Ed. Eng. 994-1000 (1966)) are known, but both of them are methods with high risk of explosion. Since it was difficult to industrially prepare β-hydroxy-γ-butyrolactones as described above, β-(meth)acryloyloxy-γ-butyrolactones using these compounds as a raw material have never been produced industrially, regardless of its expected use for various purposes For such a reason, it has been desired to develop a process for preparing β-hydroxy-γ-butyrolactones in a safe and simple manner, and a process for preparing β-(meth)acryloyloxy-γ-butyrolactones. DISCLOSURE OF THE INVENTION It is an object of the present invention to provide a process for preparing β-hydroxy-γ-butyrolactones in a safe and simple manner, and a process for preparing β-(meth)acryloyloxy-γ-butyrolactones, which are useful as a constituent component monomer of paints, adhesives, sticking agents, resins for ink, and the like, using β-hydroxy-γ-butyrolactones obtained by the above process. That is, the present invention provides a process for preparing corresponding β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone represented by the formula (1) : wherein R 1 represents a hydrogen atom or a methyl group, which comprises cyanating glycidol or 2-methyl-2,3-epoxypropanol, followed by hydrolysis and further lactonization. The present invention also provides a process for preparing corresponding β-(meth)acryloyloxy-γ-butyrolactone or β-methyl-β-(meth)acryloyloxy-γ-butyrolactone represented by the formula (2): wherein R 1 and R 2 independently represent a hydrogen atom or a methyl group, which comprises preparing β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone by the process of claim 1, and reacting the resulting β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone with (meth)acrylic acid chloride, (meth)acrylic acid or (meth)acrylic ester. In the process of the present invention, glycidol or 2-methyl-2,3-epoxypropanol is cyanated, first, in order to prepare β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone represented by the formula (1), which are referred to as β-hydroxy-γ-butyrolactones. The process of cyanation is not specifically limited, but cyanation is usually performed by the reaction with hydrocyanic acid or hydrocyanate. The process of cyanating using hydrocyanic acid includes, for example, a process of reacting glycidol or 2-methyl-2,3-epoxypropanol with hydrocyanic acid in the presence of a basic catalyst. The basic catalyst used in the reaction is not specifically limited, but an inorganic alkali salt such as sodium hydroxide, sodium carbonate and potassium carbonate is preferred because of easy control of the reaction and cheap price. Furthermore, the process of cyanating using hydrocyanate includes, for example, a process of reacting glycidol or 2-methyl-2,3-epoxypropanol with hydrocyanate in a weak acidic solution such as aqueous magnesium sulfate solution or acetic acid. The hydrocyanate used in the reaction includes various metal salts, but cheap potassium cyanate and sodium cyanate are preferably used. The reaction temperature for cyanation is preferably from -20 to 70°C, and the reaction is performed, more preferably, at a temperature ranging from -10 to 40°C for the purpose of inhibiting the side reaction. The resulting 3,4-dihydroxybutanenitrile or 3,4-dihydroxy-3-methylbutanenitrile can be used in the following reaction without being purified, but may also be purified by a conventional process. Then, the resulting 3,4-dihydroxybutanenitrile or 3,4-dihydroxy-3-methylbutanenitrile is hydrolyzed to obtain 3,4-dihydroxybutanoic acid or 3,4-dihydroxy-3-methylbutanoic acid. Hydrolysis can be performed under an acid or alkali condition, but the alkali condition is preferred in view of the yield. As an alkali used in the reaction, sodium hydroxide and potassium hydroxide are preferred because of cheap price. The reaction temperature for hydrolysis is preferably from 0 to 120°C, and more preferably from 50 to 100°C in view of the yield. The resulting alkali salt of 3,4-dihydroxybutanoic acid or 3,4-dihydroxy-3-methylbutanoic acid is neutralized by adding acid. As the acid used in this case, general mineral acids can be used. But it is preferred to use cheap sulfuric acid and hydrochloric acid, and to use an acidic ion exchange resin which is easy to remove. The 3,4-dihydroxybutanoic acid or 3,4-dihydroxy-3-methylbutanoic acid thus obtained is lactonized to obtain β-hydroxy-β-methyl-γ-butyrolactone or β-hydroxy-γ-butyrolactone. The lactonization reaction proceeds spontaneously in a usual concentration process, but may also be performed at 0-100°C under the acidic condition. As the acid used in this case, general mineral acids can be used. But it is preferred to use cheap sulfuric acid and hydrochloric acid, and to use an acidic ion exchange resin which is easy to remove. The resulting β-hydroxy-γ-butyrolactones may be purified by a conventional process, if necessary. The process for preparing β-hydroxy-γ-butyrolactones, comprising cyanating glycidol or 2-methyl-2,3-epoxypropanol, followed by hydrolysis and further lactonization was described above with reference to the respective steps, but these steps can also be performed in a single vessel without being purified during the steps according to the present invention. This means that the present invention relates to a process capable of preparing β-hydroxy-γ-butyrolactones using a simple apparatus, which is economically excellent. In the present invention, in order to obtain β-(meth)acryloyloxy-γ-butyrolactone and β-methyl-β-(meth)acryloyloxy-γ-butyrolactones represented by the formula (2), which are referred to as β-(meth)acryloyloxy-γ-butyrolactones, β-hydroxy-γ-butyrolactones obtained by the above process are esterified with (meth)acrylic acid chloride or (meth)acrylic acid, or ester-interchanged with (meth)acrylate. The β-(meth)acryloyloxy-γ-butyrolactones thus obtained may also be purified by a conventional process, if necessary. In the case of esterifying with (meth) acrylic acid chloride, a basic catalyst is usually used. The basic catalyst may be any one capable of neutralizing an acid to be produced and is not specifically limited , and examples thereof include triethylamine, pyridine and sodium hydrogencarbonate. The reaction temperature is usually from -80 to 100°C, and is preferably controlled to 0°C or lower to inhibit the side reaction, and more preferably from -80 to -20°C. In the case of esterifying with (meth)acrylic acid, a condensing agent is usually used. The condensing agent may be any general condensing agent for esterification and is not specifically limited, and examples thereof include N,N'-dicyclohexylcarbodiimide, 2-chloro-1,3-dimethylimidazolium chloride and propanesulfonic anhydride. In this case, an amine base such as 4-dimethylaminopyridine or triethylamine may be used in combination. The reaction temperature is usually from -30 to 100°C, and is preferably 0°C or higher to obtain a significant reaction rate, and more preferably from 15 to 40°C. In the case of ester-interchanging with (meth)acrylate, a conventional catalyst for esterification is used. The catalyst used in the ester interchange may be a general catalyst for ester interchange reaction and is not specifically limited, and examples thereof include tetraalkoxytitaniums such as tetrabutoxytitanium, tetraisopropoxytitanium and tetramethoxytitanium and dialkyltin oxides such as dibutyltin oxide and dioctyltin oxide. The reaction temperature is usually from -30 to 130°C, but is preferably from 60 to 110°C to remove alcohol as by-products by azeotropic distillation and to obtain a significant reaction rate. That is, in the present invention, β-(meth)acryloyloxy-γ-butyrolactones are prepared by the chemical reaction scheme shown below. (wherein R 1 and R 2 independently represent a hydrogen atom or a methyl group). BEST MODE FOR CARRYING OUT THE INVENTION The following Examples further illustrate the present invention in detail but are not to be construed to limit the scope thereof. Analysis in the Examples was performed by gas chromatography and NMR. Purity was calculated from a peak area of gas chromatogram according to the following equation. Purity (%) = (A/B) x 100 where A represents a peak area of the desired product, and B represents the sum bf a whole peak area. Furthermore, actual yield was calculated according to the following equation. Actual yield (%) = (C/D) x 100 where C represents a mol number of the desired product (calculated by multiplying a weight of the desired product containing impurities by purity, followed by division by a molecular weight of the desired product), and D represents a mol number of a raw material as a basis. <Example 1> Synthesis of β-hydroxy-γ-butyrolactone To a glass flask equipped with a stirrer, a dropping funnel, a thermometer, a Dimroth condenser and an alkali trap (aqueous sodium hydroxide solution), magnesium sulfate heptahydrate (123.2 g, 0.5 mol), potassium cyanate (32.6 g, 0.5 mol) and 300 ml of water were added, and then glycidol (37.0 g, 0.5 mol) was added dropwise from the dropping funnel with ice cooling. After stirring 7 hours, an aqueous solution obtained by adding 50 ml of water to sodium hydroxide (25 g, 0.625 mol) was added dropwise and the mixture was heated at reflux at an internal temperature of 90 to 100°C. After about 1 hour, bubbles which are considered to be ammonia gas were ovserved. After heating for 16 hours, followed by air cooling and further ice cooling, concentrated hydrochloric acid (136 g, 1.35 mol) was added dropwise. This reaction solution was concentrated by using an evaporator and water was distilled off, thereby to deposit a large amount of a salt. To the salt, 1 liter of acetone and 50 g of magnesium sulfuric anhydride were added and, after filtering together with the salt, the filtrate was concentrated to obtain 55 g of crude β-hydroxy-γ-butyrolactone. This β-hydroxy-γ-butyrolactone was purified by silica gel column chromatography to obtain β-hydroxy-γ-butyrolactone (34.8 g, 0.205 mol) . The purity of the resulting β-hydroxy-γ-butyrolactone was 98% and the actual yield was 40% (on the basis of glycidol). Spectrum data of 1 H-NMR of the product were as follows. 1 H-NMR(CDCl 3 ): 2.5 (1H, d, J=18.1Hz), 2.8 (1H, dd, J=5.9Hz, 18.1Hz), 3.5 (1H, br), 4.3 (1H, d, J=10.3Hz), 4.4 (1H, dd, J=4.3Hz, 10.3Hz), 4.7 (1H, ddd, J=2.0Hz, 4.3Hz, 5.9Hz) <Example 2> Synthesis of β-hydroxy-γ-butyrolactone In a 1 liter glass reaction vessel, glycidol (293.0 g, 3.8 mol), water (92.8 g, 5.2 mol) and potassium carbonate (8.7 g, 0.063 mol) were charged, and then a hydrocyanic acid gas (97.8 g, 3.6 mol) was fed with ice cooling over 10 hours. The reaction temperature was slowly raised within a range from 8 to 25°C. An aqueous solution obtained by adding 6. 6 g of water to potassium carbonate (3.3 g, 0.024 mol) was added twice, followed by aging at room temperature for 2 days. To the resulting reaction solution containing 3,4-dihydroxybutanenitrile, 1200 ml of water and an aqueous solution obtained by adding 500 ml of water to sodium hydroxide (197 g, 4.93 mol) were added dropwise and the mixture was heated at reflux at an internal temperature of 90 to 100°C. After about 1 hour, bubbles which are considered to be ammonia gas were observed. After heating for 18 hours, followed by air cooling and further ice cooling, concentrated hydrochloric acid (592 g, 5.92 mol) was added dropwise. This reaction solution was concentrated by using an evaporator and water was distilled off, thereby to deposit a large amount of a salt. To the salt, 1 liter of acetone and 100 g of magnesium sulfuric anhydride were added and, after filtering together with the salt, the filtrate was concentrated to obtain 348 g of crude β-hydroxy-γ-butyrolactone. This β-hydroxy-γ-butyrolactone was purified by silica gel column chromatography to obtain β-hydroxy-γ-butyrolactone (212.1 g, 2.08 mol). The purity of the resulting β-hydroxy-γ-butyrolactone was 98% and the actual yield was 51% (on the basis of glycidol). Spectrum data of 1 H-NMR of the product were as follows. 1 H-NMR(CDCl 3 ): 2.5 (1H, d, J=18.1Hz), 2.8 (1H, dd, J=5.9Hz, 18.1Hz), 3.5 (1H, br), 4.3 (1H, d, J=10.3Hz), 4.4 (1H, dd, J=4.3Hz, 10.3Hz), 4.7 (1H, ddd, J=2.0Hz, 4.3Hz, 5.9Hz) <Example 3> Synthesis of β-methacryloyloxy-γ-butyrolactone In a glass flask equipped with a stirrer, two dropping funnels, a thermometer and a Dimroth condenser, β-hydroxy-γ-butyrolactone (91.1g, 0.875mol) having a purity of 98% obtained by repeating the process of Example 1 and 500 ml of dry dichloromethane were charged, and then triethylamine (117.5 g, 1.16 mol) was charged in one dropping funnel and methacrylic acid chloride (112 g, 1.071 mol) was charged in another dropping funnel. The atmosphere in the glass flask was replaced by nitrogen and then cooled to -60 to -70°C in a dry ice-acetone bath. While stirring in the glass flask, trithylamine and methacrylic acid chloride were added dropwise with adjusting so that the amount of triethylamine becomes small excess to that of methacrylic acid chloride. After the completion of the dropwise addition, stirring was continued for 3 hours. To the reaction solution, 300 ml of water was added and a small amount of Celite was added, followed by filtration. The filtrate was washed three times with 300 ml of water using a separatory funnel and dried by adding 80 g of magnesium sulfate and, after filtering, the filtrate was concentrated to obtain 175 g of crude β-methacryloyloxy-γ-butyrolactone. This β-methacryloyloxy-γ-butyrolactone was purified by silica gel column chromatography to obtain β-methacryloyloxy-γ-butyrolactone (106.3 g, 0.625 mol). The purity of the resulting β-methacryloyloxy-γ-butyrolactone was 97% and the actual yield was 69% (on the basis of β-hydroxy-γ-butyrolactone). Spectrum data of 1 H-NMR of the product were as follows. 1 H-NMR(CDCl 3 ): 2.1 (3H, s), 2.8 (1H, d, J=18.4Hz), 3.0 (1H, dd, J=6.8Hz, 18.4Hz), 4.5 (1H, d, J=10.8Hz), 4.7 (1H, dd, J=4.8Hz, 10.8Hz), 5.6 (1H, dd, J=4.8Hz, 6.8Hz), 5.8 (1H, s), 6.3 (1H, s) INDUSTRIAL APPLICABILITY According to the process of the present invention, β-hydroxy-γ-butyrolactones can be produced in a safe and simple manner. Furthermore, by using β-hydroxy-γ-butyrolactones obtained by the process, β-(meth)acryloyloxy-γ-butyrolactones, which are useful as a constituent component monomer of paints, adhesives, sticking agents, resins for ink, and the like, can be produced.

Claims: A process for preparing corresponding β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone represented by the formula (1): wherein R 1 represents a hydrogen atom or a methyl group, which comprises cyanating glycidol or 2-methyl-2,3-epoxypropanol, followed by hydrolysis and further lactonization. A process for preparing corresponding β-(meth)acryloyloxy-γ-butyrolactone or β-methyl-β-(meth)acryloyloxy-γ-butyrolactone represented by the formula (2): wherein R 1 and R 2 independently represent a hydrogen atom or a methyl group, which comprises preparing β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone by the process of claim 1, and reacting the resulting β-hydroxy-γ-butyrolactone or β-methyl-β-hydroxy-γ-butyrolactone with (meth)acrylic acid chloride, (meth)acrylic acid or (meth)acrylic ester.

Inventors: IKEMOTO TETSUYA, MURATA NAOSHI, SAKANO KUNIHIKO, IKEMOTO, TETSUYA, MURATA, NAOSHI, SAKANO, KUNIHIKO, IKEMOTO, Tetsuya, Mitsubishi Rayon Co., Ltd., MURATA, Naoshi, Mitsubishi Rayon Co., Ltd., SAKANO, Kunihiko, Mitsubishi Rayon Co., Ltd.
Applicants: MITSUBISHI RAYON CO, MITSUBISHI RAYON CO., LTD.
Application year: 1998
Main classification: C07D307
IPC codes: C07D307