Preparation of hexabromocyclododecane

Abstract

Hexabromocyclododecane may be synthesized at a high yield in pure form by brominating 1,5,9-cyclododecatriene with bromine in a C.sub.4 -C.sub.8 saturated aliphatic alcohol in the presence of a boron trifluoride complex, neutralizing the reaction mixture with a non-aqueous base, and recovering the resulting crystals of hexabromocyclododecane.

Description

BACKGROUND OF THE INVENTION

This invention reaates to a method for preparing hexabromocyclododecane.

Hexabromocyclododecane has been widely used as a flame retardant for molded or foamed thermoplastic products such as those made of polyolefin or polystyrene. It also finds use in the fireproofing treatment of textile products in the form of a latex or water-suspension.

Hexabromocyclododecane may be synthesized by brominating 1,5,9-cyclododecatriene. It is desirable for the resulting product to be colorless and free of low melting point by-products as far as possible, particularly when it is intended to use with high impact strength polystyrene resins comprising polyolefin, polystyrene and styrene-butadiene copolymer.

In the conventional process, the bromination of 1,5,9-cyclododecatriene is carried out in a solvent such as ethanol. The mother liquor from which crystals of the resulting hexabromocyclododecane are separated is reused in the next bromination reaction.

This known process, however, suffers from certain disadvantages in that the product is contaminated with significant amounts of low melting point by-products. Further purification requires washing the raw product with a large amount of solvent such as clean ethanol one or several times. This, of course, increases cost while decreasing the yield of pure product.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an improved method for producing hexabromocyclododecane which gives the product in purer form at higher yields.

This and other objects are accomplished by providing a method for preparing hexabromocyclododecane which comprises the steps of reacting 1,5,9-cyclododecatriene with bromine in a C.sub.4 -C.sub.8 saturated aliphatic alcohol in the presence of a catalytically effective amount of a boron trifluoride complex, neutralizing the reaction mixture with a non-aqueous base, and recovering the resulting crystals of hexabromocyclododecane.

DETAILED DISCUSSION

The method of the present invention is characterized by the use of a C.sub.4 -C.sub.8 saturated aliphatic alcohol as a reaction solvent as well as the use of a boron trifluoride complex as a catalyst in the bromination of 1,5,9-cyclododecatriene.

Alcohols usable for this purpose preferably have a solubility parameter (S.P.) of about 9.2 to about 11.5. They may be straight or branched chain alkanols or a cycloalkanol having 4-8 carbon atoms. Examples thereof include n-butyl alcohol (S.P. 10.7), isobutyl alcohol (S.P. 10.8), n-amyl alcohol (S.P. 10.6), isoamyl alcohol (S.P. 10.0), n-hexyl alcohol (S.P. 10.0), cyclohexanol (S.P. 11.4) and n-octyl alcohol (S.P. 10.3). Mixtures of these alcohols such as fusel oil (S.P. 10.3) may also be used.

Examples of boron trifluoride complexes include boron trifluoride-ethyl ether complex, boron trifluoride-phenol complex, boron trifluoride-amine complexes, boron trifluoridemethanol complex and boron trifluoride-acetic acid complex.

The amount of the above reaction solvent is not critical provided that the exothermic reaction may be conveniently controlled. The amount of boron trifluoride complex catalyst is generally from 0.5 to 2%, preferably about 1% by weight of the solvent.

The amount of bromine ranges between 3.0 and 3.2 moles as Br.sub.2 per mole of 1,5,9-cyclododecatriene. This amount of bromine may be added dropwise to the mixture of 1,5,9-cyclododecatriene and the solvent containing the catalyst. Alternatively, bromine may be added concurrently with 1,5,9-cyclododecatriene to the reaction solvent containing the catalyst.

The reaction temperature may be below 40.degree. C., preferably below 30.degree. C.

After the completion of the bromination reaction, the reaction mixture is neutralized to a pH about 8.0 to 8.5 with an amount of non-aqueous base such as a solution of sodium methoxide, sodium ethoxide, potassium butoxide, sodium isobutoxide or sodium isoamyloxide in the corresponding alcohol, triethylamine, triethanolamine, diethanolamine, monoethanolamine, butylamine, ethylamine, cyclohexylamine, trimethylamine, pyridine or alcoholic solutions of these amines or ammonia.

After the neutralization, crystals of hexabromocyclododecane are filtered off and washed thoroughly with hot water or hot lower alkanol or both. The crystals may be washed further with dilute aquous ammonia if necessary. After drying, hexabromocyclododecane may be obtained at a high yield in a pure state.

The following examples illustrate the invention. All parts and percents therein are by weight unless otherwise indicated.

EXAMPLE 1

A flask was charged with 420 g of isobutyl alcohol containing 4.2 g of boron trifluoride-ethyl ether complex. Then 495 g (3.09 mols) of bromine and 162 g (1 mol) of 1,5,9-cyclododecatriene were concurrently added dropwise to the flask while maintaining the temperature at 20.degree.-30.degree. C. After the addition, the reaction mixture was stirred for 2 hours and then cooled to 20.degree. C. The mixture was neutralized to pH8.0-8.5 with a 20% solution of sodium methoxide in methanol. The resulting crystals were filtered off, washed with 320 g of boiling methanol and then 1% aqueous ammonia, successively, and dried at 50.degree. C. 559 g (87% of theory) of hexabromocyclododecane was obtained. Properties of the product are shown in Table 1.

EXAMPLES 2-3 AND COMPARATIVE EXAMPLES 1-2

The procedure of Example 1 was repeated except that the solvent and catalyst were substituted with other solvents and catalysts listed in Table 1. The results are also shown in Table 1.

TABLE 1__________________________________________________________________________ Neutralizing Yield, g M.P. HeatExample Solvent, g Catalyst, g Agent (% theory) .degree.C. Heu.sup.(1) Resistance.sup.(2)__________________________________________________________________________1 Isobutyl BF.sub.3 /ethyl 20% CH.sub.3 ONa 559 179 10 Good alcohol ether in CH.sub.3 OH (87) 420 4.22 Isoamyl BF.sub.3 /butyl 20% CH.sub.3 ONa 545.7 182 10 Good alcohol ether in CH.sub.3 OH (85) 420 4.23 Isobutyl BF.sub.3 /acetic 20% CH.sub.3 ONa 473.9 193 10 Good alcohol acid in CH.sub.3 OH (74) 450 2.5Compara- n-Butanol -- 20% CH.sub.3 ONa 436.6 176 60 Not goodtive 420 in CH.sub.3 OH (68)Ex. 1Compara- Ethanol BF.sub.3 /ethyl 20% CH.sub.3 ONa 430.2 168 120 Not goodtive 420 ether in CH.sub.3 OH (67)Ex. 2 4.2__________________________________________________________________________ .sup.(1) APHA of 2% acetone solution. .sup.(2) 2.5 g of sample is heated at 120.degree. C. for 5 hours in a 100 ml beaker. Judgement is made visually based on the entire color and the number of black spots.

EXAMPLES 4-6 AND COMPARATIVE EXAMPLES 3-4

Using various solvents and catalysts listed , in Table 2, the procedure of Example 1 was repeated. However, the whole amount of cyclododecatriene was charged initially and only the bromine was added dropwise. The results are shown in Table 2.

TABLE 2__________________________________________________________________________ Neutralizing Yield, g M.P. HeatExample Solvent, g Catalyst, g Agent (% theory) .degree.C. Heu Resistance__________________________________________________________________________4 Fusel oil BF.sub.3 /ethyl Diethanolamine 532.9 179 30 Good 420 ether (83) 4.25 Isobutyl BF.sub.3 /methanol Monoethanola- 526.5 180 20 Good alcohol 4.2 mine (82) 4206 Isobutyl BF.sub.3 /butyl 15% Na isobu- 494.4 181 20 Good alcohol ether toxide in (77) 420 4.2 isobutyl alcoholCompara- Isopropyl BF.sub.3 /butyl 28% NH.sub.4 OH 385.2 136 140 Not goodtive alcohol ether (60)Ex. 3 420 4.2Compara- n-propyl -- Ethylenediamine 430.2 167 90 Not goodtive alcohol (67)Ex. 4 420__________________________________________________________________________

EXAMPLES 7-8 AND COMPARATIVE EXAMPLES 5-6

Using various solvents, catalysts and neutralizing agents listed in Table 3, the procedure of Example 1 was repeated. However, crystals recovered from the neutralized mixture were washed with 400 g of boiling water containing a small amount of aqueous ammonia and dried at 50.degree.-80.degree. C.

The results are shown in Table 3.

TABLE 3__________________________________________________________________________ Neutralizing Yield, g M.P. HeatExample Solvent, g Catalyst, g Agent (% theory) .degree.C. Heu Resistance__________________________________________________________________________7 Isobutyl BF.sub.3 /ethyl 20% CH.sub.3 ONa 565 178 35 Good alcohol ether in CH.sub.3 OH (88) 420 4.28 Isoamyl BF.sub.3 /ethyl 20% Isoamyl 552.2 180 30 Good alcohol ether ONa in iso- (86) 420 4.2 amyl OHCompara- n-Buthyl -- 20% Isoamyl 436.6 171 60 Not goodtive alcohol ONa in iso- (68)Ex. 5 420 amyl OHCompara- Ethyl -- 20% Isoamyl 430.2 160 200 Not goodtive alcohol ONa in iso- (67)Ex. 6 420 amyl OH__________________________________________________________________________

APPLICATION EXAMPLE

100 parts of polystyrene resin, 3.5 parts of hexabromocyclododecane obtained in the above Example 1, 2 or 4 or comparative Example 1 or 4, 0.03 parts of di-n-octyl maleate polymer and 0.03 parts of dioctylphenyl phoshite were kneaded on a hot roll mill at 180.degree.-190.degree. C. for 6 minutes. The resulting compound was pressed into a sheet at 180.degree.-190.degree. C. at 200 atms for 3 minutes and cooled.

Each specimen was tested for color change, flame retardancy (oxygen index) and viscosity change. The results are shown in Table 4.

TABLE 4______________________________________Hexabromocyclododecane Comp. Comp. Ex. 1 Ex. 2 Ex. 4 Ex. 1 Ex. 4______________________________________Color change.sup.(1) No No No Slightly Totally change change change changed changedOxygen index.sup.(2) 28.1 28.1 28.1 27.2 26.4Decrease in 96.4 95.8 94.0 89.2 79.4viscosity, %.sup.(3)______________________________________ .sup.(1) Visually judged compared with a standard specimen containing no flame retardant. .sup.(2) O. I. test according to ASTM D2863-70. .sup.(3) % retention of the viscosity of the starting polystyrene resin. Measurement is made at 25.degree. C. at a concentration of 0.5 g/100 ml toluene using CannonFenske viscometer.

Claims

1. A method for preparing hexabromocyclododecane which comprises the steps of reacting 1,5,9-cyclododecatriene with bromine in a C.sub.4 -C.sub.8 saturated aliphatic alcohol in the presence of a catalytically effective amount of a boron trifluoride complex, neutralizing the reaction mixture with a non-aqueous base, and recovering the resulting crystals of hexabromocyclododecane.

2. The method according to claim 1, wherein said alcohol has a solubility parameter of 9.2 to 11.5.

3. The method according to claim 1, wherein said alcohol is n- or iso-butyl alcohol, n- or isoamyl alcohol, n-hexyl alcohol, n-octyl alcohol, cyclohexanol or a mixture thereof.

4. The method according to claim 1, wherein said boron trifluoride complex is a complex with a lower alkyl ether, an amine, phenol, methanol or acetic acid.

5. The method according to claim 1, wherein said non-aqueous base is a solution of alkali metal lower alkoxide in the corresponding alcohol, an amine or a solution of said amine or ammonia in a lower alkanol.

6. The method according to claim 1 further including the step of washing said crystals with hot water or hot lower alkanol.