Process for the Production of Tetrazolinones

Abstract

The invention relates to a process for the preparation of a tetrazolinone compound, comprising a step of reacting an isocyanate compound with an azide salt in a solvent and in the presence of a silicon derivative as a catalyst.

Claims

1. A process for the preparation of a tetrazolinone compound, comprising a step of reacting an isocyanate compound with an azide salt in a solvent and in the presence of a silicon derivative as a catalyst.

2. The process according to claim 1, wherein the azide salt is sodium azide.

3. The process according to claim 1, wherein the solvent is an amide.

4. The process according to claim 1, wherein the silicon derivative is a trialkylsilyl azide.

5. The process according to claim 1, wherein the silicon derivative is prepared by reacting a silyl halide compound with an azide salt.

6. The process according to claim 5, wherein the silyl halide compound is a trialkylsilyl halide.

7. The process according to claim 5, wherein the silyl halide compound is a silyl chloride compound.

8. The process according to claim 5, wherein the silyl halide compound is trimethylsilyl chloride.

9. The process according to claim 1, wherein the silicon derivative is employed in a molar amount of less than 1.0 equivalent, relative to the isocyanate compound.

10. The process according to claim 1, wherein the isocyanate compound is an aryl isocyanate and the tetrazolinone compound is a 1-aryl-tetrazolinone.

11. The process according to claim 1, wherein the step of reacting the isocyanate compound with the azide salt is performed at a temperature of at least 60 C.

12. The process according to claim 1, wherein a tetrazolinone salt is obtained after the step of reacting the isocyanate compound with the azide salt; and the process further comprises an additional step of treating the tetrazolinone salt with an acid to obtain the tetrazolinone compound.

13. The process according to claim 12, comprising an intermediate purification step between the step of reacting the isocyanate compound with the azide salt and the additional step of treating the tetrazolinone salt with the acid.

14. The process according to claim 12, further comprising a step of treating the tetrazolinone salt with sodium nitrite, before the additional step of treating the tetrazolinone salt with the acid.

15. The process according to claim 1, wherein the solvent is selected from dimethylformamide, dimethylacetamide, N-methylpyrrolidone and combinations thereof.

16. The process according to claim 1, wherein the silicon derivative is trimethylsilyl azide.

17. The process according to claim 1, wherein the silicon derivative is employed in a molar amount of less than 0.5 equivalent, relative to the isocyanate compound.

18. The process according to claim 1, wherein the silicon derivative is employed in a molar amount of less than 0.1 equivalent, relative to the isocyanate compound.

19. The process according to claim 1, wherein the step of reacting the isocyanate compound with the azide salt is performed at a temperature of at least 100 C.

20. The process according to claim 13, further comprising a step of treating the tetrazolinone salt with sodium nitrite, before the additional step of treating the tetrazolinone salt with the acid and after the intermediate purification step.

Description

DESCRIPTION OF EMBODIMENTS

[0024] The invention will now be described in more detail without limitation in the following description.

[0025] The present invention relates to a process for the preparation of a tetrazolinone compound, comprising a step of reacting an isocyanate compound with an azide salt in a solvent and in the presence of a silicon derivative as a catalyst.

[0026] The isocyanate compound used for the preparation of the tetrazolinone compound has the general formula (I):

##STR00001##

[0027] In this formula, R.sup.1 can be any carbon-containing group, such as an aryl group, an aryl-containing group or a non-aryl-containing group.

[0028] R.sup.1 can preferably be chosen from: [0029] C.sub.1-C.sub.12 alkyl; [0030] C.sub.2-C.sub.13 alkoxyalkyl; [0031] C.sub.7-C.sub.9 aralkyl; [0032] C.sub.3-C.sub.6 cycloalkyl; [0033] C.sub.3-C.sub.12 alkenyl; [0034] C.sub.3-C.sub.6 cycloalkenyl; [0035] C.sub.3-C.sub.12 alkynyl; [0036] naphthyl; [0037] phenyl; [0038] phenyl substituted with at least one substituent selected from the group consisting of: [0039] fluorine; [0040] chlorine; [0041] bromine; [0042] iodine; [0043] C.sub.1-C.sub.8 alkyl; [0044] C.sub.1-C.sub.8 alkoxy; [0045] methylenedioxy; [0046] NR.sup.2R.sup.3 wherein R.sup.2 and R.sup.3 can be the same or different and can be hydrogen or C.sub.1-C.sub.12 alkyl; [0047] C.sub.1-C.sub.4 alkoxycarbonyl; [0048] carboxy; [0049] phenoxy; [0050] nitro; [0051] cyano; [0052] trihalomethyl wherein each halo can be fluoro, chloro or bromo (the same or different, preferably the same); [0053] trihalomethoxy wherein each halo can be fluoro, chloro or bromo (the same or different, preferably the same); [0054] C.sub.1-C.sub.6 alkylthio; [0055] C.sub.1-C.sub.6 fluoroalkylthio; [0056] benzyl; [0057] benzyl substituted with at least one substituent selected from the group consisting of: [0058] fluorine; [0059] chlorine; [0060] bromine; [0061] iodine; [0062] C.sub.1-C.sub.8 alkyl; [0063] C.sub.1-C.sub.8 alkoxy; [0064] methylenedioxy; [0065] C.sub.1-C.sub.4 alkoxycarbonyl; [0066] phenoxy; [0067] nitro; [0068] cyano; [0069] trihalomethyl wherein each halo can be fluoro, chloro or bromo; [0070] trihalomethoxy wherein each halo can be fluoro, chloro or bromo (the same or different, preferably the same); [0071] C.sub.1-C.sub.6 alkylthio; [0072] C.sub.1-C.sub.6 fluoroalkylthio; [0073] C.sub.2-C.sub.5 aromatic heterocycles containing at least one heteroatom, wherein the heteroatom can be oxygen, nitrogen or sulfur; [0074] C.sub.2-C.sub.5 non-aromatic heterocycles containing at least one heteroatom, wherein the heteroatom can be oxygen, nitrogen or sulfur.

[0075] The alkyl, alkoxy and alkylthio radicals used as substituents can be straight-chain or branched. For example, such alkyl radicals can include methyl, ethyl, propyl, isopropyl, butyl, i-butyl, sec-butyl, tert-butyl, hexyl, octyl and their isomers. Suitable alkoxy radicals include for example methoxy, ethoxy, isopropoxy, butoxy and their isomers. Alkylthio radicals can be for example methylthio, ethylthio, isopropylthio, propylthio, butylthio, i-butylthio, sec-butylthio and tert-butylthio. Substituents composed of several generic groups such as alkoxyalkyl and fluoroalkylthio contain appropriate combinations of the abovementioned individual substituents.

[0076] Cycloalkyl radicals used as substituents can be for example: cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl.

[0077] The alkenyl and alkynyl radicals used as substituents can be straight-chain or branched and contain one or more unsaturated bonds. Double and triple bonds can be present in the same radical. Such alkenyl and alkynyl radicals can be for example: vinyl, allyl, 1-propenyl, isopropenyl, allenyl, butenyls, butadienyls, hexenyls, ethynyl, 1-propynyl, 2-propynyl, butinyls, pentynyls, hexynyls, hexadienyls and 2-pent-en-4-ynyl.

[0078] Examples of alkoxycarbonyl radicals are: methoxycarbonyl, ethoxycarbonyl, propoxycarbonyl, isopropoxycarbonyl and butoxycarbonyl.

[0079] Examples of aromatic heterocycles are: furan, pyrrole, thiophene, pyridine, pyridazine, pyrimidine, imidazole, pyrazole, thiazole, isoxazole, oxazole, triazole, oxadiazole, thiadiazole and triazine.

[0080] Examples of non-aromatic heterocycles are: ethylene sulfide, aziridine, trimethylene oxide, trimethylene sulfide, azetidine, tetrahydrofurane, pyrrolidine, thiolane, pyran, tetrahydropyran, piperidine, thiacyclohexane, dioxane, piperazine and morpholine.

[0081] Preferably, R.sup.1 is an aryl group and the isocyanate compound is an aryl isocyanate.

[0082] Examples of preferred isocyanate compounds include phenyl isocyanate, 2-chlorophenyl isocyanate, 3-chlorophenyl isocyanate, 4-chlorophenyl isocyanate, 2-bromophenyl isocyanate, 3-bromophenyl isocyanate, 4-bromophenyl isocyanate, 2-methylphenyl isocyanate, 3-methylphenyl isocyanate, 4-methylphenyl isocyanate, and 2-methoxymethyl-3-methylphenylisocyanate.

[0083] The azide salt can be notably chosen from sodium azide, potassium azide, lithium azide, or ammonium azide. The ammonium azide can notably be a quaternary ammonium azide salt, such as a tetraalkylammonium azide.

[0084] Examples of tetraalkylammonium azides are tetramethylammonium azide, tetraethylammonium azide, and tetrabutylammonium azide.

[0085] The azide salt is preferably sodium azide.

[0086] The solvent is preferably a polar solvent. Preferably the solvent comprises an amide such as dimethylformamide, dimethylacetamide or N-methylpyrrolidone.

[0087] According to some (preferred) embodiments, the solvent used in the process consists of a single compound chosen from the abovementioned compounds.

[0088] By silicon derivative is meant a silicon-containing compound, preferably a compound which contains a single silicon atom.

[0089] According to the present invention, the silicon derivative is used as a catalyst, which means that the silicon derivative is substantially not consumed during the step of reacting the isocyanate compound with the azide salt.

[0090] According to some embodiments, the silicon derivative that is used as a catalyst can have the general formula (II):

##STR00002##

[0091] In formula (II), each of R.sup.4, R.sup.5 and R.sup.6 can independently be selected from aryl, alkyl, aralkyl and alkoxyalkyl groups.

[0092] Each of R.sup.4, R.sup.5 and R.sup.6 can notably be chosen from a methyl group, an ethyl group, an isopropyl group, a tert-butyl group or a phenyl group.

[0093] R.sup.4, R.sup.5 and R.sup.6 can be the same or different.

[0094] If the substituents R.sup.4, R.sup.5 and R.sup.6 are the same, they can be for example alkyl groups (trialkylsilyl azide), such methyl groups (trimethylsilyl azide), ethyl groups (triethylsilyl azide) or isopropyl groups (triisopropylsilyl azide).

[0095] If R.sup.4, R.sup.5 and R.sup.6 are different, R.sup.4 and R.sup.5 can be for example a methyl group and R.sup.6 can be an isopropyl group (isopropyldimethylsilyl azide), or R.sup.4 and R.sup.5 can be an ethyl group and R.sup.6 can be an isopropyl group (diethyliisopropylsilyl azide), or R.sup.4 and R.sup.5 can be a methyl group and R.sup.6 can be a tert-butyl group (tert-butyldimethylsilyl azide), or R.sup.4 and R.sup.5 can be a phenyl group and R.sup.6 can be a tert-butyl group (tert-butyldiphenylsilyl azide).

[0096] Preferably, the silicon derivative is trimethylsilyl azide.

[0097] In some embodiments, the silicon derivative is prepared prior to or during the step of reacting the isocyanate compound with the azide salt. The preparation may be performed in the same reaction vessel used for reacting the isocyanate compound with the azide salt.

[0098] The preparation of the silicon derivative can notably be made by reacting a silyl halide compound with an azide salt. The azide salt used in this preparation step can notably be as defined above. It can be the same azide salt also used for the reaction with the isocyanate compound or a different one. Preferably it is the same. Sodium azide is a preferred salt for preparing the silicon derivative.

[0099] According to some embodiments, the silyl halide compound can have the general formula (III):

##STR00003##

[0100] R.sup.4, R.sup.5 and R.sup.6 are as defined above.

[0101] X is a halogen, preferably selected from chlorine, bromine and iodine. The silyl halide compound can be chosen from a silyl chloride compound, or a silyl bromide compound, or a silyl iodide compound. Preferably, the silyl halide compound is a silyl chloride compound, and more preferably, the silyl halide compound is a trialkylsilyl chloride, most preferably trimethylsilyl chloride.

[0102] According to some embodiments, the silicon derivative can be prepared by the addition of the azide salt to a mixture containing the silyl halide and the solvent.

[0103] Alternatively and preferably, the silicon derivative can be prepared by the addition of the silyl halide to a mixture containing the azide salt and the solvent.

[0104] The isocyanate compound may be added subsequently or may be present in the above mixture containing the silyl halide and solvent or containing the azide salt and the solvent.

[0105] According to some embodiments, the silicon derivative can be present in a molar amount of less than 1.0 equivalent, preferably less than 0.5 equivalent and more preferably less than 0.1 equivalent, relative to the isocyanate compound.

[0106] The silicon derivative can for example be employed in a molar amount from 0.9 to 0.99 equivalent, or from 0.8 to 0.9 equivalent, or from 0.7 to 0.8 equivalent, or from 0.6 to 0.7 equivalent, or from 0.5 to 0.6 equivalent, or from 0.4 to 0.5 equivalent, or from 0.3 to 0.4 equivalent, or from 0.2 to 0.3 equivalent, or from 0.1 to 0.2 equivalent, or from 0.075 to 0.1 equivalent, or from 0.05 to 0.075 equivalent, or from 0.025 to 0.05 equivalent, or from 0.01 to 0.025 equivalent, relative to the isocyanate compound.

[0107] According to some embodiments, the azide salt can be present in a molar amount of from 0.5 to 5.0 equivalent, relative to the isocyanate compound. Preferably, the azide salt is present in a molar amount of at least 1.0 equivalent, or at least 1.01 equivalent, or at least 1.02 equivalent, or at least 1.03 equivalent, or at least 1.04 equivalent, or at least 1.05 equivalent, relative to the isocyanate compound.

[0108] The azide salt can for example be employed in a molar amount from 0.5 to 0.9 equivalent, or from 0.9 to 1.0 equivalent, or from 1.0 to 1.1 equivalent, or from 1.1 to 1.2 equivalent, or from 1.2 to 1.5 equivalent, or from 1.5 to 2.0 equivalent, or from 2.0 to 5.0 equivalent, relative to the isocyanate compound.

[0109] The above amounts correspond to the reactants initially put into contact, after the optional step of preparing the silicon derivative.

[0110] According to some embodiments, the step of reacting the isocyanate compound with the azide salt can be performed at a temperature of at least 60 C., preferably of at least 80 C., and more preferably of at least 100 C.

[0111] The step of reacting the isocyanate compound with the azide salt can notably be performed at a temperature from 60 to 70 C., or from 70 to 80 C., or from 80 to 90 C., or from 90 to 100 C., or from 100 to 110 C., or from 110 to 120 C., or from 120 to 130 C., or from 130 to 140 C., or from 140 to 150 C.

[0112] According to some embodiments, the isocyanate compound is added to a reaction mixture comprising the azide salt and/or the silicon derivative. Said addition can in particular be carried out in less than 2 hours, more preferably in less than 1.5 hours, more preferably in less than 1 hour, more preferably in less than 50 minutes, and more preferably in less than 45 minutes.

[0113] According to some embodiments, the isocyanate compound may be diluted with an inert solvent such as toluene for example, and this mixture may be then added to the reaction mixture.

[0114] According to some embodiments, after the step of reacting the isocyanate compound with the azide salt, a tetrazolinone salt is obtained.

[0115] In particular, the tetrazolinone salt may have the general formula (IV):

##STR00004##

[0116] R.sup.1 is as defined above.

[0117] C.sup.+ is a cation coming from the cation present in the azide salt, and it can be notably chosen from sodium, potassium, lithium and ammonium ions. The ammonium ions can notably be quaternary ammonium ions, such as tetraalkylammonium ions.

[0118] Examples of tetraalkylammonium ions are tetramethylammonium ions, tetraethylammonium ions, and tetrabutylammonium ions.

[0119] Preferably, C.sup.+ is a sodium ion.

[0120] The desired tetrazolinone compound can be the above tetrazolinone salt. In this case, the tetrazolinone salt, which is soluble in the solvent in this step, can be recovered, and optionally washed and/or purified, e.g. by filtration. The aim of the filtration is to remove solid by-products.

[0121] Alternatively, the above tetrazolinone salt may be further converted to the desired tetrazolinone compound. Accordingly, the process may further comprise an additional step of treating the tetrazolinone salt with an acid. The acid may for instance directly be added to the reaction mixture obtained from the step of reacting the isocyanate compound with the azide salt. Alternatively, the tetrazolinone salt, which is soluble in the solvent in this step, may be filtered to remove solid by-products, prior to being treated with the acid.

[0122] The acid used to convert the tetrazolinone salt to the tetrazolinone compound can notably be used in an amount such that the pH of the medium containing the tetrazolinone salt is reduced to less than 3, or less than 2, or less than 1.5, or more preferably less than 1. Such acid can be either an inorganic or an organic acid. Examples of inorganic acids are: hydrochloric acid, hydrobromic acid, hydroiodic acid, sulfuric acid, phosphoric acid, carbonic acid, and nitric acid. Examples of organic acids are: trifluoroacetic acid, trichloroacetic acid, methanesulfonic acid, ethane sulfonic acid, benzenesulfonic acid, p-toluenesulfonic acid, trifluoromethanesulfonic acid, and formic acid. Combinations of the above acids can also be used. Preferably, the acid used to transform the tetrazolinone salt to the tetrazolinone compound is hydrochloric acid or sulfuric acid.

[0123] According to some embodiments, after filtration of the solid by-products and prior to being treated with the acid, the tetrazolinone salt can be treated with a substance such as e.g. sodium nitrite in order to provoke the decomposition of residual azide. The amount of sodium nitrite may be adjusted so as to fully decompose the residual azide.

[0124] Sodium nitrite can preferably be used in a molar amount of from 0.01 to 1.0 equivalent, relative to the isocyanate compound. In some embodiments, sodium nitrite is used in a molar amount of less than 1.0 equivalent, or less than 0.9 equivalent, or less than 0.8 equivalent, or less than 0.7 equivalent, or less than 0.6 equivalent, or less than 0.5 equivalent, or less than 0.4 equivalent, or less than 0.3 equivalent, or less than 0.2 equivalent, or less than 0.1 equivalent, or less than 0.05, or less than 0.02 equivalent, or equal to 0.01 equivalent, relative to the isocyanate compound.

[0125] The desired tetrazolinone compound can then be recovered, and optionally washed and/or purified, e.g. by filtration.

[0126] The desired tetrazolinone can also be used in another reaction for the synthesis of tetrazolinone derivatives, as for example described in U.S. Pat. No. 4,839,349.

[0127] The tetrazolinone compound thus obtained may have the general formula (V):

##STR00005##

[0128] R.sup.1 is as defined above.

[0129] Accordingly, the tetrazolinone compounds obtained by the process of the invention are preferably 1-substituted-5(4H)-tetrazolinones.

[0130] Preferably, R.sup.1 is an aryl group and the tetrazolinone compound is a 1-aryl-tetrazolinone.

[0131] By way of illustration, sodium azide can be used as the azide salt and trimethylsilyl chloride can be used as the silyl halide derivative to form the silicon derivative, which in this case is trimethylsilyl azide. The corresponding reaction scheme is shown below.

##STR00006##

[0132] Trimethylsilyl azide can then react with an isocyanate compound having the general formula (I), to give an intermediate trimethylsilyl tetrazolinone which after reaction with sodium azide can lead to the formation of the tetrazolinone sodium salt and trimethylsilyl azide which is thus regenerated, as shown below.

##STR00007##

[0133] The tetrazolinone salt can either be isolated as is or, alternatively and preferably, the tetrazolinone salt can be treated with an acid (for example hydrochloric acid) to give the tetrazolinone compounds having the general structure (V), as shown below.

##STR00008##

EXAMPLES

[0134] The following examples illustrate the invention without limiting it.

Example 1

[0135] To 33 mL of dimethylformamide were added 0.64 g (2.5 mol %) of trimethylsilyl chloride and 15.5 g (1.03 equiv) of sodium azide. The mixture was stirred at 100 to 105 C. and 27.6 g (1.0 equiv) of phenyl isocyanate were added over 45 min. The suspension was stirred for 1 h further at 100 to 105 C., cooled at 20 C., and slowly added to a mixture of 120 mL water and 2.0 g (5 mol %) of a sodium hydroxide solution, 25%. The solid by-products were removed by filtration. 3.8 mL (0.28 equiv) of an aqueous solution of sodium nitrite, 40% were added to the filtrate, followed by the addition of concentrated hydrochloric acid (36-37%) until the pH of the mixture was adjusted to <1. The product was then filtered and washed with 320 mL water. After drying at 50 C., 1-phenyl tetrazolinone was obtained (31.7 g) in 84% yield and with a purity of 99.4 area % (HPLC).

Example 2

[0136] To 10.6 mL of dimethylformamide were added 0.20 g (2.5 mol %) of trimethylsilyl chloride and 4.82 g (1.03 equiv) of sodium azide. The mixture was stirred at 80 C. and 13.2 g (1.0 equiv) of 2-methoxymethyl-3-methylphenylisocyanate were added over 45 min. The suspension was stirred for 1.3 h further at 80 C., cooled at 30 C., and to the mixture were slowly added (30 min) 35 mL water and 6.5 g of a sodium hydroxide solution, 25%. The solid by-products were removed by filtration and washed with water (7 mL). 1 g of an aqueous solution of sodium nitrite, 40%, was added to the filtrate, followed by the addition of 13.1 g of concentrated hydrochloric acid (36-37%). The suspension was then filtered and washed with water until the pH of the filtrate was adjusted to 3. After drying, 1-(2-methoxymethyl-3-methylphenyl)4H-tetrazolin-5-one was obtained (14.4 g) in 86% yield, with a purity of 98.3 area % (HPLC) and with an assay of 98.0% w/w.

Example 3

[0137] To 154 g of dimethylformamide were added 3 g (2.8 mol %) of trimethylsilyl chloride and 72 g (0.98 equiv) of sodium azide. The mixture was stirred at 100 C. and a mixture of 200 g (1.0 equiv) of 2-methoxymethyl-3-methylphenylisocyanate and 22 g of toluene were added over 1.3 h. The suspension was stirred for 2.5 h further at 100 C., cooled at 20 C., and to the mixture were slowly added (30 min) 619 g of sodium hydroxide 3.9% in water. The solid by-products were removed by filtration and 15 g of an aqueous solution of sodium nitrite, 40% were added to the filtrate. To the filtrate were then added at 20 to 50 C. a mixture of 196 g of concentrated hydrochloric acid (36-37%) and of 520 mL of water. This was followed by the further addition of 32 g of concentrated hydrochloric acid (36-37%). The suspension was then filtered (at 20 C.) and washed with 810 mL of water to yield 735 g water wet 1-(2-methoxymethyl-3-methylphenyl)4H-tetrazolin-5-one with an assay of 28.7% w/w (87% yield).