Abstract:
A hexakisazo dye suitable for dyeing cellulose, natural or synthetic polyamide meterials, leather, represented by the formula ##STR1## wherein X is --CH═CH--, --CONH--, --CRH-- (wherein R is phenyl which is unsubstituted or substituted by H or a sulfonic acid group), -SO 2  -- or --O--; Y is H, CH 3  OCH 3 , Cl or SO 3  M; A 1  and A 2  are each ##STR2## (wherein Z 1  is H, Cl, CH 3 , OH, OCH 3 , OC 2  H 5  or SO 3  M, and Z 2  is H, CH 3 , NO 2  or COOM); B 1  and B 2  are each ##STR3## (wherein Z 3  is H, OH, NH 2  Cl or COOM, Z 4  is H, Cl, CH 3 , OH OCH 3 , NH 2 , COOM or SO 3  M, and Z 5  is H, C 1  -C 4  alkyl or OH); M is H, Na, K, Li or NH 4  ; f is 0 or 1; m is 0, 1 or 2; and n is 0, 1 or 2.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to novel hexakisazo dyes suitable for dyeing cellulose, natural or synthetic polyamide materials, leather, etc. 
     2. Description of the Prior Art 
     Various azo dyes have heretofore been disclosed which are widely used and have great industrial usefulness. Accordingly, it has been desired in the art to provide more effective azo dyes. 
     SUMMARY OF THE INVENTION 
     To meet the demand, the present invention provides hexakisazo dyes which have an excellent black color, high water resistance and lightfastness and high solubility with good stability and which are useful for wider industrial applications than conventional products. 
     The present invention provides hexakisazo dyes represented by the formula ##STR4## wherein X is --CH═CH--, --CONH--, --CRH-- (wherein R is phenyl which is unsubstituted or substituted by H or a sulfonic acid group), --SO 2  -- or --O--; Y is H, CH 3 , OCH 3 , Cl or SO 3  M; A 1  and A 2  are each ##STR5## (wherein Z 1  is H, Cl, CH 3 , OH, OCH 3 , OC 2  H 5  or SO 3  M, and Z 2  is H, CH 3 , NO 2  or COOM); B 1  and B 2  are each ##STR6## (wherein Z 3  is H, OH, NH 2 , Cl or COOM, Z 4  is H, Cl, CH 3 , OH, OCH 3 , NH 2 , COOM or SO 3  M, and Z 5  is H, C 1  -C 4  alkyl or OH); M is H, Na, K, Li or NH 4  ; f is 0 or 1; m is 0, 1 or 2; and n is 0, 1 or 2. 
     The hexakisazo dyes according to the present invention have an excellent black color and are outstanding in properties such as water resistance, lightfastness, solution stability and the like. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The hexakisazo dyes of the present invention represented by the formula (1) are prepared by the following process. 
     First step 
     A disazo dye is prepared by tetrazotizing in the usual manner a compound represented by the formula ##STR7## wherein X is --CH═CH--, --CONH, --CRH-- (wherein R is phenyl which is unsubstituted or substituted by H or a sulfonic acid group), --SO 2  -- or --O--, Y is H, CH 3 , OCH 3 , Cl or SO 3  H, and f is 0 or 1, and coupling the product with a compound represented by the formula ##STR8## wherein m is 0, 1 or 2. 
     Second step 
     A tetrakisazo dye is prepared by diazotizing a compound represented by the formula ##STR9## wherein m is 0, 1 or 2, and n is 0, 1 or 2, or a compound represented by the formula ##STR10## wherein Z 1  is H, Cl, CH 3 , OCH 3 , OC 2  H 5  or SO 3  H, and Z 2  is H, CH 3 , NO 2  or COOH, and coupling the product with the disazo dye obtained by the first step. 
     Third step 
     The desired hexakisazo dye is prepared by tetrazotizing the tetrakisazo dye obtained again, i.e. per the second step, and coupling the resulting tetrazotized/compound with a compound represented by the formula ##STR11## wherein Z 3  is H, OH, NH 2 , Cl or COOH and/or a compound represented by the formula ##STR12## wherein Z 4  is H, Cl, CH 3 , OH, OCH 3 , NH 2 , COOH or SO 3  H and Z 5  is H, C 1  -C 4  alkyl or OH. 
     Alternatively, the desired hexakisazo dye can be prepared by diazotizing a compound of the formula (4) or formula (5), then coupling the diazotized compound with a compound of the formula (3) to obtain a monoazo dye, coupling the monoazo dye with the tetrazotized compound prepared from a compound of the formula (2) to obtain a tetrakisazo dye, tetrazotizing the tetrakisazo dye again to obtain a tetrakisazo dye, and coupling the resulting tetrazotized compound with a compound of the formula (6) and/or a compound of the formula (7). 
     It is also possible to prepare the desired hexakisazo dye by tetrazotizing again the disazo dye obtained from the first step, then coupling the resulting compound with a compound of the formula (6) and/or a compound of the formula (7) to obtain a tetrakisazo dye, and coupling the tetrakisazo dye with the diazotized compound prepared from a compound of the formula (4) or the formula (5). 
     In the process for preparing the desired substance represented by the formula (1), it is possible to use a mixture, for example, of various amines of the formula (4) or various aniline derivatives instead of using a homogeneous starting compound. In this case, a dye mixture is obtained which is similar to the individual dyes in properties. According to the contemplated purpose, the desired dye or dye mixture obtained is purified by salting out. When converted to an alkali salt with use of a desired alkali, the dye gives a highly water-soluble dye. Examples of useful alkalis are sodium hydroxide, potassium hydroxide, lithium hydroxide, ammonia water and the like. 
     Examples of useful compounds represented by the formula (2) are 4,4&#39;-diaminostilbene-2,2&#39;-disulfonic acid, 4,4&#39;-diaminodiphenyl ether, 4,4&#39;-diaminodiphenylsulfone, 3,3&#39;-dimethylbenzidine, 3,3&#39;-dimethoxybenzidine, 3,3&#39;-dichlorobenzidine, 2,2&#39;-benzidinedisulfonic acid, 4,4&#39;-diaminodiphenylmethane, 4,4&#39;-diaminoditolylmethane, 4,4&#39;-diaminotriphenylmethane, 4,4&#39;-diamino-3,3&#39;-dimethoxy-2&#34;-sulfotriphenylmethane, 4,4&#39;-diaminobenzanilide and the like. 
     Examples of useful compounds represented by the formula (3) are 1-amino-8-naphthol-4-sulfonic acid, 2-amino-5-naphthol-7-sulfonic acid, 1-amino-8-naphthol-3,6-disulfonic acid, 1-amino-8-naphthol-4,6-disulfonic acid and the like. 
     Examples of useful compounds represented by the formula (4) are 1-aminonaphthalene, 1-amino-4-naphthalenesulfonic acid, 1-amino-5-naphthalenesulfonic acid, 1-amino-6-naphthalenesulfonic acid, 1-amino-7-naphthalenesulfonic acid, 1-amino-8-naphthalenesulfonic acid, 2-amino-1-naphthalenesulfonic acid, 5-amino-1-naphthol, 1-amino-5-naphthol-7-sulfonic acid, 2-amino-8-naphthol-6-sulfonic acid, 1-amino-8-naphthol-2,4-disulfonic acid, 1-amino-8-naphthol-3,6-disulfonic acid, 1-amino-8-naphthol-4,6-disulfonic acid and the like. 
     Examples of useful compounds represented by the formula (5) are aniline, toluidine, xylidine, p-chloroaniline, m-aminophenol, anisidine, p-phenetidine, p-cresidine, anthranilic acid, 5-sulfoanthranilic acid, p-aminobenzoic acid, metanilic acid, sulfanilic acid, p-aminosalicylic acid, p-nitroaniline and the like. 
     Examples of useful compounds represented by the formula (6) are 1-naphthol, 2-naphthol, 1-naphthol-4-sulfonic acid, 1-naphthol-5-sulfonic acid, 1-naphthol-8-sulfonic acid, 2-naphthol-6-sulfonic acid, 1-naphthol-3,6-disulfonic acid, 2-naphthol-3,6-disulfonic acid, 8-chloro-1-naphthol-3,6-disulfonic acid, 2-naphthol-3-carboxylic acid, 1-amino-6-naphthalenesulfonic acid, 2-amino-1-naphthalenesulfonic acid, 5-amino-1-naphthol, 1-amino-8-naphthol-4-sulfonic acid, 2-amino-5-naphthol-7-sulfonic acid, 2-amino-8-naphthol-6-sulfonic acid, 1-amino-8-naphthol-2,4-disulfonic acid, 1-amino-8-naphthol-3,6-disulfonic acid, 1-amino-8-naphthol-4,6-disulfonic acid and the like. 
     Examples of useful compounds represented by the formula (7) are phenol, chlorophenol, cresol, resorcinol, phenol-4-sulfonic acid, m-aminophenol, 4-tert-butylphenol, catechol, phloroglucin, 4-hydroxyanisole, 2-tert-butyl-4-hydroxyanisole, salicylic acid, 5-sulfosalicylic acid and the like. 
     Examples of suitable water-soluble organic solvents which are admixed with the dye of the formula (1) are glycol solvents such as ethylene glycol, diethylene glycol, propylene glycol and thiodiglycol, cellosolve solvents, alcohol solvents, carbitol solvents, alkanolamines and the like. Examples of water-soluble surfactants which are admixed with the dye of the formula (1) when required are N-alkylpyrrolidones, vinylpyrrolidone derivatives, anionic surfactants, nonionic surfactants, ampholytic surfactants, etc. Natural or synthetic water-soluble resins are usable as the water-soluble resin to be admixed with the dye of the formula (1). The additives usable include pH adjusting agents, disinfectants, corrosion inhibitors or metal sequestering agents, etc. 
     Examples of hexakisazo dyes embodying the invention and represented by the formula (1) are shown below in the form of free acids. These dye compounds were prepared in the following examples, in which the parts are by weight. ##STR13## 
    
    
     EXAMPLE 1 
     (Synthesis of compound example 1) 
     1. Tetrazotization of 4,4&#39;-diaminostilbene-2,2&#39;-disulfonic acid 
     4,4&#39;-Diaminostilbene-2,2&#39;-disulfonic acid (74 g, 0.2 mole) was dispersed in 2000 c.c. of water, and 27.5 g of sodium carbonate was added to the dispersion to completely dissolve the acid. The solution was thereafter stirred at a temperature of 70° to 80° C. for 1 hour. A 100 g quantity of 35% hydrochloric acid was slowly added dropwise to the solution to obtain a slurry, which was then stirred for 30 minutes. After cooling the slurry to a temperature of up to 5° C. with addition of 500 g of ice, a solution of 28 g of sodium nitrite in 100 c.c. of water was added dropwise to the slurry over a period of 30 minutes. In the meantime, the pH of the mixture was adjusted to 1.5 to 1.8. The mixture was further stirred at a temperature of up to 5° C. for 2 hours, giving a yellow slurry. 
      2. First coupling (acid coupling) 
     A 136.4 g quantity (0.4 mole) of 1-amino-8-naphthol-3,6-disulfonic acid (monosodium salt) was dispersed in 500 c.c. of water, and the dispersion was stirred for 1 hour with addition of 40 g of 50% caustic soda solution to completely dissolve the acid. The solution was added dropwise to the above slurry over a period of 30 minutes. In the meantime, the mixture was adjusted to a pH of 3.0 to 3.5. The mixture was further stirred at a temperature of up to 10° C. for 15 hours and thereafter stirred with addition of 160 g of 50% caustic soda solution for 1 hour. 
     3. Second coupling (alkaline coupling) 
     Aniline (37.2 g, 0.4 mole) was admixed with 500 c.c of water and 100 g of 35% hydrochloric acid, 200 g of ice was added to the mixture, and a solution of 28 g of sodium nitrite in 100 c.c. of water was added dropwise to the resulting mixture to effect diazotization. After stirring the mixture for 1 hour, the excess of nitrous acid was decomposed with sulfamic acid, the mixture was filtered, and the resulting filtrate was added dropwise to the first coupling solution over a period of 30 minutes. The mixture was adjusted to a pH of 8.5 to 9.0 with an aqueous solution of sodium carbonate and stirred at a temperature of up to 10° C. for 15 hours. 
     4. Third diazotization-coupling 
     To the second coupling solution was added a solution of 28 g of sodium nitrite in 100 c.c. of water, and the mixture was stirred for 30 minutes and then cooled to a temperature of up to 5° C. with addition of 1 kg of ice. A 130 g quantity of 35% hydrochloric acid was thereafter added dropwise to the mixture over a period of 30 minutes to effect tetrazotization. The mixture was adjusted to a pH of 1.5 to 1.8 and further stirred for 2 hours. Resorcin (44 g, 0.4 mole) was dispersed in 500 c.c. of water and completely dissolved therein with addition of 60 g of 50% solution of caustic soda. The solution was added dropwise to the tetrazotized solution over a period of 30 minutes. The mixture was adjusted to a pH of 8.5 to 9.0 and stirred at a temperature of up to 10° C. for 15 hours to complete the reaction. 
     5. Salting out 
     The reaction mixture was heated to 80° to 85° C., and hydrochloric acid and common salt were added to the mixture for salting out. The resulting precipitate was filtered off and washed with dilute hydrochloric acid containing common salt, giving 480 g of a wet cake of compound example 1. 
     The wet cake was dispersed in 1000 c.c. of water and completely dissolved therein with addition of 50% caustic soda solution. The solution was adjusted to a pH of 10 to 10.5, followed by filtration and drying to give 140 g of bluish black sodium salt of compound example 1. 
     EXAMPLE 2 
     (Synthesis of compound example 2) 
     1. Aniline (37.2 g, 0.4 mole) was admixed with 500 c.c. of water and 100 g of 35% hyrochloric acid, 200 g of ice was added to the mixture, and a solution of 28 g of sodium nitrite in 100 c.c. of water was added dropwise to the resulting mixture to effect diazotization. After stirring the mixture for 1 hour, the excess of nitrous acid was decomposed with sulfamic acid, followed by filtration. 
     A 136.4 g quantity (0.4 mole) of 1-amino-8-naphthol-3,6-disulfonic acid (monosodium salt) was dispersed in 500 c.c. of water, and the dispersion was stirred for 1 hour with addition of 40 g of 50% caustic soda solution to completely dissolve the acid. This solution was added dropwise to the above diazotized solution over a period of 30 minutes. The mixture was adjusted to a pH of 3.0 to 3.5 and stirred at a temperature of up to 10° C. for 15 hours. With the addition of 80 g of 50% caustic soda solution, the mixture was subsquently stirred for 1 hour. 
     2. 4,4&#39;-Diaminostilbene-2,2&#39;-disulfonic acid (74 g, 0.2 mole) was tetrazotized in the same manner as in Example 1 to obtain a yellow slurry. The slurry was added dropwise to the solution resulting from the preceding step over a period of 30 minutes. The mixture was adjusted to a pH of 8.5 to 9.0 and stirred at a temperature of up to 10° C. for 15 hours. 
     3. A solution of 28 g of sodium nitrite in 100 c.c. of water was added to the reaction mixture, followed by stirring for 30 minutes. After cooling the resulting mixture to a temperature of up to 5° C. with addition of 1 kg of ice, 130 g of 35% hydrochloric acid was added dropwise to the mixture over a period of 30 minutes to effect tetrazotization. The reaction mixture was adjusted to a pH of 1.5 to 1.8 and further stirred for 2 hours. 
     Resorcin (44 g, 0.4 mole) was dispersed in 500 c.c. of water and completely dissolved therein with addition of 60 g of 50% caustic soda solution. This solution was added dropwise to the tetrazotized solution prepared above over a period of 30 minutes. The mixture was adjusted to a pH of 8.5 to 9.0 and stirred at a temperature of up to 10° C. for 15 hours to complete the reaction. 
     4. The reaction mixture was subjected to aftertreatment in the same manner as in Example 1, giving 520 g of wet cake of compound example 2. The wet cake was dispersed in 1000 c.c. of water and completely dissolved therein with addition of 50% lithium hydroxide solution. The solution was adjusted to a pH of about 10, followed by filtration and drying to give 135 g of the lithium salt of compound example 2 which was black. 
     EXAMPLE 3 
     (Synthesis of compound example 9) 
     1. Tetrazotization of 3,3&#39;-dimethylbenzidine 
     3,3&#39;-Dimethylbenzidine (42.4 g, 0.2 mole) was dispersed in 500 c.c. of water, and the dispersion was stirred at a temperature of 70° to 80° C. for 1 hour with addition of 130 g of 35% hydrochloric acid to completely dissolve the benzidine. After cooling the solution to a temperature of up to 5° C. with addition of 500 g of ice, a solution of 28 g of sodium nitrite in 100 c.c. of water was added dropwise to the solution. In the meantime, the mixture was adjusted to a pH of 1.5 to 1.8 and further stirred at a temperature of up to 5° C. for 2 hours to obtain a yellow solution. 
     2. First coupling (acid coupling) 
     A 136.4 g quantity (0.4 mole) of 1-amino-8-naphthol-3,6-disulfonic acid (monosodium salt) was dispersed in 500 c.c. of water. The dispersion was stirred for 1 hour with addition of 40 g of 50% caustic soda solution to completely dissolve the acid. This solution was added dropwise to the yellow solution over a period of 30 minutes. In the meantime, the mixture was adjusted to a pH of 3.0 to 3.5. The mixture was further stirred at a temperature of up to 10° C. for 15 hours and subsequently stirred for 1 hour with addition of 160 g of 50% caustic soda solution. 
     3. Second coupling (alkaline coupling) 
     Sulfanilic acid (69.2 g, 0.4 mole) was dispersed in 300 c.c. of water, and the dispersion was stirred at 70° to 80° C. for 30 minutes with addition of 21.2 g of sodium carbonate to completely dissolve the acid, followed by cooling to 20° C. A solution of 28 g of sodium nitrite in 100 c.c. of water was then added to the solution. The mixture was stirred for 30 minutes and cooled to a temperature of up to 5° C. with addition of 200 g of ice. A 120 g quantity of 35% hydrochloric acid was thereafter added dropwise to the mixture to effect diazotization. The resulting mixture was added dropwise to the solution obtained by the preceding step over a period of 30 minutes. The mixture was adjusted to a pH of 8.5 to 9.0 with an aqueous solution of sodium carbonate and stirred at a temperature of up to 10° C. for 15 hours. 
     4. The reaction mixture was then tetrazotized again in the same manner as in Example 1. A solution prepared by dispersing 44 g (0.4 mole) of m-aminophenol in 500 c.c. of water and adding 60 g of 50% caustic soda solution to the dispersion was added dropwise to the resulting reaction mixture. The mixture was adjusted to a pH of 8.5 to 9.0 and stirred at a temperature of up to 10° C. for 15 hours to complete the reaction. 
     5. The same aftertreatment as in Example 1 then followed to afford a wet cake of compound example 3. The wet cake was dispersed in 400 c.c. of water, and the dispersion was adjusted to a pH of 10 to 10.5 with 50% caustic soda solution and filtered. The filtrate was adjusted to an amount of 1000 g, giving a 15% concentrated aqueous solution of black compound example 3. 
     EXAMPLES 4-20 
     The following products were prepared in the same manner as in Examples 1 to 3. 
     
                       TABLE 1______________________________________Example  Compound example Color______________________________________4        3                Bluish black5        4                Black6        5                Black7        6                Bluish black8        7                Bluish black9        8                Reddish black10       10               Reddish black11       11               Reddish black12       12               Black13       13               Reddish black14       14               Reddish black15       15               Reddish black16       16               Bluish black17       17               Reddish black18       18               Reddish black19       19               Bluish black20       20               Reddish black______________________________________ 
    
     EXAMPLE 21 
     Bleached pulp of conifer (NBKP) was beaten to the desired degree of looseness by a beater. An aqueous solution of the dye prepared in Example 1 was added to the pulp to a specified concentration to dye the pulp. Fifteen minutes later, a sizing agent was added to the pulp in an amount of about 1% based on the pulp. Subsequently, about 2% of alum cake was added to the pulp for fixing. 
     Paper dyed reddish black was prepared from the paper stock. The dye had a satisfactory buildup property, and the dyed product had high color fastness. 
     EXAMPLE 22 
     Cotton cloth was dyed under the following conditions to obtain black cloth. 
     
         ______________________________________Dye of compound example 3 (Na salt)                  4.0% o.w.f.Anhydrous sodium sulfate                 10.0% o.w.f.Liquor ratio          40:1Temperature, time     100° C., 60 min.______________________________________ 
    
     The dye had a satisfactory buildup property, and the dyed product had high color fastness. 
     EXAMPLE 23 
     Chrome-tanned leather was pretreated with water at 50° C. and placed into a drum along with a 1% warm aqueous solution of the dye (Na salt) of compound example 8 in twice the quantity of the leather. The drum was rotated at 50° to 60° C. for 40 minutes, and thereafter rotated for 20 minutes with addition of a 10% aqueous solution of formic acid to fix the dye, followed by washing with water and drying. Reddish black leather was obtained. The dye had a satisfactory buildup property, and the dyed product had high color fastness. 
     Advantages of the invention 
     By suitably selecting the materials to be reacted, the present invention affords a wide variety of novel hexakisazo dyes ranging from the direct dye type to the acid dye type. The present dyes have an excellent color of the black type, are outstanding in properties such as water resistance, lightfastness and solution stability and are extremely effective for dyeing cellulose, natural or synthetic polyamide materials and leather. Thus, the dyes of the invention have great industrial usefulness.