GB1578303A - Process for producing polyglycidyl compounds - Google Patents

Abstract

Polyglycidyl compounds of the formula <IMAGE> in which A is phenylene or cyclohexylene, and R is hydrogen or methyl, are prepared by reacting a corresponding diamine with an epihalohydrin, and subsequently dehydrohalogenating the resultant product. In step (A), the diamine is slowly introduced into the epihalohydrin at a temperature below 60 DEG C in such amounts that the molar ratio between the diamine and the epihalohydrin is from 1:5.5 to 1:15. The addition reaction is carried out at a temperature of from 10 to 60 DEG C. Water is always present in the reaction system. At the time when the addition of the diamine to the epihalohydrin is complete, the water is present in an amount of from 0.5 to 15 mol per mol of the added diamine. In step (B), the water and excess, unreacted epihalohydrin are removed from the system during and/or after addition of the alkali to the reaction product obtained in step (A), and at the same time the dehydrohalogenation of the reaction product is carried out to form the polyglycidyl compound of the formula (I). The resultant compound can be used for the preparation of plastics.

Description

(54) PROCESS FOR PRODUCING POLYGLYCIDYL COMPOUNDS (71) We, MITSUBISHI GAS CHEMICAL COMPANY, INC., a Japanese body corporate of 5-2 Marunouchi, 2-Chome, Chiyoda-ku, Tokyo, Japan, do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to a process for producing polyglycidyl xylylenediamine or polyglycidyl bisaminomethylcyclohexane (sometimes hereinunder referred to as polyglycidyl compound for convenience). More particularly, the invention pertains to a process for producing a polyglycidyl compound, characterized in that the process prevents a violent advancement of the exothermic reaction of an epihalohydrin with xylylenediamine and in that the resulting polyglycidyl compound has a low hydrolyzable halogen content, a low viscosity and an excellent storage stability.

In the case of producing polyglycidyl xylylenediamine, the process of this invention is expressed by the following reaction formula:

R N-Cfl2Ctt2-NU2 + I L IH2 + ' R CH2- R I I XCfl2-C1 t CH X N CH2t Ofi xCFi2-01- CH2 R1 CH2- CH2 OH alkali

wherein R is hydrogen or methyl, and X is chlorine or bromine.

In the case of producing polyglycidyl bisaminomethylcyclohexane, the process is expressed by the reaction formulae:

NH2wCH2e CH2-G-CH2-)( 7 R R XCH2-C-CU cti2- -cH2x OH OH w--cij2Ci- N XC\\2- CH2ICH2X OH OH alkali R R cii-C- CH2 CH2-C- CH2 0 H2CH2-N CH2- CH2Cx / CF O O wherein R and X are as defined above.

The polyglycidyl compound obtained according to this invention has a low viscosity and hence is easy to handle. In addition, the cured article obtained from the polyglycidyl compound using a curing agent is resistent to deformation at high temperatures. The polyglycidyl compound is suitable for molding a complicatedly shaped article with high heat resistance.

A process for producing polyglycidyl xylylenediamine is disclosed in United States Patent No. 3,683,044. A process for producing polyglycidyl bisaminomethyicyclohexane is disclosed in United States Patent No. 3,843,565. However, these processes have the following disadvantages: (1) Solvents, such as methyl alcohol, ethyl alcohol, ethylether, benzene and toluene are employed in the reaction of epihalohydrin with xylylenediamine or bisaminomethylcyclohexane and in the after treatment of the reaction product. Such solvents not only impair the quality of the product, but also must be recovered for reuse because of their high cost.

(2) In these processes, after the whole amount of the epihalohydrin and the whole amount of xylylenediamine or bisaminomethylcyclohexane are pre viously mixed, the reactions are carried out. However, these reactions are exothermic, and it is sometimes difficult to sufficiently remove the heat generated in the reaction. Therefore, there is a possibility of losing control of the reaction. Furthermore, at the initial stage of the reaction some crystalline material precipitates out and then rapidly dissolves. The dissolu tion of the crystalline material is also accompanied by a large generation of heat.

( 3 ) The polyglycidyl xylylenediamine or polyglycidyl bisaminomethylcyclo hexane produced in the prior art is too unstable to be stored for a long period. In addition, since the product contains a relatively large amount of hydrolyzable halogen, its use in the electric and electronic fields is some times limited.

This invention provides a method of producing polyglycidyl xylylenediamine or polyglycidyl bisaminomethylcyclohexane containing low hydrolyzable halogen and having improved storage stability.

According to the present invention, there is provided a process for producing a polyglycidyl compound represented by the formula

wherein A is a phenylene or cyclohexylene group, and each R is independently hydrogen or methyl, the process comprising (A) reacting a diamine represented by the formula NH2-CH2-A-CH2-NH2 (11) wherein A is as defined above, with an epihalohydrin represented by the formula

wherein X is chlorine or bromine and R is as defined above, to form the compound represented by the formula

wherein A, R and X are as defined above, and (B) carrying out dehydrohalogenation of the compound represented by formula (IV) with at least one alkali, characterised in that (a) in step (A), said diamine is slowly introduced into said epihalohydrin at a temperature below 600C in such amounts that a molar ratio of the diamine to the epihalohydrin ranges from 1:5.5 to 1:1S; the addition reaction is carried out at a temperature from 10 to 600 C; water is always present in the reaction system while the addition reaction is carried out; and at the time at which the introduction of the diamine into the epihalohydrin has been completed said water is present in an amount of from 0.5 to 13 mol per 1 mol of said diamine added to the system; and (b) in step (B), during and/or after the addition of said alkali to the reaction product obtained in step (A), water and excess unreacted epihalohydrin are removed from the system and at the same time the dehydrohalogenation of the reaction product is carried out to form the polyglycidyl compound represented by formula (I).

The process mentioned above is more controllable and can be carried out more easily and more economically than the process of the prior art. In addition, the quality of the product obtained according to the present invention is much better.

In a preferred embodiment, which further improves the storage stability of the product, after the alkali is added to the reaction product in step (A) and the dehydrohalogenation of the compound represented by formula (IV) is carried out, the resulting polyglycidyl compound is treated as follows: Step (C): 3300 parts by weight of an organic solvent immiscible with water and inert to the polyglycidyl compound are added to 100 parts by weight of the polyglycidyl compound, with mixing, and the precipitate is then removed from the solution; and step (D): 10--500 parts by weight of water or an aqueous solution of an inorganic salt, the concentration of which is lower than 15% by weight, are added to the solution including 100 parts by weight of the polyglycidyl compound of formula (I), with mixing, the mixture is separated into an aqueous layer and an organic layer, and then volatile components, such as organic solvent, water and the epihalohydrin are stripped from the organic layer to obtain the polyglycidyl compound represented by formula (I).

It is essential that water be present in the addition reaction step (A). Water promotes the addition reaction and prevents the precipitation of the crystalline material.

It is critical that 5.5 to 1S mol of the epihalohydrin and 0.5 to 13 mol of water be used per 1 mol of the diamine. When the amount of epihalohydrin used is below 5.5 mol per 1 mol of the diamine, the resulting product has a high viscosity and a yellow color, whereas the use of the epihalohydrin in an amount of more than 1S mol per 1 mol of the diamine is not economical.

The use of water in an amount of more than 0.5 mol per 1 mol of the diamine does not precipitate the crystalline material, or even if the crystalline material precipitates, the use of such amount of water improves the control of the heat generation.

On the other hand, the use of water in an amount of more than 13 mol per 1 mol of the diamine causes a side reaction, which impairs the quality of the resulting product, and also consumes much epihalohydrin.

The following four processes allow water to be present in the reaction system of step (A): (1) incorporating water into the epihalohydrin before the diamine is introduced into the epihalohydrin.

(2) incorporating water into the diamine before the diamine is introduced into the epihalohydrin, (3) slowly introducing the diamine containing water into the epihalohydrin containing water, and (4) introducing water and the diamine to the epihalohydrin independently from two inlets.

In step (A), during the introduction of the diamine as well as during the reaction, the temperature of the reaction system should be maintained at a temperature of from 10 to 60"C. The reaction is exothermic and therefore, in order to maintain the temperature of the reaction system at lower than 60"C, a tube through which cooling liquid, such as water, is flowed may be installed inside the reactor, or the diamine may be introduced into the epihalohydrin slowly. Before the introduction of the diamine, it is unnecessary to heat the epihalohydrin to the desired temperature. The temperature of the reaction system may be raised by the introduction of the diamine to the epihalohydrin. Preferably the reaction is carried out at a temperature of from 20 to 400 C.

After the introduction of the diamine into the epihalohydrin, the addition reaction is preferably continued until more than 95% of the amino groups present is converted to the tertiary amine. The tertiary amine thus formed can quantitatively be determined by a conventional analytical method. When the addition reaction of the epihalohydrin with the diamine is insufficient, or when the addition product contains much primary or secondary amines, the successive dehydrohalogenation of such addition product can not completely be carried out.

A gradual introduction of the epihalohydrin into the diamine for carrying out said addition reaction is not practical, because the viscosity of the reaction mixture becomes so high that stirring becomes difficult. The viscosity of the polyglycidyl compound obtained is also too high.

In step (B), during and/or after the addition of the alkali to the reaction product of step (A), water and excess unreacted epihalohydrin are stripped off to complete the dehydrogenation reaction. Examples of the alkalis include solid sodium hydroxide and potassium hydroxide and aqueous solutions of these alkalis having an alkali concentration of more than 40% by weight. The use of a dilute aqueous solution of the alkali in step (B) makes the stripping time longer and tends to cause side reactions and to result in a poor quality of the product. The dehydrohalogenation reaction proceeds as the epihalohydrin and water is removed from the reaction system through stripping. When the step (B) reaction is carried out at a high temperature, the epoxy group produced in the dehydrohalogenation reaction tends to react with water or unreacted epihalohydrin to form undesirable by-product. Therefore, the dehydrohalogenation reaction is preferably carried out at a temperature of not higher than 100"C, preferably not higher than 60"C. The reaction may be effected at a reduced pressure of from 20 to 60 mmHg.

The epihalohydrin which is stripped off in step (B) is separated from water and can be recycled to step (A) of another batch for the addition reaction.

Preferably the degree of dehydrohalogenation, when calculated according to the following equation 4[284+a+4(b+c)] xY D= - x 100 (V) 4-4 (b+ 1) x Y wherein Y is the number of mols of hydrolyzable halogen per 1 gr. of dehydrohalogenation reaction product, a is the weight (gram) of the atomic group represented by "A" in formula (II), b and c are the atomic weight of X in formula (III) and the weight (gram) of the atomic group represented by "R" in formula (I), respectively, and D is the degree of dehydrohalogenation, is more than 98%, preferably more than 99%. The values of Y, a, b and c can easily be measured by conventional analytical methods as disclosed in "Handbook of Epoxy Resin" written by Lee & Neville, pages 4-28, 1967 by McGraw-Hill, Inc.

The epihalohydrin and water remaining in the dehydrohalogenation reaction system decrease in proportion to the amount of epihalohydrin and water stripped off.

The stripping of the epihalohydrin and water may be continued until the total weight of the epihalohydrin and water remaining in the reaction mixture amounts to less than 10 parts by weight, preferably 5 parts by weight per 100 parts by weight of the resulting polyglycidyl compound.

If the polyglycidyl compound contains much epihalohydrin and is treated as mentioned in steps (C) and (D), the separation of the aqueous layer and the organic layer in step (D) becomes incomplete and furthermore, a portion of the epihalohydrin remaining in the system is lost with water and the remainder of the epihalohydrin is incorporated into the solvent to be recovered, whereby the purification of the solvent becomes costly.

In step (C), the amount of the organic solvent employed may be 30 to 500 parts by weight, preferably 50 to 300 parts by weight, per 100 parts by weight of the polyglycidyl compound. When the amount of the solvent employed is less than 30 parts by weight per 100 parts by weight of the polyglycidyl compound, separation of the organic layer and the aqueous layer in step (D) becomes difficult. Too much solvent is not preferred, however, because it needs much time and energy to remove the solvent employed.

It is preferred from the view point of workability to carry out steps (C) and (D) at 1S to 20"C.

In step (C), the separation of the solid material from the organic layer may be carried out by any suitable known process, for example filtration or centrifugal separation. The solid material separated in step (C) may be dumped, but it is preferable to wash it with the same organic solvent as used in step (C) to recover the object product contained in the solid material.

The solvent employed in step (C) is immiscible with water, is inert to the polygiycidyl compound, and dissolves the polyglycidyl compound. Examples of the solvents include benzene, toluene, ethylbenzene, o-xylene, m-xylene, p-xylene, mixed xylene, n-propylbenzene, isopropyl benzene, 1,2,3-trimethylbenzene, 1,2,4-trimethylbenzene, 1,2,5-trimethylbenzene and 1,3,5-trimethylbenzene. One or a mixture of the solvents may be used.

The aqueous layer formed in step (D) is dumped, whereas the volatile component obtained by stripping off can be recovered.

In step (D), the amount of the water or the aqueous solution of inorganic salt employed may be 10 to 500 parts, preferably 20 to 100 parts, by weight per 100 parts by weight of the product. When the amount of the water or the aqueous solution is less than 10 parts by weight per 100 parts of the product, the product can not be washed sufficiently. When the amount of the water or the aqueous solution is more than 500 parts, the disposal of much waste liquid is costly.

Where an aqueous solution of an inorganic salt is employed in step D, the concentration of the salt in the solution is less than 15% by weight and is preferably 2 to 10%, to make it easier to separate the organic layer and the aqueous layer.

The process for stripping the volatile component may be a batchwise or a cortinuous process. In general, the process is carried out at a reduced pressure. When the stripping is effected batchwise in a thickening tank, the maximum temperature in the tank is preferably 1000C.

When the stripping is continuously effected by thin film type evaporator, it is preferable to feed the organic layer into the evaporator after most of the volatile component has been removed batchwise from the layer in a thickening tank. This enhances the effectiveness of the evaporator. When using the thin film type evaporator, the temperature of the interface may be more than 1000 C, since the residence time of the organic layer at the interface for evaporation is short.

It is preferable that the evaporation be continued until the content of the volatile component amounts to 1% or less, more preferably 0.5% or less by weight.

The diamines to be used as a raw material for producing the polyglycidyl compound include meta-xylylenediamine and 1,3 -bisaminomethylcyclohexane. Meta-xylylenediamine containing less than 40% by weight of para-xylylenediamine and 1,4-bisaminomethylcyclohexane may be also used as the raw material.

The epihalohydrins to be used as a raw material for producing the polyglycidyl compound include epichlorohydrin as well as epibromohydrin and beta-methylepichlorohydrin.

Examples of the alkalis employed in step (B) include sodium hydroxide and potassium hydroxide. The alkali metal hydroxide may contain sodium and potassium carbonates.

Examples of the inorganic salt employed in step (D) in the aqueous solution include sodium chloride and sodium sulfate.

By means of the present invention polyglycidyl compounds having the formula I may be produced having low hydrolyzable halogen content, low viscosity, pale-color and improved storage stability.

The polyglycidyl compounds produced according to the present invention are polyfunctional epoxy resins and are liquid at room temperature. The compounds can be cured by heating without incorporating any curing agent or any curing-promotor thereinto. When a specific curing agent is added to the compound, a cured resin with high heat resistance, high rigidity and/or high elongation can be obtained. The polyglycidyl compounds can be mixed with one or more of the following other epoxy resins: Glycidylether type epoxy resins or ,methyl glycidylether type epoxy resins synthesized from a compound having phenolic hydroxy group, such as bisphenol A, bisphenol F, brominated bisphenol A, phenol novolak, cresol novolak, or resorcinol; glycidylether type epoxy resin or beta-methyl glycidylether type epoxy resin synthesized from a compound having alcoholic hydroxy groups, such as ethylene glycol, diethyleneglycol, triethylene glycol, polyethyleneglycol, propyleneglycol, dipropyleneglycol, tripropyleneglycol, polypropyleneglycol, glycerol or hydrogenated bisphenol A; glycidylester type epoxy resins or beta-methylglycidylester type epoxy resins synthesized from a dicarboxylic acid, such as phthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, methyl tetrahydrophthalic acid or methyl hexahydrophthalic acid; glycidylamine type epoxy resins or beta-methyl glycidylamine type epoxy resins synthesized from a compound having an aromatic amine group, such as aniline, toluidine, meta-phenylenediamine para-phenylenediamine, diamino diphenylmethane, hydantoin or its derivative, or isocyanuric acid; glycidylether-amine type epoxy resins or beta-methylglycidyl etheramine type epoxy resins synthesized from amino phenols, such as meta-aminophenol or para-aminophenol; glycidyletherester type epoxy resins or beta-methylglycidyletherester typc epoxy resins synthesized from hydroxybenzoic acids, such as meta-hydroxybenzoic acid or para-hydroxybenzoic acid; or alicyclic epoxy resins, such as epoxidized soybean oil, or epoxidized polybutadiene. Particularly, the polyglycidyl compounds produced according to the present invention can be mixed with highly viscous epoxy resins to lower the viscosity of the resin and improve the workability thereof without impairing the good physical properties of the cured product.

The polyglycidyl compounds of this invention can be also used in place of solvents for dissolving a solid epoxy resin, thereby preventing the shortcomings inherent in the use of solvents which are well known to those skilled in the art.

The polyglycidyl compounds of this invention can be cured using one or more of the following curing agents; aliphatic amines, such as diethylene triamine, triethylene tetramine, xylylenediamine, bis-aminomethylcyclohexane, 3 -aminomethyl-3 ,5,3-tri- methylcyciohexylamine, and 3,3'-dimethyl-4,4'-diaminodicyclohexylmethane; poiyamides synthesized from aliphatic amines and dibasic acids; aromatic amines, such as meta-phenylenediafi.ine, diaminodiphenylmethane, and diaminodiphenylsulfone; acid anhydrides, such as phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, dodecenyl succinic anhydride, methyl nadic anhydride (methyl cyclopentadiene adduct of maleic anhydride), and chloreindic nadic anhydride; polysulfide resins; borontrifluoride-amine complexes; dicyandiamide; and imidazoles.

The polyglycidyl compounds of this invention may be modified by adding thereto the following materials: Glassfiber, glass powder, glass beads, carbon fiber, carbon black, graphite, asbestos fiber, asbestos powder, polyamide fiber, polyester fiber, polyacrylonitrile fiber, polyethylene, polypropylene, polybutadiene, acrylonitrile-butadiene copolymers with functional groups, such as carboxyl or hydroxy-end groups, coal tar, pitch, mica, kaolin, silica, alumina, aluminium oxide trihydrate, gypsum, antimony trioxide, bentone, silica aerosil, titanium dioxide, silicon carbide, boron nitride, iron oxide, iron powder, aluminium powder and diamond. Diluents, thickeners, defoamers, binders, plasticizers, slipping agents, fire retardants and colorants may also be added to the polyglycidyl compounds.

The polyglycidyl compounds of this invention can be used in a wide variety of fields, since the compounds are completely soluble in organic solvents such as benzene, toluene, xylene, methanol, ethanol, isopropanol, butanol, ethyl acetate, butyl acetate, acetone, methyl ethyl ketone, methyl isobutyl ketone, diacetone alcohol, tetrahydrofuran, dioxane, ethyleneglycol monoethylether, and ethyleneglycol monobutylether.

The polyglycidyl compounds of this invention can be used in the following fields: As matrix resins for fiber-reinforced composite materials, binders for granular or powder fillers, resins for casting encapsulating, potting or impregnating electric or electronic parts, primers for surface-protecting, resins for top coating, resin-constituting instruments for machine work, metallurgical work, or resin treatment, cross-linking agents for functional chain polymers used as adhesives in civil engineering and construction, electric machinery and tools, transportation machinery and household applications and modifiers for phenol resin and unsaturated polyesters.

The present invention is further illustrated by the following Examples and Comparative Examples. However, this invention is not limited by these examples and comparative examples. The percent and parts in the Examples are based on weight unless otherwise specified. Viscosity was measured by using B Type Viscometer made by Tokyo Keiki Seisakusho.

Example 1.

Into a reactor equipped with a tube for cooling water, a stirring means, a thermometer and a dropping funnel were charged 1480 g. of epichlorohydrin and 80 g. of water. The mixture was heated to 40"C with stirring; and 272 g. of meta-xylylenediamine was introduced from the dropping funnel to the mixture over about 50 minutes. During the introduction of the diamine, the temperature of the reactor was maintained within the range of 40 to 500C by passing cooling water through the tube.

After the introduction of the diamine had been completed, the addition reaction was further continued at the above temperature range for 2 hours. Thereafter, 1000 g. of a 40% aqueous solution of sodium hydroxide was added dropwise to the system over 2 hours. During and after the period of the addition, epichlorohydrin was azeotropically distilled off with water for 3.3 hours. At this stage, the reaction mixture was analyzed, and it was found that the degree of dehydrochlorination was 98.6%. After the reaction mixture was cooled, crude sodium chloride precipitate was removed by filtration. The filtrate was washed with water, and then the volatile components composed of water and epichlorohydrin were stripped off at a reduced pressure. Polyglycidyl metaxylylenediamine was obtained in a yield of 95% based on meta-xylylenediamine. The viscosity of the resulting polyglycidyl meta-xylylenediamine was 2470 centipoises and the hydrolyzable chlorine content thereof was 0.09%. When this compound was stored at room temperature for 3 and 5 months, the viscosity increased 1.04 and 1.24 times, respectively.

Example 2.

Polyglycidyl 1,3-bisaminomethylcyclohexane was synthesized using the reactor employed in Example 1. Into the reactor were charged 1480 g. of epichlorohydrin and 144 g. of water. The mixture was heated to 500C with stirring; 227 g. of 1,3-bisaminomethylcyclohexane was introduced from the dropping funnel to the mixture over 0.5 hour. During the introduction of 1,3-bisaminomethylcyclohexane, the temperature in the reactor was maintained within the range of 48 to 530C by passing cooling water through the tube. After the introduction had been completed, the addition reaction was further continued within the above temperature range for 1.5 hours. 310 g. of solid sodium hydroxide was divided into 7 approximately equivalent portions and the portions were added to the reaction mixture one by one at 5 minutes intervals.

Water was distilled off azeotropically with epichlorohydrin for 3 hours at a pressure within the range of 35 to 50 mmHg. The reaction mixture was analyzed at this stage and, it was found that the degree of dehydrochlorination was 98.1%.

The reaction mixture was further treated as in Example 1. The viscosity of the resulting polyglycidyl-1,3-bisaminomethylcyclohexane was 3500 centipoises and the hydrolyzable chlorine content was 0.073%. The yield of polyglycidyl-1,3-bisaminomethylcyclohexane was 93% based on 1,3-bisaminomethylcyclohexane. When the poly glycidyl-1,3-bisaminomethylcyclohexane was stored at room temperature for 5 months, the viscosity increased 1.04 times.

Example 3.

The procedure of Example 1 was repeated except that meta-xylylenediamine containing 30% of para-xylylenediamine was employed in place of pure meta-xylylenediamine. Polyglycidyl xylylenediamine was obtained in a yield of 92% based on the diamine. The viscosity of the polyglycidyl xylylenediamine was 3320 centipoises and the hydrolyzable chlorine content thereof was 0.1%.

Example 4.

Into a reactor equipped with a coil tube for cooling water, a stirring means, a thermometer, a raw material-feeding inlet, a nitrogen gas inlet and a line for evacuation were charged 476 parts of epichlorohydrin and 26.5 parts of water. The mixture was heated to 400C with stirring. Thereafter, 100 parts of meta-xylylenediamine was slowly introduced over 85 minutes. During the introduction of the diamine, the temperature in the reactor was maintained within the range of 37 to 40"C by passing cooling water with a temperature of 5 C through the tube. After the introduction of m-xylylenediamine had been completed, the addition reaction was further continued within the above temperature range for 2 hours. While the temperature of the reactor was maintained within the range of 37 to 41"C, 270 parts of a 48% aqueous solution of sodium hydroxide was added to the reaction mixture over 15 minutes. Then, epichlorohydrin and water were distilled off for 4 hours at a reduced pressure. During this distilling step, the degree of dehydrochlorination was measured periodically. The variation with time is shown in Table 1.

TABLE 1

Number of hours after the addition of NaOH 1 2 3 4 Degree of dehydro chlorination 97.0 99.4 99.7 99.7 Thereafter, 418 parts of m-xylene was added to the reaction mixture. After the mixture was cooled to 1S"C, the insoluble matter was filtered off. The precipitate was dispersed again in 111 parts of m-xylene and was filtered and the two filtrates were mixed together. To this solution were added 89 parts of a 3% aqueous solution of sodium chloride. The resulting mixture was stirred, and then allowed to stand to form an aqueous layer and 758 parts of an organic layer. M-xylene and water were stripped off from the organic layer at a reduced pressure at a temperature lower than sodium chloride. The resulting mixture was stirred, and then allowed to stand to form an aqueous layer and 688 parts of an organic layer. Xylene and water were stripped off from the organic layer at a reduced pressure and at a temperature lower than 93"C for 11 hours to obtain polyglycidyl-1,3-bisaminomethylcyclohexane. The viscosity of the polyglycidyl- 1,3 -bisaminomethylcyclohexane was 2800 centipoises. When this compound was stored at 250C for 5 months, the viscosity increased 1.02 times.

Comparative Example 1.

Polyglycidyl m-xylylenediamine was synthesized using the reactor employed in Example 1 of this invention according to Example 1 of United States Patent No.

3,683,044, and the product was analyzed. The viscosity of the compound was 3700 centipoises and the hydrolyzable chlorine content thereof was 0.64%. When this compound was stored at 250C for 5 months, its viscosity increased 2.72 times.

Comparative Example 2.

Polyglycidyl- 1,3 -bisaminomethylcyclohexane was synthesized using the reactor employed in Example 1 of this invention according to Example 1 of United States Patent No. 3,843,565 and the product was analyzed. The viscosity of the compound was 4500 centipoises, and the hydrolyzable chlorine content thereof was 0.80%. When this compound was stored at 250C for 5 months, its viscosity increased 1.5 times.

Comparative Example 3.

The procedure of Example 1 was repeated exccpt that 925 g. (10 mol) of epichlorohydrin, 72 g. (4 mol) of water and 272 g. (2 mol) of m-xylylenediamine were employed. The resulting polyglycidyl compound was analyzed. Though the hydrolyzable chlorine content of the polyglycidyl compound was as low as 0.16%, the compound was colored and the viscosity was as high as 4350 centipoises. When the compound was stored at 250C for 5 months, the viscosity increased 2.30 times.

Comparative Example 4.

The procedure of Example 4 was repeated up to the point where the combined filtrate solution was prepared but the resultant solution was not washed with water.

The volatile components were stripped off at a reduced pressure and at temperatures lower than 890C for 1S.5 hours to obtain polyglycidyl m-xylylenediamine. The viscosity of the product was 2460 centipoises. When the product was stored at 250C for 5 months, its viscosity increased 1.67 times.

Comparative Example 5.

Into the reactor employed in Example 1 were charged 476 parts of epichlohydrin and 26.5 parts of water. The mixture was heated to 40"C with stirring. Thereafter, 100 parts of m-xylylenediamine was slowly introduced to the mixture over 55 minutes. During the introduction of the diamine, the temperature in the reactor was maintained within the range of 39 to 42"C by passing cooling water with a temperature of 5 C through the tube. After the introduction of the diamine had been completed, the addition reaction was further continued within the above temperature range for 2 hours. While the temperature of the mixture was maintained within the range of 38 to 410C, 270 parts of 48% aqueous solution of sodium hydroxide was added to the mixture for 15 minutes. The dehydrochlorination reaction was continued within the above temperature range for 3.5 hours. During the above period, the degree of the dehydrochlorination was measured periodically. The variation with time is shown in Table 3.

TABLE 3

Number of hours after the addition of NaOH 1 2 3 Degree of dehydro chlorination Thereafter, the reaction mixture was cooled to 20"C and was filtered to divide it into a cake and a filtrate. After the filtrate had been allowed to stand, the organic layer was separated from the aqueous layer. To the organic layer was added 88 parts of water; and the mixture was stirred and was allowed to stand. The mixture was separated into two layers, an aqueous layer and an organic layer. The resulting organic layer was in an amount of 334 parts. Epichlorohydrin and water were stripped off from the organic layer at a reduced pressure at temperature lower than 94"C for 8 hours and 40 minutes to obtain polyglycidyl m-xylylenediamine. The viscosity was 2370 centipoises. When this compound was stored at 250C for 5 months, its viscosity increased 2.04 times.

WHAT WE CLAIM IS: 1. A process for producing a polyglycidyl compound represented by the formula

wherein A is a phenylene or cyclohexylene group, and each R is independently hydrogen or methyl, the process comprising (A) reacting a diamine represented by the formula NH2-Cll2-AH,-NH, (II) wherein A is as defined above, with an epihalohydrin represented by the formula

wherein X is chlorine or bromine and R is as defined above, to form the compound represented by the formula

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (16)

**WARNING** start of CLMS field may overlap end of DESC **. Thereafter, the reaction mixture was cooled to 20"C and was filtered to divide it into a cake and a filtrate. After the filtrate had been allowed to stand, the organic layer was separated from the aqueous layer. To the organic layer was added 88 parts of water; and the mixture was stirred and was allowed to stand. The mixture was separated into two layers, an aqueous layer and an organic layer. The resulting organic layer was in an amount of 334 parts. Epichlorohydrin and water were stripped off from the organic layer at a reduced pressure at temperature lower than 94"C for 8 hours and 40 minutes to obtain polyglycidyl m-xylylenediamine. The viscosity was 2370 centipoises. When this compound was stored at 250C for 5 months, its viscosity increased 2.04 times. WHAT WE CLAIM IS:

1. A process for producing a polyglycidyl compound represented by the formula

wherein A is a phenylene or cyclohexylene group, and each R is independently hydrogen or methyl, the process comprising (A) reacting a diamine represented by the formula NH2-Cll2-AH,-NH, (II) wherein A is as defined above, with an epihalohydrin represented by the formula

wherein X is chlorine or bromine and R is as defined above, to form the compound represented by the formula

wherein A, R and X are as defined above, and (B) carrying out dehydrohalogenation of the compound represented by formula (IV) with at least one alkali, characterized in that (a) in step (A), said diamine is slowly introduced into said epihalohydrin at a temperature below 600C in such amounts that a molar ratio of the diamine to the epihalohydrin ranges from 1:5.5 to 1:1S; the addition reaction is carried out at a temperature from 10 to 600C; water is always present in the reaction system while the addition reaction is carried out; and at the time at which the introduction of the diamine into the epihalohydrin has been completed said water is present in an amount of from 0.5 to 15 mol per 1 mol of said diamine added to the system; and (b) in step (B), during and/or after the addition of said alkali to the reaction product obtained in step (A), water and excess unreacted epihalohydrin are removed from the system and at the same time the dehydrohalogenation of the reaction product is carried out to form the polyglycidyl compound represented by formula (I).

2. A process as claimed in claim 1 and further comprising the following steps (C) and (D); step (C): adding 30 to 500 parts by weight of an organic solvent immiscible with water and inert to the polyglycidyl compound to 100 parts by weight of the polyglycidyl compound, with mixing, and then removing the precipitate from the solution; step (D): adding 10 to 500 parts of water or an aqueous solution of an inorganic salt, the concentration of which is lower than 15% by weight, to the organic solution including 100 parts by weight of the polyglycidyl compound, with mixing, separating the mixture into an aqueous layer and an organic layer, and stripping volatile components from the organic layer.

3. The process as claimed in claim 2 wherein the precipitate separated in step (C) is washed with the organic solvent employed in step (C), and the resulting solution is combined with the organic solution separated in step (C).

4. The process as claimed in claim 2 or claim 3 wherein a 2 to 10% aqueous solution of an inorganic salt is used in step (D).

5. The process as claimed in any one of claims 1 to 4 wherein in step (A), the water is added to the epihalohydrin represented by formula (III) before the diamine represented by formula (II) is introduced into the epihalohydrin.

6. The process as claimed in any one of claims l to 4 wherein in step (A), the water is added to the diamine represented by the formula (II) before the diamine is introduced into the epihalohydrin represented by formula (III).

7. The process as claimed in any one of claims 1 to 4 wherein the water and the diamine represented by formula (II) are slowly introduced into the epihalohydrin represented by formula (III) independently.

8. The process as claimed in any one of claims 1 to 7 wherein the degree of dehydrohalogenation calculated according to the following equation 4-[284+a+4(b+c)] xY D= x 100 (V) 4-4 (b+l)xY wherein Y is the number of mols of hydrolyzable halogen per 1 g. of dehydrohalogenation reaction product, a is the weight (gram) of the atomic group represented by "A" in formula (II), b and c are the atomic weight of X in formula (III) and the weight (gram) of the atomic group represented by "R" in formula (I), respectively, and D is the degree of dehydrohalogenation, is more than 98%.

9. The process as claimed in any one of claims 1 to 8 wherein the diamine represented by formula (II) is m-xylylenediamine.

10. The process as claimed in any one of claims 1 to 8 wherein the diamine represented by formula (II) is 1,3-bisaminomethylcyclohexane.

11. The process as claimed in any one of claims 1 to 10 wherein the epihalohydrin represented by formula (III) is epichlorohydrin.

12. The process as claimed in any one of claims 1 to 11 wherein the epihalohydrin recovered in step (B) is recycled into the reaction system of step (A).

13. The process as claimed in any one of claims 1 to 12 wherein the addition reaction of the diamine represented by formula (II) with the epihalohydrin represented by formula (III) is carried out at a temperature of 20 to 400C.

14. A process as claimed in claim 1, substantially as hereinbefore described with particular reference to the Examples.

15. A process as claimed in claim 1 substantially as illustrated in any one of Examples 1 to 5.

16. A polyglycidyl compound when prepared by the process claimed in any one of the preceding claims.