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3,390,162 United States Patent Office Patented June 25, 1968 2 Alkylaluminum chlorides, which are available com 3,390,162 -- mercially, have a much greater solubility in organic mate ORGANOSILICON COMPOUNDS AND METHOD rials than the organocadmium compounds, and may thus OF MANUFACTURE be used with any standard solvent. Further, while dialkyl Abe Berger, Schenectady, N.Y., assignor to General Elec cadmium compounds are extremely toxic, the alkylalumi tric Company, a corporation of New York num compounds are essentially non-toxic. In accordance No Drawing. Filed Nov. 13, 1964, Ser. No. 411,084 with the present invention, it has unexpectedly been found 5 Claims. (C. 260-448) that ketosilanes and keto-substituted organopolysiloxanes may be formed from the less expensive, less dangerous alkyl-aluminum compounds. Not only is the formation of ABSTRACT OF THE DISCLOSUIRE 10 the organosilicon compounds possible, but the process is Ketosilanes, such as ethoxydimethylsilylpropylmethyl even more versatile and provides higher yields than any ketone and dichloromethylsilylpropylmethyl ketone com of the previously disclosed processes. plexes of aluminum chloride, are prepared by reacting Briefly, the process of the present invention involves alkyl aluminum halides, such as methyl aluminum chlo contacting a silyl acyl chloride having the formula, ride, with corresponding silylpropionyl chlorides. The complexes are decomposed by reaction with water and the (1) hydrolysis and condensation products of the silanes are YmR3-nSi(CH2) a C Cl useful in the formation of silicone fluids. and an alkyl aluminum halide having the formula: 20 (2) RATY This invention relates to a novel process for forming to produce a ketosilane having the formula: organosilicon compounds, and to particular organosilanes (3) O and organopolysiloxanes produced thereby. More particu larly, this invention is concerned with a process for form 25 ing ketosilanes and keto-substituted organopolysiloxanes where Y is a halide substituent; R is selected from the and to particular novel products produced by the process. class consisting of monovalent hydrocarbon radicals, The prior art has shown a number of processes for halogen-substituted monovalent hydrocarbon radicals, and forming organosilicon compounds containing alkyl ke alkyl radicals substituted with OR' groups, where R' is tone substituents. Included among these processes are the 30 a member selected from the class consisting of monoval reaction of silanes and siloxanes containing alkyl chains ent hydrocarbons free of aliphatic unsaturation, and with unsaturated terminals with a compound containing monovalent radicals free of aliphatic unsaturation and an aldehyde group, as shown by Marsden in Patent 2,989,- consisting of carbon, hydrogen, and oxygen atoms, with 559, and the two methods shown by Sommer in Patent each oxygen atom being attached to two carbon atoms; 2,635,108. The Sommer methods include (a) the forma R’ is any alkyl radical; m is an integral number of from tion of ketone-substituted organosilicon compounds by the 0 to 3, inclusive; a is an integral number of from 2 to 10, reaction of substituted acetoactic esters with iodosilanes, inclusive; and p is an integral number of from 0 to 3, followed by hydrolysis and decarboxylation with hydro inclusive, and is no larger than m. Further when m-p chloric acid or a dilute alkali-metal hydroxide solution, is from 1 to 3, inclusive, the compound can be subjected and (b) the formation of an acyl chloride chain on a to further reaction to form other hydrolyzable groups on silane followed by reaction of the acyl chloride with an the ketosilane, or the ketosilane can be subjected to hy organocadmium compound. Each of these methods is sub drolysis to produce keto-substituted organopolysiloxanes. ject to severe limitations. The novel organosilanes of the present invention are The aldehyde-olefin reaction for the formation of alkyl those having silicon-bonded hydrolyzable groups and hav ketone-bearing organosilicon compounds is applicable only 45 ing the formula: to organopolysiloxanes. In addition, the yields are ex (4) O tremely low, the Marsden patent reporting yields varying X, R-Si(OH), R. from 8% to only 31%. Still further, the presence of reac where R and R' are as previously defined; X is a group tive functional groups other than the ketone is excluded. selected from the class consisting of halides, alkoxy radi The first method disclosed by Sommer, the reaction 50 cals, aryloxy radicals, acyloxy radicals, and substituted of acetoacetic esters with iodosilanes, is subject to two and unsubstituted amine radicals; a is as previously de severe limitations. The first is that the iodosilane raw ma fined and n is an integral number of from 1 to 3, inclu terial is extremely difficult to produce, unstable, and ex sive. Thus, the novel organosilanes of the present invention tremely expensive. Thus, the utility of the acetoacetic are those which carry not only a reactive keto-substituent, ester-iodosilane process is correspondingly reduced. Sec but, additionally, have functional groups attached directly ond, the only alkyl ketone which can be produced by that to the silicon atom and thus provide at least two reaction process, is the 4-silyl-2-one compound. The acyl chloride sites. organocadmium process for producing alkyl ketone sub The novel organopolysiloxanes to which the present stituents on organosilicon compounds is more versatile. invention relates are the diorgano-substituted cyclopoly However, notwithstanding the versatility, the process is 60 siloxanes where one of the organic substituents has a ke subject to limitations inherent in the use of organo tone group. These cyclopolysiloxanes are described by the cadmium compounds. One of the major methods dis closed for forming organocadmium compounds involves formula: a Grignard reaction in an ether solution. Additionally, (5) the reaction of the dialkylcadmium with the acyl chloride 65 (RIRC(CH2)SiO). substituted silane is also carried out in ether solution. Such where R, R', and a are as described above, and x is an ether solutions, obviously, present an inherent problem in integral number of from 4 to 16. These cyclosiloxanes are handling. Further, Sommer shows yields of only 53% and particularly valuable in the formation of longer chain 59% utilizing the acetoacetic ester cleavage process and organopolysiloxanes, such as in the formation of organo yields of only 29% and 45% based on the more versatile 70 polysiloxane elastomers. diorganocadmium reaction with the acyl chloride-sub The process of the present invention is, therefore, stituted silane. broadly one for producing organosilicon compounds hav 3,390,162 3. 4. ing alkyl ketone substituents. The process, as noted, is ga-chlorodimethylsilylvaleryl chloride, omega-dichloro adaptable not only to the particular novel organosilanes ethylsilyl-n-caproyl chloride, and omega-chlorobenzyl and organopolysiloxanes described above, but is useful in propylsilylcapryl chloride. This list should, of course, be producing a broader range of alkyl ketone-substituted taken as illustrative only of the compounds which can be organosilicon compounds, including those described by described by Formula 1, and not as limiting in any way Formula 3. Thus, the process allows the production of the full scope of the compounds. organosilanes having a wide variety of alkyl ketone Sub The alkylaluminum halides described by Formula 2 are stituents, the remaining valences of the silicon atom being preferably chlorides, for example, methylaluminum chlo satisfied either by hydrolyzable groups, or by hydrocarbon ride, ethylaluminum chloride, n-butylaluminum chloride, and oxygenated hydrocarbon groups, such as those set IO n-heptylaluminum chloride, n-nonylaluminum chloride, forth in the definitions of X and R. Further, when the n-decylaluminum chloride, and even longer chain con ketosilane of Formula 3 where m-p is 1, is subjected pounds, such as n-nonadecylaluminum chloride, n-eico to hydrolysis, alkyl ketone-containing organodisiloxanes Sylaluminum chloride, n-tetracontylaluminum chloride, having the formula: and others. These represent the preferred alkylaluminum (6) 5 halide reactants but, as described in Formula 2, the alkyl (RC (CH). SiRO aluminum compound can be any alkylaluminum halide and thus the bromides, chlorides, and iodides of alkyl where R, R', and a are as defined above, can be produced. aluminum are also within the scope of this invention. The These disiloxane materials are particularly useful as chain constituency of R as shown in Formulas 2, 3, 4, 5, 6, stoppers for organosiloxane polymers. 20 and 7 is thus determined by the particular alkylaluminum The keto-silanes having hydrolyzable groups which can halide which is utilized in the process. The group defined be produced by the process of the present invention are as R in Formulas 1, 3, 4, 5, 6, 7, and 8 represents essen particularly useful in the production of other ketosilanes, tially any hydrocarbon substituent which does not con alkyl ketone-substituted organopolysiloxanes, and espe tain a reactive group. Within its scope are alkyl radicals cially in the production of copolymers having from 0.1 25 such as methyl, ethyl, propyl, isopropyl, butyl, isobutyl, to 99.9 mole percent of units having the formula: etc.; halogen-substituted alkyl radicals such as chloro (7) methyl, chloroethyl, dichloropropyl, etc.; aryl radicals such as benzyl, tolyl, xylyl, phenethyl, etc.; halogen-Sub RR/C (CH)SiO stituted aryl radicals such as