EP1425342A2

EP1425342A2 - Novel symmetrical substituted benzaldehyde alditol derivatives and compositions and articles containing same

Info

Publication number: EP1425342A2
Application number: EP02753760A
Authority: EP
Inventors: John D. Anderson; Darin L. Dotson; Shawn R. Sheppard; Nathan A. Mehl; Jeffrey R. Jones
Original assignee: Milliken and Co
Current assignee: Milliken and Co
Priority date: 2001-03-23
Filing date: 2002-03-01
Publication date: 2004-06-09
Also published as: EP1425342A4; WO2002077086A2; AU2002335911A1; JP2004533423A; CN1514851A; WO2002077086A3

Abstract

Plastic additives which are useful as nucleating agents and which are especially useful for improving the optical properties of polymeric materials are provided. More particularly, this invention relates to certain alkyl (or alkoxy) substituted halo-benzylidene sorbitol acetals, as well as symmetric DBS compounds comprising specific pendant groups, such as C3-C6 alkyl, C1-C6 alkoxy, nitro, as well as phenyl and methylenedioxy(as the combination of two available sites on the pertinent ring system), and furthermore the benzylidene rings may be indan or tetralin, and polymer compositions thereof any such compounds and mixtures thereof. Such compounds may be utilized within, as merely examples, food or cosmetic containers and packaging. The inventive halogenated (that is, chlorinated, brominated, or iodinated) and alkylated benzylidene sorbitol acetals are also useful as gelling agents for water and organic solvents, particularly those used in the preparation of antiperspirant gel sticks.

Description

NOVEL SYMMETRICAL SUBSTITUTED BENZALDEHYDE ALDITOL

DERIVATIVES AND COMPOSITIONS AND

ARTICLES CONTAINING SAME

Field of the Invention

This invention relates to plastic additives which are useful as nucleating agents and which are especially useful for improving the optical properties of polymeric materials. More particularly, this invention relates to certain alkyl (or alkoxy) substituted halo-benzylidene sorbitol acetals, as well as symmetric DBS compounds comprising specific pendant groups, such as C₃-C₆ alkyl, Cι-C₆ alkoxy, nitro, as well as phenyl and methylenedioxy(as the combination of two available sites on the pertinent ring system), and furthermore the benzylidene rings may be indan or tetralin, and polymer compositions thereof any such compounds and mixtures thereof. Such compounds may be utilized within, as merely examples, food or cosmetic containers and packaging. The inventive halogenated (that is, chlorinated, brominated, or iodinated) and alkylated benzylidene sorbitol acetals are also useful as gelling agents for water and organic solvents, particularly those used in the preparation of antiperspirant gel sticks.

Background of the Prior Art All U.S. Patents cited below are herein entirely incorporated by reference.

Numerous attempts have been made to improve the clarity and physical properties of polyolefins through the incorporation of certain kinds of additives. Certain applications require good clarity or transparency characteristics. These include certain types of plastic plates, sheets, films, containers, and syringes that need to exhibit clarity primarily to facilitate identification of articles, etc., stored, wrapped, and/or covered therewith. Such commercially available plastic additives fall into two categories termed "melt sensitive" and "melt insensitive". Melt sensitive additives possess melting points below or near the normal processing temperatures of polyolefm-based resins and include dibenzylidene sorbitol (DBS) systems. Melt insensitive additives do not melt at normal processing temperatures and include sodium benzoate and salts of organic phosphates as examples.

U.S. Pat. No 4,016,118 to Hamada, et al. teaches that a polyolefin plastic composition containing 0.1% to 0.7% dibenzylidene sorbitol (DBS) as an additive will show improved transparency and reduced molding shrinkage over compositions containing a substituted benzoic acid salt. Additional advancements in sorbitol-based clarification technology have been driven by the need for improved transparency, reduction of plate-out during processing, and improved organoleptic properties (e.g., odor, taste, etc.). In order to overcome these deficiencies, many derivatives of DBS in which the aromatic rings are substituted with various groups have been proposed.

Mahaffey, in U.S. Pat. No. 4,371,645 discloses a series of dibenzylidene sorbitols having the general formula:

wherein R, R_ls R₂, R , and R₄, are selected from hydrogen, lower alkyl, hydroxy, methoxy, mono- and di-alkylamino, amino, nitro, and halogen, with the proviso that at least one of Rj, R₂, R₃, and R₄ is chlorine or bromine. Effective concentrations of the disclosed substituted DBS derivatives range from 0.01 to about 2 percent of the total composition by weight. Further improvements in transparency characteristics are disclosed by Titus, et al. in U.S. Pat. No. 4,808,650. In this patent mono and disubstituted DBS derivatives having the formula:

in which R may be hydrogen or fluorine provide improved clarity applications in polyolefins. Rekers, in U.S. Pat. No. 5,049,605 discloses a series of dibenzylidene sorbitols having the general formula:

in which Ri and R₂ are independently selected from lower alkyl groups containing 1-4 carbons or which together form a carbocyclic ring containing up to 5 carbon atoms. Also disclosed are polyolefin plastics containing the above group of dibenzylidene sorbitols. Videau, in U.S. Patent No. 5,696,186 discloses substituted DBS derivatives with an alkyl group (methyl, ethyl, or the like) or halogen (fluorine, chlorine, or the like) on the benzene rings for use as nucleation/clarification agents in polyolefins.

Dibenzylidene sorbitol (DBS) is a well known gelling agent for a variety solvent systems as disclosed in U.S. Pat. No. 4,154,816, Roehl et al.; U.S. Pat. No. 4,816,261, Luebbe et al.; and U.S. Pat. No. 4,743,444 to McCall. U.S. Pat. No. 5,609,855 to Oh et al. and PCT Patent Application WO/92/19221 to Juneja et al.; disclose that di(meta-fluorobenzylidene) sorbitol and di(meta-chlorobenzylidene) sorbitol are extremely useful as gelling agents in the preparation of antiperspirant gel sticks. These two respective DBS systems form effective hard gels and show improved gel stability in the acidic environment of antiperspirant formulations.

Detailed Description of the Invention

According to the present invention, a polyolefin plastic composition having improved transparency is provided which comprises a polymer selected from aliphatic polyolefins and copolymers containing at least one aliphatic olefin and one or more ethylenically unsaturated comonomers and at least one one mono-, di-, or tri-acetal which is the reaction product of at least one mole of alditol (such as sorbitol, xylitol, ribitol, and the like) and at least one mole of a benzaldehyde selected from the compounds conforming with either of Formula (I) or Formula (II)

(I)

wherein R is independently selected from hydrogen, lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, and halogen; R₃, and R are selected from lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, chlorine, bromine, iodine, and fluorine; with the proviso that one and only one of R₃ and ^ is selected from the group consisting of chlorine, bromine and iodine;

(II)

wherein Ri, R₂, R₃, }, and R₅ are independently selected from the group consisting of hydrogen, alkyl groups containing 3-6 carbon atoms, alkoxy groups containing 1-6 carbon atoms, and phenyl, or any two adjacent groups may be combined to form a cyclic group, wherein said cyclic group is selected from the group consisting of methylenedioxy, cyclopentyl, and cyclohexyl; with the proviso that at least one group of R_ls R₂, R₃, R , and R₅ is a group other than hydrogen. Preferably, such a reaction product is a di-acetal (and thus the result of a 1 :2 molar ratio reaction between the alditol and benzaldehyde), and particularly where the alditol is sorbitol, said di-acetal of the alditol having the structure of either Formula (III) [in correlation with the benzaldehyde of Formula (I)]:

(III)

wherein p is 0,1, or 2, R is independently selected from hydrogen, lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, and halogen; R_ls R₂, R₃, and J ₄ are selected from lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, chlorine, bromine, iodine, and fluorine; with the proviso that one and only one of Ri and R₂ is selected from chlorine, bromine, and iodine, and one and only one of R₃ and R is the same chlorine, bromine or iodine as the Ri or R group, such that the entire compound is symmetrical; or

Formula (IV) [correlating with the benzaldehyde of Formula (II)]

(IN)

wherein p is 0, 1, or 2, R_1} R₂, R₃, R₄, and R₅ are independently selected from the group consisting of hydrogen, alkyl groups containing 3-6 carbon atoms, alkoxy groups containing 1-6 carbon atoms, or any two adjacent groups may be combined to form methylenedioxy; with the proviso that at least one group of R_ls R₂, R₃, T , and R₅ is a group other than hydrogen.

It should be appreciated with regard to the structural foπnula set forth above that while only the 1,3:2,4 isomer is represented, this structure is provided for convenience only and the invention is not limited to only isomers of the 1,3:2,4 type, but may include any and all other isomers as well so long as the compound contains two aldehyde substitutents on the alditol moiety.

Throughout this specification, the term "symmetrical" as it pertains to di- or tri-acetals of alditols is intended to mean wherein such alditol acetals that possess all acetal linkages (such as 1,3- and 2,4- for di-acetals) derived from the same benzaldehyde. The diacetals, triacetals, and monoacetals of the present invention are condensation products of alditol, such as sorbitol or xylitol, and a chloro-, bromo-, or iodo-alkyl substituted benzaldehyde. Examples of suitable substituted benzaldehydes include 4-chϊoro-3- methylbenzaldehyde, 3-chloro-4-methylbenzaldehyde, 4-chloro-2,3-dimethylbenzaldehyde,

3-chloro-2,4-dimethylbenzaldehyde, 2,4-dichloro-3-methylbenzaldehyde, 4-chloro-3,5- dimethylbenzaldehyde, 3-chloro-4-methoxybenzaldehyde, 4-chloro-3- isopropylbenzaldehyde, 3-chloro-4-isopropylbenzaldehyde, 3-chloro-4-t-butylbenzaldehyde,

3-chloro-4-ethylbenzaldehyde, 4-bromo-3-methylbenzaldehyde, 3-bromo-4- methylbenzaldehyde, 4-bromo-2,3-dimethylbenzaldehyde, 3-bromo-2,4~ dimethylbenzaldehyde, 2,4-bromo-3-methylbenzaldehyde, 4-bromo-3,5- dimethylbenzaldehyde, 3-bromo-4-methoxybenzaldehyde, 4-bromo-3- isopropylbenzaldehyde, 3-bromo-4-isopropylbenzaldehyde, 3-bromo-4-t-butylbenzaldehyde, 3-bromo-4-ethylbenzaldehyde, 4-iodo-3-methylbenzaldehyde, 3-iodo-4-methylbenzaldehyde, 4-iodo-2,3-dimethylbenzaldehyde, 3-iodo-2,4-dimethylbenzaldehyde, 2,4-iodo-3- rnethylbenzaldehyde, 4-iodo-3,5-dimethylbenzaldehyde, 3-iodo-4-methoxybenzaldehyde, 4- iodo-3 -isopropylbenzaldehyde, 3-iodo-4-isopropylbenzaldehyde, and 3-iodo-4- ethylbenzaldehyde. Preferred di-acetals of the present invention include l,3:2,4-bis(4-chloro- 3-methylbenzylidene) sorbitol, l,3:2,4-bis(3-chloro-4-methylbenzylidene) sorbitol, 1,3:2,4- bis(3-bromo-4-isopropylbenzylidene) sorbitol, l,3:2,4-bis(3-bromo-4-methylbenzylidene) sorbitol, and l,3:2,4-bis(3-bromo-4-ethylbenzylidene) sorbitol. Further specific examples of suitable substituted benzaldehydes include 4-t-butylbenzaldehyde, 4-isopropylbenzaldehyde, 3,4-methylene-dioxybenzaldehyde, 3,4-dimethoxybenzaldehyde, 3,4-diethoxybenzaldehyde, and the like, to provide the required symmetrical compounds in reaction with an alditol (such as sorbitol, xylitol, ribitol, and the like). Other suitable substituted benzaldehydes for this inventive compounds include, without limitation, 2,4-diisopropylbenzaldehyde, 2,4-di-t- butylbenzaldehyde, 2,4-dimethoxybenzaldehyde, 2,4,5-trimethoxybenzaldehyde, 2,4- diethoxybenzaldehyde, 4-?ϊ-pentylbenzaldehyde, 3-methyl-4-methoxybenzaldehyde, 4- methoxy-2,3-dimethylbenzaldehyde, 3-methoxy-2,4-dimethylbenzaldehyde, 2,4-dimethoxy- 3-methylbenzaldehyde, 4-ethoxy-3,5-dimethylbenzaldehyde, and 3-isopropyl-4- methoxybenzaldehyde, and the like. Preferred di-acetals of the present invention include l,3:2,4-bis(4-t-butylbenzylidene) sorbitol and l,3:2,4-bis(3,4-methylenedioxybenzylidene) sorbitol.

The compositions of the present invention also include solvent gels containing 0.2% to 10% of the above di-acetals as a gelling agent. Solvents useful herein include, as merely examples, lower monohydric alcohols, polyhydric alcohols, and mixtures thereof. Water may also be included as a portion of the solvent. However, the solvent will generally comprise water at levels no greater than 5% by weight of the final composition. Examples of solvents which may be utilized in the present invention include liquid polyethylene glycols (e.g., diethylene glycol, triethylene glycol), liquid polypropylene glycols (e.g., dipropylene glycol, tripropylene glycol), liquid polypropylene polyethylene glycol copolymers, ethanol, n- propanol, n-butanol, t-butanol, 2-methoxyethanol, 2-ethoxyethanol, ethylene glycol, 1,2- propylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 1,2-butylene glycol, isopropanol, isobutanol, diethylene glycol, monomethyl ether, diethylene glycol, monoethylether, 1,3- butylene glycol, 2,3-butylene glycol, 2,4-dihydroxy-2-methylpentane, trimethylene glycol, glycerine, 1,3-butane diol, 1,4-butane diol, and the like, and mixtures thereof. As used herein, polyethylene glycols, polypropylene glycols, and polypropylene polyethylene glycol copolymers include alkyl ether derivatives of these compounds (e.g., ethyl, propyl, and butyl ether derivatives). Examples of such compounds are butyl ether derivatives of polypropylene polyethylene glycol copolymers, such as PPG-5-buteth-7. These solvents are fully described, for example, in U.S. Pat. No. 4,518,582 to Schamper et al. and European Published Application 107,330 to Luebbe et al. incorporated herein by reference. The preferred solvents for use herein include liquid polyethylene glycols, liquid polypropylene glycols, liquid polypropylene polyethylene glycol copolymers, propylene glycol, 1,3-butylene glycol, and 2,4-dihydroxy-2-methylpentane (sometimes referred to as hexylene glycol), and mixtures thereof. Particularly preferred solvents include propylene glycol, dipropylene glycol, tripropylene glycol, triethylene glycol, hexylene glycol, and mixtures thereof.

Other organic solvents useful herein include aromatics, halogenated aromatics, nitrated aromatics, ketones, amines, nitriles, esters, aldehydes, and mixtures thereof. Examples of solvents which may be utilized in the present invention include xylenes (o, m, and p- substituted), 2-chlorotoluene, fluorobenzene, nitrobenzene, benzonitrile, dimethylsulfoxide (DMSO), N,N-dimethylformamide (DMF), and l-methyl-2-pyrrolidinone (NMP).

The di-acetals and monoacetals of the present invention may be prepared by a variety of techniques, some of which are known in the art. Generally, such procedures employ the reaction of one mole of D-sorbitol with about 2 moles of aldehyde (for diacetals), with 1 mole of aldehyde for monoacetals, in the presence of an acid catalyst (of course, to produce triacetals a 1 : 3 molar ratio should be followed; for monoacetals, 1 : 1 ratios are necessary) . The temperature employed in the reaction will vary widely depending upon the characteristics, such as melting point, of the aldehyde or aldehydes employed as a starting material in the reaction. The reaction medium may be an aqueous medium or a non-aqueous medium. One very advantageous method that can be employed to prepare di-acetals of the invention is described in U.S. Pat. No. 3,721,682, to Murai et al. (New Japan Chemical Company Limited), the disclosure of which is hereby incorporated herein by reference.

While the disclosure of the patent is limited to benzylidene sorbitols, it has been found that the di-acetals of the present invention may also be conveniently prepared by the method described therein. Additional methods for preparing DBS systems can be found in U.S. Pat.

No. 5,731,474 to Scrivens et al., U.S. Pat. No. 4,902,807 to Kobayashi et al. which discloses DBS having an alkyl group or halogen for use as clarifying agents, and U.S. Pat. No.

5,106,999 to Gardlik et al. which discloses the preparation of di(meta-fluorobenzylidene) sorbitol, di(meta-chlorobenzylidene) sorbitol, and di(meta-bromobenzylidene) sorbitol. The inventive sorbitol di-acetals, triacetals, and monoacetals prepared by the above techniques may contain mixtures of any correlated types of acetals (such as the related di-, tri-, and/or mono-acetals of the target acetal). Although it may not always be necessary to remove these impurities (particularly if they are present in very low proportions) prior to incorporation of the di-acetal, triacetal, or monoacetal into the target polyolefin, it may be desirable to do so and such purification may serve to enhance the transparency of the resin produced thereby. Purification of the di-acetal may be accomplished, for instance, by removal of any tri-acetals by the extraction thereof with a relatively non-polar solvent. As one non-limiting example, by removal of the impurities, the product may be purified so that the amount of di-acetal in the additive composition contains at least about 90 percent and even up to 95 percent di-acetal or more.

The proportion of di-acetal, triacetal, or monoacetal in the composition of this invention is an amount sufficient to improve the transparency of the composition, generally from about 0.01 to about 2 percent by weight, preferably about 0.1 to about 1 percent by weight, based upon the total weight of the composition may be provided. When the content of the di-acetal is less than about 0.01 percent by weight, the resulting composition may not be sufficiently improved in respect to transparency characteristics. When the content of di-acetal, triacetal, or monoacetal is increased beyond about 2 percent by weight, no additional advantage can be observed.

The polyolefin polymers of the present invention may include aliphatic polyolefins and copolymers made from at least one aliphatic olefin and one or more ethylenically unsaturated comonomers. Generally, the comonomers, if present, constitute a minor amount, e.g., about

10 percent or less or even about 5 percent or less, of the entire polyolefin, based upon the total weight of the polyolefin. Such comonomers may serve to assist in clarity improvement of the polyolefin, or they may function to improve other properties of the polymer. Examples include acrylic acid and vinyl acetate, etc. Examples of olefin polymers whose transparency can be improved conveniently according to the present invention are polymers and copolymers of aliphatic monoolefins containing 2 to about 6 carbon atoms which have an average molecular weight of from about 10,000 to about 2,000,000, preferably from about

30,000 to about 300,000, such as polyethylene, linear low density polyethylene, polypropylene, crystalline ethylenepropylene copolymer, poly(l-butene), 1-hexene, 1-octene, vinyl cyclohexane, and polymethylpentene. The polyolefins of the present invention may be described as basically linear, regular polymers that may optionally contain side chains such as are found, for instance, in conventional, low density polyethylene.

Other polymers that may benefit from the nucleation and clarification properties of the sorbitol acetals of the present invention include polyethylene terephthalate, polybutylene terephthalate, and polyamides, among others.

The olefin polymer or copolymer used in the composition of the present invention is crystalline, and the diffraction of light caused by micro crystals contained in it is considered to be responsible for the deterioration of the transparency of the polymer. It is thought that the di-acetal functions in the composition to reduce the size of the microcrystals thereby improving the transparency of the polymer.

The composition of the present invention can be obtained by adding a specific amount of the di-acetal or monoacetal directly to the olefin polymer or copolymer, and merely mixing them by an suitable means. Alternatively, a concentrate containing as much as about 20 percent by weight of the di-acetal in a polyolefin masterbatch may be prepared and be subsequently mixed with the resin. Furthermore, the inventive alditol derivatives (and other additives) may be present in any type of standard polyolefin additive form, including, without limitation, powder, prill, agglomerate, liquid suspension, and the like, particularly comprising dispersion aids such as polyolefin (e.g., polyethylene) waxes, stearate esters of glycerin, montan waxes, mineral oil, and the like. Basically, any form may be exhibited by such a combination or composition including such combination made from blending, agglomeration, compaction, and/or extrusion. Other additives such as a transparent coloring agent or plasticizers (e.g., dioctyl phthalate, dibutyl phthalate, dioctyl sebacate, mineral oil, or dioctyl adipate), can be added to the composition of the present invention so long as they do not adversely affect the improvement of transparency of the product. It has been found that plasticizers such as those exemplified above may in fact aid in the improvement of the transparency by the di-acetal.

With regard to other additives it may also be desirable to employ the di-acetals or monoacetals disclosed above in combination with other conventional additives having known transparency improving effects such as, for instance, para-t-butylbenzoic acid, its salts, low molecular weight waxy polypropylene and the like. It may even be desirable to provide the particular di-acetals or monoacetals of the present invention in the polyolefin composition in combination with the previously described dibenzylidene sorbitol additive disclosed in U.S. Pat. Nos. 4,016,118 to Hamada et al., 5,049,605 to Rekers, and the like. In such applications, generally at least about 10 percent, preferably about 25 percent, or even about 50 percent or more of the clarity improving component will be the diacetals of the present invention, with the remainder being comprised of other known clarifying agents, plasticizers, etc.

The compositions of the present invention may be obtained by adding the inventive symmetrical benzylidene sorbitol acetal to the polymer or copolymer and merely mixing the resultant composition by any suitable means. The composition may then be processed and fabricated by any number of different techniques, including, without limitation, injection molding, injection blow molding, injection stretch blow molding, injection rotational molding, extrusion, extrusion blow molding, sheet extrusion, film extrusion, cast film extrusion, foam extrusion, thermoforming (such as into films, blown-films, biaxially oriented films), thin wall injection molding, and the like into a fabricated article.

Other additives may also be used in the composition of the present invention, provided they do not interfere with the primary benefits of the invention. It may even be advantageous to premix these additives or similar structures with the nucleating agent in order to reduce its melting point and thereby enhance dispersion and distribution during melt processing. Such additives are well known to those skilled in the art, and include plasticizers, lubricants, catalyst neutralizers, antioxidants, light stabilizers, colorants, other nucleating agents, and the like. Some of these additives may provide further beneficial property enhancements, including improved aesthetics, easier processing, and improved stability to processing or end use conditions. In particular, it is contemplated that certain organoleptic improvement additives be added for the purpose of reducing the migration of degraded benzaldehydes from reaching the surface of the desired article. The term "organoleptic improvement additive" is intended to encompass such compounds and formulations as antioxidants (to prevent degradation of both the polyolefin and possibly the target alditol derivatives present within such polyolefin), acid neutralizers (to prevent the ability of appreciable amounts of residual acids from attacking the alditol derivatives), and benzaldehyde scavengers (such as hydrazides, hydrazines, and the like, to prevent the migration of foul tasting and smelling benzaldehydes to the target polyolefin surface). Such compounds and formulations can be added in any amounts in order to provide such organoleptic improvements as needed. However, the amounts should not appreciably affect the haze results for the target polyolefin itself. Thus, lower amounts on the order of from about 20 ppm to about 2,000 ppm of the total polyolefin component are desired.

The compositions of the present invention are suitable as additives to improve the clarity of packaging materials and container materials for cosmetics, food-stuffs, and the like, because they give film, sheet, and other fabricated articles having excellent transparency and physical properties.

Preferred Embodiments of the Invention The following examples further illustrate the present invention but are not to be construed as limiting the invention as defined in the claims appended hereto. All parts and percents given in these examples are by weight unless otherwise indicated.

DBS Formation

EXAMPLE !

Preparation of is(4-c}ύoro-S-methylbenz lidene)sorhitol A one liter four-necked cylindrical shaped reaction flask equipped with a Dean-Stark trap, condenser, thermometer, nitrogen inlet, and a mechanical stirrer was charged with 40.55g of sorbitol (0.2226 mole), 600 mL of cyclohexane, 61.50g of 4-chloro-3- methylbenzaldehyde (0.4452 moles), 2.90g of p-toluenesulfonic acid, 2.4 mL of water, and 210 mL of methanol. The reaction was stirred and heated under reflux with removal of water through the Dean Stark trap. The reaction becomes very thick and additional solvent is added as needed. After about six hours, the reaction is cooled, neutralized with potassium hydroxide, and filtered. The wet cake was washed thoroughly with water and cyclohexane, dried in a vacuum oven at 110°C to give 74.20g of bis(4-chloro-3-methylbenzylidene)sorbitol

(as determined through through Infrared Spectroscopy, Gas Chromatography/Mass Spectrometry, 1H NMR, and C¹³ NMR, all collectively hereinafter referred to as "standard analyses"). The purity was about 95% as determined by gas chromatography (GC). The melting point was determined to be [by Differential Scanning Calorimetry (DSC) @

20°C/min] about 254.2°C.

EXAMPLE 2

Preparation ofBis(3-chloro-4-methylbenzylidene)sorbitol A one liter four-necked cylindrical shaped reaction flask equipped with a Dean-Stark trap, condenser, thermometer, nitrogen inlet, and a mechanical stirrer was charged with 42.00g of sorbitol (0.2306 mole), 600 mL of cyclohexane, 63.70g of 3-chloro-4- methylbenzaldehyde (0.4611 moles), 3.00g of p-toluenesulfonic acid, 2.5 mL of water, and 210 mL of methanol. The reaction was stirred and heated under reflux with removal of water through the Dean Stark trap. The reaction becomes very thick and additional solvent is added as needed. After about six hours, the reaction is cooled, neutralized with potassium hydroxide, and filtered. The wet cake was washed thoroughly with water and cyclohexane, dried in a vacuum oven at 110°C to give 85.18g of bis(3-chloro-4-methylbenzylidene)sorbitol (as determined by standard analyses). The purity was about 95% as determined by GC. The peak melting transition was determined to be (DSC @ 20°C/min) about 239.8°C.

EXAMPLE 3 Preparation ofBis(3-bromo-4-ethylbenzylidetιe)sorbitol

A one liter four-necked cylindrical shaped reaction flask equipped with a Dean-Stark trap, condenser, thermometer, nitrogen inlet, and a mechanical stirrer was charged with 42g of D-sorbitol (0.23 mole), 500 mL of cyclohexane, 98g of 3-bromo-4~ethylbenzaldehyde (0.46 moles), 80 mL of methanol, and 2.5 g of water. The system was then flushed with argon and heated in an oil bath with stirring. The mixture was then heated to a vapor temperature of 40°C, at which time 3.0 g of p-toluenesulfonic acid in 40 mL of methanol was slowly added. The reaction was stirred and heated under reflux with removal of water through the Dean Stark trap as cyclohexane was returned to the system. Heating was then recommenced until the vapor temperature reached 70°C, at which time 40 mL of methanol were added slowly. The reaction mixture was allowed to heat up to the same vapor temperature and methanol was added slowly again, and repeated another 4 times. The reaction product was then cooled, neutralized with potassium hydroxide (4 g in 40 mL of methanol), and stripped of the resultant cyclohexane layer (by azeotrope with water). The solids remaining were then filtered and purified in boiling methanol, giving 3-bromo-4- ethylbenzaldehyde as a white solid (as determined through standard analyses) exhibiting a melting transition of 246.6-246.9°C.

EXAMPLE 4

Preparation of bis (3 -bromo-4-methylbenzylidene) sorbitol To an open reaction vessel equipped with a mechanical stirrer was charged with D- sorbitol (20.1 g, 0.1110 g), concentrated HC1 (24.34 g) and 0.27 g of, dodecylbenzene sulfonate. After five minutes of stirring, 43.8 g (0.220 m) of 3-bromo-4-methylbenzaldehyde and 10.72 g of water were added as a mixture. A solution of cold water (1 L, cooled in ice) and KOH (32.3 g) was then added after 48 hours of further stirring. The resultant solids were then filtered, washed in hot water, then hot methanol, then cold toluene, and finally boiling methanol again. Deionized water (400 mL) was then added to the resultant filtrate, precipitating a white solid, which was then filtered and washed in methanol to give 3-bromo- 4-methyldibenzylidene sorbitol as a white solid (as determined through standard analyses). DSC analysis of the solid @ 20°C/min showed a melting transition of 277.4-279.3°C.

EXAMPLE 5

Preparation ofbis(3-bromo-4-isopropylbenzylidene)sorbitol A one liter four-necked cylindrical shaped reaction flask equipped with a Dean-Stark trap, condenser, thermometer, nitrogen inlet, and a mechanical stirrer was charged with 42g of D-sorbitol (0.23 mole), 700 mL of cyclohexane, 105g of 3~bromo-4-ethylbenzaldehyde (0.46 moles), 80 mL of methanol, and 2.5 g of water. The system was then flushed with argon and heated in an oil bath with stirring. The mixture was then heated to a vapor temperature of 41.8°C, at which time 3.0 g of p-toluenesulfonic acid in 40 mL of methanol was slowly added. The reaction was seeded with 1.0 g of 3,4-dimethylbenzylidene sorbitol in 20 mL of methanol. The reaction was then stirred and heated (to about 120°C) under reflux with removal of water through the Dean Stark trap as cyclohexane was returned to the system. Heating was then recommenced until the vapor temperature reached 70°C, at which time 40 mL of methanol were added slowly. The reaction mixture was allowed to heat up to the same vapor temperature and methanol was added slowly again, and repeated another 5 times. The reaction product (a white gel) was then cooled, neutralized with potassium hydroxide (7 g in 40 mL of methanol), and stripped of the resultant cyclohexane layer (by azeotrope with water). The gel remaining was then filtered and purified in boiling water and boiling methanol, giving 3-bromo-4-isopropylbenzaldehyde as a white solid (108.5 g, 78% yield)(as determined through standard analyses) exhibiting a peak melting transition of

216.3°C by DSC at 20°C/min.

EXAMPLE 8

Preparation ofbis(4-t-butylbenzylidene) sorbitol D-Sorbitol (27 g, 0.15 mol), cyclohexane (500 mL), 4-t-butylbenzaldehyde (73 g, 0.45 mol), methanol (80 mL), water (2.5 g) /j-toluenesulfonic acid (3.0 g, 16 mmol) were added to a 2 L reaction kettle fitted with a mechanical stirrer, Dean-Stark trap with condenser and a thermometer. The system was flushed with argon and heated in an oil bath to reflux for 5 h. The methanol/water layer was continuously drained from the reaction. Methanol was added as needed. The reaction mixture was cooled to room temperature and neutralized with KOH. The mixture was concentrated on a rotary evaporator to afford a dark viscous oil that was shown by GC to be a mixture of several diacetals (50%) and two main triacetals (50%). Tlie crude mixture was used without further purification.

The oil was dissolved in NMP. Concentrated HC1 was added and the solution was stirred. The reaction mixture was poured into a solution of KOH and water and the dark orange precipitate was collected by vacuum filtration. The solid was purified with water and cyclohexane to give bis(4-t-butylbenzylidene) sorbitol as a white solid (23 g, 33%) at a purity of 93% as determined by Infrared Spectroscopy, Gas Chrornatography/Mass Spectrometry, ^!H NMR, and C¹³ NMR, all collectively hereinafter referred to as "standard analyses", and melting transition of from 217.9 to 225.6 °C, as determined by differential scanning calorimetry. EXAMPLE 7

Preparation of bis (3, 4-methylenedioxybenzylidene) sorbitol

D-Sorbitol (27 g, 0.15 mol), cyclohexane (500 mL), piperonal (45 g, 0.30 mol), methanol (80 mL), water (2.5 g) and p-toluenesulfonic acid (3.0 g, 16 mmol) were added to a 2 L reaction kettle fitted with a mechanical stirrer, Dean-Stark trap with condenser and a thermometer. The system was flushed with argon and heated in an oil bath to reflux for 5 h. The methanol/water layer was continuously drained from the reaction. Methanol was added as needed. The reaction mixture was cooled to room temperature and neutralized with KOH. The white solid was collected by vacuum filtration and dried in a vacuum oven to give bis(3,4-methylene-dioxybenzylidene) sorbitol as a white solid (60 g, 90%) having a purity of 95% as determined by standard analyses, and exhibiting a melting transition of from 222.0 to 227.8°C.

Polyolefin Formation and Testing

One kilogram batches of target polypropylene were produced in accordance with the following table:

POLYPROPYLENE COMPOSITION TABLE

Component Amount Polypropylene random copolymer flake (3% ethylene)(MF=12) 1000 g

Irganox® 1010, Primary Antioxidant (from Ciba) 500 ppm

Irgafos® 168, Secondary Antioxidant (from Ciba) 1000 ppm Calcium Stearate, Acid Scavenger 800 ppm

Inventive Diacetal (and diacetal compositions) as noted

The base resin (random copolymer, hereinafter "RCP") and all additives were weighed and then blended in a Welex mixer for 1 minute at about 1600 rpm. All samples were then melt compounded on a KilHon single screw extruder at a ramped temperature from about 204° to 232°C through four heating zones. The melt temperature upon exit of the extruder die was about 246°C. The screw had a diameter of 2.54 cm and a length/diameter ratio of 24: 1. Upon melting the molten polymer was filtered through a 60 mesh (250 micron) screen. Plaques of the target polypropylene were then made through extrusion into an Arburg 25 ton injection molder. The molder barrel was set at a temperature anywhere between 190 and

260°C, with a range of from about 190 to 240°C preferred, and most preferably from about

200 to 230°C. The plaques had dimensions of about 51 mm X 76 mm X 1.27 mm, and were made in a mold having a mirror finish. The mold cooling circulating water was controlled at a temperature of about 25 °C.

The haze values were measured by ASTM Standard Test Method D1003-61

"Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics" using a BYK Gardner XL-211 Hazemeter. Nucleation capabilities were measured as polymer recrystallization temperatures (which indicate the rate of polymer formation provided by the presence of the nucleating additive) by melting the target plaques, cooling at a rate of about

20°C/minute, and recording the temperature at which polymer re-formation occurs. Control plaques without alditol additives were produced for comparative purposes for some or all of the above-noted measurements. An asterisk (*) denotes no measurements were taken.

EXPERIMENTAL TABLE 1

Thus, the inventive symmetrical benzaldehyde alditol derivatives provided much better haze and, at times, recrystallization temperature characteristics within the target thermoplastics as compared with the control.

Gel Formation and Testing

Solid gels were also produced comprising the inventive alditol derivatives through recognized, simple methods. In particular, specific organic solvents were combined with the additives in certain concentrations and mixed thoroughly. The resultant mixture was then heated to a temperature between about 170°F (77°C) and 300°F (149°C), as indicated below, under agitation for between 5 and 120 minutes. The resultant solution was then poured into a mold to produce a gel stick. The solvents listed below are not intended to be exhaustive as to the potential types which may be utilized to form gels with the inventive alditol derivatives, and thus are merely listed as preferred solvents for such purposes. The examples below were analyzed empirically and by touch to determine if a gel actually formed and the hardness properties as well as any formed gels.

EXPERIMENTAL TABLE 2

15

Thus, the inventive halogenated and alkylated alditol derivatives provide excellent gelling capabilities for solvents, depending on their concentration within the target solvents.

Compositions with Other Clarifiers Formulations of certain inventive compounds from above were then produced incorporating DMDBS in various proportions. RCP polypropylene was compounded as noted above but with mixtures of DMDBS and the Example 2 compound into 50 mil plaques. Haze measurements were taken as noted above as well. The results are tabulated as follows:

EXPERIMENTAL TABLE 3

Physical Mixtures DMDBS and Inventive DBS Compounds

Thus, such inventive compounds also exhibited excellent haze measurements in polypropylene in the presence of another clarifying agent.

Foπnulations of the inventive compound of Example 7 were then produced incorporating DMDBS in various proportions. RCP polypropylene was compounded as noted above but with mixtures of DMDBS and the Example 7 compound into 50 mil plaques. Haze measurements were taken as noted above as well. The results are tabulated as follows:

EXPERIMENTAL TABLE 4

Physical Mixtures DMDBS and 3,4-Methylenedioxy DBS

Thus, the inventive compound also exhibited excellent haze measurements in polypropylene in the presence of another clarifying agent.

There are, of course, many alternative embodiments and modifications of the present invention which are to be included within the spirit and scope of the following claims.

Claims

CLAIMSWhat is claimed is:

1. A compound which is the reaction product of at least one mole of an alditol and at least one mole of an arylaldehyde selected from the compounds conforming with either of

Formula (I) and Formula (II)

(I)

wherein R is independently selected from hydrogen, lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, and halogen; R₃, and R are selected from lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, chlorine, bromine, iodine, and fluorine; with the proviso that one and only one of R₃ and R is selected from the group consisting of chlorine, bromine and iodine; (II)

wherein Rj, R₂, R₃, R₄, and R₅ are independently selected from the group consisting of hydrogen, alkyl groups containing 3-6 carbon atoms, alkoxy groups containing 1-6 carbon atoms, and phenyl, or any two adjacent groups may be combined to form a cyclic group, wherein said cyclic group is selected from the group consisting of methylenedioxy, cyclopentyl, and cyclohexyl; with the proviso that at least one group of R_1} R₂, R₃, R , and R₅ is a group other than hydrogen.

2. The compound of Claim 1 wherein said reaction product is a diacetal and said alditol is sorbitol.

3. A compound conforming to the structure of Formula (III) (III)

wherein p is 0,1, or 2, R is independently selected from hydrogen, lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, and halogen; Ri, R₂, R₃, and R₄ are selected from lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, chlorine, bromine, iodine, and fluorine; with the proviso that one and only one of Ri and R₂ is selected from chlorine, bromine, and iodine, and one and only one of R₃ and ₄ is the same chlorine, bromine or iodine as the Rj or R₂ group, such that the entire compound is symmetrical.

4. A compound conforming to the structure of Formula (IV)

(IN)

wherein p is 0, 1, or 2, R_1} R₂, R₃, R₄, and R₅ are independently selected from the group consisting of hydrogen, alkyl groups containing 3-6 carbon atoms, alkoxy groups containing 1-6 carbon atoms, or any two adjacent groups may be combined to form methylenedioxy; with the proviso that at least one group of R_ls R₂, R₃, R^ and R₅ is a group other than hydrogen.

5. The compound of Claim 3 wherein said di-acetal is selected from the group consisting ofbis(4-chloro-3-methylbenzylidene)sorbitol; bis(3-chloro-4-methylbenzylidene)-sorbitol; bis(4-chloro-2,3-dimethylbenzylidene)sorbitol; bis(3-chloro-2,4-dimethylbenzyl- idene)sorbitol; bis(3-chloro-4-methoxy-benzylidene)sorbitol; and bis(2,4-dichloro-3- methylbenzylidene)sorbitol, bis(3-bromo-4-methylbenzylidene ) sorbitol; bis(3-bromo- 4ethylbenzylidene) sorbitol; bis(3-bromo-4-isopropylbenzylidene) sorbitol; bis(4-bromo-3- methylbenzylidene)sorbitol; bis(3-iodo-4-methylbenzylidene) sorbitol; and bis(4-iodo-3- methylbenzylidene) sorbitol, bis(4-t-butylbenzylidene) sorbitol, and bis(3,4-methylene- dioxybenzylidene) sorbitol.

6. A polyolefin composition comprising any of the compounds as defined in Claim 3.

7. A polyolefin composition comprising any of the compounds as defined in Claim 4.

8. A polyolefin composition comprising any of the compounds as defined in Claim 5.

9. A polyolefin plastic composition having improved transparency, which comprises at least one homopolymer of an aliphatic monoolefin or a copolymer containing an aliphatic monoolefin, said monoolefin containing from 2 to about 6 carbon atoms having an average molecular weight of from about 10,000 to about 500,000 and one or more ethylenically unsaturated aliphatic comonomers, said copolymer having been made by polymerizing said monoolefin with said comonomer; and at least one di-acetal of the compounds defined in Claim 3.

10. The composition of Claim 9 wherein said di-acetal is present within said polyolefin composition in an amount from about 0.01 to about 2 percent by weight based upon the total weight of the composition.

11. The composition of claim 9, wherein the aliphatic monoolefin is selected from the group consisting of ethylene, propylene, 1-butene, vinyl cyclohexane, and methylpentene

12. A physical mixture of at least one compound as defined by Claim 1 and a clarifying agent other than the compound as defined by Claim 1.

13. The physical mixture of Claim 12 wherein said other clarifying agent is a dibenzylidene sorbitol derivative.

14. The physical mixture of Claim 13 wherein said dibenzylidene sorbitol is bis(3,4- benzylidene) sorbitol.

15. A physical mixture of at least one compound as defined by Claim 3 and a clarifying agent other than the compound as defined by Claim 3.

16. The physical mixture of Claim 15 wherein said other clarifying agent is a dibenzylidene sorbitol derivative.

17. The physical mixture of Claim 16 wherein said dibenzylidene sorbitol is bis(3,4- benzylidene) sorbitol.

18. A benzylidene alditol acetal comprising at least one substituted benzylidene component wherein said at least one substituted benzylidene component at least possesses one halogen pendant group in the 3- or 4- position and one other pendant group selected from the group consisting of lower alkyl and lower alkoxy in the 3- or 4- position.

19. A solid gelled composition comprising:

(a) about 0.25% to about 10% of a gelling agent selected from at least one diacetal of an alditol (such as sorbitol, xylitol, and ribitol) and mixtures thereof; said diacetal of the alditol having the structure (III)

(III)

wherein p is 0, 1, or 2, R is independently selected from the group consisting of hydrogen, lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, chlorine, bromine, iodine, and fluorine; R_ls R₂, R₃, and R₄ are independently selected from the group consisting of lower alkyl groups containing 1-4 carbon atoms, lower alkoxy groups, and chlorine; with the proviso that one and only one of Ri and R₂ is selected from chlorine, bromine, and iodine, and one and only one of R and R is the same chlorine, bromine or iodine as the R] or R₂ group, such that the entire compound is symmetrical; and (b) from about 10% to about 98% of a solvent for said gelling agent.

20. A solid gel according to claim 19 wherein the solvent is selected from the group consisting of monohydric alcohols, polyhydric alcohols, propylene carbonate, propylene glycol, dipropylene glycol, DMSO, DMF, NMP, water, and mixtures thereof.

21. A solid gel according to claim 19 wherein the solvent is selected from the group consisting of propylene carbonate, methanol, ethanol, n-propanol, n-butanol, 2- methoxyethanol, 2-ethoxyethanol, ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 1,2-butylene glycol, diethylene glycol, isopropanol, isobutanol, diethylene glycol monomethyl ether, diethylene glycol monoethyl ether, 1,3-butylene glycol, 2,3-butylene glycol, dipropylene glycol, 2,4-dihydroxy-2-methylpentane, and mixtures thereof.

22. A solid gel according to claim 20 wherein the solvent is selected from aromatics, halogenated aromatics, nitrated aromatics, ketones, amines, nitriles, esters, aldehydes, and mixtures thereof.