Title of Invention

A METHOD FOR PREPARING A GRIGNARD REACTION PRODUCT USING CYCLOPENTYL METHYL ETHER AS SOLVENT

Abstract The invention discloses a method for preparing a Grignard reaction product such as herein described by reaction of a Grignard reagent such as herein described with an aldehyde such as herein described or a ketone such as herein described in the presence of a reaction solvent and under the usual reaction conditions known for such Grignard reaction characterized in that said reaction solvent for the Grignard reaction comprising a cyclopentyl methyl ether.
Full Text DESCRIPTION
A METHOD FOR PREPARING A GRIGNARD REACTION PRODUCT USING
CYCLOPENTYL METHYL ETHER AS SOLVENT
TECHNICAL FIELD
The invention is in the field of Grignard reaction
particularly a method for preparing a Grignard reaction product
using cyclopentyl methyl ether as solvent.
The present invention relates to a solvent comprising
a cycloalkyl alkyl ether compound and a process for producing
the cycloalkyl alkyl ether compound. More particularly, the
present invention relates to a solvent containing a cycloalkyl
alkyl other compound useful as a cleaning solvent for electronic
parts, precision machinery components, and the like, a reaction
solvent for various chemical reactions, an extraction solvent
for extracting objective organic substances from varices
mixtures, a solvent or remover agent for electronic and electric
materials, and the like, to a method for cleaning articles, a
method for reacting an organic metal, a Grignard reaction method,
a method for extracting organic compounds, and a method for
producing parts for electronic and electrical materials using
the solvent, and to a process for advantageously producing the
cycloalkyl alkyl ether compound in an industrial scale.
BACKGROUND ART
Conventionally, a cleaning operation using a cleaning
solvent is carried out during manufacturing electronic
equipment, precision machines, and the like to prevent
degradation of electrical characteristics and mechanical
characteristics. Chemically stable chlorine or flon solvents
have been used for this purpose. The use of a number of these
solvents has been regulated due to the problems in safety,
toxicity, and environmental pollution.
Cleaning solvents and cleaning compositions that are
safe, less toxic, and less pollutant to the environment have
been proposed as substitutes for these solvents. For example,
cleaning solvents and cleaning compositions described in USi
4,511,488, USP 4,640,719, USP 4,740,247, JP-A 3-62897- JP-A
6-49495, and the like are given.
However, these cleaning solvents are not necessarily
satisfactory in their detergency, particularly detergency for
oils and fats. Therefore, development of a novel cleaning
solvent excelling in both safety and detergency has been
desired.
Conventionally, ether solvents that are non-proronic and
polar have widely been used as reaction solvents for various
organic reactions (hereinafter referred to as "reaction") such
as a Grignard reaction. Tetrahydrofuran (THF), which is a
typical ether solvent, is a non-protonic and polar solvent
having a moderate boiling point. THF is commonly used as a
reaction solvent, particularly for Grignard reactions,
reactions using an organolithium compound or the like, and other
similar reactions. However, if THF is used as a solvent for
a reaction mixture to which water is added, it is difficult to
remove THF from the reaction mixture since THF is mutually
soluble with water and forms an azeotrope. A special
distillation process involving addition of an entrainer or
other third components is required for industrially separating
one component from another in an azeotrope. The distillation
unit, which must be equipped with at least two columns and
auxiliary equipment such as a decanter, can be operated only
with difficulty requiring a high cost.
When THF is used as a reaction solvent for Grignard
reaction in which a Grignard reagent such as phenyl magnesium
bromide (PhMgBr) is reacted with a ketone that can be easily
enolated such as acetone, a self-aldol condensation reaction
which is a side reaction is predominant over the target
nucleophilic reaction, producing the target reaction product
(a,a-dimethylbenzyl alcohol) only in a low yield. Therefore,
development of a reaction solvent that can be easily recovered
after use and exhibits excellent reaction selectivity has been
desired.
A solvent extraction is a well-known method for
extracting a desired compound from a mixture using an
appropriate extraction solvent. Various extraction solvents
that can be used are known. Examples include halogenated
hydrocarbons such as dichloromethane and chloroform; aliphatic
hydrocarbons such as n-hexane and cyclohexane; aromatic
hydrocarbons such as benzene and toluene; esters such as methyl
acetate and ethyl acetate; ketones such as acetone and
cyclohexanone; and ethers such as diethyl ether and dipropyl
ether.
Requirements for the extraction solvents include (i)
being inactive under the extraction conditions, (ii) being
capable of sufficiently dissolving extracted substances, (iii)
having an appropriate boiling point, producing vapor that has
a minimal risk of being absorbed during the solvent extraction
operation, and being easily evaporated, and (iv) having only
a slight possibility of polluting the environment.
However, only a few extraction solvents currently
available satisfy these requirements. For example, since
halogenated hydrocarbons such as dichloromethane and
chloroform having excellent capability of dissolving various
organic compounds have a strong toxicity and a low boiling point,
their vapor have a risk of being inhaled during the extraction
operation and cause an environmental pollution problem.
Esters such as ethyl acetate and aromatic hydrocarbons such as
toluene are also extraction solvents with wide versatility, but
exhibit only limited capability of dissolving organic compounds
having a moderate polarity and insufficient extraction
efficiency. Therefore, development of a novel extraction
solvent advantageous from the viewpoint of extraction operation
and environmental safety has been desired.
Conventionally, various organic solvents such as
aromatic hydrocarbon solvents, aliphatic hydrocarbon
solvents,and halogenated hydrocarbon solvents have been used
as a solvent and parting agents for electronic materials,
electrical materials, and the like. It is desirable that these
solvents and parting agents exhibit high solubility and
dispersibility of electronic and electrical materials and are
safe and free from the problem of environmental pollution.
However, not a few currently available solvents and
parting agents lack solubility and dispersibility of electronic
and electrical materials, are strongly toxic, and pollute the
environment. Therefore, development of a solvent and parting
agent exhibiting high solubility and dispersibility of
electronic and electrical materials and being safe and free from
the problem of environmental pollution has been desired.
As the method for producing ethers by the addition
reaction of an olefin to an alcohol, a method of using
crystalline alumino silicate as a catalyst (Japanese Patent
Application Laid-open No. 59-25345), a method of using HZSM-5
zeolite as a catalyst USP No. 4,306,100), a method of using
special alumino silicate having many acid points on the surface
as a catalyst (Japanese Patent Application Laid-open No.
61-249945), a method of using tungsten oxide in which the
crystal water possessed by a heteropoly acid has been adjusted
to about 3.0 or less molecules per one molecules of the
heteropolyacid as a catalyst (Japanese Patent Application
Laid-open No. 5-163188), and the like are known.
However, the activity of the catalysts used in these
methods has been insufficient to manufacture the target
compound at an industrially acceptable selectivity and
conversion rate, particularly to manufacture a cycloalkyl alkyl
ether compound from an alicyclic olefin as a starting raw
material.
A method of using an acidic ion-exchange resin is an old
method for producing ethers by the addition reaction of an
olefin to an alcohol. However, the method involves problems
such as isomerization of olefins as a side reaction and thermal
instability of used resins if conventional acidic ion-exchange
resins are used as described in Japanese Patent Application
Laid-open No. 5-163188, for example.
The present invention has been achieved in view of this
situation. A first object of the present invention is therefore
to provide (a) a novel cleaning solvent that can be safely
handled, can be mixed with many organic solvents and dissolve
various pollutant organic substances such as fats and oils,
waxes, and natural resins, and can be promptly decomposed in
the atmosphere without adversely affecting the ozone layer, (b)
a reaction solvent that can be easily recovered after use and
exhibits excellent reaction selectivity, (c) an extraction
solvent advantageous from the viewpoint of operational
efficiency and environmental safety, (d) a solvent for
electronic and electrical materials exhibiting high solubility
and dispersibility of the materials and being safe and free from
the problem of environmental pollution, and (e) a solvent usable
as a parting agent used for removing a photo-sensitive layer
from an OPC (Organic Photo Conductor) drum or for removing
semiconductor materials and the like glued to jigs with an
adhesive from the adhesive or the jig.
A second object of the present invention is to provide
an industrially advantageous process for producing a cycloalkyl
alkyl ether compound useful as such a cleaning solvent, reaction
solvent, extraction solvent, parting agent for electronic or
electrical materials.
BRIEF DESCRIPTION OF THE/DRAWINGS
Fig. 1 is a drawing illustrating a reactor used for the
manufacturing process of the present invention.
Fig. 2 is a drawing illustrating a reactor used for the
manufacturing process of the present invention.
Fig. 3 is a drawing illustrating an apparatus combining
a reactor and distillatory used for the manufacturing process
of the present invention.
DISCLOSURE OF THE INVENTION
The present inventors have found that cycloalkyl alkyl
ether compounds (1) has a moderate boiling point, can be safely
handled, can be promptly decomposed in the atmosphere without
adversely affecting the ozone layer, and can be mixed with many
organic solvents, exhibiting excellent solubility to fats and
oils, waxes, natural resins, and the like, (2) can be used as
a reaction solvent that can be easily recovered after use and
can produce the target product in a high yield when used as an
organic synthetic chemical reaction such as a Grignard reaction,
(3) can be used as an extraction solvent advantageous from the
viewpoint of operational efficiency and environmental safety,
(4) can be used as a solvent for electronic and electrical
materials exhibiting high solubility and dispersibility to the
materials, exhibiting least toxicity, and being almost free
from the problem of environmental pollution, and (5) can be used
as a parting agent exhibiting excellent solubility to
sensitizers, organic adhesives, photo resists, and organic
insulating materials, exhibiting least toxicity, and being
almost free from the problem of environmental pollution.
The present inventors have found that the target
cyclopentyl methyl ether can be obtained at a high selectivity
and high conversion rate if cyclopentene as an alicyclic olefin
is reacted with methanol as an alcohol in the presence of an
acidic ion-exchange resin catalyst with a water content of 5
wt% or less. The inventors have continued the studies based
on this finding and completed the present invention.
Specifically, the present invention provides, in the
first place, a solvent comprising at least one cycloalkyl alkyl
ether compound represented by the formula (1) : R1-O-R2, wherein
R1 represents a cyclopentyl group or cyclohexyl group which may
have a substituent and R2 represents an alkyl group having 1-10
carbon atoms or a cycloalkyl group having 3-8 carbon atoms which
may have a substituent.
In the present invention provides, the cycloalkyl alkyl
ether compound represented by the formula (1) is preferably a
cycloalkyl alkyl ether compound represented by the formula (2) :
R1-O-R3, wherein R1 is the same as defined above and R3 represents
an alkyl group having 1-10 carbon atoms or a cycloalkyl group
having 3-8 carbon atoms and, more preferably, a cycloalkyl alkyl
ether compound represented by the formula (3) : R4-O-R3, wherein
R4 is a cyclopentyl group and R3 is the same as defined above.
The solvent of the present invention is preferably a
cleaning solvent, a reaction solvent, an extraction solvent,
a solvent for electronic and electrical materials, or a parting
solvent. When the solvent of the present invention is reaction
solvent, the reaction is preferably an organometallic reaction
or a Grignard reaction.
It is preferable that the water content of the solvent
of the present invention be 100 ppm or less,, with a further
preferable solvent comprising an antioxidant.
In the second place, the present invention provides an
organometallic reaction method using the solvent of the present
invention.
In the third place, the present invention provides a
Grignard reaction method using the solvent of the present
invention.
In the fourth place, the present invention provides a
method for extracting an organic compound using the solvent of
the present invention.
In the fifth place, the present invention provides a
method for cleaning articles using the solvent of the present
invention.
In the sixth place, the present invention provides a
method for manufacturing electronic and electrical components
using the solvent of the present invention.
In the seventh place, the present invention provides a
process for producing a cycloalkyl alkyl ether compound of the
formula (1), (2), or (3) comprising reacting an alicyclic olefin
with an alcohol in the presence of an acidic ion-exchange resin
having a water content of 5 wt% or less.
BEST MODE FOR CARRYING OUT THE INVENTION
1) Solvent comprising a cycloalkyl alkyl ether compound
The solvent of the present invention comprises one or
more types of cycloalkyl alkyl ether compounds shown by the
above formula (1), preferably formula (2), and even more
preferably formula (3) (hereinafter simply referred to as
"cycloalkyl alkyl ether compound" from time to time).
(A) Cycloalkyl alkyl ether compound
In the cycloalkyl alkyl ether compound shown by the above
formulas (1) and (2), R1 represents a cyclopentyl group which
may have a substituent or a cyclohexyl group which may have a
substituent.
As examples of the substituent group, an alkyl group
having 1-4 carbon atoms, alkoxy group having 1-4 carbon atoms,
alkylthio group having 1-4 carbon atoms, and halogen atom can
be given. Of these, an alkyl group having 1-4 carbon atoms is
preferable, with a methyl group or ethyl group being
particularly preferable.
As specific examples of R1, a cyclopentyl group or
cyclohexyl group; an alkyl cyclopentyl group or alkyl
cyclohexyl group such as 2-methyl-cyclopentyl group,
3-ethyl-cyclohexyl group, 3-sec-butyl-cyclopentyl group, and
2-tert-butyl-cyclohexyl group; an alkoxy cyclopentyl group or
alkoxy cyclohexyl group such as S-methoxy-cyclopentyl group,
3-ethoxy-cyclohexyl group, 2-sec-butoxy-cyclopentyl group,
and 3-tert-butoxy-cyclohexyl group; an alkyl thiocyclopentyl
group or alkyl thiocyclohexyl group such as
3-methylthio-cyclopentyl group, 3-ethylthio-cyclohexyl group,
2-sec-butylthio-cyclopentyl group, and
3-tert-butylthio-cyclohexyl group; and a halogenated
cyclopentyl group or halogenated cyclohexyl group such as
2-chloro-cyclopentyl group, 3-chloro-cyclopentyl group,
2-bromo-cyclohexyl group, and 3-bromo-cyclohexyl group can be
given.
In the cycloalkyl alkyl ether compound shown by the above
formula (1), R2 represents an alkyl group having 1-10 carbon
atoms which may have a substituent or a cycloalkyl group having
3-8 carbon atoms which may have a substituent.
As specific examples of R2, an alkyl group having 1-10
carbon atoms such as a methyl group, ethyl group, n-propyl group,
isopropyl group, n-butyl group, sec-butyl group, tert-butyl
group, n-pentyl group, neopentyl group, n-hexyl group, n-heptyl
group, n-octyl group, n-nonyl group, and n-decyl group; a
cycloalkyl group having 3-8 carbon atoms such as a cyclopropyl
group, cyclobutyl group, cyclopentyl group, cyclohexyl group,
cycloheptyl group, and cyclooctyl group; an alkoxyalkyl group
such as a methoxymethyl group, 1-methoxyethyl group,
2-ethoxy-tert-butyl group, and 2-ethoxy-n-hexyl group; an
alkoxycycloalkyl group such as a 2-methoxy-cyclopropyl group
and 3-ethoxy-cyclohexyl group; an alkyl thioalkyl group such
as a methyl thiomethyl group, 1-methyl thioethyl group,
2-methylthio-tert-butyl group, and 4-methylthio-n-hexyl
group; an alkyl thiocycloalkyl group such as a
2-methylthio-cyclopropyl group and 3-ethylthio-cyclohexyl
group; a halogenated alkyl group such as a chloromethyl group,
bromomethyl group, 1-chloroethyl group, 2-bromo-tert-butyl
group, and 2-chloro-n-hexyl group; and a halogenated cycloalkyl
group such as a 2-chloro-cyclopropyl group and
3-bromo-cyclohexyl group can be given.
In the cycloalkyl alkyl ether compound shown by the above
formulas (2) and (3), R3 represents an alkyl group having 1-10
carbon atoms or a cycloalkyl group having 3-8 carbon atoms.
As specific examples of R3, an alkyl group having 1-10
carbon atoms such as a methyl group, ethyl group, n-propyl group,
isopropyl group, n-butyl group, sec-butyl group, tert-butyl
group, n-pentyl group, neopentyl group, n-hexyl group, n-heptyl
group, n-octyl group, n-nonyl group, and n-decyl group, and a
cycloalkyl group having 3-8 carbon atoms such as cyclopropyl
group, cyclobutyl group, cyclopentyl group, cyclohexyl group,
cycloheptyl group, and cyclooctyl group can be given.
In the present invention, R4 represents a cyclopentyl
group.
In the present invention, of the cycloalkyl alkyl ether
compounds shown by the above formula (1) , in view of cleaning
effect, environmental safety, reaction selectability,
extraction effect, volatility, chemical stability, and
production cost, the cycloalkyl alkyl ether compounds shown by
the above formula (2) are preferable, with the cycloalkyl alkyl
ether compounds shown by the above formula (3) being
particularly preferable.
In the present invention, of the cycloalkyl alkyl ether
compounds shown by the above formula (3), the cycloalkyl alkyl
ether compound wherein R4 is an alkyl group having 1-4 carbon
atoms or a cycloalkyl group having 3-6 carbon atoms is
preferable, with cyclopentyl methyl ether (hereinafter,
abbreviated as "CPME"), cyclopentyl ethyl ether, or
dicyclopentv,l ether being even more preferable, and CPME being
particularly preferable.
(B) Method for producing cycloalkyl alkyl ether compound
Cycloalkyl alkyl ether compounds are well known in the
art and can be produced by known methods.
Specific examples of such a method include (a) a method
of reacting a cyclopentyl alcohol which may have a substituent
the same as that possessed by the group R1 (hereinafter referred
to as "a cyclopentyl alcohol") or a cyclohexyl alcohol which
may have a substituent the same as that possessed by the group
R1 (hereinafter referred to as "a cyclohexyl alcohol") with an
alkylating agent in the presence of a base or (b) a method of
reacting a cyclopentene which may have a substituent the same
as that possessed by the group R1 (hereinafter referred to as
"cyclopentenes") or a cyclohexene which may have a substituent
the same as that possessed by the group R1 (hereinafter referred
to as "cyclohexenes") with a compound represented by the formula
R'-OH, wherein R' represents a hydrogen atom and an alkyl group
having 1-10 carbon atoms which may have a substituent the same
as that possessed by the group R2 or a cycloalkyl group having
3-8 carbon atoms which may have a substituent the same as that
possessed by the group R2 in the presence of a solid acid. Of
these, method (b) is preferable due to lower cost, and the
unnecessary consumption of a large quantity of a base.
As examples of the alkylating agent used in method (a),
halogenated alkyl, dialkyl sulfuric acid, alkyl sulfonate, and
the like can be given. The alkylating agent is usually used
in an amount of 0.9-10 mol and preferably 1.1-5.0 mol for 1 mol
of the cyclopentyl alcohol or cyclohexyl alcohol.
As examples of the base used in the alkylating reaction,
a metal hydride, alkali metal, carbonate, hydrogen carbonate,
organic base, and the like can be given. The base is usually
used in an amount of 1-10 mols and preferably 1-5 mols for 1
mol of the cyclopentyl alcohol or cyclohexyl alcohol.
The method (a) can be carried out either without using
a solvent or using an inert solvent. The reaction in the
presence of an inert solvent is more preferable. A non-protonic
polar solvent is preferably used.
Either commercially available cyclopentyl alcohols and
cyclohexyl alcohols or those produced by a known method can be
used as the raw materials.
The alkylation reaction can be carried out by a method
of suspending or dissolving a prescribed amount of a base to
an inert solvent, adding a cyclopentyl alcohol or cyclohexyl
alcohol, and further adding an alkylating, agent, a method of
adding a prescribed amount of a base to a solution of a
cyclopentyl alcohol or cyclohexyl alcohol in an inert solvent
and adding a prescribed amount of an alkylating agent, and the
like.
In these instances, after adding the base and before
adding the alkylating agent, it is preferable to form a
cyclopentyl alcohol or cyclohexyl alcohol salt by stirring and
heating the reaction mixture. The reaction is usually carried
out at a temperature ranging from room temperature to the
boiling point of the solvent used for several minutes to several
hours.
In the method of (b), cyclopentenes or cyclohexenes is
caused to come in contact with the compound shown by the formula
R'OH in the presence of a solid acid.
As specific examples of the cyclopentenes, cyclopentene,
1-methylcyclopentene, 3-methylcyclopentene,
1,3-dimethylcyclopentene, 1-fluorocyclopentene, and
1-phenylcyclopentene can be given. As examples of
cyclohexenes, cyclohexene, 1-methylcyclohexene,
4-methylcyclohexene, 1,3-dimethylcyclohexene,
1-fluorocyclohexene, 4-chlorocyclohexene,
1-phenylcyclohexene, and 4-phenylcyclohexene can be given. Of
these, cyclopentene or cyclohexene are preferable, with
cyclopentene being particularly preferable.
As specific examples of the compounds shown by the formula
R'OH, water, methanol, ethanol, 2-methoxyethanol, n-propanol,
2-chloro-n-propanol, isopropanol, n-butanol,
3-methylthio-n-butanol, 2-bromo-n-butanol, sec-butanol,
isobutanol, tert-butanol, n-pentanol, n-hexanol, cyclopropyl
alcohol, cyclopentyl alcohol, 2-chlorocyclopentyl alcohol,
cyclohexyl alcohol, cycloheptanol, and cyclooctanol can be
given.
The compound shown by the formula R'OH is usually used
in an amount of 0.002-11 mol, and preferably 0.02-7 mol, for
1 mol of cyclopentenes (cyclohexenes). The reaction is usually
carried out at 50-200°C, and preferably at 80-180°C.
As examples of the solid acid used in the method (b
) , an acidic ion exchange resin or crystalline solid acid
can be given, with an acidic ion exchange resin being
preferable.
The acidic ion-exchange resin is an insoluble porous
synthetic resin comprising a polymer matrix having a fine
three-dimensional network structure and acidic ion-exchange
groups and is commonly called a cationic exchange resin.
As examples of the acidic ion-exchange resin, a strongly
acidic cation-exchange resin comprising a styrene polymer
substrate and sulfonic acid groups as ion-exchange groups and
a weakly acidic cation-exchange resin comprising an acrylic or
methacrylic polymer matrix and acrylic or methacrylic acid
groups as ion-exchange groups can be given., The acidic
ion-exchange resins are broadly classified into a gel type,
porous type, and high porous type from the viewpoint of a
geometrical structure. Any types can be used in the present
invention.
As specific preferable examples of the acidic
ion-exchange resin, styrene based strongly acidic
cation-exchange resin gel DIAION SK1B, SK012, SK104, SK106,
SK11O, SK112, and SK116 (manufactured by Mitsubishi Chemical
Corp.); porous styrene based strongly acidic cation-exchange
resin PK208, PK212, PK216, PK220, and PK228 (manufactured by
Mitsubishi Chemical Corp.); highly porous styrene based
strongly acidic cation-exchange resin HPK25 (manufactured by
Mitsubishi Chemical Corp.); heat resistant styrene based
strongly acidic cation-exchange resin RCP145 (manufactured by
Mitsubishi Chemical Corp.) ; acrylic acid based and methacrylic
acid based weakly acidic cation-exchange resin WK10, WK11,
WK100, WT01S, WK40 (manufactured by Mitsubishi Chemical Corp.);
sulfonic acid based cation-exchange resin UBK530, UBK550,
UBK535, and UBK555 (manufactured by Mitsubishi Chemical Corp.);
SPC type styrene based acidic cation-exchange resin SPC108 and
SPC118; strongly acidic Bayer catalyst gel K1221, K1431, K1481,
and K14 91 (manufactured by Bayer) ; macroporous strongly acidic
Bayer catalyst K2431, K2621, and K2641 (manufactured by Bayer);
Amberlite (XE-284) (manufactured by Rohm and Haas), and
Amberlyst 15 (manufactured by Organo Corporation) can be given.
Of these, from the viewpoint of easy availability and
easy handling, a sulfonic acid-type strong acid cation exchange
resin comprising a sulfonic acid group as the ion-exchange group
is preferable, with a sulfonic acid-type styrene strong acid
cation exchange resin comprising a copolymer of styrene or
halogenated styrene and divinyl benzene as the polymer
substrate and a sulfonic acid group as the ion-exchange group
being particularly preferable.
The apparent density(g/L-R) of the acidic ion-exchange
resin is usually 500-1,000, and preferably 600-900. The water
content before drying is usually 30-70 wt%. There are no
specific limitations to the average particle size of the acidic
ion-exchange resin. The particle size, which is appropriately
determined based on the inner diameter of the reaction tube used
in the additional reaction mentioned later on, is usually in
the range of 0.02-10 mm, and preferably 0.5-2 mm. Usually, a
common proton-type acidic ion-exchange resin is used and can
be recycled using common methods for repeated use.
Of these acidic ion-exchange resins, the acidic
ion-exchange resins comprising water in an amount of 5 wt% or
less, preferably 3 wt% or less, and particularly preferably 2
wt% or less are preferably used as the acidic ion-exchange resin
of the present invention. The target cycloalkyl alkyl ether
compound can be obtained at a high selectivity and high
conversion rate by using the acidic ion-exchange resin
containing water in an amount of 5 wt% or less as a reaction
catalyst.
To obtain the acidic ion-exchange resin comprising water
in an amount of 5 wt% or less, the resin is dried before use
to remove the water. There are no specific restrictions to the
method for drying the acidic ion-exchange resin as long as the
acidic ion-exchange resin comprising 5 wt% or less of water
after drying can be obtained.
A common method of dehydration with heating can be used
as the method of drying. As examples of the heat dehydration
method, (i) a method wherein the acidic ion-exchange resin is
placed in a common dryer and heated at 50-120°C, and preferably
80-100°C, for several minutes to several hours; (ii) a method
wherein the acidic ion-exchange resin is heat dried under a
circulation of an inert gas at a prescribed temperature (about
100°C above room temperature) for several minutes to several
hours; and (iii) a combination of the methods (i) and (ii) can
be given.
As examples of the inert gas, air, nitrogen, argon, helium,
hydrogen, aliphatic hydrocarbon, and aromatic hydrocarbon can
be given. There are no specific restrictions to the speed at
which the inert gas is circulated. The hourly space velocity
on a gaseous basis at heating temperature inside the apparatus
is usually 0.01-100 vol/Hr•vol.
When an acidic ion-exchange resin comprising 5 wt% or
less of water is used, an ether compound can be produced by
contacting an alicyclic olefin other than the above-mentioned
cyclopentene (cyclohexene) with the compound shown by the
formula R'OH.
As examples of the alicyclic olefin, an aliphatic
compound having a monocyclic or polycyclic structure with 3-20
carbon atoms and having at least one carbon-carbon double bond
in the cyclic skeleton, excluding cyclopentenes and
cyclohexenes, can be given. Furthermore, alicyclic olefins
comprising substituents such as an alkyl group, aryl group,
halogen atom, nitro group, amino group, alkoxy group, sulfone
group, and cyano group on the cyclic skeleton may be used. As
examples of other alicyclic olefins, seven-inembered cyclic
compounds such as cycloheptene, 1-methyl cycloheptene, and
1-phenyl cycloheptene; and eight-membered cyclic compounds
such as cyclooctene, 1-methyl cyclooctene, and 1-phenyl
cyclooctene can be given.
There are no specific limitations to the method for
contacting the cyclopentenes (cyclohexenes) with the compound
of the formula R'OH in the presence of the acidic ion-exchange
resin. As examples of this method, a method of adding the acidic
ion-exchange resin to a mixture of cyclopentenes (cyclohexenes)
and the compound of the formula R'OH (hereinafter, also referred
to as "mixture") while stirring (batch type) and a method
comprising filling a column with the acidic ion-exchange resin
and flowing the mixture through the column (hereinafter
referred to as "reaction column") (flow type) can be given. Of
these, from the viewpoint of efficient and continuous
purification of the reaction product, use of the flow type is
preferable.
In the production of the above-mentioned mixture, the
cyclopentenes (cyclohexenes) and the compound shown by the
formula R'OH are mixed at a predetermined ratio. In this
instance, the mixture comprising cyclopentenes (cyclohexenes)
and the compound of the formula R' OH can be prepared beforehand,
stored in a tank, and sent to the column in a gaseous cr liquid
state, or cyclopentenes (cyclohexenes) and the compound shown
by the formula R'OH can be stored in separate tanks, sent to
the column separately in a liquid state, and mixed immediately
before entering the column. The mixture preferably contains
as little water as possible to ensure efficient production of
the target product. The mixture preferably contains water in
an amount of 1 wt% or less, with 500 ppm or less being
particularly preferable.
In the batch-type, the acidic ion-exchange resin,
cyclopentenes (cyclohexenes), and the compound shown by the
formula R'OH are added to the reactor in predetermined amounts
and the reaction mixture is stirred at a predetermined
temperature and pressure. In this instance, the acidic
ion-exchange resin is usually used in an amount of 0.01-200
parts by weight, preferably 0.1-150 parts by weight, and
particularly preferably 1-100 parts by weight for 100 parts by
weight of cyclopentenes (cyclohexenes).
In the batch-type, even though there are no specific
limitations to the proportion of cyclopentenes (cyclohexenes)
and the compound shown by the formula R'OH, the compound shown
by the formula R'OH is preferably used in an excessive
proportion. Since the mixture is heated for a long period of
time in the batch-type, a polymer of cyclopentenes
(cyclohexenes) may be produced if an excessive amount of
cyclopentenes (cyclohexenes) is used. The proportion of
cyclopentenes (cyclohexenes) and the compound shown by the
formula R'OH (the mol ratio of (cyclopentenes
(cyclohexenes) / (compound shown by the formula R' OH) ) is usually
1/1-1/50, preferably 1/1-1/30, and particularly preferably
1/1-1/20.
When the flow-type is used, the mixture is flowed through
the reaction column. In this instance, the column possessing
a heating apparatus is used and the mixture is flowed through
the reaction column heated to the prescribed temperature
(reaction temperature) . Even though the mixture may be flowed
through the reaction column in a liquid or gaseous state, the
mixture is preferably flowed through the reaction column in a
gaseous state to obtain high selectivity and a high conversion
rate of the target product.
When the mixture is flowed through the reaction column
in a gaseous state, a gaseous phase-solid phase reaction occurs.
As an example of a method for conducting this reaction, as shown
in figure 1(a), a method wherein the mixture liquid exits from
the mixture liquid storage tank la, is transformed into a gas
by the heat/gasification device 2a, and enters the reaction
column 3a in a gaseous state can be given. When several reaction
columns are used, the pipes connecting the reaction columns,
in addition to the reaction columns, are preferably maintained
at the prescribed temperature.
As specific examples of the flow-type, a method of using
a reaction column 3a packed with the acidic ion-exchange resin
as shown in figure 1(a), a method of using a plurality of reaction
columns 3b and 3c packed with the acidic ion-exchange resin and
connected in series as shown in figure 2(b), and a method of
using a plurality of reaction columns 3d, 3e, and 3f connected
in series and in parallel as shown in figure 1(c) can be given.
When several columns are used in combination, the conversion
rate of cyclopentenes [(cyclohexenes) or the compound of the
formula R'OH] can be improved.
There are no specific limitations to the size of the
columns used. The size may be selected in accordance with the
scale of the reaction. When a combination of several reaction
columns is used, the type of the acidic ion-exchange resin
packed in each of the columns may be the same or different.
As the method for flowing the mixture through the reaction
columns packed with the acidic ion-exchange resin, a down flow-
type wherein the mixture is flowed from the top of the reaction
columns 3b and 3c as shown in figure 1(b) or an up flow-type
wherein the mixture is flowed from the bottom of the reaction
columns 3b and 3c as shown in fig 2 can be used. From the
viewpoint of high conversion rate and selectivity of the target
product, the down flow-type is preferable.
The mixture passes through the reaction column usually
at a pressure of 30 MPa above the atmospheric pressure, with
10 MPa above the atmospheric pressure being preferable and 5MPa
above the atmospheric pressure being particularly preferable.
When the flow-type is used, the space velocity of the liquid
mixture (LHSV) is usually 0.01-100 hr-1, and preferably 0.1-20
hr-1, and that of the gaseous state mixture (GHSV) is usually
0.01-40,000 hr-1, and preferably 0.1-8,000 hr-1. When several
reaction columns are used, the reaction temperature, flow speed,
and the like may be different for each reaction column.
In the flow-type, even though there are no specific
limitations to the proportion of the cyclopentenes
(cyclohexenes) and the compound of the formula R'OH, the
cyclopentenes (cyclohexenes) is preferably used in an excessive
amount. Since the mixture is heated for only a short period
of time in the flow-type, polymerization of the cyclopentenes
(cyclohexenes) does not occur, on the other hand, the amount
of dialkyl ether by-products increases when the compound of the
formula R'OH is used in an excessive amount. The proportion
of the cyclopentenes (cyclohexenes) and the compound of the
formula R'OH (the mol ratio of (cyclopentenes
(cyclohexenes)/(compound of the formula R'OH)) is usually
1/3-20/1, preferably 1/3-10/1, more preferably 1/3-5/1, and
particularly preferably 1/3-3/1.
After the reaction, the targeted cycloalkyl alkyl ether
compound can be isolated from the reaction liquid by using
common isolation and purification methods such as solvent
extraction and distillation. Distillation may be conducted
several times. Distillation devices known in the art such as
a continuous rectification device comprising a rectification
column can be used. It is also possible, as shown in Figure
3, to circulate the mixture through a reaction column 3g packed
with an acidic ion-exchange resin, cause the resulting reaction
mixture to pass through a reaction column 3h, and continuously
distill the mixture using a distillation apparatus 4 packed with
Rashich rings. In this method, the unreacted alicyclic olefin
and alcohol can be returned to the reaction column 3g by the
pipe 5 and reacted once again to obtain a high conversion rate
of the target product.
In the above production method (b), a solid acid in
crystalline form (crystalline solid acid) may be used as the
solid acid. The crystalline solid acid is a general term for
acidic inorganic substances in which silicon, phosphorus,
aluminum oxide, and the like form specific chemical
constitution unit and form unit with regularity and includes
naturally occurring zeolite, synthetic zeolite, and the like.
Acidic or neutral zeolites are preferable as the crystalline
solid acid. These zeolites may be used as a mixture. As
examples of such a zeolite, ZSM-type zeolite such as H-ZSM-5
and Na-ZSM-5; faujasite such as Na-Y-type zeolite, H-Y-type
zeolite, K-Y-type zeolite, Na-X-tyep zeolite, and 13X-type
zeolite; H-mordenite, Na-mordenite, molecular sieve 3A,
molecular sieve 4A, and molecular sieve 5A; and metallo alumino
silicate or metallo silicate containing hetero atoms such as
boron, iron, gallium, titanium, copper, or silver can be given.
In addition, Si-substituted aluminum phosphate zeolite (SAPO)
having a a phosphoric acid skeleton can also be used. Either
commercially available products or products produced by a known
method may be used.
Although zeolites with a proton type cationic moiety are
usually used, those with a cationic moiety replaced with at
least one of the elements selected from the group consisting
of alkaline earth metals such as Mg, Ca, and Sr, rare earth
elements such as La and Ce, and elements in the groups 8-10 in
the periodic table such as Fe, Co, Ni, Ru, Pd, and Pt, or those
containing Ti, Zr, Hf, Cr, Mo, W, Th, or the like can also be
used.
Various types of zeolite can be appropriately selected
according to the molecular size of the cycloalkyl alkyl ether
compounds to be produced. Of these various types of zeolite,
molecular sieve 3A, molecular sieve 4A, molecular sieve 5A,
H-mordenite, Na-mordenite, ZSM-5, and the like are preferable.
H-mordenite, Na-mordenite, ZSM-5, and the like are more
preferable, with the H-type zeolite having a penta-sil
structure being still more preferable, and ZSM-series zeolite
being particularly preferable. The pore diameter of zeolite
used is usually 2-12 A, and preferably 2-10 A. Although there
are no specific limitations to the composition of zeolite, those
having silica/alumina molar ratio of 10 or more are preferable,
with those having silica/alumina molar ratio of 20 or more being
still more preferable.
There are no specific limitations to the form of the
crystalline solid acid. Any crystalline solid acid in the form
of powder, particles, or formed solid acids may be used.
Primary particles in powdery crystalline solid acid has a
diameter preferably or 1 µm or less. The primary particles may
be independently present or may be present as secondary
aggregates. The particle or formed solid acids may have a
spherical, disk-like, column-like, or cylindrical outward
configuration. The average particle size of the particle or
formed solid acids is not specifically limited and can be
appropriately selected from the range usually of 1-40 mm, and
preferably of 2-20 mm. The specific surface area can be
appropriately selected from the range usually of 1-100 m2/g
without any specific limitations.
The crystalline solid acid is usually used in an amount
of 0.001-200 parts by weight, preferably 0.1-200 parts by weight,
and more preferably 1.0-150 parts by weight for 100 parts by
weight of the cyclopentenes (cyclohexenes) ..
Any reactors commonly used in the industry such as a fluid
bed-type reactor, a batch-type reactor, and a fixed-bed
flow-type reactor can be applied to using crystalline solid acid.
In the case of a batch-type reactor, any conventionally known
stirrer such as a vibration-type and rotation-type can be used
for stirring the mixture inside the reactor. The number of
vibration, number of rotation, and stirring rate can be
appropriately determined. In the case of the fixed-bed
flow-type reactor, a formed catalyst manufactured by extrusion
molding or compression molding is preferably used. The LHSV
(Liquid Hourly Space Velocity) is usually in the range of
0.1-5.0 h-1, and preferably 0.5-3.0 h-1.
The above production method (b) may be carried out without
using a solvent or using an inert solvent that does not mix with
water, in which case the raw material cyclopentene compounds
or cyclohexene compounds are diluted with the inert solvent.
As examples of the solvent, aliphatic saturated hydrocarbons
such as n-butane, n-pentane, n-hexane, n-heptane, n-octane,
n-nonane, and n-decane; aromatic hydrocarbons such as benzene,
toluene, ethyl benzene, xylene, anisol, cumene, and
nitrobenzene; alicyclic saturated hydrocarbons such as
cyclopentane, alkyl-substituted cyclopentane,
alkoxy-substituted cyclopentane, nitro-substituted
cyclopentane, cyclohexane, alkyl-substituted cyclohexane,
alkoxy-substituted cyclohexane, nitro-substituted
cyclohexane, cycloheptane, alkyl-substituted cycloheptane,
alkoxy-substituted cycloheptane, nitro-substituted
cycloheptane, cyclooctane, alkyl-substituted cyclooctane,
alkoxy-substituted cyclooctane, and nitro-substituted
cyclooctane; nitrogen, argon, air, and helium can be given. The
amount of the diluent used can be selected without any
particular limitations as long as the reaction is not hindered.
The solvent is used in an amount of usually 10-90 vol% and
preferably 20-80 vol% of the total amount of the reaction
liquid.
(C) Solvent containing cycloalkyl alkyl ether compound
The solvent of the present invention comprises at least
one type of cycloalkyl alkyl ether compound. The cycloalkyl
alkyl ether compound is included in an amount of usually 30 wt%
or more, and preferably 50 wt% or more of the total amount of
the solvent.
The solvent of the present invention may comprise one
or more types of other liquid organic compounds in addition to
the cycloalkyl alkyl ether compound. As examples of the other
liquid organic compound, aliphatic hydrocarbons such as
n-pentane, n-hexane, n-heptane, n-octane, n-nonane, and
n-decane; alicyclic hydrocarbons such as cyclopentane,
cyclohexane, and cyclooctane; aromatic hydrocarbons such as
benzene, toluene, and xylene; alcohols such as methanol,
ethanol, n-propanol, isopropanol, n-butanol, and carbitol;
ethers such as diethyl ether, diisopropyl ether, dibutyl ether,
tetrahydrofuran, monoglyme, diglyme, 1,2-dimethoxyethane, and
dioxane; ketones such as acetone, methylethyl ketone,
2-pentanone, 3-pentanone, cyclopentanone, and cyclohexanone;
esters such as formate and acetate; nitriles such as
acetonitrile; amides such as N,N-dimethyl formamide,
N,N-dimethyl acetoamide, hexamethyl phosphoric acid triamide,
and N-methyl pyrrolidone; organic nitrogen compounds such as
nitrobenzene; organic sulfur compounds such as dimethyl
sulfoxide and sulfolane; organosilicon compounds such as
tetramethylsilane, tetraethylsilane, methoxytrimethylsilane,
ethoxytrimethylsilane, hexamethyldisiloxane,r and
octamethylcyclotetrasiloxane; cyclic hydrocarbons such as
bicyclo[2.2.1]heptane, bicyclo[2.2.2]octane, pinane,
dihydrocyclopentadiene, and tetrahydrodicyclopentane diene;
and terpene hydrocarbons such as limonene, a-pinene, ß-pinene,
and dipentene can be given.
The other liquid organic compounds are included in an
amount of usually 30 wt% or less, preferably 10 wt% or less,
and particularly preferably 5 wt% or less of the total amount
of the solvent.
The solvent of the present invention contains water
preferably in an amount of 100 ppm or less, with 60 ppm or less
being even more preferable, and 30 ppm or less being
particularly preferable. If the water content of the solvent
exceeds 100 ppm, the reaction may not produce the target yield
when the solvent of the present invention is used in a reaction
in which an organic metal is used. For example, in the Grignard
reaction for producing a Grignard reagent shown by the formula
RaMgXa (wherein Ra is an alkyl group and Xa is a halogen atom) ,
the Grignard reagent is not produced at a sufficient yield if
water is present in a large amount. Since the Grignard reagent
produced easily reacts with water, the Grignard reagent in an
amount equivalent to the water remaining in the solvent is
consumed by the reaction with the water, thereby lowering the
reaction yield.
In one of the methods for reducing the water content of
the solvent to 100 ppm or less, the solvent of the present
invention prior to drying is caused to come in contact with a
dehydrating agent.
As the dehydrating agent, those known in the art that
are stable when used in combination with a cycloalkyl alkyl
ether compound may be used without any particular limitations.
As specific examples of the dehydrating agent, adsorptive
porous substances such as molecular sieve (hereinafter
abbreviated as "MS"), activated alumina and silica gel, and
salts possessing neutral or near neutral absorption properties
such as anhydrous magnesium sulfate, anhydrous sodium sulfate,
and calcium chloride can be given. Of these, MS, calcium
chloride, and anhydrous magnesium sulfate capable of
effectively dehydrating in a short period of time are preferable,
with MS being particularly preferable.
Tetrahydrofuran (THF) is given as a typical solvent that
has been conventionally used with Grignard reactions.
According to the investigation of the present inventors,
lowering the water content of THF below 250 ppm is difficult
when THF is contacted with MS or the like as the dehydrating
agent on an industrial scale. On the other hand, if the solvent
of the present invention is caused to come in contact with MS
or the like as the dehydrating agent, the water content is easily
reduced to 30 ppm or less. Therefore, by using the solvent of
the present invention as a reaction solvent in a Grignard
reaction or an organic metal reaction, a high reaction yield
can be achieved in comparison to using THF.
There are no specific limitations to the method of
contacting the solvent of the present invention with the
dehydrating agent. For example, a flow-type comprising using
a column packed with a dehydrating agent such as MS and causing
the solvent of the present invention to passed through the
column, or a batch-type comprising placing the solvent of the
present invention and the dehydrating agent in a reactor
equipped with a stirrer and stirring the mixture to cause the
solvent and the dehydrating agent to come into contact can be
given. The water content of the solvent of the present
invention can be analyzed using Karl-Fischer coulometric
titration.
The solvent of the present invention preferably
comprises an antioxidant. If the antioxidant is added, the
peroxide content of the solvent can be maintained below 100 ppm
even if the solvent is stored for a long period of time or
repeatedly distilled for recovery. When the solvent of the
present invention is used as a cleaning solvent, the solvent
is used for a long period of time at a high temperature of 90°C
or more to achieve an increased cleaning effect or repeatedly
distilled for recovery. Adding an antioxidant can prevent an
increase in the peroxide content in the cleaning solvent. In
other words, a cleaning solvent possessing excellent cleaning
effect and stability can be obtained by the combination of at
least one type of cycloalkyl alkyl ether compound and an
antioxidant.
The amount of the antioxidant can be selected from a wide
range depending on the conditions of use. However, from the
viewpoint of stability, cleaning power, and cost, the
antioxidant is preferably used in an amount of 0.0005-5 wt% of
the total amount of the solvent.
As examples of the antioxidant, phenols, aromatic amines,
and phosphorous acid esters can be given, with phenols being
preferable from the viewpoints of antioxidation effect and
cost.
The phenols is an essential component for the solvent
of the present invention for preventing deterioration and
soiling during processing at a high temperature such as heating,
distillation, and recovery. A specific phenol compound is
selected from those capable of suppressing production of
peroxides without adversely affecting the solvent.
As specific examples of the phenols,
2,6-di-t-butyl-p-cresol, timor, pyrocatechin,
4-methoxyphenol, n-propyl gallate, and 2-t-butylhydroquinone
can be given. Of these, 2,6-di-t-butyl-p-cresol is
particularly preferable.
The solvent of the present invention may also contain
other components in addition to the cycloalkyl alkyl ether
compound and the above-mentioned other liquid organic compounds .
The other components may be appropriately selected in
accordance with the application such as cleaning solvent,
reaction solvent, extraction solvent, and electronic and
electrical solvent.
(D) Cleaning solvent
The cycloalkyl alkyl ether compound shown by the above
formulas (1), (2), and (3) excels in dissolving a wide range
of organic compounds such as machine oil, cutting oil, rosin,
waxes, and higher fatty acids. Therefore, the solvent of the
present invention is useful as a cleaning solvent for fats and
oils, resins, coating materials, lacquers, and varnishes. The
cleaning solvent of the present invention comprises the
cycloalkyl alkyl ether compound usually in an amount of 70 wt%
or more, with 90 wt% or more being preferable, and 95 wt% being
even more preferable.
When the solvent of the present invention is used as a
cleaning solvent, anionic surfactants, cationic surfactants,
ionic surfactants, nonionic surfactants, rust preventive
agents, and polishing agents may be added to the solvent as the
above-mentioned other additives. The other additives may be
added in an amount of usually 0-30 wt% of the total amount of
the cleaning solvent.
The cleaning solvent of the present invention is
effective for cleaning articles made from metal, ceramic, glass,
plastic, elastomer, and fiber in the industries of precision
machinery, automobiles, aircrafts, heavy machinery, metal
processing, metal assembly, steel, non-iron, steel pipe, heat
treatment, plating, metallurgy, optical machines, office
machines, electronics, electrics, plastics, glass, ceramics,
printing, fibers, and cleaning.
As specific examples of the articles that can be cleaned
with the cleaning solvent of the present invention, automotive
parts such as bumpers, gears, transmission parts, and radiator
parts; electronic and electrical parts used in computers and
the peripheral devices, electrical household appliances,
communication machines, OA machines, and other electronic
application machines such as electric printed wiring substrates,
IC parts, lead frames, resistors, relays, hoops used for relay
contact points, motor parts, condensers, liquid crystal display
machines, magnetic recording parts, semiconductor materials
such as silicon wafers and ceramic wafers, parts for
electrostriction such as crystal oscillators, opto-electronic
transformer parts, brushes, rotors, ticket dispensing parts for
vending machines, and currency inspection parts for vending
machines and cash dispensers; precision machinery components
such as super-hard chips, bearings, gears, gears made of
engeneering plastic, watch parts, camera parts, and optical
lenses; large machinery parts such as printing machines,
printing machine blade, printing rolls, rolling machines,
construction machines, and heavy machinery parts; high
precision processing products with resin such as cameras and
cars; daily life products such as tableware, metal fittings,
tools, eyewear frames, and watch belts; textiles (stain remover,
removing and cleaning grease on cotton, oil stains, and
protein); devices for producing electronic equipment (removal
and cleaning of attached resin and oil) such as dry etching
apparatus, normal pressure CVD (Chemical Vapor Deposition)
devices, reduced pressure CVD devices, dry etching devices,
plasma CVD devices, optical CVD devices, plasma etching devices,
and RIE (Reactive Ion Etching) devices; and the like can be
given.
There are no specific limitations to the pollutants that
can be cleaned with the cleaning solvent of the present
invention. For example, oils such as cutting oils, water
soluble cutting oils, quenching oils, heat treatment oils,
rolling oils, stretching oils, lubricating oils, rust
prevention oils, forging oils, machine oils, handicraft oils,
processing oils, press processing oils, punching oils, pattern
cutout oils, drawing oils, assembling oils, line pulling oils,
oils containing extreme pressure additives, and synthetic oils
(silicon, glycol, and ester types); greases, waxes, paint, inks,
rubber, varnishes, coating materials, polishing agents,
adhesives, adhesive solvents, surface delaminating materials,
fats and oils, parting agents used during molding, asphalt pitch,
dirt from the print, fingerprints, proteins, flux after
soldering, resists, antireflection films for resists, coatings
for optical lenses, OPC (Organic Photo Conductor) drum
photosensitizers, photosensitive resins (photosensitive
resists), masking agents, compounds, surface active agents,
solder paste, cutting scraps, cutting powder, lens pitch (lens
polishing agents) , metallic powder, metallic polishing agents,
lubricants, resins (melamine resins, polyurethanes,
polyesters, epoxy resins, and rosin), processing waste, burrs,
resin powders, non-organic powders, paper powders, puff powders,
particles, ionic stains, dust, and water can be given.
Favorable results can be achieved when the cleaning
solvent of the present invention is used in various cleaning
methods such as immersion, ultrasonic cleaning, agitation,
spraying, showering, vapor cleaning, and wiping. Physical
means such as stirring, agitation, and brushing may be employed
during use of the cleaning solvent when necessary.
(E) Reaction solvent
The cycloalkyl alkyl ether compounds of the above
formulas (1), (2), or (3) exhibit excellent solubility to a
variety of chemicals and ionic substances and are chemically
stable with various reactive substances in a wide temperature
range. Therefore, the solvent of the present invention may be
used as a reaction solvent in various types of reactions.
The reaction solvent of the present invention comprises
the cycloalkyl alkyl ether compound usually in an amount of 30
wt% or more, and preferably 50 wt% or more.
When the solvent of the present invention is used as a
reaction solvent, aliphatic hydrocarbons, aromatic
hydrocarbons, alicyclic hydrocarbons, ethers, nitriles, and
amides, for example, may be added to the solvent as the
above-mentioned liquid organic compounds. The other liquid
organic compounds are included in an amount of usually 30 wt%
or less, preferably 10 wt% or less, and particularly preferably
5 wt% or less of the total amount of the solvent.
There are no specific limitations to the type of reaction
in which the reaction solvent of the present invention is used.
Since the reaction solvent of the present invention comprises
a cycloalkyl alkyl ether compound, which is one type of ether
compound, it is preferably used as a reaction solvent in the
reaction using other types of ether solvents such as diethyl
ether and tetrahydrofuran.
As examples of such a reaction, various polymerization
reactions such as anionic polymerization, cationic
polymerization, and radical polymerization,
(co)oligomerization, oxidation reaction, reduction reaction,
nucleophilic displacement reaction, electrophilic
displacement reaction, rearrangement reaction, addition
reaction, elimination reaction, addition elimination reaction,
insertion reaction, isomerization, decomposition reaction,
solvolysis reaction, coupling reaction, metathesis reaction,
carbene reaction, condensation reaction, asymmetric synthesis
reaction, pericyclic reaction, photochemical reaction,
electrochemical reaction, radical reaction, ring-opening
reaction, cyclization reaction, cleavage reaction,
hydrogenation reaction, esterification reaction, halogenation
reaction, carbonylation reaction, heterocycle synthesis
reaction, dehydration reaction, hydration reaction, reaction
V
using a transition element or an organic metal of typical
element, chemical reaction using a metal catalyst (metal
complex) , and reaction using a rare earth element can be given.
Of these reactions, the solvent of the present invention
is preferably used as a reaction solvent in the reactions in
which a Grignard reagent, organiolithium, lithium amide, alkali
metal or alkaline earth metal, metal hydride, alkali metal
hydroxide, alkaline earth metal hydroxide, alkali metal
carbonate, alkaline earth metal carbonate, alkali metal
hydrogencarbonate, alkaline earth metal hydrogencarbonate,
metal alkoxide, an organic base such as pyridine,
triethylamine, organometalic compound such as organoaluminum
compound, organotin compund is used.
In particularly, the solvent of the present invention
is preferably used in the reactions in which Grignard reagents
such as methyl magnesium bromide, methyl magnesium iodide,
ethyl magnesium bromide, ethyl magnesium iodide, isopropyl
magnesium bromide, cyclopentyl magnesium bromide, cyclohexyl
magnesium bromide, phenyl magnesium bromide, phenyl magnesium
iodide, 2, 4, 6-trimethylphenyl magnesium bromide, and
2,4,6-trimethylphenyl magnesium iodide; organolithiums such
as methyl lithium, n-butyl lithium, sec-butyl lithium,
tert-butyl lithium, and phenyl lithium; lithium amides such as
lithium diisopropylamide and lithium hexamethyl disilazide;
metal hydrides such as lithium hydride, sodium hydride, calcium
hydride, lithium aluminum hydride, and diisobutyl aluminum
hydride; and the like are used as a nucleophile agent.
The reaction solvent of the present invention is
particularly useful in the reaction of producing a secondary
alcohol of the formula (Rb)(Rc)CHOH by reacting a Grignard
reagent of the formula RbMgXb with an aldehyde of the formula
RcCHO and the reaction of producing a tertiary alcohol of the
formula (Rb) (Rd) (Re)COH by reacting a Grignard reagent of the
formula RbMgXb with a ketone of the formula RdReC(=O), wherein
Rb, Rc, Rd, and Re individually represent a hydrocarbon group
provided that Rd and Re may form a carbon ring with 3-8 carbon
atoms in combination, wherein the carbon ring may contain a
hetero atom such as a sulfur atom or nitrogen atom.
As examples of the hydrocarbon group,, an alkyl group,
alkenyl group, alkynyl group, and aryl group can be given.
There are no specific limitations to the number of carbon atoms
possessed by the hydrocarbon group. The hydrocarbon group
usually possesses 1-30 carbon atoms, and preferably 1-20 carbon
atoms. As examples of the alkyl group, a linear alkyl group
such as a methyl group, ethyl group, n-propyl group, isopropyl
group, n-butyl group, isobutyl group, sec-butyl grcup,
tert-butyl group, n-pentyl group, neopentyl group, isopentyl
group, n-hexyl group, n-heptyl group, n-octyl group, and
n-decyl group, and a cycloalkyl group such as a cyclopropyl
group, cyclobutyl group, cyclopentyl group, cyclohexyl group,
cycloheptyl group, and cyclooctyl group can be given. As
examples of the alkenyl group, a vinyl group, 1-propenyl group,
2-propenyl group, 1-butenyl group, 2-butenyl group, 3-butenyl
group, butadienyl group, 1-pentenyl group, 2-pentenyl group,
3-pentenyl group, 4-pentenyl group, 1, 3-pentcidienyl group, and
2, 4-pentadienyl group can be given. As examples of the alkynyl
group, an ethynyl group, propargyl group, and 2-butynyl group
can be given. As examples of the aryl group, a phenyl group,
2-pyridyl group, 3-pyridyl group, 4-pyridyl group, 5-pyridyl
group, 2-furyl group, 3-furyl group, 2-thienyl group, 3-thienyl
group, 1-naphthyl group, and 2-naphthyl group can be given.
These hydrocarbon groups may possess substituents such
as a nitro group, alkyl group, alkoxy group, alkylthio group,
alkylsulfonyl group, dialkylamino group, dialkyl sulfamoyl
group, and dialkyl phosphoryl group attached to any position.
When these hydrocarbon groups possess more than one substituent,
the substituents may be the same or different.
Xb represents a halogen atom such as a chlorine atom,
bromine atom, or iodine atom. Although there are no specific
limitations to the amount of the reaction solvent used in the
present invention, the reaction solvent is usually used in an
amount of 0.001-1,000 parts by weight, and preferably 0.01-100
parts by weight, for one part by weight of the total amount of
the reaction materials. The reaction using the reaction
solvent of the present invention is usually conducted at a
reaction temperature from -100°C to the boiling point of the
solvent.
The reaction solvent of the present invention excels in
reaction selectivity. For example, if a Grignard reagent is
reacted with a ketone that can be easily enolized using other
ether solvent such as THF, a self-aldol reaction predominates.
However, the target alcohol can be obtained in a high yield by
using the reaction solvent of the present invention.
The cycloalkyl alkyl ether compound possesses a very low
miscibility with water. Even though this compound produces an
azeotrope with water, the compound can be easily separated from
the water. Therefore, after conducting the reaction using the
reaction solvent of the present invention, the reaction solvent
can be conveniently and efficiently recovered from the reaction
mixture. The target reaction solvent can be easily isolated
from the reaction mixture, for example, by adding water (or an
aqueous acid solution) to the reaction mixture using the
reaction solvent of the present invention to terminate the
reaction, separating the reaction mixture into a water layer
and an organic layer, removing the reaction solvent from the
organic layer, and purifying the residue using a known method
such as distillation and column chromatography.
Furthermore, since the reaction solvent of the present
invention has a moderate boiling point, the reaction solvent
can be efficiently recovered from the reaction mixture. The
recovered reaction solvent is purified, as required, and can
be reused as a reaction solvent.
(F) Extraction Solvent
The cycloalkyl alkyl ether compounds of the above
formulas (1), (2), or (3) exhibit excellent solubility to a
variety of chemicals and are chemically stable with various
reactive substances. Therefore, the solvent of the present
invention is also useful as an extraction solvent for extracting
organic compounds from a solid or liquid mixture containing the
organic compounds.
The content of the cycloalkyl alkyl ether compound in
the extraction solvent of the present invention is usually 70
wt% or more, preferably 90 wt% or more, and still more preferably
95 wt% or more.
There are no specific limitations to the extracted
organic compounds inasmuch as such compounds can be dissolved
in the cycloalkyl alkyl ether compound. From the viewpoint that
the extraction solvent of the present invention functions as
a substitute for conventional extraction solvents, organic
compounds exhibiting excellent solubility in conventional
extraction solvents such as aliphatic halogenated hydrocarbons,
esters, and aromatic hydrocarbons are preferable.
Organic compounds having a polar group in the molecule
can be given as such organic compounds. The polar group here
indicates a group containing atoms having electronegativity
different from that of the carbon atom such as an oxygen atom,
nitrogen atom, and sulfur atom. As examples of the polar group,
an amide group, carboxyl group, ester group, hydroxyl group,
carbonyl group, amino group, nitro group, cyano group, alkoxy
group, mercapto group, and alkylthio group can be given.
As examples of the organic compound having a pclar group
in the molecule, naturally occurring substances, active
ingredients of medical supplies and agricultural chemicals,
industrial chemicals, perfumes, intermediates for
manufacturing these substances, and the like having one or more
polar groups in the molecule can be given. Although there are
no specific limitations, the molecular weight of these organic
compounds is usually 100-500, and preferably 100-300.
In the case where the organic compound to be extracted
has an asymmetrical carbon atom in the molecule, such an organic
compound may be either a mixture of optical isomers or one of
the optical isomers. No racemization reaction occurs during
the extraction operation.
As a method of solvent extraction, liquid-liquid
extraction for extracting an organic compound from a solution
that comprises adding an extraction solvent immiscible with the
solvent of the organic compound solution to cause the organic
compound to move to the extraction solvent by utilization of
the difference in the distribution coefficient, solid-liquid
extraction that comprises adding the extraction solvent to a
solid mixture containing the organic compound to cause the
organic compound to be extracted in the solvent, and the like
can be given. The extraction solvent of the present invention
is particularly useful for extracting an organic compound from
an aqueous solution of the organic compound, since the
extraction solvent dissolves with water only very slightly and
can be easily separated from water.
More specifically, the liquid-liquid extraction
includes (i) a method of adding the extraction solvent of the
present invention to an aqueous solution of an organic compound
of which the solubility in the extraction solvent is higher than
that in water, sufficiently shaking the mixture, allowing the
mixture to stand still to be separated into a water layer and
an organic layer, and to remove the organic layer, (ii) a method
for extracting a salt of an acidic organic compound such as
carboxylic acid or a salt of a basic organic compound from an
aqueous solution comprising adding an acid (in the case of the
salt of an acidic compound) to liberate the acidic compound or
a base (in the case of the salt of a basic compound) to liberate
the basic compound and extracting the liberated acidic organic
compound or basic organic compound using the extraction solvent
of the present invention, and the like. In this instance, the
extraction operation can be repeated several times. The
extraction temperature is usually -20 to 100°C, preferably
0-90°C, and still more preferably 20-50°C.
The liquid-liquid extraction is carried out using a
separating funnel in experiments in laboratories. When a large
quantity of materials are processed, a known separating
apparatus (a mixer settler), a multiple mixer decanter type
contactor, a gravity fractionation column type contactor, and
the like can be used.
When a separating funnel is used, an appropriate amount
of the extraction solvent of the present invention is added to
the aqueous solution containing the target compound to be
extracted and the mixture is sufficiently shaken. Then, the
mixture is allowed to stand to completely separate into two
layers, an organic layer and a water layer, and the organic layer
is removed.
A known separating apparatus (mixer settler), which is
a large scale separating funnel, can be operated according to
the method of operating an experimental-scale separating
funnel.
The multiple mixer decanter type contactor is a
non-agitating type extractor that is typically operated by
charging a light liquid with a small specific gravity (the
extraction solvent of the present invention) from the bottom
of the extractor and a heavy liquid with a large specific gravity
(an aqueous solution, etc.) from the top. Since the light
liquid flows upwardly and the heavy liquid flows downwardly in
the apparatus, the two liquids contact in the column. The
components dissolved in the light liquid and the heavy liquid
are distributed to each liquid layer according to the
distribution coefficient. In this instance, if multi stage
porous plates are installed in the extraction column, the light
liquid ascends the column as droplets through pores in the
porous plates and the drops come into contact with the heavy
liquid. A large number of droplets further ascend the column
through pores in the porous plates. The two liquids efficiently
contact each other by repeating the formation and association
of droplets in this manner.
The gravity fractionation column type contactor is an
extractor in which stirring is mechanically performed. As the
method for stirring, a method of using stirring blades, a method
of vibrating by pulse, and the like can be given.
As a specific example of the solid-liquid extraction,
a method of sufficiently mixing the solid containing the organic
compound to be extracted with the extraction solvent of the
present invention, extracting the target organic compound, and
removing insoluble matters by filtration or the like can be
given. The solid mixture may be finely pulverized before
extraction to increase the extraction efficiency. The
extraction solvent may be heated during the extraction.
As the extraction apparatus used for the solid-liquid
extraction, known extractors such as an extractor of the type
having a cloth filter or a porous plate installed in the bottom
can be used. The solid containing the organic compound to be
extracted is placed on the cloth filter or porous plate and the
extraction solvent is circulated through the extractor. When
a large quantity of materials is processed by solid-liquid
extraction, a continuous extractor described in Published
Japanese Translation of PCT Application 9-510913, for example,
can be used.
In any apparatus, the extraction solvent phase is removed
and dried, as required, following which the extraction solvent
is evaporated. The resulting residue is purified by a known
purification means such as washing with a solvent,
recrystallization, column chromatography, and distillation to
isolate the target product. When the extract is a thermally
unstable compound such as a natural product, a means such as
a method of removing extraction solvent under reduced pressure,
a method of decreasing partial pressure of the solvent by
injecting steam (steam stripping), or the like is necessary.
The extraction solvent used for the extraction is
recovered by a solvent recovery apparatus, purified by
distillation or the like, as required, and again used as the
extraction solvent.
(G) Solvent for electronic and electrical materials
The cycloalkyl alkyl ether compounds of the above
formulas (1), (2), or (3) can exhibit excellent solubility to
electronic and electrical materials, exhibit only slight
toxicity, and are almost free from the problem of environmental
pollution. Therefore, the solvent of the present invention is
also useful as a solvent for electronic and electrical
materials.
When the solvent of the present invention is used as a
solvent for electronic and electrical materials, other liquid
organic compounds such as alcohol solvents, ether solvents,
ketone solvents, ester solvents, amide solvents, aliphatic
hydrocarbons, and aromatic hydrocarbons may be added.
The electronic and electrical materials indicate
materials used for manufacturing information recording media,
OA machines, communication machines, electronic equipment,
electronic parts, electrical products, and the like . Specific
examples that can be given include a material for forming a
recording layer of information recording media, a material for
forming a photosensitive layer of OA equipment and
communication machines, a material for forming insulating layer
used in OA equipment, communication machines, electronic
equipment, electronic parts, and electrical appliances, and a
raw material for manufacturing separator porous membranes of
battery cells.
Coloring matters conventionally known as recording
materials for information recording media can be used as the
material for forming recording layers (hereinafter referred to
as "recording material") . As examples of the coloring matter,
cyanine dyes, phthalocyanine dyes, pyrylium dyes, thiopyrylium
dyes, azulenium dyes, squalelium dyes, metal complex salts of
Ni, Cr, or other metals, naphthoquinone dyes, anthraquinone
dyes, indophenol dyes, indoaniline dyes, triphenylmethane dyes,
triallylmethane dyes, aluminum dyes, diimmonium dyes, and
nitroso compound dyes can be given.
The recording layer can be formed by coating a coating
solution for forming a recording layer onto a substrate and
drying the coating. As the substrate, a synthetic resin
substrate such as a methyl methacrylate resin substrate, vinyl
chloride resin substrate, epoxy resin substrate, and
polycarbonate resin substrate; a glass substrate such as a soda
lime glass substrate; ceramics substrate; and the like can be
given. A substrate provided with a primer coating layer and/or
a pre-groove layer on the surface of the side on which the
recording layer is provided can be used.
The primer coating layer is formed to improve the surface
properties, increase adhesiveness, and prevent denaturing of
the recording layer. As materials for the primer coating layer,
polymers such as polymethylmethacrylate, acrylic
acid-methacrylic acid copolymer, polyvinyl alcohol,
N-methylolacrylamide, styrene-sulfonic acid copolymer,
styrene-vinyltoluene copolymer, chlorosulfonated
polyethylene, nitro cellulose, polyvinyl chloride,
chlorinated polyolefin, polyester, polyimide, vinyl
acetate-vinyl chloride copolymer, ethylene-vinyl acetate
copolymer, polyethylene, polypropylene, and polycarbonate;
organic materials such as silane coupling agent; inorganic
materials such as inorganic oxide (SiO2, Al2O3, etc.) and
fluorinated inorganic compounds (MgF2, etc.); and the like can
be given. The thickness of the primer coating layer is usually
0.005-20 µm, and preferably 0.01-10 µm.
The pre-groove layer is provided to form tracking grooves
or irregularities expressing information such as address
signals. As materials for the pre-groove layer, a curing agent
obtained from a mixture of at least one monomer (or oligomer)
selected from the group consisting of monoester, diester,
triester, and tetra ester of acrylic acid and a photoinitiator
can be given. The thickness of the pre-groove layer is usually
0.05-50 µm, and preferably 0.1-20 µm.
In addition to the above-described coloring matters, the
coating solution for forming recording layer may include
naturally occurring organic polymers such as gelatin, cellulose
derivatives, dextran, rosin, and natural rubber and synthesis
organic polymers such as polystyrene, polyisobutylene,
polyvinylidene chloride to increase spreadability of the
coloring matter on substrates, as well as binders, antioxidants,
UV absorbents, plasticizers, lubricants and the like.
The coating solution for forming recording layer can be
prepared by dissolving or dispersing the coloring matter and
other optional components such as binders, antioxidants, UV
absorbents, plasticizers, and lubricants in the solvent of the
present invention. The content of solid components such as
coloring matters and binders in the solution of the coating
solution for forming recording layer is usually 0.1-30 wt%, and
preferably 0.2-20 wt%.
The recording layer can be formed by coating the coating
solution onto a substrate and drying the coating. As a method
of applying the coating composition to the substrates, a spin
coating method, spray method, dip method, roll coating method,
blade coating method, doctor roll method, screen printing
method, and the like can be given. The recording layer may be
either a single layer or multiple layers, with a thickness of
usually 0.01-10 µm, and preferably 0.02-1 µm. The recording
layer may be formed either on one side or on both sides of the
substrate.
In addition, a reflecting layer made from a metal such
as Al, Cr, or Ni exhibiting a high reflectance to laser beams
may be formed on the recording layer to increase the S/N ratio
during reproduction of information and to promote sensitivity
during recording. The thickness of the reflecting layer is
usually 10-300 nm. A protective layer may be formed on the
recording layer or the reflecting layer to increase scratch
resistance and moisture resistance. The thickness of the
protective layer is usually 0.1-100 µm.
The photosensitive layer can be formed by preparing a
coating solution for forming a photosensitive layer by
dissolving or dispersing at least one photoconductive substance
in the solvent of the present invention and applying the
solution to a supporting substrate for the photoconductive
substance and drying the coating. The photosensitive layer may
also be formed from a combination of a charge generating layer
and a charge transport layer. For example, the charge
generating layer can be formed by preparing a coating solution
for forming a charge generating layer by dissolving or
dispersing a charge generating material in an appropriate
solvent, applying the solution to a supporting substrate for
the photoconductive substance and drying the coating. The
charge transport layer can be formed by preparing a coating
solution for forming a charge transport layer by dissolving or
dispersing a charge transport material in the solvent of the
present invention and applying the solution to the surface of
the charge generating layer and drying the coating.
As examples of the conductive supporting material,
conductive supporting materials in which the supporting
materials themselves are conductive, such as aluminum, aluminum
alloy, stainless steel, chromium, and titanium; conductive
supporting materials composed of an insulating substrate such
as a formed synthetic resin and a coating of aluminum, aluminum
alloy, or indium-tin oxide alloy formed thereon by vacuum vapor
deposition or the like; and conductive supporting materials
produced by impregnating plastic or paper with carbon black or
tin oxide particles together with an appropriate binder. A drum
for an OPC drum can be given as a particularly preferable example
of the conductive supporting material.
As examples of the photoconductive material, organic
photoconductive polymers such as poly-N-vinylcarbazole and
polyvinyl anthracene; low molecular weight organic
photoconductive compounds such as carbazole, anthracene,
pyrazolines, oxadiazoles, hydrazones, and polyacetal alkanes;
and inorganic photoconductive materials such as amorphous
silicon and selenium can be given. As examples of the charge
generating materials, one or more types of azo pigments, quinone
pigments, quinocyanine pigments, perylene pigments, indigo
pigments, bisbenzimidazole pigments, phthalocyanine pigments,
and quinacdorine pigments can be given. As examples of the
charge transfer materials, hydrazone compounds, stilbene
compounds, pyrazoline compounds, oxazole compounds, thiazole
compounds, and triaryl methane compounds can be given.
A binder may optionally be added to the coating solution
for forming photosensitive layer, coating solution for forming
charge generating layer, and the coating solution for forming
charge transport layer. As the binder that can be added,
insulating resins such as polyvinyl butyral, polyallylate,
polycarbonate, polyester, phenoxy resin, acrylic resin,
polyacrylamide, polyamide, cellulose resin, urethane resin,
epoxy resin, casein, and polyvinyl alcohol; organic
photoconductive polymers such as carbazole, polyvinyl
anthracene, and polyvinyl pyrene; and the like can be given.
Although not specifically limited, the content of solid
components in the above coating solution for forming
photosensitive layer, coating solution for forming charge
generating layer, and the coating solution for forming charge
transport layer is usually 1-90 wt%, and preferably 10-80 wt%.
The thickness of the photosensitive layer formed is
usually in the range of 5-200 µm, and preferably 5-100 µm, and
the thickness of the charge generating layer formed is usually
in the range of 0.01-20 µm, and preferably 0.01-15 µm. The
thickness of the charge transport layer is usually 3-100 µm,
and preferably 5-50 µm.
It is possible to use a drum for an OPC drum as the
conductive supporting material. When a photosensitive layer
is formed on the drum, it is possible to form an under layer
having both the barrier function and the attaching function
between the drum and the photosensitive layer. The under layer
can be formed from casein, polyvinyl alcohol, nitro cellulose,
ethylene-acrylic acid copolymer, polyamide, polyurethane,
gelatin, aluminium oxide, and the like. The thickness of the
under layer is preferably 5 µm or less, and more preferably 0. 5-3
µm.
The porous membrane for the cell separator is provided
between the positive electrode active material and the negative
pole active material in the cell to prevent a short circuit.
In the case of a closed-type cell, the porous membrane also has
a function of holding the electrolyte. Such a porous membrane
can be formed using a solution of resin dissolved in the solvent
of the present invention by a uniaxial or biaxial drawing.
Polypropylene, polyethylene, and the like are used as the resin.
A porous membrane with a multilayer structure such as a
monolayer structure or two or more layer structure can be formed
from a resin solution in which one or more types of these resins
are dissolved.
An electric insulating layer for OA equipment,
communication equipment, electronic equipment, electronic
parts, electric appliances, and the like can be formed using
a resin solution prepared by dissolving or dispersing an organic
insulating material in the solvent of the present invention.
Polyurethane, epoxy resin, polyethylene terephthalate,
polyester imide, heat resistant polyester, polyimide,
polyamideimide, and norbornene-type resin can be given as
examples of the organic insulating material to be used with the
solvent of the present invention.
As examples of the method for forming an electric
insulating layer, a method of applying the resin solution
prepared by dissolving or dispersing an organic insulating
material in the solvent of the present invention to a substrate
and drying the resulting coating, a method of forming films or
sheets of insulating resin from a resin solution prepared by
dissolving or dispersing an organic insulating material in the
solvent of the present invention and laminating the films or
sheets can be given. There are no specific limitations to the
substrate inasmuch as the material is an intermediate for
fabricating OA equipment, communication equipment, electronic
equipment, electronic parts, electric appliances, and the like
and can be provided with an insulating layer thereon.
(H) Parting agent
The cycloalkyl alkyl ether compounds of the above
formulas (1), (2), or (3) can exhibit excellent solubility to
photosensitizers, organic adhesives, photosensitive resists,
and organic insulating materials, exhibit only slight toxicity,
and are almost free from the problem of environmental pollution.
Therefore, the solvent of the present invention is also useful
as a parting agent. Specific examples include (a) a parting
agent for removing a photosensitive layer from a photosensitive
drum and (b) a parting agent that can be used for removing
adhesive parts from jigs for fabrication in the case when
semiconductor materials, crystal materials, electronic part
materials, magnetic materials, piezo materials, and the like
(hereinafter referred to as "adhered materials") are caused to
adhere to jigs and are processed by cutting, grinding, or the
like.
In the case of manufacturing OPC drums by forming a
photosensitive layer on a photosensitive drum, if the thickness
of the photosensitive layer is not uniform, defective goods with
an impaired image are produced due to uneven charge conditions.
For this reason, the photosensitive layer must be removed from
the drum and a new photosensitive layer must be formed. In this
instance (in the case of (a)), the photosensitive layer can be
easily parted from the drum by dipping the defective OPC drum
in the solvent of the present invention and removing it
therefrom.
In the case of (b), the adhered materials attached to
the jigs using an organic adhesive can be easily parted by
dipping the adhered materials in the solvent of the present
invention and then removing therefrom. In the above cases (a)
and (b) , the drums and materials may be heated or treated with
supersonic waves to promote the effect of parting.
As examples of the semiconductor material, silicon,
gallium-arsenic, and gallium-phosphorus can be given. Crystal
materials, rock crystals, quartz, and glass can be given as
examples of crystal and electronic part-related materials. As
the magnetic material, ferrite, samarium, cobalt and the like
can be given. As the magnetic material and piezo material,
magnetic heads and the like can be given.
As examples of the organic adhesive, synthetic resin
adhesives such as epoxy resin adhesive and polyurethane
adhesive; elastomer-type adhesives such as chloroprene rubber
adhesive, acrylonitrile-butadiene rubber adhesive,
styrene-butadiene rubber adhesive, and thermoplastic
elastomer adhesives (adhesives containing styrene-butadiene
block copolymer elastomer, styrene-isoprene block copolymer
elastomer, or styrene-ethylene-butylene block copolymer
elastomer as main components); mixed adhesives such as a mixed
adhesive of vinyl resin and phenol resin, mixed adhesive of
nitrile rubber and phenol resin, and mixed adhesive of
chloroprene rubber and phenol resin, mixed adhesive of epoxy
resin and phenol resin, and a mixed adhesive of epoxy resin and
soluble nylon can be given.
The parting agent of the present invention is particular
preferable for removing epoxy resin adhesive among these
adhesives. The epoxy resin adhesive comprises an epoxy resin
and a curing agent as essential components and optionally
contains additives such as fillers and denaturing agents. As
the main component epoxy resin, glycidyl ether-type epoxy
resins such as bisphenol A-based epoxy resin, novolak-based
epoxy resin, and bisphenol F-based epoxy resin; alicyclic epoxy
resin, glycidyl ester-type epoxy resin, glycidyl amine-type
epoxy resin, hydantoin-type epoxy resin, heterocyclic epoxy
resin such as triglycidyl isocyanurate, low viscosity epoxy
resin, and the like can be given.
As examples of the curing agent, curing agents of primary
amine such as aliphatic amine, alicyclic amine and. aromatic
amine, room-temperature curing-type such as secondary amine,
tertiary amine, polyamide, imidazole, acid anhydride, and
mercaptan-type curing agents; potential curing type such as
dicyandiamide, organic acid hydrazide, and Lewis acid amine
complex curing agents can be given.
As the type of epoxy resin adhesives, two-solution type
room temperature setting adhesives, one-solution potential
curing type paste adhesives, one-solution potential curing type
film adhesives, one-solution curing type powdery adhesives, and
the like can be given. The solvent of the present invention
can be used as parting agent for any types of adhesive.
The epoxy resin adhesives are used, for example, for
adhering a semiconductor ingot of silicon or the like fabricated
to have a prescribed outside configuration to a slice space of
carbon or the like. The adhered material is cut into wafers
or plates using a slicing machine (slicer) of inner circle
edge-type, band saw-type, or wire saw-type. After removing the
slice space and epoxy resin adhesive, the wafers or plates are
sent to the next steps for annealing, wrapping, and the like.
The solvent agent of the present invention is particular
preferably used as the parting agent for removing the slice
space and the epoxy resin adhesive from the wafers.
The solvent of the present invention can also be used
as a solvent for crystallization or recrystallization, raw
material for lacquers, solvent for regenerating reclaimed
rubber, solvent for extracting wax and resins, octane booster
for gasoline, antiknock agent, miscibility improver for
lacquers, dispersant for organosol, dying stabilizer,
electrolyte for lithium cell or the like, particle removing
agent, cleaning solution, plasticizer, lubricant, humectant,
solvent for gel permeation chromatography (GPC), solvent for
high performance liquid chromatography (HPLC), solvent for
column chromatography, dissolution agent for polymer and the
like, casting solvent, primer for adhesives, solvent for spin
coat, and the like.
EXAMPLES
The present invention will be described in more detail
by way of examples and comparative examples. The present
invention, however, should not be limited to these examples.
In the examples and comparative examples below "parts"
indicates "parts by weight", unless otherwise specified.
The following conditions were applied to analysis by gas
chromatography, unless otherwise indicated.
Analytical apparatus: Hitachi GC390
Column: Neutrabond Capillary Column 60xID 0.25 (1.5 µm
df manufactured by GL Science Inc.)
Column temperature: 50°C (10 minutes) 100°C -> 300°C
(20°C/min)
Temperature at the inlet port: 200°C
Detector temperature: 300°C
Carrier gas: N2
Detector: FID
Injection amount: 1 µl
Preparation Example 1 Preparation of cyclopentyl methyl ether

A 1 little four-necked flask was charged with 283 parts
of N,N-dimethylformamide. After replacing the internal
atmosphere with nitrogen, 58.0 parts of 60 wt% oily sodium
hydride was added. Then, 103 . 3 parts of cyclopentanol was added
dropwise at a temperature between room temperature and 50°C.
The mixture was heated to 110°C in one hour and refluxed at
110-120°C for one hour. After cooling the mixture to 50°C, 341.0
parts of methyl iodide was added dropwise. After the addition,
the mixture was refluxed at 110-120°C for five hours.
After evaporating low boiling point components from the
reaction mixture, 100 parts of water was added to partition the
mixture into two layers. The organic layer was dried over
anhydrous magnesium sulfate and filtered to obtain about 210
parts of a filtrate. The filtrate was rectified using a Vigreux
rectification column under atmospheric pressure. 77.1 parts
of fraction 1 (Fr. 1) with a distillation temperature up to 100°C,
3. 40 parts of fraction 2 (Fr. 2) with a distillation temperature
of above 100°C and below 106°C, 70.0 parts of fraction 3 (Fr.
3) with a distillation temperature of 106°C, and 53.5 parts of
tank bottom were obtained. The yields and. the results of gas
chromatography analysis of these fractions (Fr. 1, Fr. 2, Fr.
3, and tank bottom) are shown in Table 1.
CPME: Cyclopentyl methyl ether, CPL: Cyclopentanol
Example 1 Oil and fat solubility test
Solubility of oils and fats (oil, rosin, wax, and fatty
acids) shown in Table 2 in CPME obtained in Preparation Example
1 as a cleaning solvent was examined. 1 g (in the case of oil)
or 0.5 g (in the case of rosin, wax, and fatty acid) of the sample
was added dropwise to a test tube containing 5 ml of CPME to
observe the solubility by the naked eye. The results of
observation are summarized in Table 2.
Comparative Examples 1 and 2 Oil and fat solubility test
1 g (in the case of oil) or 0.5 g (in the case of rosin,
wax, and fatty acid) of the sample was added dropwise to a test
tube containing 5 ml of NS-100 (a hydrocarbon cleaning solvent
manufactured by NIKKO PETROCHEMICALS CO., Ltd.) and. a test tube
containing 5 ml of t-butyl methyl ether (a component for
cleaning solvent described in Japanese Patent Application
Laid-open No. 6-49495) to observed the solubility by the naked
eye. The results of observation are summarized in Table 3.
It can be seen from Tables 2 and 3 that the cleaning
solvent of Example 1 exhibits far more excellent solubility than
NS-100 of Comparative Example 1 and equivalent to or better than
t-butyl methyl ether of Comparative Example 2. The cleaning
solvent of the present invention has thus been proven to be
useful as a solvent for cleaning articles stained with oils and
fats.
Example 2 Preparation of a,a-dimethylbenzyl alcohol using CPME
as a reaction solvent
45 ml (0.045 mol) of a 1 M phenylmagnesium bromide
(PhMgBr) solution in THF was added to a flask, of which the
atmosphere had been replaced with nitrogen, and stirred at 0°C
for 30 minutes. A solution of 1.74 g (0.03 mol) of acetone in
50 ml of CPME was slowly added dropwise to the PhMgBr solution
at 0°C. After stirring at 0°C for one hour, the reacted mixture
was heated to 50°C and stirred for a further one hour. The
reaction mixture was allowed to cool to room temperature and
20 ml of 1 N hydrochloric acid aqueous solution was added to
terminate the reaction. The reaction mixture was analyzed by
gas chromatography to confirm that the target
a,a-dimethylbenzyl alcohol was obtained in a yield of 70%.
Example 3 Preparation of l-hydroxy-l-phenylcyclopentane and
phenylcyclopentene using CPME as a reaction solvent
The same experiment as in Example 2 was carried out,
except for using 2. 5 g (0.03 mol) cyclopentanone instead of 1.74
g of acetone. The resulting reaction mixture was analyzed by
gas chromatography to confirm that the target
1-hydroxy-1-phenylcyclopentane and phenylcyclopentene were
obtained in a yield of 90% in total.
Example 4 Preparation of 2-mesityl-2-propanol and
a-methyl-2,4,6-trimethylstyrene using CPME as a reaction
solvent
The same experiment as in Example 2 was carried out,
except for using 45 ml (0.045 mol) of a 1 M
2,4,6-trimethylphenylmagnesium bromide solution in CPME
instead of 45 ml of the 1 M phenylmagnesium bromide solution
in THF. The resulting reaction mixture was analyzed by gas
chromatography to confirm that 2-mesityl-2-propanol and
a-methyl-2,4,6-trimethylstyrene were obtained in a yield of
81.9% and 1.6%, respectively.
Example 5 Preparation of 2-mesityl-2-propanol and
a-methyl-2,4,6-trimethylstyrene using CPME-THF mixture as a
reaction solvent
The same experiment as in Example 4 was carried out,
except for using a mixed solvent of CPME and THF (1:1 by volume)
instead of 50 ml of CPME. The resulting reaction mixture was
analyzed by gas chromatography to confirm that
2-mesityl-2-propanol and a-methyl-2,4,6-trimethylstyrene
were obtained in a yield of 66.8% and 14.7%, respectively.
Comparative Example 3 Synthesis of a,a-dimethylbenzyl alcohol
using THF as a reaction solvent
The same experiment as in Example 2 was carried out,
except for using 50 ml of THF instead of 50 ml of CPME. The
resulting reaction mixture was analyzed by gas chromatography
to confirm that the yield of the target compound was only 40%.
Comparative Example 4 Preparation of 1-hydroxy-l-
phenylcyclopentane and phenylcyclopentene using THF as a
reaction solvent
The same experiment as in Example 3 was carried out,
except for using 50 ml of THF instead of 50 ml;of CPME. The
resulting reaction mixture was analyzed by gas chromatography
to confirm that the target 1-hydroxy-1-phenylcyclopentane and
phenylcyclopentene were obtained in a yield of 85% in total.
Comparative Example 5 Preparation of 2-mesityl-2-propanol and
a-methyl-2,4,6-trimethylstyrene using THF as a reaction
solvent
The same experiment as in Example 4 was carried out,
except for using 50 ml of THF instead of 50 ml of CPME. The
resulting reaction mixture was analyzed by gas chromatography
to confirm that 2-mesityl-2-propanol and
a-methyl-2,4,6-trimethylstyrene were obtained in a yield of
44.6% and 33.1%, respectively.
The results of Examples 2-5 and Comparative Example 3-5
confirmed that the target compounds could be produced in a high
yield by using the reaction solvent of the present invention.
Example 6 Extraction of a,a-dimethylbenzyl alcohol using CPME
as an extraction solvent
An aqueous solution obtained by neutralizing the product
of Example 2 with hydrochloric acid was charged into a
separating funnel. After the addition of 20 ml of CPME and 30
ml of water, the mixture was sufficiently shaken and allowed
to stand still for 30 minutes to separate the water layer from
the organic layer. The organic layer was removed and stored
in a separate vessel. 20 ml of CPME was added to the water layer
and the same extraction procedure as above was repeated. The
organic layer was removed and put into the same vessel. This
extraction procedure was repeated three times. The combined
organic layer was washed with a saturated aqueous solution of
sodium hydrogencarbonate and water, dried over anhydrous
magnesium sulfate, and filtered. The filtrate was
concentrated under reduced pressure to obtain 6.4 g of a crude
product. The crude product was analyzed by gas chromatography
to confirm that a,a-dimethylbenzyl alcohol was obtained in a
yield of 71%. In addition, about 99 ml of CPME was collected
in the trap of the evaporator (recovery rate of CPME: 90%).
Example 7 Extraction of 1-hydroxy-1-phenylcyclopentane and
phenylcyclopentene using CPME as an extraction solvent
An aqueous solution obtained by neutralizing the product
of Example 3 with hydrochloric acid was charged into a
separating funnel to carry out the same extraction experiment
as in Example 6. 6.8 g of a crude product was obtained. The
recovery rate of the target product calculated from the results
of gas chromatography analysis of the reaction mixture before
extraction procedures was 91%. In addition, about 100 ml of
CPME was collected in the trap of the evaporator (overall
recovery rate of CPME: 91%).
Comparative Example 6 Extraction of a, a-dimethylbenzyl alcohol
using diethyl ether as an extraction solvent
An aqueous solution obtained by neutralizing the product
of Example 2 with hydrochloric acid was charged into a
separating funnel to carry out the same extraction experiment
as in Example 6, except that diethyl ether was used as the
extraction solvent and the extraction procedure was carried out
three times using 20 ml of diethyl ether. 5.5 g of a crude
product was obtained. The recovery rate of the target product
calculated from the results of gas chromatography analysis of
the reaction mixture before extraction procedures was 73%.
Almost no diethyl ether was collected in the trap of evaporator.
Comparative Example 7 Preparation of 1-hydroxy-1-
phenylcyclopentane and phenylcyclopentene using diethyl ether
as an extraction solvent
An aqueous solution obtained by neutralizing the product
of Example 3 with hydrochloric acid was charged into a
separating funnel to carry out the same extraction experiment
as in Example 6, except that diethyl ether was used as the
extraction solvent and the extraction procedure was carried out
three times using 20 ml of diethyl ether. 5.2 g of a crude
product was obtained. The recovery rate of the target product
calculated from the results of gas chromatography analysis of
the reaction mixture before extraction procedures was 73%.
Almost no diethyl ether was collected in the trap of evaporator.
The results of Examples 6-7 and Comparative Example 6-7
confirmed a superior extraction effect of the extraction
solvent of the present invention. Efficient recovery of CPME
used for extraction was also confirmed.
Example 8 Fabrication of information recording medium
Cyanine dyes of the following formulas A, B, and C were
dissolved in CPME obtained in Preparation Example 1 to obtain
coating solutions, each having a dye concentration of 2. 0 wt%.
The coating solutions were applied to the surface of
polycarbonate substrates (outside dimension: 130 mm, internal
diameter 15 mm, thickness 1.2 mm, track pitch: 1.6 µm, groove
depth: 80 nm) by spin coating (2000 rpm). The coatings were
dried at 100°C for 10 minutes to obtain recording medium layers
with a thickness of 0.08 µm.
Neither swelling nor dissolution of the polycarbonate
resin was observed during the process of forming the recording
medium layers (coating and drying). The resulting recording
media were checked for recording-reproduction characteristics
to confirm that the characteristics were excellent.
Example 9 Production of OPC drum
10 aluminum pipes (thickness: 0.4 mm, diameter: 30 mm,
length: 253 mm) were used for the experiment. Notches (width:
2 mm, length: 3mm) were formed at the ends of the pipes using
a 5 kW carbon dioxide laser to obtain drums for preparing OPC
drums. 3 parts by weight of X-type metal-free phthalocyanine
and 20 parts by weight of 2-butanone were added to and
homogeneously dispersed in a solution of one part by weight
polyvinyl butyral resin (BM-1, manufactured by Sekisui Chemical
Co., Ltd.) in 20 parts by weight of CPME to obtain a coating
solution for forming a charge generation layer. The drum was
dipped in this coating solution at 25°C for one minute, removed
from the solution, and dried at 100°C for five minutes in a
nitrogen gas stream, thereby forming a charge generation layer
with a thickness of 0.25 µm.
Next, 300 parts of N,N'-diphenyl-N,N'-(m-tolyl)
benzidine and 64 parts of polycarbonate resin were added to and
dissolved in a mixed solvent of CPME prepared in Preparation
Example 1 and n-hexane (5:1 by weight), thereby obtaining a
coating solution for forming a charge transfer layer. The above
drum on which the charge generation layer has been formed was
dipped in this coating solution for forming a charge transfer
layer at 25°C for one minute, removed from, the solution, and
dried at 110°C in a nitrogen gas stream to form a charge transfer
layer on the charge generation layer, thereby obtaining an OPC
drum. This procedure was repeated to obtain 10 OPC drums. The
charge generation layer of the resulting OPC drums has a uniform
thickness (18-19 µm), with only the least defects such as uneven
coating.
Comparative Example 9 Production of OPC drum
10 photosensitive drums were obtained in the same manner
as in Example 9, except for using 300 parts of a mixed solvent
of THF and n-hexane (5:1 by weight) instead of 300 parts of the
mixed solvent of CPME and n-hexane. The charge transfer layer
of the resulting OPC drums has a uniform thickness (17-20 µm) ,
with greater unevenness in the coating thickness as compared
with the thickness of the charge transfer layer of the OPC drums
in Example 9. One photosensitive drum having a charge transfer
layer thickness of 17 µm and another drum having a charge
transfer layer thickness of 20 µm were regarded as defective
products.
Example 10 Peeling of photosensitive layer from OPC drum
The two OPC drums evaluated as defective products in
Comparative Example 9 were dipped in the mixed solvent of CPME
prepared in Preparation Example 1 and n-hexane (5:1 by weight) .
After 10 minutes, the photosensitive drum was removed from the
solution to confirm that the photosensitive layers (charge
generating layer and charge transfer layer) were completely
peeled from the drum surface and clean drums were recovered.
The photosensitive layers can be formed on the recovered drums
according to the same procedure as in Example 9.
Examples 11-12 and Comparative Examples 10-11 Test for
releasability of epoxy resin adhesive
Specimens for the releasability test were prepared by
attaching orientation flat parts of three sheets of 8 inch
silicon wafer at intervals of 1 cm on a glass plate (1 cm x 6
cm x 15 cm) using an epoxy resin adhesive (W-BOND manufactured
by Nikka Seiko Co., Ltd.) The epoxy resin adhesive was used
by mixing the main component with a curing agent at a ratio by
weight of 2:1. The mixture was applied to the glass plate to
which the silicon wafer was caused to adhere, cured at 90°C for
one hour, and allowed to stand for 3 hours at room temperature.
The test specimens obtained above were dipped in parting
agent solutions listed in Table 4 under the conditions
(temperature and supersonic treatment) shown in Table 4. The
test specimens were removed from the solutions to determine the
period of time required for three sheets of silicon wafer to
become detached. The average time for three sheets was regarded
as the parting time (minute). A short parting time indicates
that only a short period of time was required for removing the
epoxy adhesive and the solvent used has excellent parting
capability. An ultrasonic irradiation apparatus (Type: SILENT
SONICUT-204, 39 kHz, 200 W, 8.6 L, manufactured by Sharp Corp.
was used for the ultrasonic treatment.
Parting agents used, dipping temperature (°C) ,
application of ultrasonic treatment, and parting time (minute)
are shown in Table 4.
i-PrOH: iso-propyl alcohol, BnOH: Benzyl alcohol
It can be seen from Table 4 that the solvent of the present
invention exhibits more excellent releasability performance
for an epoxy resin adhesive than comparative parting agents
(isopropyl alcohol and benzyl alcohol) ..
Preparation Example 2
10 g of a commercially available styrene-based acidic
ion-exchange resin (RCP 145, water content 46 wt%, manufactured
by Mitsubishi Chemical Corp.) was dried in a drier at about 105°C
for 10 hours and then in a desiccator at room temperature for
two weeks. The water content of the dry ion-exchange resin was
analyzed by Karl-Fischer coulometric titration and found to be
3.0 wt%.
The dry ion-exchange resin was filled in a reaction tube
with a diameter of 1" (2.54 cm) and a length of 40 cm. After
feeding dry nitrogen gas for five hours
at 100°C, the reaction
tube was cooled to room temperature. The water content of the

resulting dry ion-exchange resin was analyzed by Karl-Fischer
coulometric titration to find that water content was 1.5 wt%.
The acidic ion-exchange resin (hereinafter referred to as "dry
acidic ion-exchange resin") obtained in this manner was used
for the reaction.
Hiranuma water content analyzer (AQ-7, manufactured by
Hiranuma Industry Co., Ltd.) was used for the determination of
water content by the Karl Fischer method. Hydeliner (R) and
Aqualite (RS-A) were used as generating solutions and Aqualite
(CN) was used as a counter electrode solution.
Example 13 Preparation of cyclopentyl methyl ether
A tightly closable reaction vessel (internal volume: 200
ml) made of stainless steel was charged with 3.4 g (0.05 mol)
of cyclopentene, 32 g (1.0 mol) of methanol, and 3.0 g of dry
acidic ion-exchange resin. After tightly closing the reaction
vessel, the mixture was stirred for 6-8 hours at 120°C under
a pressure of 2.5 Mpa. After the reaction, the reaction vessel
was opened and the reaction mixture was analyzed by gas
chromatography to confirm that the conversion rate of
cyclopentene was 30%.
Insoluble matters were separated from the reaction
mixture by filtration. The resulting filtrate was distilled
under atmospheric pressure using a Vigreux rectifying column
to obtain cyclopentyl methyl ether in an isolation yield of 27%.
Comparative Example 12
The same experiment as in Example 13 was carried out,
except for using an acidic ion-exchange resin with a water
content of 4 6 wt% (RCP145, manufactured by Mitsubishi Chemical
Corp.) instead of the dry acidic ion-exchange resin. The
resulting reaction mixture was analyzed by gas chromatography
to confirm that the conversion rate of cyclopentyl methyl ether
was only 0.4%.
In the same manner as in Example 13, insoluble matters
were separated from the reaction mixture by filtration. The
resulting filtrate was distilled under atmospheric pressure
using a Vigreux rectifying column to obtain cyclopentyl methyl
ether in an isolation yield of 0.3%.
Comparative Example 13
A tightly closable reaction vessel (internal volume: 200
ml) made of stainless steel was charged with 3.4 g (0.05 mol)
of cyclopentene, 32 g (1.0 mol) of methanol, and 3.0 g of
synthetic zeolite catalyst (ZSM-5 manufactured by Mobile R&D
Corp.) . After tightly closing the reaction vessel, the mixture
was stirred for 6-8 hours at 120°C under a pressure of 1.0 Mpa.
The resulting reaction mixture was analyzed by gas
chromatography to confirm that the conversion rate of
cyclopentyl methyl ether was only 0.07%. Distillation of the
mixture in the same manner as in Example 13 failed to isolate
the cyclopentyl methyl ether which was only present in a slight
amount.
Preparation Example 3-8
Various acidic ion-exchange resins Al-Gl were dried in
the same manner as in Preparation Example 2 to obtain dry acidic
ion-exchange resins A2-G2, respectively. The water content of
the dry acidic ion-exchange resins was analyzed to find that
water content was 1.5 wt% or less for all of them as shown in
Table 5.
The sources of the acidic ion-exchange resins Al-Gl were
as follows.
Acidic ion-exchange resins A1: SPC108 (manufactured by
Bayer AG)
Acidic ion exchange resins B1: SPC118 (manufactured by
Bayer AG)
Acidic ion exchange resins C1: PK208LH (manufactured by
Mitsubishi Chemical Corp.)
Acidic ion exchange resins D1: PK216LH (manufactured by
Mitsubishi Chemical Corp.)
Acidic ion exchange resins E1: PK228LH (manufactured by
Mitsubishi Chemical Corp.)
Acidic ion exchange resins F1: Amberlyst 15
(manufactured by Japan Organo Co., Ltd.)
Acidic ion exchange resins G1: RCP145 (manufactured by
Mitsubishi Chemical Corp.)
In the following description, the ion-exchange resin
produced by drying the acidic ion-exchange resin Al is called
dry acidic ion-exchange resin A2. The same applies to dry
acidic ion-exchange resins B2-G2.
Examples 14-20
The reactor shown in Figure 1(b) was used in Examples
14-20. The reaction columns 3b, 3c made by SUS with a diameter
of 2.54 cm (1") and a length of 40 cm was packed with the above
dry acidic ion-exchange resins A2-G2 (amount: about 80 ml) . The
whole columns 3b, 3c were maintained at 90°C.
A mixture of cyclopentene and methanol (mol ratio: 1.6:1)
was sent from a storage tank 1, heated at 90°C to vaporize in
a heater/vaporizer 2b, and continuously charged to the reaction
column 3b at a flow rate of 0.8 ml/min at 90°C under atmospheric
pressure. Seven hours after start of the reaction, the reaction
liquid flowing from one of the exits of the reaction column 3c
was analyzed by gas chromatography.
The reaction solutions extracted from the reaction
column 3c during the seven hours after start of the reaction
were combined and distilled under atmospheric pressure using
a Vigreux rectifying column to obtain cyclopentyl methyl ether.
The purity of the resulting cyclopentyl methyl ether was 99%
or more.
The type and water content of the dry acidic ion-exchange
resin, isolation yield of cyclopentyl methyl ether, conversion
rate of methanol, and reaction selectivity of cyclopentyl
methyl ether are summarized in Table 5, wherein CPME indicates
cyclopentyl methyl ether and MeOH indicates methanol.
Comparative Examples 14-20
The same experiment as in Examples 14-20 was carried out,
except for using acidic ion-exchange resins Al-Gl with a water
content of 40-70 wt% instead of the dry acidic ion-exchange
resins A2-G2. The type of the acidic ion-exchange resins,
content, conversion rate of methanol, and reaction selectivity
are summarized in Table 5. Cyclopentyl methyl ether could not
be isolated because the amount produced was too small.
As can be seen from Table 5, better results have been
obtained for all of the isolation yield of cyclopentyl methyl
ether (CPME), the conversion rate of methanol, and the reaction
selectivity in the experiments in Examples 14-20 in which dry
acidic ion-exchange resins were used than in the experiments
in Comparative Examples 14-20 in which acidic ion-exchange
resins with a water content of 30-70 wt% were used.
Example 21 Preparation of reaction solvent
A vessel with a stirrer was charged with 100 parts of
CPME obtained in Example 13 and 10 parts of a commercially
available dehydrating agent (MS-4A). After stirring for five
minutes., the CPME was allowed to stand in the vessel, which was
placed at a room temperature in a dry box in which nitrogen gas
was circulated, for 18 hours during which change in the water
content in CPME over time was measured. The results are shown
in Table 6.
2,6-di-tert-butyl-p-cresol was added to the dehydrated
CPME to a concentration of 250 ppm. The mixture was stirred
to obtain a reaction solvent (hereinafter referred to as
"Solvent A") with a water content of 25 ppm.
Comparative Example 21 Preparation of reaction solvent
A vessel with a stirrer was charged with 100 parts of
a commercially available THF (purity: 99.9%, manufactured by
Aldrich Co.) and 10 parts of a commercially available
dehydrating agent (MS-4A). After stirring for five minutes,
the THF was allowed to stand in the vessel, which was placed
at a room temperature in a dry box in which nitrogen gas was
circulated, for 18 hours to obtain THF for reaction (hereinafter
referred to as "Solvent B"). Change in the water content in
THF over time was measured and the results are shown in Table
6.
It can be seen from the results shown in Table 6 that
CPME can be dehydrated with MS more easily than THF.
Example 22 Synthesis of a,a-dimethylbenzyl alcohol using
Solvent A
40 parts of a 1 M phenylmagnesium bromide (PhMgBr)
solution in Solvent A was added to a flask, of which the
atmosphere has been replaced with nitrogen, and stirred at 0°C
for 30 minutes. A solution of 1.74 parts of acetone in 70 parts
of Solvent A was slowly added dropwise to the PhMgBr solution
at 0°C. After stirring at 0°C for one hour, the reaction mixture
was heated to 50°C and stirred for a further one hour. After
cooling to room temperature, the reaction was terminated with
the addition of 20 parts of 1 N hydrochloric acid aqueous
solution. The reaction mixture was analyzed by gas
chromatography to confirm that the target a,a-dimethylbenzyl
alcohol was obtained in a yield of 85%.
50 parts of water was added to partition the mixture into
two layers. The organic layer was removed and distilled under
atmospheric pressure using a Vigreux rectification column to
obtain 99 parts of fractions distilled at 100-106°C. Gas
chromatography analysis confirmed that the distillate
contained 99% or more of CPME. The distillate can be used again
as a solvent.
Example 23 Synthesis of a,a-dimethylbenzyl alcohol using
recovered CPME
a,a-dimethylbenzyl alcohol was prepared in the same
manner as in Example 22 using the CPME recovered in the Example
22 to obtain the a,a-dimethylbenzyl alcohol in a yield of 85%.
The experiment confirmed that cyclopentyl methyl ether can be
repeatedly used as a reaction solvent.
Comparative Example 22 Synthesis of a,a-dimethylbenzyl alcohol
using Solvent B
The same experiment as in Example 22 was carried out,
except for Solvent B instead of Solvent A. The resulting
reaction mixture was analyzed by gas chromatography under the
same conditions as above to confirm that the yield of the target
compound was only 50%.
Example 24 Oil and fat solubility test
The same solubility test as in Example 1 was carried out
except for using a cleaning solvent prepared by adding 250 ppm
of 2, 6-di-tert-butyl-p-cresol to CPME produced in Example 13.
The results shown in Table 2 were obtained.
Example 25 Peroxide production test
A cleaning solvent with the same composition as that used
in Example 24 was put into a 20 ml clear glass bottle and allowed
to stand at room temperature without shielding from light to
observe peroxide production. Peroxides were measured using
the iodine ion reduction titration method based on the JIS K9705.
The results are shown in Table 7.
As is clear from Table 7, the solvent of the present
invention is difficult to produce peroxides and thus excels in
storage stability.
INDUSTRIAL APPLICABILITY
The solvent comprising the cycloalkyl alkyl ether
compound of the present invention (1) can be mixed with various
organic solvents and exhibits excellent solubility to fats and
oils, waxes, and natural resins, (2) does not adversely affect
the ozone layer even if decomposed in the atmosphere due to the
absence of halogen atoms such as chlorine and bromine, (3) can
be handled with ease as a cleaning solvent due to the moderate
boiling point, (4) can be easily recovered after use as a
reaction solvent and can produce the target product in a high
yield when used in an organic chemical reaction such as a
Grignard reaction, and (5) is advantageous from the viewpoint
of operational efficiency and environmental safety. Therefore,
the solvent of the present invention is useful as a solvent for
cleaning electronic and electrical materials, precision
machinery components, and the like, as a reaction solvent for
various chemical reactions, as an extraction solvent for
extracting organic compounds from mixtures, and as a solvent
and parting agent for electronic and electrical materials . The
target cycloalkyl alkyl ether compound can be advantageously
manufactured in an industrial scale according to the
manufacturing method of the present invention.
We Claim :
1. A method for preparing a Grignard reaction product
such as herein described by reaction of a Grignard reagent
such as herein described with an aldehyde such as herein
described or a ketone such as herein described in the
presence of a reaction solvent and under the usual reaction
conditions known for such Grignard reaction characterized
in that said reaction solvent for the Grignard reaction
comprising a cyclopentyl methyl ether.
2. The method as claimed in claim 1, wherein said
reaction solvent has a water content of 100 ppm or less.
3. The method as claimed in claim 1 or 2, wherein
said reaction solvent optionally comprises an antioxidant.
The invention discloses a method for preparing a Grignard
reaction product such as herein described by reaction of a
Grignard reagent such as herein described with an aldehyde such
as herein described or a ketone such as herein described in the
presence of a reaction solvent and under the usual reaction
conditions known for such Grignard reaction characterized in
that said reaction solvent for the Grignard reaction comprising
a cyclopentyl methyl ether.

Documents:


Patent Number 225638
Indian Patent Application Number 01661/KOLNP/2003
PG Journal Number 47/2008
Publication Date 21-Nov-2008
Grant Date 19-Nov-2008
Date of Filing 23-Dec-2003
Name of Patentee ZEON CORPORATION
Applicant Address 6-1, MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO
Inventors:
# Inventor's Name Inventor's Address
1 KIN IDAN C/O ZEON CORPORATION, 6-1, MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8323
2 OHTA GENICHI C/O ZEON CORPORATION, 6-1, MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8323
3 TERAISHI KAZUO C/O ZEON CORPORATION, 6-1, MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8323
4 WATANABE KIYOSHI C/O ZEON CORPORATION, 6-1, MARUNOUCHI 2-CHOME, CHIYODA-KU, TOKYO 100-8323
PCT International Classification Number C07C 41/06, 43/184
PCT International Application Number PCT/JP2002/006501
PCT International Filing date 2002-06-27
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2001-196766 2001-06-28 Japan
2 2002-94269 2002-03-29 Japan
3 2001-332009 2001-10-30 Japan
4 2002-123832 2002-04-25 Japan
5 2001-377483 2001-12-11 Japan