| PATENT NUMBER | This data is not available for free |
| PATENT GRANT DATE | November 22, 1994 |
| PATENT TITLE |
Process for producing a composition comprising an epoxy compound having a hydroxyl group |
| PATENT ABSTRACT |
The present invention provides a composition represented by the formula ##STR1## (wherein x is an integer of 3 to 7, y is an integer of 0 to 50, and R.sub.a and R.sub.b are H, methyl group, or propyl group and each of the R.sub.a and R.sub.b groups may be replaced with any of the other groups simultaneously) and useful as a raw material or modifier for resins for use in coating compositions, adhesives, epoxy resins, and the like, and further provides a process for producing a composition comprising compounds represented by the above formula (I) which process is characterized in that a compound represented by the formula ##STR2## is reacted with a lactone at 30 to 20.degree. C. or compounds represented by the formula ##STR3## (wherein x, y, R.sub.a, and R.sub.b have the meanings as defined above) are epoxidized at 0 to 80.degree. C. using a peroxide. |
| PATENT INVENTORS | This data is not available for free |
| PATENT ASSIGNEE | This data is not available for free |
| PATENT FILE DATE | September 21, 1993 |
| PATENT FOREIGN APPLICATION PRIORITY DATA | This data is not available for free |
| PATENT PARENT CASE TEXT | This data is not available for free |
| PATENT CLAIMS |
We claim: 1. A process for producing a composition comprising compounds having the following structural formula: ##STR13## wherein x represents an integer of 3 to 7, y represents a statistical distribution of integers of 0 to 50, R.sub.a and R.sub.b each independently represents a hydrogen atom, a methyl group or a propyl group, comprising reacting a compound having the following structure: ##STR14## with a lactone at 30.degree. to 200.degree. C. in the presence of a catalyst. 2. The process as claimed in claim 1, wherein said catalyst is selected from the group consisting of a tin catalyst, a titanium catalyst and a tungsten catalyst. 3. The process as claimed in claim 1, wherein said lactone is selected from the group consisting of .epsilon.-caprolactone, trimethylcaprolactone and .beta.-methyl .delta.-valerolactone. 4. The process as claimed in claim 1, wherein said catalyst is present in an amount of 0.01 ppm to 2,000 ppm of said compound (II) and said lactone. 5. The process as claimed in claim 1, wherein said lactone is present in a molar amount of 1 to 15 times the molar amount of said compound (II). -------------------------------------------------------------------------------- |
| PATENT DESCRIPTION |
TECHNICAL FIELD The present invention relates to a composition which comprises compounds having an epoxy group and a hydroxyl group and is industrially useful as a raw material or modifier for various resins for use in coating compositions, adhesives, epoxy resins, and the like, and also relates to a process for producing the composition. BACKGROUND ART Conventionally known as compounds having an epoxy group and hydroxyl group are glycidol and the like. However, these compounds have poor storage stability because they are unstable in the presence of a slight amount of an acid or alkali, so that the epoxy group readily reacts with a hydroxyl group and a polymerization reaction thus proceeds, and further, side reactions are apt to take place when these compounds are subjected to various reactions. On the other hand, as another compound having an epoxy group and hydroxyl group, the compound ##STR4## is known. However, although stable as compared with the above-described glycidol and the like, this compound has been unsuited for use in various applications because the following intramolecular reaction takes place. ##STR5## This may be because the compound becomes stable in entropy due to the formation of the 6-membered rings within the molecule. Further, since the above compound (II) is poor in flexibility, it poses problems when used in applications such as, for example, coating compositions. DISCLOSURE OF THE INVENTION An object of the present invention is to provide a compound having an epoxy group and hydroxyl group and free from the above-described disadvantages. The present inventor has conducted intensive studies in order to attain the above object and, as a result, it has been found that a compound having a specific structure is excellent in stability, ring-opening polymerization reactivity, and the property of imparting flexibility. Further, processes for efficiently producing such a compound have also been found. The present invention has thus been accomplished. That is, the present invention is: "a composition comprising compounds having the following structure ##STR6## (wherein x represents an integer of 3 to 7, y represents a statistical distribution of integers of 0 to 50, R.sub.a and R.sub.b represent H, methyl group, or propyl group, and each of the groups of R.sub.a and R.sub.b may be replaced with any of the other groups simultaneously)"; and "a process for producing a composition comprising compounds having the following structural formula ##STR7## (wherein x represents an integer of 3 to 7, y represents an integer of 0 to 50, R.sub.a and R.sub.b represent H, methyl group, or propyl group, and each of the groups of R.sub.a and R.sub.b may be replaced with any of the other groups simultaneously), characterized in that a compound having the structure ##STR8## is reacted with a lactone at 30.degree. to 200.degree. C. in the presence of a catalyst"; and "a process for producing a composition comprising compounds having the following structural formula ##STR9## (wherein x represents an integer of 3 to 7, y represents an integer of 0 to 50, R.sub.a and R.sub.b represent H, methyl group, or propyl group, and each of the groups of R.sub.a and R.sub.b may be replaced with any of the other groups simultaneously), characterized in that a composition comprising compounds having the following structure ##STR10## is epoxidized at 0.degree. to 80.degree. C. using a peroxide". The composition of this invention which comprises epoxy compounds (I) having a hydroxyl group can be produced by either of the following two processes. That is, these are a process in which compound (II) is reacted with a lactone in the presence of a catalyst (hereinafter referred to as Route A) ##STR11## and a process in which a composition comprising compounds (III) is reacted with an epoxidizing agent (hereinafter referred to as Route B). ##STR12## In the process of Route A, compound (II) as a raw material can be obtained by epoxidizing 3-cyclohexene 1-methanol with an epoxidizing agent. Examples of the above epoxidizing agent include organic percarboxylic acids such as performic acid, peracetic acid, perpropionic acid, perbenzoic acid, m-chloroperbenzoic acid, and the like, peracetic acid produced from hydrogen peroxide and acetic acid, acetic anhydride, or sulfuric acid, and the like. Examples of the lactone include .epsilon.-caprolactone, trimethylcaprolactone, .beta.-methyl .delta.-valerolactone, and butyrolactone. The composition comprising compounds (I) can be obtained by reacting those in the presence of a catalyst. As this catalyst, use may be made of a titanium compound such as tetrabutoxy titanate, tetrapropoxy titanate, tetraethoxy titanate, or the like, an organotin compound such as tin octylate, dibutyltin oxide, dibutyltin laurate, or the like, a tin halide such as stannous chloride, stannous bromide, stannous iodide, or the like, or a heteropoly-acid such as phosphotungstic acid, silicotungstic acid, or the like. The reaction may be conducted at a temperature of 30.degree. to 230.degree. C. In the case of using a titanium- or tin-based catalyst, the temperature desirably is from 100.degree. C. to 180.degree. C. This is because if the reaction temperature is 100.degree. C. or lower, the amount of the catalyst used is increased and this produces an adverse influence when the compound (II) is further reacted with an isocyanate and with a urethane resin and, further, there are cases where the increased catalyst amount causes the coating composition to suffer discoloration. On the other hand, if the reaction temperature is 180.degree. C. or higher, there is the possibility that the epoxy in compound (II) might undergo ring opening or the lactone that has undergone addition might be depolymerized. In the case of using phosphotungstic acid or the like, on the other hand, the reaction may be allowed to proceed at a lower temperature of 30.degree. to 100.degree. C. The amount of the catalyst used is from 0.01 ppm to 2,000 ppm of the starting materials. It is desirable that the catalyst be used in a smaller amount because there is the possibility that the catalyst might adversely affect as described above. However, if the catalyst amount is 0.01 ppm or less, much time is required for completing the reaction even at an elevated temperature and, hence, such a process is uneconomical. The molar amount of the lactone reacted is desirably from 1 to 15 times that of compound (II). This is because if the molar amount of the addition-reacted molar amount exceeds 15 times, use of the thus-obtained compounds as a coating composition results in coating films which are too soft. In the case where 2 mol of .epsilon.-caprolactone is allowed to undergo addition to 1 mol of compound (II), the reaction product is a composition which comprises compounds represented by formula (I) and in which the unreacted compound of y=0 and adducts of y=1, 2, 3, . . . are distributed statistically, since the rate of the ring- opening reaction of the lactone with the hydroxyl group of compound (II) does not differ so much from the rate of the ring-opening reaction of the lactone with the lactone terminal of the product. However, there is no need of separating these, and the mixture may be used as it is in various applications such as synthesis of a urethane resin etc. It is also unnecessary that the lactone used be reacted completely to 0%, and the reaction mixture can be used, as it is, as a raw material for syntheses, although it may be used after the unreacted lactone is evaporated, For example, the product obtained by reacting compound (II) with .epsilon.-caprolactone at 140.degree. C. using tetrabutoxytitanium (hereinafter TBT) as a catalyst is a composition containing the following. ______________________________________ Caprolactone 0.8% Compound (II) 0.6% Compounds (I) 89.6% TBT 0.0010% ______________________________________ By reacting this composition as it is with an isocyanate compound, a urethane compound can be obtained. If required, the reaction may be carried out using a solvent which is of the aromatic or aliphatic hydrocarbon, ester, ether, amide, or amine type. The thus-obtained solution (dope) of the composition comprising compounds (I) in the solvent used can be handled as it is as a commodity. It is desirable that the above reaction be conducted so as to yield a less colored product. Accordingly, better results are obtained when the reaction is effected under N.sub.2 to avoid oxidation by oxygen. On the other hand, the composition comprising compounds (I) has a molecular weight distribution, which generally is apt to be wide if the reaction has been conducted at a high temperature for a long time period. Further, when an Sn-based catalyst and a Ti-based catalyst are compared, use of a Ti-based catalyst is prone to result in a wider distribution. In order to obtain a product having a narrow molecular weight distribution, a low temperature and low-concentration use of an Sn-based catalyst are preferred. Further, in order to obtain one with a wide molecular weight distribution, a high temperature and use of a Ti-based catalyst are desirable. According to applications, the molecular weight distribution of the composition to be produced can be made either narrow or wide. The composition comprising compounds (I) may also be synthesized by the copolymerization of two or more kinds of lactones. For example, a composition comprising (I) which is copolymers obtained from a mixture of .epsilon.-caprolactone and .beta.-methyl .delta.-valerolactone or of .epsilon.-caprolactone and trimethylcaprolactone can be obtained. Although the composition comprising compounds (I) which has been produced by this process and is in a crude liquid form after the reaction may be used as it is, it contains the catalyst. This catalyst may cause runaway or inhibition of reactions or discoloration, according to applications. For this reason, a chelating agent or the like may be added to this crude liquid to mask the catalyst. For example, masking of the catalyst can be attained by adding 2-ethylhexyl acid phosphate in a molar amount 1 to 100 times that of the catalyst. According to the process of Route B, on the other hand, the composition comprising compounds (I) can be obtained by allowing a lactone to undergo addition to 3-cyclohexene 1-methanol and epoxidizing the resulting adduct with an epoxidizing agent. The composition comprising compounds (III) is obtained by allowing a lactone to undergo addition to 3-cyclohexene 1-methanol in the presence of a catalyst. 3-Cyclohexene 1-methanol to be used as a raw material can be obtained by the hydrogenation reaction of tetrahydrobenzaldehyde. As the catalyst for the lactone addition, use may be made of a titanium compound such as tetrabutoxy titanate, tetrapropoxy titanate, tetraethoxy titanate, or the like, an organotin compound such as tin octylate, dibutyltin oxide, dibutyltin laurate, or the like, a tin halide such as stannous chloride, stannous bromide, stannous iodide, or the like, or a heteropoly-acid such as phosphotungstic acid, silicotungstic acid, or the like. The reaction may be conducted at a temperature of 30.degree. to 230.degree. C. In the case of using a titanium- or tin-based catalyst, the temperature desirably is from 100.degree. to 180.degree. C. If the temperature is 100.degree. C. or lower, the amount of the catalyst used is increased and this adversely affects the subsequent epoxidization reaction etc. On the other hand, if the temperature is 230.degree. C. or higher, there is the possibility that the lactone that has undergone addition might be depolymerized. In the case of using phosphotungstic acid or the like, on the other hand, the reaction may be allowed to proceed at a lower temperature of 30.degree. to 100.degree. C. The amount of the catalyst used is from 0.01 ppm to 2,000 ppm. It is desirable that the catalyst be used at a lower concentration because there is the possibility that the catalyst might adversely affect as described above. However, if the catalyst amount is 0.01 ppm or less, much time is required for completing the reaction even at an elevated temperature and, hence, such a process is uneconomical. The amount of the lactone reacted is desirably from 1 to 15 mol per mol of tetrahydrobenzyl alcohol (hereinafter referred to as THBA). This is because if the addition-reacted molar amount exceeds 15, coating compositions to be prepared by using an epoxidized product are too soft. In the case where 2 mol of .epsilon.-caprolactone is allowed to undergo addition to mol of THBA, the reaction product is a composition which comprises compounds represented by formula (III) and in which the unreacted compound of y=0 and adducts of y=1, 2, 3 . . . are distributed statistically, since the rate of the ring-opening reaction of the lactone with the hydroxyl group of the THBA does not differ so much from the rate of the ring-opening reaction of the lactone with the lactone terminal of the product. However, there is no need of separating these, and the mixture may be used as it is in the subsequent epoxidization step. It is also unnecessary that the lactone used in the reaction be made completely 0%, and the reaction mixture can be used, as it is, as a raw material for syntheses, although it may be used after the unreacted lactone is evaporated. For example, the composition comprising compounds (III) is a product which is obtained by reacting .epsilon.-caprolactone at 160.degree. C. using tetrabutoxytitanium (TBT) as a catalyst and which is a composition containing the following. ______________________________________ Caprolactone 0.2% (III) 96.2% THBA 3.6% TBT 0.0010% ______________________________________ By reacting this composition as it is with an epoxidizing agent, a product can be obtained. It is desirable that the above reaction be conducted so as to yield a less colored product. Accordingly, better results are obtained when the reaction is effected under N.sub.2 to avoid oxidation by oxygen. Since the composition comprising the thus-yielded compounds (III) has a relatively high viscosity, it is desirable that a solvent be added in order to uniformly disperse the epoxidizing agent to be added in the reaction system. As the solvent, an aromatic compound, ether, aliphatic hydrocarbon, ester, or the like may be used in the case of peracetic acid. Examples of epoxidizing agents that can be used include peracids and hydroperoxides. Examples of the peracids include performic acid, peracetic acid, perbenzoic acid, trifluoroperacetic acid, and the like. Of these, peracetic acid is the preferred epoxidizing agent since it is being industrially produced in large quantities, is available at low cost, and has good stability. Examples of the hydroperoxides include hydrogen peroxide, tert-butyl hydroperoxide, cumene peroxide, and the like. In conducting the epoxidization reaction, whether a solvent is used or not is determined and the reaction temperature is regulated, according to the apparatus and the properties of the raw materials. The range of usable reaction temperatures is determined by the reactivity of the epoxidizing agent used. In the case of peracetic acid which is the preferred epoxidizing agent, 0.degree. to 70.degree. C. is preferred. At 0.degree. C. or lower, the reaction is slow, while at 70.degree. C., decomposition of the peracetic acid takes place. Further, in the case of combined use of tert-butyl hydroperoxide, which is an example of hydroperoxides, and molybdenum dioxide diacetylacetonate, 20.degree. C. to 150.degree. C. is preferred for the same reason. The molar ratio of an introduced epoxidizing agent to unsaturated bonds may be varied according to purposes such as how many unsaturated bonds are to be allowed to remain. In the case where compounds having a large proportion of epoxy groups are desired, it is preferred to add an epoxidizing agent in an amount equimolar with unsaturated groups or in a larger amount. However, it is usually disadvantageous to exceed two times in mol from the standpoints of economy and the problem of side reactions as described next. In the case of peracetic acid, its amount preferably is 1 to 1.5 times in mol. Since there are cases where peracids decompose to generate oxygen in the presence of a slight amount of metal ions, it is desirable to add a stabilizer to the reaction system. For example, it is phosphoric acid, phosphoric acid-potassium, phosphoric acid-sodium, sodium ammonium hydrogenphosphate, pyrophosphoric acid, potassium pyrophosphate, sodium pyrophosphate, potassium 2-ethylhexylpyrophosphate, sodium 2-ethylhexyltripolyphosphate, potassium 2-ethylhexyltripolyphosphate, sodium 2-ethylhexyltetrapolyphosphate, or potassium 2-ethylhexyltetrapolyphosphate. The incorporated amount is from 1 ppm to 1,000 ppm in the crude reaction liquid. After completion of the reaction, the solvent is removed from the crude liquid and the residue can be a product as it is. However, since discoloration may occur, a less colored product can be obtained by adding water before the solvent is removed, washing the crude reaction liquid, and then removing the solvent etc. For example, in the case where peracetic acid was used as epoxidizing agent and ethyl acetate was used as solvent, water may be added in an amount almost equivolume with the crude reaction liquid. After washing, the resulting mixture is allowed to separate, subsequently the aqueous layer as the lower layer is removed and the upper layer is taken out, and then the solvents are removed to obtain the desired product as the residue. It is desirable to further repeat the water-washing once or twice. This is for removing slight amounts of impurities which will be coloring ingredients. With respect to conditions for the removal of low-boiling ingredients by distillation, it can be attained by heating to the boiling point of the solvent at ordinary pressure. However, since it is desirable that the heating temperature be as low as possible because the decomposition etc. of the product itself are accelerated, it is preferred to conduct it under a reduced pressure. The reaction is carried out continuously or batch-wise, and in the case of continuous reaction, either of a complete mixing type and a piston flow type is possible. For the industrial removal of low-boiling ingredients, a thin film-type evaporator can be used. In the case where the product has been synthesized by the B Route process, there are cases where since low-molecular compounds are dissolved in the aqueous layer by water-washing, the product remaining in the organic layer contains a reduced amount of low-molecular compounds. This, however, does never practically adversely affect the final product. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an NMR spectral chart for the product obtained in Example 1, FIG. 2 is an infrared absorption spectral chart for the same, and FIG. 3 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 4 is an NMR spectral chart for the product obtained in Example 2, FIG. 5 is an infrared absorption spectral chart for the same, and FIG. 6 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 7 is an NMR spectral chart for the product obtained in Example 3, FIG. 8 is an infrared absorption spectral chart for the same, and FIG. 9 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 10 is an NMR spectral chart for the product obtained in Example 4, FIG. 11 is an infrared absorption spectral chart for the same, and FIG. 12 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 13 is an NMR spectral chart for the product obtained in Example 5, FIG. 14 is an infrared absorption spectral chart for the same, and FIG. 15 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 16 is an NMR spectral chart for the product obtained in Example 6, FIG. 17 is an infrared absorption spectral chart for the same, and FIG. 18 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 19 is an NMR spectral chart for the product obtained in Example 7, FIG. 20 is an infrared absorption spectral chart for the same, and FIG. 21 is a chart obtained in a molecular weight distribution measurement of the same. FIG. 22 is an NMR spectral chart for the product obtained in Example 8, FIG. 23 is an infrared absorption spectral chart for the same, and FIG. 24 is a chart obtained in a molecular weight distribution measurement of the same. BEST MODES FOR CARRYING OUT THE INVENTION |
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