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The invention will be further illustrated by the following specific examples, which are given by way of illustration and not as limitations on the scope of this invention. Recent refinements in analytical techniques reveal that up to about 20% of what has been believed to be solely the 2,4'-isomer is 2,2'-isomer. Accordingly, it is intended that the 2,4'-isomer content should be construed to include any 2,2'-isomer may be present.
EXAMPLE I
In a three-necked flask equipped with mechanical stirrer, thermometer, reflux condenser, nitrogen inlet tube and additional funnel, were placed 280 g. of aniline (three mols) and 28 g. of Superfiltrol acid-washed clay catalyst. The system was swept with a slow stream of nitrogen and the temperature was raised to 125.degree. to 130.degree. C. Forty-one grams of formalin solution (37% by weight HCHO, 0.5 mol) was added during 30 minutes and water was removed continuously by means of a Dean-Stark type trap. The temperature of the reaction mixture was maintained at 125.degree. C. for an additional 30 minutes and then the catalyst was removed by filtration.
Distillation of the filtrate at reduced pressure gave 177 g. of unreacted aniline and 96 g. of residue, which was light yellow in color. This residue on distillation at 0.05 mm. Hg gave 81 g. (84% yield) of material boiling at 175.degree. to 185.degree. C. which solidified to a white crystalline product (the diaminodiphenylmethane) and 14 g. of non-volatile residue (higher molecular weight aniline-HCHO condensation products).
The product had a neutral equivalent of 101 (calculated for the diaminodiphenylmethanes, 99) and melted at 66.degree. C. An infrared analysis of the product showed that it contained 41% of the 2,4'-isomer.
EXAMPLE II
The experiment of Example I was repeated except one-half as much catalyst was used and the reaction temperature was kept at 150.degree. to 160.degree. C.
Distillation of the mixture gave 174 g. unreacted aniline, 83 g. diaminodiphenylmethanes and 13 g. of non-volatile polymeric aniline/formaldehyde condensation products. The diaminodiphenylmethanes contained 58% of the 2,4'-isomer, according to quantitative infrared analysis.
EXAMPLE III
The experiment of Example I was repeated except one-half as much catalyst was used and the temperature was maintained at 100.degree. C. On distillation of the reaction mixture, there was obtained 205 g. of unreacted aniline, 44 g. of diaminodiphenylmethanes and 34 g. of nonvolatile residue. The diamine thus obtained contained 32% by weight of the 2,4'-isomer and 68% by weight of the 4,4'-isomer.
EXAMPLE IV
A one-gallon, stainless steel, stirred autoclave was charged with 3,350 g. of aniline (36 mols) and 168 g. of Superfiltrol clay, flushed with nitrogen and heated to 250.degree. C. Over a 2-hour period was added 675 ml. of aqueous formalin solution (37% HCHO = 9 mols) and the reaction mixture was heated for 1 hour longer. The catalyst was filtered, water and excess aniline were removed by distillation at reduced pressure. The resulting residue was further distilled at low pressure and found to consist of 67% of diaminodiphenylmethane and 33% of higher molecular weight condensation products. The diamine was found by quantitative infrared analysis to consist of 94% of the 2,4'-isomer and 6% of the 4,4'-isomer.
EXAMPLE V
In the equipment described in Example IV was charged 3,350 g. of aniline (36 mols) and 168 g. of Superfiltrol clay, flushed with nitrogen and heated to 80.degree. C. Over a 3-hour period was added 675 ml. of aqueous formalin solution (37% HCHO = 9 mols) and the reaction mixture was heated for three hours longer. The catalyst was filtered, water and excess aniline were removed by distillation at reduced pressure. The resulting residue was further distilled at low pressure and found to consist of 41% of diaminodiphenylmethane and 59% of higher molecular weight condensation products. The diamine was found by quantitative infrared analysis to consist of 34.5% of the 2,4'-isomer and 65.5% of the 4,4'-isomer.
Examples IV and V illustrate the wide variance possible in the practice of my invention using the same proportions of reactants but varying the temperature and time of the reaction in the presence of the acid activated (Superfiltrol) clay.
EXAMPLE VI
When 558 g. of aniline (6 mols) and 33 g. of flake paraformaldehyde (91% HCHO = 1 mol) were reacted in the presence of 28 g. of silica-magnesia fluidized cracking catalyst, work-up of the product provided 359 g. of excess aniline and 200 g. of residue (100% yield). The residue was found by vacuum distillation to consist of 87% diaminodiphenylmethanes and 13% of higher molecular weight aniline/formaldehyde condensation products. The diamine comprised 22% of the 2,4'-isomer and 78% of the 4,4'-isomer as determined by quantitative infrared analysis.
EXAMPLE VII
In the equipment described in Example I were placed 186 g. of aniline (2 mols) and 10 g. of Superfiltrol acid clay catalyst. The mixture was heated to 125.degree. to 130.degree. C. under a nitrogen sweep and 81 g. of formalin (1 mol HCHO) was added over a 1-hour period. The reaction was continued for 1/2 hour after completion of addition of formalin. The catalyst was then filtered from the hot mixture.
Distillation gave 41 g. unreacted aniline 73 g. volatile diamine and 71 g. nonvolatile polymers.
This experiment illustrates that a 2:1 mol ratio of aniline to formaldehyde can be used conveniently with a solid catalyst to yield a product containing an increased proportion of polyamines.
EXAMPLE VIII
The experiment of Example VII was repeated except a mol ratio of 1.35:1 of aniline to formaldehyde was used. It was necessary to add a solvent (o-dichlorobenzene) in order to maintain a fluid system so that catalyst could be filtered.
The mixture was distilled at reduced pressure to remove solvent and unreacted aniline. The residue, weighing 152 g., was further fractionated at 0.5 mm. Hg to give 20 g. volatile diamine and 130 g. nonvolatile polyamines.
EXAMPLE IX
A 1-gallon, stainless steel, stirred autoclave was charged with 1,256 g. of aniline (13.5 mols) and 62 g. of fluidized silica-alumina cracking catalyst. The autoclave was flushed with nitrogen and heated to 200.degree. C. Over a 2-hour period, 450 ml. of aqueous formalin solution (37% HCHO = 6 mols) was added. Heating was continued at 200.degree. C. for 2 hours after addition of formalin. The catalyst was filtered and water and excess aniline were removed from the filtrate by distillation at reduced pressure. There was obtained 911 g. of residue consisting of 43.3% diaminodiphenylmethane and 56.7% of higher molecular weight aniline/formaldehyde condensation products. The diamine contained 37% of the 2,4'-isomer and 63% of the 4,4'-isomer.
This example illustrates a preferred embodiment of the invention for preparation of a polyamine containing substantial amounts of higher molecular weight condensation products.
EXAMPLE X
Four hundred sixty-five grams of aniline (5 mols) was contacted with 68 g. of 37% formalin solution (0.83 mol HCHO) in a nitrogen atmosphere at 150.degree. C. in the presence of 24 g. of vanadium oxide catalyst.
After 1 hour the catalyst was filtered from the reaction mixture and the filtrate was distilled at reduced pressure, giving 333 g. of aniline (3.58 mols) and 90 g. of a nonvolatile polymeric residue.
This example shows that a typical transition metal oxide, vanadium oxide, is unsatisfactory as a catalyst for forming diaminodiphenylmethane.
EXAMPLE XI
The polyamine phosgenated in this example was prepared by adding 37% aqueous formalin to a mixture of aniline and Superfiltrol activated clay at 130.degree. C. (aniline: HCHO molar ratio, 6:1) as in Example I. The product contained 89% diamine of which 47% was the 2,4'-isomer.
A solution of 200 g. of the above polyamine in 1,200 g. of monochlorobenzene was run into a solution of 350 g. of phosgene dissolved in 1,900 g. of monochlorobenzene while maintaining the temperature at 25.degree. to 30.degree. C.
The resulting slurry was heated rapidly to 110.degree. C. to 120.degree. C. while passing a slow stream of phosgene through the reaction mixture. When there was no longer any solid material in the flask, the reaction was halted. A total of 650 g. of phosgene had been used. Excess phosgene was removed with a stream of dry nitrogen and solvent was removed by flash evaporation.
The residue weighed 248 g. (theory 250 g.) and was a dark, fairly fluid liquid with the following properties:
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--NCO content 7.58 meq./g. (theory 8.0)
Hydrolyzable Cl 0.28
Viscosity, cps. at 25.degree. C.
35
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EXAMPLE XII
The amine to be phosgenated in this example was a distilled diamine prepared over Superfiltrol clay and containing 34.8 wt. % of the 2,4'-isomer.
Phosgenation of 200 g. of this diamine yielded 250 g. of a light-colored liquid diisocyanate with the following properties:
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--NCO content 7.96 meq./g. (theory 8.0)
Hydrolyzable Cl
0.31%
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EXAMPLE XIII
A crude diisocyanate was prepared from a distilled diamine containing approximately 50 wt. % of the 2,4'-isomer of diaminodipheylmethane. Four hundred grams of the crude diisocyanate was flash distilled at .about.0.5 mm. Hg. The volatile distillate weighed 315 g. and was a light yellow, low viscosity material which remained liquid at room temperature. The following physical properties were observed.
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--NCO content 7.98 meq./g. (theory 8.0)
n(25/D) 1.6011
d(20/20) 1.2061
Hydrolyzable Cl
0.06%
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An infrared spectrum showed a high 2,4'-isomer content, as indicated by a strong absorption band at 13.2.mu..
I have further discovered that the hydrolyzable chloride content of higher polyisocyanates is reduced when the final temperature of the aniline/formaldehyde condensation reaction is held between 175.degree. and 200.degree. C. for a period of time of from about 1 to about 5 hours, depending upon the temperature, during the condensation reaction. The following examples illustrate this aspect of my invention.
EXAMPLE XIV
The polyamine phosgenated in this example was prepared by reacting 37% aqueous formalin with aniline in the presence of a silica-alumina catalyst (aniline:HCHO molar ratio, 2.25:1) at 200.degree. C. The polyamine contained 43.3% dimer of which 37% was the 2,4'-isomer. A solution of 200 g. of this polyamine in 1,400 g. monochlorobenzene was run into a solution of 400 g. phosgene dissolved in 1,600 g. monochlorobenzene while maintaining the temperature at 25.degree. to 30.degree. C. The resulting slurry was further phosgenated as described in Example XI, yielding 246 g. product polyisocyanate.
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--NCO content 7.72 meq./g. (theory 8.0)
Hydrolyzable Cl 0.85%
Viscosity, cps. 25.degree. C.
231
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EXAMPLE XV
The polyamine to be phosgenated in this example was prepared by the condensation of aniline and paraformaldehyde at a molar ratio of 2.5:1 and at 175.degree. C. for 5 hours over a silica-alumina catalyst. The product contained 61 wt. % dimer of which 22.5% was the 2,4'-isomer.
The phosgenation of 200 g. of this polyamine was performed as in Example XI, yielding 248 g. of a fairly light-colored, crude polyisocyanate with the following properties:
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--NCO content 7.72 meq./g. (theory 8.0)
Hydrolyzable Cl 0.41%
Viscosity, cps. at 25.degree. C.
53
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EXAMPLE XVI
A rigid polyurethane foam was prepared from the polyisocyanate described in Example XV using the following formulations (parts by weight): 194 parts of crude isocyanate, 192 parts of Tetrol MG-525 (a polyoxypropylene polyol based on methyl-glucoside), 64 parts of Freon 11, 4 parts of silicone oil and 1.5 parts of 2-methyl-(2.2.2)diazabicyclooctane. The following properties were found:
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Cream time, sec. 40
Rise time, sec. 150
Tack-free time, sec. 150
Density, lb./ft..sup.3
1.91
Compressive strength, psi.
26.58
Tensile strength, psi.
52.3
Heat distortion temp., .degree. C.
172.0
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Dimensional stability
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158.degree. F., 100% R.H.
12 hours, % vol. change
+2.33
% wt. change -1.26
24 hours, % vol. change
+3.55
% wt. change -0.75
1 week, % vol. change +5.38
% wt. change -1.76
0.degree. F., dry
1 week, % vol. change -1.03
% wt. change 0.0
180.degree. F., dry
1 week, % vol. change +1.83
% wt. change 0.0
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EXAMPLE XVII
In a three-necked flask was placed 1,465 g. aniline (15.75 mols), 231 g. paraformaldehyde (7.0 mols HCHO) and 73 g. of Superfiltrol acid clay. The temperature was raised and water was removed in the interval 100.degree. to 115.degree. C. The temperature was further raised to 150.degree. C. and held at that point for two hours. The catalyst was filtered from the product, and 374 g. unreacted aniline was recovered by distillation at a reduced pressure. The residue weighed 1,046 g. molecular weight 268, and contained 53.5 wt. % diamine.
EXAMPLE XVIII
Two hundred grams of the polyamine of Example XVII was dissolved in 1,400 g. of monochlorobenzene and added to a solution of 437 g. of phosgene dissolved in 1,600 g. of chlorobenzene at such a rate that the temperature was maintained in the range 25.degree. to 30.degree. C. The resulting slurry was then heated to 130.degree. C. over a 2-hour period while passing in a slow stream of phosgene. Heating was continued at 130.degree. C. for an additional hour. A total of 560 g. of phosgene was used. All excess phosgene was removed by sparging the solution with a stream of dry nitrogen. Solvent was removed by flash evaporation and the polyisocyanate residue was finished by stripping to a pot temperature of 150.degree. C. at 2 mm. Hg pressure. The product weighed 247 g. Table 1 gives the properties of this polyisocyanate, which represents the product obtained before the improvement of the present invention.
EXAMPLE XIX
The experiment of Example XVII was repeated except a synthetic silica-alumina cracking catalyst, 15 mols of aniline and 6 mols of formaldehyde (as 37% formalin) were used. The product was converted to the polyisocyanate by the procedure of Example XVIII. The properties of this polyisocyanate given in Table 1 represent those of a product before the improvement of the present invention.
EXAMPLE XX
The experiment of Example XVII was repeated except a synthetic silica-alumina cracking catalyst, 15 mols of aniline and 6 mols of formaldehyde were used and after water was removed, the temperature was raised to 175.degree. C. and the reaction product digested for 5 hours. The product was converted to the polyisocyanate by the procedure of Example XVIII and the properties given in Table 1 show the improvement in hydrolyzable chloride content over the polyisocyanates of Examples XVIII and XIX.
EXAMPLE XXI
In a 1-gallon, stainless-steel autoclave were placed 13.5 mols aniline, 6 mols formaldehyde (as paraformaldehyde) and 63 g. synthetic silica-alumina cracking catalyst. The autoclave was flushed with nitrogen, heated to 200.degree. C. and held at that temperature for one hour. The autoclave was cooled, the product was removed and filtered to remove catalyst. Excess aniline was removed by distillation at reduced pressure, giving 939 g. polyamine. The product was converted to the polyisocyanate by the procedure of Example XVIII. The properties are given in Table 1.
TABLE 1
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EXAMPLE XVIII XIX XX XXI
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Polyamine
Mols aniline/mol HCHO
2.25 2.5 2.5 2.25
Catalyst Acid clay Si-Al Si-Al Si-Al
Reaction temp., .degree. C.
150 150 150 200
Reaction time., hrs.
2 2 2 1
Digestive temp., .degree. C.
-- -- 175 --
Digestive time., hrs.
-- -- 5 --
% Diamine 53.5 60 61 57
Polyisocyanate
NCO, meq./g. 7.50 7.64 7.72 7.38
Hydrolyzable Cl, %
6.04 3.0 0.41 1.02
Viscosity, cps. 25.degree. C.
9,600 200 53 315
Carbonyl (carbamoyl)
High Very Very Fairly
5.75.mu. strong weak low
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EXAMPLE XXII
This example shows the further reduction of the hydrolyzable chlorine content achieved by adding the formaldehyde to the hot aniline and catalyst mixture rather than following a cold premixing procedure.
A mixture of 10.8 mols of aniline and 50 g. of synthetic silica-alumina cracking catalyst was placed in a stainless steel autoclave, flushed with nitrogen and heated to 200.degree. C. Aqueous formalin (6 mols HCHO) was injected over a period of 1.3 hours. Heating was continued at 200.degree. C. for 2 hours. The reaction mixture was cooled, removed from the autoclave and filtered to remove catalyst. Unreacted aniline was removed by distillation at reduced pressure and the polyamine residue weighed 1,023 grams. The product was phosgenated by the procedure given in Example XVIII. Table 2 shows the effectiveness of this technique in terms of decreased hydrolyzable chloride.
TABLE 2
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Polyamine Example XXII
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Mixing procedure
Cold premixing
Hot addition
Aniline/HCHO 1.8/1 1.8/1
Temperature, .degree. C.
200 200
Time, hours 2 2
% Diamine 41.4 34
Polyisocyanate
NCO, meq./g. 7.42 7.50
Hydrolyzable Cl, %
1.60 0.65
Carbonyl, 5.75.mu.
Fairly Low
strong
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In Example XXIII is given a preferred embodiment of the practice of my invention wherein a two-step process is used to give higher polyamine suitable for conversion to polyisocyanate. The polyisocyanate thus produced has low hydrolyzable chloride content, low visocity and is highly satisfactory for the commerical production of rigid polyurethane products.
EXAMPLE XXIII
In a 25-gallon, heated, stirred, stainless steel kettle equipped with a back pressure regulator was placed 100 lbs. of aniline and 2.2 lbs. of silica-alumina cracking catalyst under a nitrogen blanket. The temperature was raised to 140.degree. C. and 43.6 lbs. of aqueous formaldehyde (37% HCHO) were added. The temperature was held a 140.degree. C. for 1 hour and then raised to 200.degree. C for 2 hours. The reaction mixture was cooled to 100.degree. C., filter-aid was added, and the catalyst was removed by filtration. Water and excess aniline were removed by vacuum distillation. The residue weighed 71.5 lbs. A portion of the product was converted to the polyisocyanate by the phosgenation procedure described in Example XVIII.
In Table 3 are given the properties of the polyamine and derived polyisocyanate after the 140.degree. C. heating stage and also after the 200.degree. C. digestion stage to illustrate the improvement realized by the practice of the present invention.
TABLE 3
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Reaction
Polyamine Reaction Only
and Digestion
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Aniline/formaldehyde
ratio 3.0 3.0
Catalyst Silica-alumina
Silica-alumina
Temperature, .degree. C.
140.degree. for 1 hr.
140.degree. for 1 hr.
then
200.degree. for 2 hrs.
% Diamine 51 65
% 2,4'-Isomeric
diamine 19.4 28.8
Polyisocyanate
NCO, meq./g. 7.49 7.78
Chloride, % 3.68 0.70
Viscosity, cps. 25.degree. C.
5,880 52.5
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