Antioxidants and process of preparing said antioxidants
The present invention relates to the preparation of compounds and their use as antioxidants. 
     Those in the field of polymer stabilization are constantly searching for new antioxidants and processes for preparing them. 
     It is an object of the present invention to provide a new class of antioxidants. It is also an object of the present invention to provide a process for preparing said antioxidants. Other objects will become apparent subsequently herein. 
     Objects of the present invention are accomplished by (I) reacting under basic conditions, a combination comprising (A) a phenolic compound having the following structural formula: ##STR1## wherein R and R 1  are tertiary alkyl radicals having 4 to 8 carbon atoms, R 2  is selected from the group consisting of hydrogen and alkyl radicals having 1 to 6 carbon atoms and X is selected from the group consisting of Cl, Br, ##STR2## wherein R 5 , R 6 , R 7  and R 8  are alkyl radicals having 1 to 4 carbon atoms, and (B) a nitroalkane having the following structural formula: ##STR3## wherein R 3  is selected from the group consisting of hydrogen and alkyl radicals having 1 to 6 carbon atoms and R 4  is an alkyl radical having 1 to 6 carbon atoms and (II) reducing the product of step (I). 
     The product of step II has the following structural formula: ##STR4## wherein R, R 1 , R 2 , R 3  and R 4  are as described above. These compounds can be used to stabilize polymers against oxidative degradation. They can also be reacted with an α-β unsaturated acid halide such as acryloyl chloride or methacryloyl chloride under basic conditions to produce an antioxidant capable of being polymerized in free radical polymerization systems with conventional monomers to form self-stabilizing polymers. 
     Illustrative of phenolic reactants are the following: 
     3,5-di tert.butyl-4-hydroxybenzyl chloride 
     3,5-di tert.butyl-4-hydroxybenzyl bromide 
     2,6-di tert. butyl-4-dimethylaminomethylphenol 
     3,5-di tert.butyl-4-hydroxybenzyl N,N-dimethyldithiocarbamate 
     2,6-di tert.butyl-4-(1-chloroethyl)phenol 
     3,5-bis(1,1-dimethylbutyl)-4-hydroxybenzyl chloride 
     3,5-di tert.butyl-4-hydroxybenzyl N,N-diethyldithiocarbamate 
     2,6-di tert.butyl-4-piperidinomethylphenol 
     3,5-bis(1,1,3,3-tetramethylbutyl)-4-hydroxybenzyl chloride 
     Illustrative of the nitroalkanes are the following: nitroethane, 1-nitropropane, 2-nitropropane, 1-nitrobutane, 2-nitrobutane, 3-nitropentane, and 1-nitrohexane. 
     Illustrative of the phenolic reaction products of step (I) of the present invention are the following: 
     1,1-dimethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)-1-nitroethane 
     1-methyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)-1-nitroethane 
     1-(3,5-di tert.butyl-4-hydroxybenzyl)-1-nitropropane 
     1-(3,5-di tert.butyl-4-hydroxybenzyl)-1-nitrobutane 
     2-(3,5-di tert.butyl-4-hydroxybenzyl)-2-nitrobutane 
     1-(3,5-di tert.butyl-4-hydroxybenzyl)-1-nitrohexane 
     1,2-dimethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)-1-nitroethane 
     1,1,2-trimethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)-1-nitroethane 
     1-methyl-2-ethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)-1-nitroethane 
     1-methyl-2- 3,5-bis(1,1-dimethylbutyl)-4-hydroxyphenyl!-1-nitroethane 
     1,1-dimethyl-2-(3,5-di tert.amyl-4-hydroxyphenyl)-1-nitroethane 
     1- 3,5-bis(1,1,3,3-tetramethylbutyl)-4-hydroxybenzyl!-1-nitropropane 
     3-(3,5-di tert.amyl -4-hydroxybenzyl)-3-nitropentane 
     1-methyl-2- 3,5-bis(1,1-dimethylpentyl)-4-hydroxyphenyl!-1-nitroethane 
     1-methyl-2-propyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)-1-nitroethane 
     The products of step (I) have a structural formula identical to structural formula (3) with the exception that the compound contains a nitro group rather than an amine group. Said compounds are antioxidants themselves. 
     The products of structural formula (3) are illustrated by the following compounds. 
     1,1-dimethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)ethylamine 
     1-methyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)ethylamine 
     1-(3,5-di tert.butyl-4-hydroxybenzyl)-1-aminopropane 
     1-(3,5-di tert.butyl-4-hydroxybenzyl)-1-aminobutane 
     2-(3,5-di tert.butyl-4-hydroxybenzyl)-2-aminobutane 
     1-(3,5-di tert.butyl-4-hydroxybenzyl)-1-aminohexane 
     1,2-dimethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)ethylamine 
     1,1,2-trimethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)ethylamine 
     1-methyl-2-ethyl-2-(3,5-di tert.butyl-4-hydroxyphenyl)ethylamine 
     1-methyl-2- 3,5-bis(1,1-dimethylbutyl)-4-hydroxyphenyl!ethylamine 
     1,1-dimethyl-2-(3,5-di tert.amyl-4-hydroxyphenyl)ethylamine 
     1- 3,5-bis(1,1,3,3-tetramethylbutyl)-4-hydroxybenzyl!-1-aminopropane 
     3-(3,5-di tert.amyl-4-hydroxybenzyl)-3-aminopentane 
     1-methyl-2- 3,5-bis(1,1-dimethylpentyl)-4-hydroxyphenyl!ethylamine 
     Generally the process of the present invention proceeds as follows. On equivalent of a base such as an alkali metal hydroxide is dissolved in a solvent such as methanol or ethanol and one to five equivalents of an aliphatic nitro compound are added. To this mixture is added, beginning at about room temperature, one equivalent of a 3,5-di tert.alkyl-4-hydroxybenzyl chloride. The addition is carried out over a period of from 15 to 60 minutes. The reaction is exothermic with the maximum temperature being reached in the range of 40° C. to 50° C. The reaction mixture is stirred for a period of up to several hours and the product, a 2-(3,5-di tert.alkyl-4-hydroxyphenyl)-1-nitroalkane, is then separated and purified following established procedures. 
     The 2-(3,5-di tert.alkyl-4-hydroxyphenyl)-1-nitroalkane is dissolved in a solvent suitable for hydrogenation such as ethanol or 1,4-dioxane, and a hydrogenation catalyst such as platinum, palladium, or nickel is added. The catalyst is added in an amount (based on metal content) ranging from 0.1 percent to 10 percent by weight of the nitro compound. The reaction mixture is hydrogenated in a pressurized reactor under a hydrogen pressure of 50 to 150 pounds per square inch at a temperature between room temperature and 150° C. When the theoretical amount of hydrogen has been absorbed, the reaction mixture is removed from the reactor and the product is isolated and purified following established procedures. 
     Polymers subject to deterioration by oxidation that can be conveniently protected by the antioxidants described herein include substituted and unsubstituted, saturated and unsaturated, natural and synthetic polymers. The oxidizable natural polymers of interest include natural rubber in its various forms, e.g., pale crepe and smoked sheet, and balata and gutta percha. The oxidizable synthetic polymers are prepared from a single monomer (homopolymer)or a mixture of two or more copolymerizable monomers (copolymers) wherein the monomers are combined in a random distribution or block form. The monomers may be substituted or unsubstituted and may possess one or more double bonds, for example, diene monomers, both conjugated and nonconjugated, and monoolefins including cyclic and acyclic monoolefins, especially vinyl and vinylidene monomers. Examples of conjugated dienes are 1,3-butadiene, isoprene, chloroprene, 2-ethyl-1,3-butadiene, 2,3-dimethyl-1,3-butadiene and piperylene. Examples of nonconjugated dienes are 1,4-pentadiene, 1,4-hexadiene, 1,5-hexadiene, dicyclopentadiene, 1,5-cyclooctadiene and ethylidene norbornene. Examples of acyclic monoolefins are ethylene, propylene, 1-butene, isobutylene, 1-pentene and 1-hexene. Examples of cyclic monoolefins are cyclopentene, cyclohexene, cycloheptene, cyclooctene and 4-methylcyclooctene. Examples of vinyl monomers are styrene, acrylonitrile, acrylic acid, ethylacrylate, butylacrylate, methyl vinyl ether, vinyl acetate and vinyl pyridine. Examples of vinylidene monomers are α-methylstyrene, methacrylic acid, methyl methacrylate, ethyl methacrylate, glycidyl methacrylate and vinylidene chloride. Representative examples of the synthetic polymers used in the practice of this invention are polychloroprene; homopolymers of a conjugated 1,3-diene such as isoprene and butadiene, and in particular, polyisoprenes and polybutadienes having essentially all of their repeat units combined in a cis-1,4 structure; copolymers of a conjugated 1,3-diene such as isoprene and butadiene with up to 50 percent by weight of at least one copolymerizable monomer including ethylenically unsaturated monomers such as styrene or acrylonitrile; butyl rubber, which is a polymerization product of a major proportion of a monoolefin and a minor proportion of a multiolefin such as butadiene or isoprene; polyurethanes containing carbon to carbon double bonds; and polymers and copolymers of monoolefins containing little or no unsaturation, such as polyethylene, polypropylene, ethylene propylene copolymers and terpolymers of ethylene, propylene and a nonconjugated diene such dicyclopentadiene, 1,4-hexadiene, ethylidene norbornene and methylene norbornene. 
     When added in free form normally 0.001 to 10.0 percent of the antioxidant by weight, i.e., parts by weight based on the weight of the polymer, i.e., 100 parts by weight of the polymer can be used, although the precise amount of the antioxidant which is to be employed will depend somewhat on the nature of the polymer and the severity of the deteriorating conditions to which the polymer is to be exposed. In unsaturated polymers such as those made from conjugated dienes, the amount of age resister necessary is greater than that required by a saturated polymer such as polyethylene. It has been found that an effective antioxidant amount of the disclosed stabilizers in rubbery unsaturated polymers will generally range from 0.05 to 5.0 percent by weight, i.e., parts by weight based on the weight of the polymer, although it is commonly preferred to use from 0.5 to 3.0 percent by weight, i.e., parts by weight based on the weight of the polymer. Mixtures of the age resisters may be used. 
     The following examples illustrate the practice of the present invention. Unless otherwise indicated, all parts are parts by weight. 
    
    
     EXAMPLE 1 
     A mixture of 21.5 grams of 1-methyl-2-(3,5-di t. butyl-4-hydroxyphenyl)-1-nitroethane, 200 ml of absolute ethanol and 2.0 grams of a 5 percent Palladium on carbon catalyst was shaken in a Parr pressure reaction apparatus under an initial hydrogen pressure of 55 pounds/square inch. The mixture was heated and after a short while the reaction became exothermic with the temperature rising to a maximum of 63° C. The theoretical amount of hydrogen was absorbed in 45 minutes. The reaction mixture was then removed from the apparatus and filtered to remove the catalyst. The filtrate was poured into 700 ml of water. An oil precipitated which crystallized on standing. The solid was filtered off and dried. There was obtained 18.5 grams of 1-methyl-2-(3,5-di t.butyl-4-hydroxyphenyl) ethyl amine with a melting point of 89°-92° C. 
     EXAMPLE 2 
     Using the same procedure, there was obtained from 28.8 grams 1,1-dimethyl-2-(3,5-di t.butyl-4-hydroxyphenyl)-1-nitroethane a yield of 25.0 grams of 1,1-dimethyl-2-(3,5-di t.butyl-4-hydroxyphenyl) ethyl amine which melted at 105°-107° C. 
     EXAMPLE 3 
     Again, using the same procedure, there was obtained from 26.5 grams of 1-(3,5-di t.butyl-4-hydroxybenzyl)-1-nitropropane a yield of 22.5 grams of 1-(3,5-di t.butyl-4-hydroxybenzyl)-1-aminopropane. This product melted at 77°-81° C. 
     EXAMPLE 4 
     A mixture of 29.1 grams of 1,1-dimethyl-2-(3,5-di t.butyl-4-hydroxyphenyl)-1-nitroethane, 200 ml of ethanol, and 3.0 grams of a 65 percent nickel on keiselguhr catalyst was shaken in a Parr pressure reaction apparatus under an initial hydrogen pressure of 55 pounds/square inch. The mixture was heated. Absorption of hydrogen began about 100° C. and the theoretical amount of hydrogen was absorbed in 21/2 hours. The reaction mixture was worked up as described in Example 1. There was obtained 26.0 grams of 1,1-dimethyl-2-(3,5-di t.butyl-4-hydroxyphenyl) ethyl amine which melted at 103°-106° C. 
     An SBR polymer (1006) was stabilized with two of the stabilizers of the present invention as follows. The SBR polymer was dissolved in benzene and benzene solutions of the age resisters were added to portions of the SBR solutions to provide 1.00 part of the antioxidant per 100 parts of rubbery polymer. The benzene solutions were used to form films and tested in an oxygen absorption apparatus. The testing procedure is of the type described in further detail in Industrial and Engineering Chemistry, Vol. 43, page 456 (1951) and Industrial and Engineering Chemistry, Vol. 45, page 392 (1953). 
     
                       Table I                                                     
______________________________________                                    
Oxygen Absorption at 100° C.                                       
Antioxidant       Hours to Absorb 1% Oxygen                               
______________________________________                                    
1,1-dimethyl-2-(3,5-di t.butyl-4-                                         
hydroxyphenyl) ethyl amine                                                
                229                                                       
1-methyl-2-(3,5-di t.butyl-4-                                             
hydroxyphenyl) ethyl amine                                                
                199                                                       
______________________________________                                    
 
    
     Unstabilized SBR would have an oxygen absorption value of about 5 to 10 hours. The above data therefore indicates that the compounds of the present invention do offer antioxidant protection. 
     Any compound within the generic descriptions recited herein could be substituted for its generic counterpart in the previous examples to produce an antioxidant or behave as an antioxidant. Likewise the other polymers described herein could be substituted for the SBR and benefit from the addition of the antioxidants. 
     The polymers described earlier herein will benefit by incorporation of the aforementioned antioxidants whether the polymer is vulcanized or unvulcanized and whether it is uncompounded or contains compounding ingredients such as carbon black, vulcanization agents and accelerators. 
     The antioxidants can be incorporated according to any conventional compounding technique, e.g., by milling, banburying or addition to polymer latices or polymer solutions or suspensions. The method of incorporation is not critical to the practice of the present invention. 
     The nitro compounds used in the preparation of the amine compounds of Examples 1 to 4 were prepared in accordance with the generic teachings herein. 
     In accordance with the practice of the present invention the nitroethane used in the preparation of the ethyl amine of Examples 2 and 4 can be prepared as follows. 
     1,1-dimethyl-2-(3,5-di t.butyl-4-hydroxyphenyl)-1-nitroethane was prepared by adding dropwise 25.5 grams of 3,5-di t.butyl-4-hydroxybenzyl chloride to a solution of 9.8 grams of 2-nitro propane and 4.0 grams of sodium hydroxide in 100 ml of ethanol. The addition was completed in 40 minutes at 31°-43° C. The reaction mixture was stirred for 30 minutes and was then poured into 600 ml of water. The solid which precipitated was filtered off and allowed to dry. The crude product weighed 29.5 grams (96% of theory) and melted at 95°-100° C. 
     In accordance with the practice of the present invention the nitroethane used in the preparation of the ethyl amine of Example 1 and the nitropropane used in the preparation of the aminopropane of Example 3 can be prepared as follows. 
     1-Methyl-2-(3,5-di t.butyl-4-hydroxyphenyl)-1-nitroethane was prepared by adding 15.0 grams of nitroethane to a solution of 4.0 grams of sodium hydroxide in 100 ml of ethanol. To the resulting suspension was added dropwise 25.5 grams of 3,5-di t.butyl-4-hydroxybenzyl chloride. The addition was completed in 30 minutes at 28°-42° C. The reaction mixture was stirred for 15 minutes and was then poured into 600 ml of water. A yellow oil precipitated, which gradually crystallized on standing. The crystalline solid was filtered off, allowed to dry, and the crude product recrystallized from hexane. A yield of 21.4 grams (73% of theory) of product was obtained which melted at 68°-71° C. 
     1-(3,5-di t.butyl-4-hydroxybenzyl)-1-nitropropane was prepared by adding 26.7 grams of 1-nitropropane to a solution of 4.0 grams of sodium hydroxide in 100 ml of ethanol. To the resulting suspension was added 25.5 grams of 3,5-di t.butyl-4-hydroxybenzyl chloride. The addition was completed in 20 minutes and the maximum temperature reached during the addition was 41° C. The reaction mixture was stirred for 21/2 hours and was then poured into 600 ml of water. The oil which precipitated was separated by extraction with hexane. Hexane and excess 1-nitropropane were separated from the extract by the use of a rotary evaporator. The residue was dissolved in hexane and the solution was cooled with dry ice. The solid which crystallized was filtered off and allowed to dry. The product weighed 20.0 grams and melted at 54.5°-59° C. The filtrate was worked up to yield another 6.5 grams of material melting at 51°-57° C. The total crude yield was 26.5 grams which was 86% theory. 
     The above descriptions of the preparation of the nitro compounds are illustrative and not limiting. 
     While certain representative embodiments and details have been shown for the purpose of illustrating the invention, it will be apparent to those skilled in this art that various changes and modifications may be made therein without departing from the spirit or scope of the invention.