Patent Description:
THIS INVENTION relates to a phosphate ester composition and its use.

The use of phosphate esters of the above general formula (Formula A) as lubricants and flame retardants are well known in the art.

Tri-aryl Phosphate esters ( see Formula B below) have been used for many years and are well known in the art as additives for flame retardant plasticizers, flame retardants, anti-wear agents, boundary lubricants, antioxidants as well as functional fluids (self-extinguishing hydraulic fluids).

The first generation tri-aryl phosphates were based on phenol or refined cresols/xylenols from coal tar. These tri-aryl phosphate esters can be ortho [<NUM>, <NUM>], meta [<NUM>, <NUM>], or para [<NUM>] substituted (see Formula C below).

These "natural" materials have been slowly replaced with "synthetic" alkyl phenols (isopropyl, t-butyl, amyl, octyl, nonyl, etc.) as the performance (technical and regulatory) requirements have become more stringent. Unfortunately, in many applications the narrowing of technical performance requirements results in a trade-off with other attributes like regulatory performance and vice versa. Those versed in the art will recognize that for synthetic materials, alkyl substituent(s) is(are) most easily and directly connected at the <NUM>, <NUM>, and <NUM> positions of the phenol, as per Formula C. Commonly used synthetic alkyl phenols for phosphate esters are mostly substituted at the para (<NUM>) position. A drawback of para (mono) substituted synthetic aryl groups is that the resulting tris aryl phosphate ester is a high melt point solid or a high viscosity fluid. This has a deleterious effect on critical properties like liquidity, polymer miscibility, air entrainment, and pour point.

Combinations of triaryl, alkyl-diaryl, and di-alkyl-monoaryl phosphate esters have also been developed to meet specific requirements.

Performance requirements like volatility, exudation, toxicity (acute and neuro-) hydrolytic/oxidative/thermal stability and hazard classification are important properties of phosphate esters when used as flame retardants and lubricants. It is therefore a desire to improve the properties like volatility, exudation, neurotoxicity, without sacrificing pour point, viscosity or fluid life (hydrolytic, thermal, and oxidative stability).

<CIT>, incorporated herein by reference for all purposes, teaches the use of triaryl phosphate esters as flame retardants. The aryl ring has a single hydrocarbyl substituent on any carbon atom of the ring structure, with the total carbon number of the substituents being from <NUM> to <NUM>. The phosphate esters are incorporated into polymer compositions alone or in combination with other flame retardants.

<CIT> discloses the use of triaryl phosphate esters as anti-wear agents with reduced neurotoxicity. Some or all of the aryl groups are mono-substituted with the same alkyl group, which may be located at the ortho-, meta-, or para- position of the ring structure.

<CIT> discloses a phosphate ester composition comprising tri(<NUM>,<NUM>,<NUM>-trimethylphenyl)phosphate and/or tri(<NUM>,<NUM>-di-tert-butylphenyl)phosphate. <CIT> discloses a flame retardant thermoplastic polyurethane composition comprising organic phosphate compounds which list comprises trixylyl phosphate, tris(<NUM>,<NUM>-di-tert-butylphenyl)phosphate, tris(<NUM>,<NUM>-di-butylphenyl)phosphate, (<NUM>,<NUM>-diisopropylphenyl)-diphenylphosphate. <CIT> discloses a flame-retardant composition comprising a major portion of an isoproylated triphenyl phosphate ester. <CIT> discloses bis[bis(<NUM>,<NUM>-di-tertiary butyl-<NUM>-methylphenoxy-phosphino]biphenyl.

The first aspect of the invention provides for a phosphate ester composition comprising more than <NUM> mass% of a phosphate ester represented by Formula <NUM> below,
<CHM>
wherein X, Y, and Z are independently selected from the group consisting of alkyl, heteroalkyl, heteroaryl or aryl, with at least one of X, Y and Z being aryl, represented by Formula <NUM> below,
<CHM>
and wherein two or more of R3, R4 and R5 have from <NUM> to <NUM> carbon atoms, and the total number of carbon atoms in R3, R4 and R5 is from <NUM> to <NUM> and wherein more than <NUM> mass% of the phosphate esters in the composition has R2 and R6 being H on all of the aryl groups present.

Preferably at least two or all of X,Y and Z are aryl, represented by Formula <NUM>. The substituents R3, R4 and R5 of Formula <NUM> may be the same or different and may have different numbers of carbon atoms and structure. Substituents R3, R4 and R5 of Formula <NUM> may have from <NUM> to <NUM> or from <NUM> to <NUM> carbon atoms. The total number of carbon atoms in R3, R4 and R5 may be from <NUM> to <NUM>, or from <NUM> to <NUM>.

The Applicant has found that multiple short chain substituents on the aryl group leads to improved physical properties like melt point, viscosity and pour point of the phosphate esters.

Preferably the aryl group of Formula <NUM> is selected from the group consisting of <NUM>-methyl-<NUM>-ethylphenol, <NUM>-methyl-<NUM>-propylphenol, <NUM>-methyl-<NUM>-isopropylphenol <NUM>-methyl-<NUM>-butylphenol, <NUM>-methyl-<NUM>-tert-butylphenol, <NUM>-methyl-<NUM>-sec-butylphenol, <NUM>-methyl-<NUM>-isobutylphenol, <NUM>-methyl-<NUM>-pentylphenol, <NUM>-methyl-<NUM>-hexylphenol, <NUM>-methyl-<NUM>-sec-hexylphenol, <NUM>-methyl-<NUM>-heptylphenol, <NUM>-methyl-<NUM>-octylphenol, <NUM>-methyl-<NUM>-sec-octylphenol, <NUM>-methyl-<NUM>-nonylphenol <NUM>-methyl-<NUM>-decylphenol, <NUM>-methyl-<NUM>-isopropyl phenol, <NUM>-isopropyl-<NUM>-methylphenol, <NUM>,<NUM>,<NUM>-trimethylphenol, <NUM>-ethyl-<NUM>-methylphenol, <NUM>,<NUM>-dimethyl-<NUM>-ethylphenol, <NUM>,<NUM>-dimethyl-<NUM>-propylphenol, <NUM>,<NUM>-dimethyl-<NUM>-isopropyl phenol, <NUM>,<NUM>-dimethyl-<NUM>-butylphenol, <NUM>,<NUM>-dimethyl-<NUM>-sec-butylphenol, <NUM>,<NUM>-dimethyl-<NUM>-iso-butylphenol, <NUM>,<NUM>-dimethyl-<NUM>-pentylphenol, <NUM>,<NUM>-dimethyl-<NUM>-hexylphenol, <NUM>,<NUM>-dimethyl-<NUM>-(<NUM>,<NUM>-dimethylpropyl)-phenol, <NUM>,<NUM>-dimethyl-<NUM>-(<NUM>,<NUM>-dimethylbutyl)-phenol, <NUM>,<NUM>-dimethyl-<NUM>-(<NUM>-ethyl, <NUM>-methylpropyl)-phenol, <NUM>,<NUM>-dimethyl-<NUM>-heptylphenol, <NUM>,<NUM>-dimethyl-<NUM>-octylphenol, <NUM>,<NUM>-dimethyl-<NUM>-nonylphenol, <NUM>,<NUM>-dimethyl-<NUM>-decylphenol, <NUM>,<NUM>-diethylphenol, <NUM>,<NUM>-diethylphenol, <NUM>,<NUM>-dimethyl-<NUM>-ethylphenol, <NUM>-methyl-<NUM>-isopropylphenol, <NUM>-isopropyl-<NUM>-methylphenol, <NUM>-methyl-<NUM>-(<NUM>,<NUM>-dimethylpropyl)-phenol, <NUM>-methyl-<NUM>-(<NUM>,<NUM>-dimethylbutyl)-phenol, <NUM>-methyl-<NUM>-(<NUM>-ethyl,<NUM>-methylpropyl)-phenol.

More preferably the aryl group of Formula <NUM> is selected form the group consisting of <NUM>,<NUM>,<NUM>-trimethylphenol, <NUM>-methyl-<NUM>-ethylphenol, <NUM>-methyl-<NUM>-isopropylphenol, <NUM>-methyl-<NUM>-isopropylphenol, <NUM>-methyl-<NUM>-tert-butylphenol, <NUM>,<NUM>-dimethyl-<NUM>-ethyl phenol, <NUM>,<NUM>-dimethyl-<NUM>-isopropylphenol, <NUM>,<NUM>-dimethyl-<NUM>-propylphenol, <NUM>,<NUM>-dimethyl-<NUM>-butylphenol <NUM>,<NUM>-dimethyl-<NUM>-ethyl phenol, <NUM>-methyl-<NUM>-isopropylphenol, <NUM>-isopropyl-<NUM>-methylphenol, <NUM>-methyl-<NUM>-(<NUM>,<NUM>-dimethylpropyl)-phenol, <NUM>-methyl-<NUM>-(<NUM>,<NUM>-dimethylbutyl)-phenol, <NUM>-methyl-<NUM>-(<NUM>-ethyl,<NUM>-methylpropyl)-phenol.

Most preferably the aryl group of Formula <NUM> is selected from the group consisting of <NUM>,<NUM>,<NUM>-trimethylphenol, <NUM>-methyl-<NUM>-ethylphenol, <NUM>-methyl-<NUM>-isopropylphenol, <NUM>-methyl-<NUM>-isopropylphenol, <NUM>-methyl-<NUM>-tert-butylphenol, <NUM>,<NUM>-dimethyl-<NUM>-ethyl phenol, <NUM>,<NUM>-dimethyl-<NUM>-isopropylphenol, <NUM>,<NUM>-dimethyl-<NUM>-butylphenol.

When X, Y or Z is aryl, more than <NUM> mass%, more than <NUM> mass% or even more than <NUM> mass% of the phosphate esters in the composition has R2 and R6 being H (hydrogen) on all of the aryl groups present. The applicant has found that when R2 and R6 are hydrocarbyl groups with an active α-carbon hydrogen, this leads to an increase in toxicity of the phosphate ester.

The phosphate ester composition may comprise more than <NUM> mass%, or more than <NUM> mass%, or more than <NUM> mass% or even more than <NUM> mass% of the phosphate ester represented by Formula <NUM>.

Preferably the phosphate ester of the present invention is according to Formula <NUM> below,
<CHM>
wherein R3, R4 and R5 are as described with respect to Formula <NUM>. It will be understood that R'<NUM>, R'<NUM>, and R'<NUM>, as well as R"<NUM>, R"<NUM>, and R"<NUM>, are also as described with respect to R3, R4, and R5 in Formula <NUM>. It will further be understood that each set of R3, R4, and R5; R'<NUM>, R'<NUM>, and R'<NUM>; and R"<NUM>, R"<NUM>, and R"<NUM> may be the same as or differ from the other such sets in a particular phosphate ester.

According to a second aspect of the invention there is provided a phosphate ester composition as described herein, which comprises more than <NUM> mass% of a phosphate ester represented by Formula <NUM> below,
<CHM>
wherein Z is a hydrocarbyl or heterohydrocarbyl group having from <NUM> to <NUM> carbon atoms, X, Y, W and U are independently selected from the group consisting of alkyl, heteroalkyl, heteroaryl or aryl, with at least one of X, Y, U and W being aryl, represented by Formula <NUM> below,
<CHM>
and wherein two or more of R3, R4 and R5 have from <NUM> to <NUM> carbon atoms, and the total number of carbon atoms in R3, R4 and R5 is from <NUM> to <NUM>.

According to a third aspect of the invention, there is provided the use of the phosphate ester composition as described herein as a flame retardant, a lubricant, an anti-wear additive, a hydraulic fluid, a self-extinguishing functional fluid, or an additive therefore.

The applicant has found that multiple substituents located on the <NUM>, <NUM>, and/or <NUM> positions of the aryl group leads to improved physical properties like melt point, viscosity and pour point of phosphate (phosphite) esters, while avoiding neurotoxicity and GHS classification concerns.

As per the invention the following terms are defined as hereunder:
An "alkyl group" as defined herein and by IUPAC is a univalent groups derived from alkanes by removal of a hydrogen atom from any carbon atom -CnH<NUM>n+<NUM>.

A "heteroalkyl" as defined herein is an alkyl group in which at least one atom is an element other than carbon or hydrogen.

An "aryl group" as defined herein and by Hawley's Condensed Chemical Dictionary (<NUM>th Ed. ) is a compound whose molecules have the ring structure characteristic of benzene, naphthalene, phenanthrene, anthracene, etc., (i.e., either the <NUM>-carbon ring of benzene or the condensed <NUM>-carbon rings of the other aromatic derivatives). For example, an aryl group may be phenyl C<NUM>H<NUM> or naphthyl C<NUM>H<NUM>.

A "heteroaryl group" as defined herein is an aryl group in which one or more of the atoms in the ring is an element other than carbon, e.g. sulphur, nitrogen, etc..

A "hydrocarbyl group" as defined herein and by IUPAC is a univalent groups formed by removing a hydrogen atom from a hydrocarbon.

A "heterohydrocarbyl group" as defined herein is a univalent group formed by removing one hydrogen atom from a carbon atom of a heterohydrocarbon, that is a hydrocarbon compound which includes at least one hetero atom (that is, not being H or C), and which group bonds with one other moiety through the resultant free valency on that carbon atom.

The phosphate esters of the present invention are produced by methods which are well known in the art. Firstly, an alkylated phenol (cresol, xylenol, ethylphenol) is produced by alkylation of phenol (cresol, xylenol, ethylphenol) and/or by isomerisation of an alkylated phenol (cresol, xylenol, ethylphenol). <CIT>, discloses the alkylation of phenol with propylene to produce alkylated phenol. Those versed in the art will recognize that alkylating phenols can be accomplished via catalysed reaction of phenolic compounds with olefins and/or alcohols. The placement of substituents is directed by the orientation to the phenoxy group. Direct alkylation is limited to substituting the <NUM>, <NUM>, and/or <NUM> positions (Formula C) of the phenolic ring. It is commonly known that by adjusting the catalyst and conditions, the <NUM>, <NUM>, and /or <NUM> position can be favoured or disfavoured for alkyl substitution. Additionally the selection of olefin and/or alcohol reactant can have similar affect on the location (<NUM>, <NUM>, and/or <NUM>) of the alkyl substituent. Once prepared, the positional isomers (ortho, para) can be separated via distillation, crystallisation, and/or extraction.

Substituents at the meta (<NUM>, and/or <NUM>) positions are not produced as a normal course of alkylation, but rather as the product of isomerisation. Isomerisation catalysts are known e.g. as disclosed in <CIT>, and some have the ability to both alkylate and isomerise. The alkylated phenol is then subjected to phosphorylation to yield the phosphate ester.

The Invention will now be described with reference to the following examples.

GC means gas chromatography, Hewlett-Packer (HP) <NUM> GC System with G4513A series injector (<NUM>µL @ <NUM> (<NUM>:<NUM> split), Open Lab control software, <NUM> x <NUM> ID x <NUM> HP-PONA (<NUM>% dimethylpolysiloxane), <NUM>/min (constant flow mode) Helium, <NUM> (<NUM> hold) <NUM>/min ramp rate to <NUM> (<NUM> hold), detection via flame ionization detector (FID) with air@ <NUM>/min, Hydrogen@ <NUM>/min, makeup Nitrogen@ <NUM>/min.

LCMS means liquid chromatography mass spectrometry, Thermo Ultimate-<NUM> Ultra High Performance Liquid Chromatography (UHPLC), Thermo Accucore RP-MS <NUM> (length) x <NUM> (diameter) x <NUM>. 6micron column with water/acetonitrile as the mobile phase gradient programmed to <NUM>% acetonitrile, flow rate of <NUM>. 3cc/min, Advion CMS Expression single quadrapole, time of flight (tof), atmospheric pressure chemical ionization (APCI), positive ion (+) mode, mass scan range from <NUM> - <NUM> atomic mass units (amu).

HPLC means high performance liquid chromatography, Thermo U-<NUM> Ultra High Performance Liquid Chromatography (UHPLC), UV detection at <NUM>, <NUM>µL sample volume, ACE C18-PFP (ACE C18-PFP is a C18 bonded HPLC column with a pentafluorophenyl (PFP) phase), <NUM> (length) x <NUM> (diameter) x <NUM> micron, mobile phase <NUM>% methanol at <NUM>/min, UV detection at <NUM>, <NUM>µL sample volume.

The melting point was measured via differential scanning calorimetry (DSC, TA instrument DSC Q20), standard cell, <NUM> ramp rate to <NUM>, -<NUM>/min ramp rate to - <NUM>, <NUM>/min ramp rate to <NUM>.

The kinematic viscosity was measured using an Anton Paar SVM <NUM> Viscometer following American Society for Testing and Materials (ASTM) test method D7042 - "Standard Test Method for Dynamic Viscosity and Density of Liquids by Stabinger Viscometer (and the Calculation of Kinematic Viscosity)".

The pour point was measured via an iSL CPP 5Gs, following ASTM test methos D97 - "Standard Test Method for Pour Point of Petroleum Products".

A commercial sample of mixed m-,p-cresol (<NUM>% m-cresol, <NUM> % p-cresol) was obtained and confirmed to be <NUM>% m-,p-cresol (GC). This material was used as is without further purification. In a <NUM> litre reaction flask, <NUM> of m-,p-cresol (MW-<NUM>, <NUM> moles), <NUM> of phosphorus oxychloride (MW-<NUM>, <NUM> mole), <NUM> magnesium chloride and <NUM> boiling chips were introduced. The reaction mixture was stirred and heated to <NUM> for over <NUM> hours. Once at this temperature the mixture was held at <NUM> for an additional <NUM> to <NUM> hours until there were no signs of ongoing reaction (i.e. no bubbling observed in the reaction flask). The reaction product was allowed to cool to at least <NUM> before proceeding to the purification step. The reaction product was purified by vacuum distillation. Fractions collected during the distillation were analysed by LCMS and HPLC to determine composition. Fractions of acceptable triaryl phosphate ester quality were recombined (<NUM>, <NUM> % yield) and used for evaluation.

Using a method similar to that outlined in Comparative Example <NUM> but with a different feedstock as shown in Table <NUM>, the phosphate ester:(Tri-xylyl phosphate ester [TXP]) was synthesized.

Using a method similar to that outlined in Comparative Example <NUM>, but with a different feedstock as shown in Table <NUM>, the phosphate ester (Tri-p-tert-butylphenol phosphate ester [TBPP]), was synthesized
<CHM>.

Using a method similar to that outlined in Comparative Example <NUM>, but with a different feedstock as shown in Table <NUM>, the phosphate ester <NUM> (Tri-<NUM>-methyl-<NUM>-propylphenol phosphate ester was synthesized.

The Properties of the phosphate esters made as per the Examples are summarised in Table <NUM>.

The applicant has found (Example <NUM>) that by eliminating substituents at the <NUM>, and/or <NUM> position that regulatory neurotoxicity concerns are addressed, and that by varying the i) number (at least two), ii) location (<NUM>, <NUM>, and/or <NUM>) and iii) size of substituents that improvements in physical properties (like viscosity and pour point, Table <NUM>) can be realized versus mono-substituted aryl phosphate esters. Otherwise solid <NUM>-monoalkyl aryl(phenyl) phosphate esters can be redesigned into room temperature liquids of less than <NUM> pour point while maintaining equivalent molecular weight.

Furthermore, the improvement in certain physical properties does not come at the expense of properties like volatility, boiling point, or acute toxicity (GHS Classification). Additionally, the improved viscosity reduces the need to add phenyl groups, which are prone to hydrolysis and have acute toxicity (marine pollutant) issues.

The effect of multiply substituted <NUM>, <NUM>, and/or <NUM> aryl groups on the finished phosphate ester is not discernible from the physical characteristics of the starting materials, (see Table <NUM>).

Claim 1:
A phosphate ester composition comprising more than <NUM> mass% of a phosphate ester represented by Formula <NUM>,
<CHM>
wherein X, Y, and Z are independently selected from the group consisting of alkyl, heteroalkyl, heteroaryl or aryl, with at least one of X, Y and Z being aryl, represented by Formula <NUM>,
<CHM>
and wherein two or more of R3, R4 and R5 have from <NUM> to <NUM> carbon atoms, and the total number of carbon atoms in R3, R4 and R5 is from <NUM> to <NUM> and wherein more than <NUM> mass% of the phosphate esters in the composition has R2 and R6 being H on all of the aryl groups present.