Patent Description:
Certain <NUM>,<NUM>-bis(aminophenyl)fluorene compounds, such as <NUM>,<NUM>-bis(<NUM>,<NUM>-dichloro-<NUM>-aminophenol)fluorene compound ("CAF"), are known to be useful as curing agents for epoxy resins (see, for example, <CIT>).

Synthesis of high purity CAF can generate a large amount of waste. For example, in the CAF synthesis method described in <CIT> is conducted in a large excess of <NUM>-chloroaniline, the reaction product is precipitated in methanol and then washed in methanol. Handling the large excess volume of <NUM>-chloroaniline, which is difficult to recycle, and large volume of waste methanol wash liquid add cost to the process.

<CIT> relates to a method for preparing a halogenated diamine oxime compound by using a <NUM>-fluorenone as a raw material and a halogenated aniline as a raw material, and a titanium-based solid super acid as a catalyst to catalyze the preparation of a bisamine compound.

The present invention is defined in claims <NUM> to <NUM> as annexed. The invention is directed to a method for making a di(aminoaryl)fluorene compound, comprising:.

In one embodiment, the di(aminoaryl)fluorene compound is <NUM>,<NUM>-bis(<NUM>,<NUM>-dichloro-<NUM>-aminophenol)fluorene.

As used herein, the term "alkoxy" means a saturated straight or branched alkyl ether radical, more typically a (C<NUM>-C<NUM>) alkyl ether radical, such as, for example, methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, tert-butoxy, sec-butoxy, n-pentoxy, or nonoxy.

As used herein, the term "alkyl" means a monovalent straight or branched saturated hydrocarbon radical, more typically, a monovalent straight or branched saturated (C<NUM>-C<NUM>) hydrocarbon radical, such as, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-hexyl, n-octyl, or n-hexadecyl.

As used herein in reference to an organic compound, the term "aromatic" means that the organic compound that comprises one or more one aryl moieties, which may each optionally be interrupted by one or more heteroatoms, typically selected from oxygen, nitrogen, and sulfur heteroatoms, and one or more of the carbon atoms of one or more one aryl moieties may optionally be substituted with one or more organic groups such as, for example, alkyl, alkoxyl, hydroxyalkyl, cycloalkyl, alkoxyalkyl, haloalkyl, aryl, alkaryl, or aralkyl.

As used herein, the term "aryl" means cyclic, coplanar <NUM>- or <NUM>-membered organic group having a delocalized, conjugated π system, with a number of π electrons that is equal to 4n+<NUM>, where n is <NUM> or a positive integer, including compounds where each of the ring members is a carbon atom, such as benzene, compounds where one or more of the ring members is a heteroatom, typically selected from oxygen, nitrogen and sulfur atoms, such as furan, pyridine, imidazole, and thiophene, and wherein one or more of the ring carbons may be substituted with one or more organic groups.

As used herein, the terminology "(Cn-Cm)" in reference to an organic group, wherein n and m are each integers, indicates that the group may contain from n carbon atoms to m carbon atoms per group.

The terms "cure" and "curing" as used herein may include polymerizing and/or cross-linking of the curable resin composition.

As used herein, the term "curing agent" means a compound or complex that is capable of dissociating to provide one or more species capable of initiating polymerization of the curable resin component of the curable resin composition of the present invention.

As used herein, the term "cycloalkyl" means a saturated (C<NUM>-C<NUM>) hydrocarbon radical that includes one or more cyclic alkyl rings, such as, for example, cyclopentyl, cyclooctyl, or adamantanyl.

As used herein, "epoxide group" means a vicinal epoxy group, that is, a <NUM>,<NUM>-epoxy group.

As used herein, the term "halo" means a halogen radical, that is, a chloro, fluoro, bromo, or iodo group.

Groups that are inert in the polymerization and are suitable as R<NUM>, R<NUM>, R<NUM>, and R<NUM> of the fluorenone compound according structure (I) and R<NUM> and R<NUM> of the aminobenzene according to structure (II) include: H, alkyl, alkoxyl, cycloalkyl, and monocylic aryl, which may optionally be substituted on one or more carbon atoms of the aryl ring with alkyl. More typically, each R<NUM>, R<NUM>, R<NUM>, and R<NUM> of the fluorenone compound according structure (I) and R<NUM> and R<NUM> of the aminobenzene according to structure (II) is independently H, (C<NUM>-C<NUM>)alkyl, (C<NUM>-C<NUM>)alkoxyl, cyclohexyl, or phenyl.

In one embodiment, each R<NUM>, R<NUM>, R<NUM>, and R<NUM> is independently H or (C<NUM>-C<NUM>)alkyl.

In one embodiment, each R<NUM>, R<NUM>, R<NUM>, and R<NUM> is H.

Suitable fluorenone compounds include fluorenone,.

In one embodiment, the fluorenone compound comprises fluorenone.

In one embodiment, R<NUM> is H or (C<NUM>-C<NUM>)alkyl, and each R<NUM> and R<NUM> is independently H, (C<NUM>-C<NUM>)alkyl, nitro, hydroxyl, or halo.

In one embodiment, R<NUM> is H and each R<NUM> and R<NUM> is independently H, (C<NUM>-C<NUM>)alkyl, nitro, hydroxyl, or halo, provided that at least one R<NUM> or R<NUM> is halo.

In one embodiment, R<NUM> is H, one R<NUM> is halo, more typically chloro, the other R<NUM> is H, and each R<NUM> is H.

In one embodiment, the aminobenzene according to structure (II) is initially present in from <NUM> to <NUM>, <NUM> to <NUM>, more typically <NUM> to <NUM>, times the stoichiometric amount, based on the amount of the fluorenone compound.

In one embodiment, the acid catalyst comprises a non-volatile strong acid that is soluble in the liquid medium, selected from the group consisting of Lewis acids having a high affinity for oxygen and Brønsted acids. Suitable Lewis acids include AlCl<NUM>, YbCl<NUM>, GdCl<NUM>, TiCl<NUM>, Al<NUM>(SO<NUM>)<NUM>, CuSO<NUM>, Yb(SO<NUM>)<NUM>, and ytterbium trifluoromethane sulfonate. Suitable Brønsted acids include methane sulfonic acid, ethane sulfonic acid, <NUM>,<NUM>-ethane disulfonic acid, propane sulfonic acid, benzene sulfonic acid, p-toluene sulfonic acid, trifluoromethane sulfonic acid, H<NUM>SO<NUM>, HCl, and H<NUM>PO<NUM>.

In one embodiment, the acid catalyst comprises a Lewis acid.

In one embodiment, the acid catalyst comprises a Brønsted acid.

In one embodiment, the acid catalyst comprises methane sulfonic acid.

The catalyst is present in a catalytically effective amount, typically from <NUM> to <NUM>, more typically from <NUM> to <NUM>, pbw catalyst per <NUM> pbw the fluorenone compound according structure (I).

In one embodiment, the solvent in which the reaction is conducted comprises an aromatic or substituted aromatic solvent:.

In one embodiment, the solvent in which the reaction is conducted is a solvent in which the fluorenone compound according to structure (I) and the aminobenzene according to structure (II) are each soluble at or near the boiling point of the solvent as well as at reduced temperature, such as at room temperature or at a temperature in the range of from <NUM> to <NUM>.

As referred to herein, an indication that a crystalline compound is "crystallizable from" a solvent means that the compound can be dissolved in the solvent at an elevated temperature and can be precipitated from the solvent in crystalline solid form by reducing the temperature of a solution of the compound in the solvent, such as wherein the compound is soluble in the solvent at near or the boiling point of the solvent and is not soluble or is only slightly soluble in the solvent at reduced temperature, such as a temperature in the range of from <NUM> to <NUM>.

As referred to herein, the terminology "at or near the boiling point of the solvent" means at temperatures in the range of from <NUM> less than the boiling point of the solvent to the boiling point of the solvent or from <NUM> less than the boiling point of the solvent to the boiling point of the solvent or from <NUM> less than the boiling point of the solvent to the boiling point of the solvent.

In one embodiment, the solvent comprises benzene, toluene, orthodichlorobenzene, xylene, napthalene, tristyrylphenol, or a mixture thereof.

In one embodiment, the solvent comprises ortho-dichlorobenzene.

In one embodiment the reaction mixture comprises from <NUM> to <NUM>, more typically <NUM> to <NUM>, parts by weight ("pbw") of the solvent per <NUM> pbw of the fluorenone compound according structure (I) initially present in the reaction mixture.

In one embodiment the reaction mixture initially comprises, per <NUM> pbw reaction mixture:.

The method of the present invention may be conducted as batch process or as a continuous process.

The fluorenone compound according structure (I), aminobenzene, catalyst, and solvent are introduced into a reaction vessel. In one embodiment, the reaction vessel comprises a continuously stirred tank reactor (a "CSTR"). Optionally, more than one CSTR may be used in series.

In one embodiment, the reaction mixture comprising the fluorenone compound according structure (I), aminobenzene, catalyst, and solvent is sparged while being stirred in the reaction vessel with an inert gas, typically nitrogen gas, for a time period, such as, for example, from <NUM> minutes to <NUM> hours, that is sufficient to reduce the amount of oxygen dissolved in the reaction mixture to no more than a negligible amount.

The reaction mixture comprising the fluorenone compound according structure (I), aminobenzene, catalyst, and solvent is heated to a temperature of from <NUM> to the boiling point of the solvent, typically from a temperature of from <NUM> less than the boiling point of the solvent up to, but not including, the boiling point of the solvent and maintained at a temperature within that range for a time period, such as, for example, from <NUM> hour to <NUM> hours, that is sufficient to run the reaction of the fluorenone compound according structure (I) and aminobenzene to the desired degree of completion.

The reaction of the fluorenone compound according structure (I) with the aminobenzene according structure (II) in the solvent and in the presence of the catalyst produces a crude product mixture comprising di(aminoaryl)fluorene compound, solvent, unreacted aminobenzene, unreacted fluorenone compound according structure (I), and acid catalyst.

Water is produced as a by-product of the reaction of the fluorenone compound according structure (I) with the aminobenzene according structure (II). In one embodiment, the water by-product of the reaction is continuously removed from the reaction vessel during the reaction.

In one embodiment, once the reaction has reached the desired degree of completion, the product mixture is cooled, typically to a temperature of less than or equal to <NUM>, and a quantity of crystalline di(aminoaryl)fluorene compound, typically from <NUM> to <NUM> pbw of crystalline di(aminoaryl)fluorene compound per <NUM> pbw of the fluorenone compound according structure (I) initially present in the reaction mixture, is added to the product mixture to seed crystallization of the di(aminoaryl)fluorene compound reaction product.

The di(aminoaryl)fluorene compound is crystallized in the product mixture by cooling the product mixture to a sufficiently low temperature, typically a temperature of from -<NUM> to <NUM>, more typically from -<NUM> to <NUM>, even more typically from <NUM> to <NUM>, and still more typically from <NUM> to <NUM>, for a sufficient period of time, typically for from <NUM> minutes to <NUM> hours, to achieve such crystallization.

In one embodiment, step (b) of the method of the present invention comprises crystallizing di(aminoaryl)fluorene compound in and directly, that is, without any intervening steps, from the product mixture formed in step (a) of the method by:.

The crystallized di(aminoaryl)fluorene compound is then isolated from the cooled product mixture by separating the cooled product mixture into crystallized di(aminoaryl)fluorene compound and a product mixture filtrate. The separation may be achieved by any applicable liquid-solid separation process, such as centrifugation, sedimentation, and/or filtration, including filtration by gravity, under pressure, with compression, or under vacuum.

The product mixture filtrate comprises solvent, unreacted aminobenzene according structure (II), unreacted fluorenone compound according structure (I), some (di(aminoaryl)fluorene compound, and acid catalyst.

In one embodiment, the method of the present invention further comprises recycling the product mixture filtrate from step (c) of the method to step (a) of the method.

In one embodiment the method of the present invention, wherein the product mixture filtrate from step (c) of the method is recycled to step (a) of the method, the global yield of di(aminoaryl)fluorene compound is greater than or equal to <NUM>%.

In one embodiment, the method further comprises washing the di(aminoaryl)fluorene compound isolated from the product mixture with a first washing liquid that comprises an aromatic or substituted aromatic solvent.

In one embodiment, the first washing liquid comprises an aromatic or substituted aromatic solvent having a boiling point of greater than or equal to <NUM> and in which the di(aminoaryl)fluorene compound is not soluble or is only slightly soluble at room temperature.

Solvents suitable as the solvent for the reaction are also suitable as the first washing liquid. In one embodiment, the choice of reaction solvent and choice of first washing solvent is the same.

In one embodiment, the first washing liquid comprises benzene, toluene, orthodichlorobenzene, a xylene, napthalene, tristyrylphenol, or a mixture thereof.

In one embodiment, the first washing liquid comprises ortho-dichlorobenzene.

In one embodiment, the step of washing with the aromatic or substituted aromatic solvent comprises one or more, more typically one, washing step(s) wherein each such washing step comprises:.

In one embodiment, the method further comprises washing the washed di(aminoaryl)fluorene compound isolated from the first washing liquid filtrate with a second washing liquid comprising water, a (C<NUM>-C<NUM>)alkanol, or a mixture thereof. In one embodiment, the second washing liquid comprises a mixture of <NUM> to <NUM> parts by weight (C<NUM>-C<NUM>)alkanol and <NUM> to <NUM> parts by weight water.

In one embodiment, the step of washing with water, alkanol, or mixture thereof comprises one or more, typically from <NUM> to <NUM>, washing steps, wherein each washing step comprises:.

Following completion of washing steps, the di(aminoaryl)fluorene compound isolated from the second washing liquid filtrate of the final washing step is dried. The drying may be active, such as, for example, subjecting the di(aminoaryl)fluorene compound to elevated temperature and/or reduced pressure, and/or passive, such as, for example, allowing the di(aminoaryl)fluorene compound to dry under ambient conditions.

In one embodiment, the di(aminoaryl)fluorene compound is dried by heating the washed di(aminoaryl)fluorene compound and/or subjecting the washed di(aminoaryl)fluorene compound to reduced pressure, typically by heating to a temperature of from ambient temperature to <NUM> at a pressure of less than <NUM> hPa (<NUM> Hg) and maintaining such conditions for a time sufficient to reduce the amount of aromatic or substituted aromatic solvent and aqueous, alcoholic, or mixed aqueous/alcoholic washing liquid filtrate to less than or equal to a desired maximum level.

In one embodiment, the washed di(aminoaryl)fluorene compound is dried at a temperature of from <NUM> to <NUM> at a pressure of from <NUM> hPa to <NUM> hPa (<NUM> Hg to <NUM> Hg) for a time period of from <NUM> to <NUM> hours.

In one embodiment, the method of the present invention consists essentially of step (a) to (d), wherein in step (a) the acid catalyst is a Bronsted acid selected from: methane sulfonic acid, ethane sulfonic acid, <NUM>,<NUM>-ethane disulfonic acid, propane sulfonic acid, benzene sulfonic acid, p-toluene sulfonic acid, trifluoromethane sulfonic acid, H<NUM>SO<NUM>, HCl, and H<NUM>PO<NUM>, preferably, methane sulfonic acid, wherein in step (c), optionally, at least a portion of the filtrate is recycled to step (a), and wherein in step (d) in one or more iterations, the di(aminoaryl)fluorene compound with the aromatic or substituted aromatic solvent is washed, and further.

In one embodiment, the method of the present invention consists of the above-described steps (a), (b), (c), (d), (e), and (f).

In one embodiment, the washed di(aminoaryl)fluorene compound comprises less than <NUM> parts by weight per million parts by weight ("ppm") residual acid catalyst.

In one embodiment, the washed di(aminoaryl)fluorene compound comprises less than <NUM> ppm of a combined amount of residual aminobenzene and aromatic or substituted aromatic solvent.

In one embodiment, the di(aminoaryl)fluorene compound made by the method of the present invention is a compound according to structure (III):
<CHM>
wherein R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, and R<NUM> are each as described above.

In one embodiment of the di(aminoaryl)fluorene compound made by the method of the present invention:.

The method of the present invention produces a high yield of di(aminoaryl)fluorene compound having a low level of impurities and generates a reduced waste stream compared to prior art methods. In one embodiment, di(aminoaryl)fluorene compound made by the method exhibits reduced toxicity compared to di(aminoaryl)fluorene compound made by prior art methods.

In Comparative Example <NUM> (which is analogous to Example <NUM> of <CIT>), fluorenone (<NUM> pbw), <NUM>-chloroaniline (<NUM> pbw), methylsulfonic acid (<NUM> pbw) were each charged to a continuously stirred tank reactor, sparged with N<NUM> for <NUM> hour, heated to <NUM>, and then held at <NUM>, while removing water formed in the reaction of the fluorenone and <NUM>-chloroaniline, for <NUM> hours to form a crude product mixture of CAF and methyl sulfonic acid in excess <NUM>-chloroaniline. The crude product mixture was allowed to cool and then introduced into a volume of methanol (<NUM> pbw) containing <NUM> pbw trimethylamine to precipitate CAF product. The precipitated CAF was separated from the mixture by filtration and washed once with methanol (<NUM> pbw) and dried.

The method of Comparative Example <NUM> yielded <NUM> pbw CAF and <NUM> pbw of waste, comprising <NUM>-chloroaniline and methanol. The washed CAF comprised <NUM> ppm methyl sulfonic acid and <NUM> ppm <NUM>-chloraniline. The global yield of CAF was <NUM>%.

In Example <NUM> of the method present invention, fluorenone (<NUM> pbw), excess <NUM>-chloroaniline (<NUM> pbw), methylsulfonic acid (<NUM> pbw), and in ortho-dichlorobenzene (<NUM> pbw) were each charged to a continuously stirred tank reactor, sparged with N<NUM> for <NUM> hour, heated to <NUM>, and then held at <NUM>, while removing water formed in the reaction of the fluorenone and <NUM>-chloroaniline, for <NUM> hours to form a crude product mixture comprising CAF, methyl sulfonic acid and <NUM>-chloroaniline in ortho-dichlorobenzene. The crude product mixture was cooled to <NUM> and solid CAF seed crystals (<NUM> pbw) were introduced to the mixture. The CAF was then recrystallized from the mixture by allowing the mixture to cool to <NUM>. The crystalline CAF was separated from the cooled mixture by filtration, washed once with ortho-dichlorobenzene (<NUM> pbw), and then washed three times in succession with volumes (<NUM> pbw, <NUM> pbw, and <NUM> pbw, respectively) of a mixture isopropyl alcohol in water (<NUM> pbw isopropyl alcohol /<NUM> pbw water).

The method of Example <NUM> yielded <NUM> pbw CAF and <NUM> pbw of waste comprising <NUM>-chloroaniline, ortho-dichlorobenzene, isopropyl alcohol, and water. The washed CAF comprised <NUM> ppm methyl sulfonic acid, <NUM> ppm <NUM>-chloraniline, and <NUM> ppm ortho-diclorobenzene. The global yield of CAF was <NUM>%.

Example <NUM> of the method of present invention was analogous to Example <NUM> of the present invention, with the added feature of recycling of ortho-dichlorobenzene. In Example <NUM> of the present invention, fluorenone (<NUM> pbw), excess <NUM>-chloroaniline (<NUM> pbw), methylsulfonic acid (<NUM> pbw), fresh ortho-dichlorobenzene (<NUM> pbw) and recycled filtrate, that is, a mixture comprising ortho-dichlorobenzene, <NUM>-chloroaniline, and methyl sulfonic acid from a previous reaction (<NUM> pbw) were each charged to a continuously stirred tank reactor, sparged with N<NUM> for <NUM> hour, heated to <NUM>, and then held at <NUM>, while removing water formed in the reaction of the fluorenone and <NUM>-chloroaniline, for <NUM> hours to form a crude product mixture of CAF, methyl sulfonic acid, and <NUM>-chloroaniline in ortho-dichlorobenzene. The crude product mixture was cooled to <NUM> and solid CAF seed crystals (<NUM> pbw) were introduced to the mixture. The CAF was then recrystallized from the mixture by allowing the mixture to cool to <NUM>. The crystalline CAF was separated from the cooled mixture by filtration, washed once with ortho-dichlorobenzene (<NUM> pbw), and then washed three times in succession with volumes (<NUM> pbw, <NUM> pbw, and <NUM> pbw, respectively) of a mixture isopropyl alcohol in water (<NUM> pbw isopropyl alcohol /<NUM> pbw water).

Claim 1:
A method for making a di(aminoaryl)fluorene compound, comprising:
(a) reacting a fluorenone compound according structure (I):
<CHM>
with excess aminobenzene according to structure (II):
<CHM>
wherein:
each R<NUM>, R<NUM>, R<NUM>, R<NUM>, R<NUM>, and R<NUM> is independently a group that is inert in the polymerization of epoxy compounds, and
R<NUM> is H or (C<NUM>-C<NUM>)alkyl,
in the presence of an acid catalyst, in a liquid medium comprising an aromatic or substituted aromatic solvent having a boiling point of greater than or equal to <NUM> and from which the di(aminoaryl)fluorene compound is crystallizable, to form a crude product mixture comprising the di(aminoaryl)fluorene compound,
(b) crystallizing di(aminoaryl)fluorene compound in the crude product mixture,
(c) separating the product mixture into crystallized di(aminoaryl)fluorene compound and a filtrate, and
(d) washing the di(aminoaryl)fluorene compound with the aromatic or substituted aromatic solvent,
wherein the solvent at steps (a) and (d) comprises ortho-dichlorobenzene.