GB2161478A - Preparing citrate esters - Google Patents

Abstract

Citrate esters are formed utilizing organic titanates as a catalyst allowing excess alcohol to be removed. The hydroxy group is then acylated. Four citrate esters have been found which provide advantageous plasticizing properties to PVC compositions which include superior toxicity test results and superior soapy water extraction test results. The four citrate esters are: acetyltri-n-(hexyl/octyl/decyl) citrate, and acetyltri-n-(octyl/decyl) citrate. Articles formed from the PVC plasticized mixtures are extremely useful in the medical or health care field as they demonstrate a low order of toxicity.

Description

SPECIFICATION Citrate esters -and methods Background of the invention 1.Field of the invention Citrate esters are useful as plasticizers for polyvinyl chloride (PVC) resins as certain of these esters provide a low order of toxicity when compared to phthalate esters which have been conventionally used.

Other advantages have been noted using certain citrate esters as plasticizers in PVC compositions and articles, including improved resistance to soapy water extraction and low temperature and transport properties.

The preparation of the citrate esters has been found to be significantly enhanced by the utilization of certain organic titanate catalysts which allow the excess alcohol to be removed after the esterification step.

2.Description of the prior art and objectives of the invention Citrate esters commercially produced using citric acid have long been available and have been used as plasticizers for PVC resins. However, the performance of articles produced from the PVC resin compositions whether utilizing citrate esters known to date or conventional phthalate plasticizers have had many inherent disadvantages.For example, medical-grade PVC compositions are used to form blood bags, tubing and a variety of health-related articles and in recent years toxicity has been a major concern for manufacturers of such articles. Recent reports have identified di-2-ethylhexyl phthalate (DEHP) or (DOP) and di- 2-ethyl-hexyl adipate (DEHA) as hepatocarcinogens in rodents.While certain of the phthalates have excellent plasticizing qualities, their suspected carcinogenic nature renders them doubtful candidates for future medical-grade uses. As an alternative, known citric acid esters such as acetyltri-n-butyl and tri-nbutyl citrate were tried as PVC plasticizers in medical-grade applications but it was determined that these compounds were not entirely satisfactory due to their high soapy water extraction percentages and would therefore not be useful in many medical area applications. Also, it has been found that new production techniques had to be devised for the newer citric acid esters which were determined to have suitable toxicity and physical characteristics when used as PVC plasticizers.

It is therefore an objective of the present invention to provide PVC plasticizers which provide superior toxicity test results in biological studies.

It is also an objective of the present invention to provide plasticizers for PVC compositions which can be processed without difficulty using conventional extrusion, calendering, or plastisol techniques.

It is yet another objective of the present invention to provide new citric acid esters namely acetyltri-nhexyl citrate, n-butyryltri-n-hexyl citrate, acetyltri-n-(hexyl:octyl/decyl) citrate, and acetyltri-n-(octylldecyl) citrate which can be used as plasticizers having desirable physical characteristics when imparted into PVC compositions.

It is still another objective of the present invention to provide PVC compositions and formed articles therefrom having superior results in toxicology studies concerning dermal-toxicity, oral toxicity and genetic assays.

It is also an objective of the present invention to provide a new process for the low temperature manufacture of the four new citric acid esters utilizing organic titanates to provide economical and efficient production methods.

Other objectives and advantages of the present invention will be demonstrated to those skilled in the art as set forth in detail below.

Summary of the invention Citrate esters of the formula:

where R1, R2, and R3 = CH to C,aH37 R4 =CH3 to C7H15 and more specifically acetyltri-n-hexyl citrate, n-butyryltri- n-hexyl citrate, acetyltri-n-(hexyl/octyl/decyl) citrate, and acetyltri-n-(octylldecyl) citrate are produced utilizing an organictitanate catalyst and such esters have been found useful as medical-grade plasticizers in PVC compositions. The plasticizers have a low order of toxicity and inpart to PVC the proper balance of physical properties needed in health care and medical-grade uses.The production steps for the citric acid esters include low temperature esterification at 140"C or below, removal of any excess alcohol and thereafter, alkoxylation. Conventional neutral; zation and finishing steps are then carried out. The alkoxylation step is carried out at a temperature less than approximately 110 C.

A PVC resin can be combined with one of the above-mentioned citric acid esters, along with suitable stabilizers and lubricants, to form a plasticized PVC which can be extruded, calendered or otherwise processed into suitable articles of manufacture including blood bags, tubing and other products. Articles so made have a low order of toxicity and provide superior extraction properties, particularly in soapy water extraction tests. The soapy water extraction test is a standard test, the results of which closely resemble the results obtained with body fluids such as huntan blood.

Description Df the preferred emhodiments The four preferred forms of the citrate esters are as follows: 1. acetyltri-n-hexyl citrate:

2. n-butyryltri-n-hexyl citrate:

3. acetvltri-n-( h exvl!octvl/decvl) citrate:

4. acetyltri-n-(octyl!decyl) citrate:

The preferred method of manufacture of the above-identified citrate esters comprises low temperature esterification below 150"C and preferably at a temperature range of from 125"C to 130"C of the proper alcohol (such as n-hexyl alcohol for acetyltri-n-hexyl citrate) with citric acid in the presence of the organic titanate, tetra-n-butyl titanate, removal of any excess n-hexyl alcohol, and then alkoxylation of the esters produced with an acid anhydride.At esterification temperatures above 150sC citrates undergo rapid degradation resulting in numerous products of decomposition. At temperatures somewhat below 150"C the major decomposition product is an aconitate ester. The alkoxylation takes place at a temperature of below approximately 110'C. Tetra-n-butyl titanate is preferred since the ester interchange which takes place between the titanate alkyl groups and citrate alkyl groups does not result in the introduction of alkyl groups not normally present in the citrate esters.

The preferred PVC composition comprises blending and milling a medium molecular weight PVC resin with one of the above citrate esters on a two to one ratio, resin to plasticizer, along with stabilizers, lubricants and extenders as required. Articles manufactured from the preferred PVC compositions include blood bags, tubing and other articles for the medical and health care fields.

Detailed description of the invention Certain citrate esters, namely acetyltri-n-hexyl citrate, .n-butyryltri-n-hexyl citrate, acetyltri-n-(hexyl/octyl/ decyl-) citrate and acetyltri-n-(octylidecyl) citrate have been found to be particularly useful in medical applications when compounded with PVC resins through conventional plastisol, calendering or extrusion techniques. Such plasticized PVC exhibits good clarity, good low temperature properties, low volatility and low extractability into various media. Also, a low order of-acute toxicity has been shown and complete compatibility with medium molecular weight PVC resins make the four named esters unique and valuable.Studies have shown that the four citrate esters are not toxic substances, primary skin irritants or ocular irritants to unrinsed eyes and oral administration has produced no signs of systemic toxicity and has shown no mortality in fasted mice or rats. Genetic toxicology assays for detecting mutagenic activity at the gene or chromosomal level have shown that these esters do not induce gene mutation in either microbial cells or in mammalian cells in vitro or chromosomal mutation in vivo or in vitro .Studies have also shown that under il7 vivo conditions, these citrate esters hydrolyze rapidly and completely in concentrations at expected realistic levels Df human exposure.

Preparation of the citrate esters are as follows: Example 1: Preparation of acetyltri-n-hexyl citrate 330 Ibs. of n-hexyl alcohol, 180 Ibs. of citric acid and 1.54 Ibs. of tetra-n-butyl titanate and 15 gallons of heptane are charged to a vessel equipped with agitator, thermometer, vapor column, condenser and a decanter set to allow removal of water formed during the reaction while refluxing heptane. The esterification is effected at 140"C to maintain the aconitate (THA) level below .5% for general production.As shown in Fig. 7 the aconitate level can be kept well below the .2% range by longer reaction times at lower temperatures with the optimum time, and aconitate levels reached by temperatures of from approximately 125"C to 130"C. As shown, at a temperature of approximately 130"C a unique result is achieved in that the aconitate formation levels out to provide a citrate ester having excellent purity. During esterification water is periodically removed from the decanter in order to maintain proper temperature and reaction rates. The esterification is continued at 140"C until the esterification mixture tests .5% maximum acidity calculated as citric acid although lower temperature esterification and acidity percentage may be used for higher purity products as mentioned above.Next, the vessel is cooled to 1200C and any water is removed from the separator and any heptane therein is also removed for future use. The reflux line of the vessel is closed and pressure on the system is reduced slowly. The kettle is heated to 130 - 140"C and steam is introduced to help remove any residual alcohol. This vacuurn steam stripping is continued until alcohol cannot be detected by conventional laboratory tests.When no more alcohol can be found, the steam is discontinued and the temperature is reduced to 100"C and the vacuum is broken with nitrogen gas.

Next, .4lb. concentrated sulfuric acid (H2SO4) is charged into the vessel after which it is sealed and approximately 107 Ibs. of acetic anhydride (in a determined molar amount) are added at a slow rate so that the temperature does not exceed 110 C. When all the anhydride has been added, agitation of the mix continues for approximately one hour until the acetylation reaction has been completed.

Next, a full vacuum is put on the system and enough heat is added for distillation to proceed at a suitable rate. This step continues until acetic acid is shown to be 5% or less by conventional lab tests whereupon the mixture is cooled to 75"C for neutralization.

The remaining steps of neutralization, bleaching, washing, etc. are carried out as in conventional esterification processes.

Example 2 : Preparation of n-butyryltri-n-hexyl citrate: The vessel used in example 1 is again charged with 330 Ibs. of n-hexyl alcohol, 180 Ibs. of citric acid and 1.54 Ibs. of tetra- n-butyl titanate. Esterification is carried out as in example 1 as is the heptanealcohol strip. Butyrylization is thereafter done with the addition of .4 Ibs. of concentrated sulfuric acid and 166 Ibs. of n-butyryic an hydride as shown above in the acetylation process. The butyric acid may be removed as shown above or by neutralization.

Examples 1 and 2 produce esters with the following characteristics: Analytical data Property A cetyltri-n-hexyl n-ButyrWrn-n-hexy Citrate Citrate Purity wt% 99 99 Color APHA 50 max. 50 max.

Neut. No. mg KOH/g 0.2 max. 0.2 max.

Moisture K.F. 0.25 max. 0.25 max.

S.G. C 25125'C 1.0045-1.0055 0.991-0.995 R.l. @ 25/25"C 1.445-1.447 1.444-1.448 Viscosity C 25 C cps 25-35 25-35 Odor @ 25 C Little or none Little or none Color APHA 50-60 50-60 Neut. No. mg KOH/g 0.2 max. 0.2 max.

Odor C 25"C Mild Mild It has been determined that a citrate ester yield can be achieved of 99+% purity with a minimum of aconitate formation and unacetylated esters by lowering the esterification temperatures to 1300C or below with a preferable temperature range of 125"C to 130"C. Figs. 4 and 7 demonstrates the percentage of tri- n-hexyl aconitate (THA) formed during the production of acetyltri-n-hexyl citrate whereby the reaction is terminated at approximately .2% acidity, as citric acid. As shown in Figs. 4 and 7 below, the aconitate levels range from approximately .14 to .19 with a reaction time of from 25 to 19 hours at temperatures of from 125"C to 1300c.It has been determined that by lowering the temperature from 1400C to 1300C an additional reaction time of only 90 minutes is required with the aconitate level dropping from .35 to .19%, a decrease of approximately 45%. As shown, the aconitate level can be tremendously decreased by lowering the temperature approximately 10 degrees from 140"C to 130"C without substantially increasing the reaction time based on .2% acidity (citric acid) as the reaction completion indicator.As shown in Fig. 7 a stabilization of the aconitate formation occurs during esterification at a critical temperature of approximately 130"C providing a technique for the manufacture of high purity esters having low aconitate levels. Lower aconitate percentages and other impurities provide the high quality plasticizer needed for medicalgrade products.

Fig. 4 Reaction tíme and aconitate Formation rates at various temperatures Esterification Reaction Final THA % Acidity as Temperature CC) Time rHrs.J Content ( ,h) Citric acid 120 24 1/4 0.07 0.17 125 25 0.14 0.17 130 19 0.19 0.17 140 17 112 0.41 0.16 150 13 0.59 0.19 It is believed that acids such as citric acid with low pK values exhibit a synergistic effect with titanate catalysts at low temperatures in the 1500C or lower range. Phthalic acid which has a high pK value will not undergo esterification with the titanate catalysts at these low temperatures.

Also, other organic titanate catalysts can be used to produce the four (4) esters of this invention such as tetrakis-2-ethylhexyl titanate although superior results have been demonstrated using tetra-n-butyl titanate.

Preparation and tesdng df PVC compositions Formulation Parts by weight Resin (Medium Molecular Weight PVC) 100 Plasticizer 50 Stabilizer (CalciumlZinc) 2.5 Lubricant (stearic acid) 0.25 The above formulation was blended and milled for 5- 10 minutes at 325" to 340"F. The milled stock was pressed (3 min. at 340 -360 F and 32,000 psi) to 40- and 70-mil sheets, and aged for 48 hours at room temperature for evaluation. All tests were made with samples cut from 70-mil pressed stock except for extraction tests which were obtained on 40-mil samples. The performance data was obtained by accepted ASTM methods with modifications as detailed below-in Fig. 5.

Tensile strength Determined with Instron TT, 1100 Ultimate Elongation series (2 inemin.) using a Modulus (100% elongation) dumbbell-shaped specimen. Test (ASTM D638) carried out at 70 t 51F.

Hardness Determined with Shore Durometer A (ASTM D676) (10 sec.) at 75; + 5"F.

Torisonal Flex (T4 and T,) Determined with Torsion Flex (ASTM D1043) Tester of Clash and Berg design.

T4 is the temperature at which the Modulus of Rigidity is 10,000 psi; T, is the temperature at which the Modulus of Rigidity is 100,000 psi.

Brittle Point Determined by impact method using (ASTM D7546) Scott Tester, Model E.

Volatile Loss (A/C) Determined on specimens 2 inches in (ASTM D1203) diameter heated in activated carbon at 70"C for 24 hours. Results are expressed as percent of plasticizer lost.

Water extraction (Tap) Determined on specimens 2 inches in Soapy Water Extration diameter suspended in appropriate (1% Ivory Flakes) liquid at 60"C for 24 hours.

Oil Extraction Results are expressed as percent (ASTM NO. 3) of plasticizer lost.

Migration Loss (silica) Determined on specimens 2 inches in diameter heated in silica (100 mesh), at 70"C for 24 hours. Results are expressed as percent of plasticizer lost.

Volatile Loss (air) Determined by Oven Method (24 hr. at 100to) on specimens 2 inches in diameter. Results are expressed as percent of plasticizer lost.

Figure 5 (Plasticizer performance data) Plasticizer DEHP DEHA *1 *2 *3 #2 *3 #4 #5 HARDNESS, Durometer A, 10 Sec. 79 78 78 81 81 87 87 TENSILE, psi 2748 1797 2862 2978 2924 2743 2789 ULTIMATE ELONGATION, MO 395 414 400 390 427 364 374 100% MODULUS, psi 1368 1092 1348 1574 1362 1656 1700 T4 (10,000 psi), "C. -8.4 -30.8 -7.6 -9.1 -11.9 -6.9 -4.0 T, (100,000 psi), "C. -38.8 -66.5 -35.6 -41.6 -48.7 -53.1 -59.7 BRITTLE-POINT,'C. -24.5 -56.5 -18.5 -26.0 -33.5 -36.8 37.8 VOLATILE LOSS, (air),% 4.8 7.1 12.1 2.6 1.7 .3 .1 VOLATILE LOSS, (AlC),% 3.4 7.6 7.0 1.7 1.4 2.8 4.5 WATER EXTRACTION, % .7 1.5 1.2 1.9 1.7 1.5 3.3 SOAPY WATER EXTRACTION, % 2.7 11.0 9.5 5.4 2.2 3.4 2.4 OIL EXTRACTION, % 11.4 34.7 10.9 13.8 15.7 15.2 19.3 SILICA GEL MIGRATION, % 12.2 23.0 17.0 4.4 3.6 4.8 7.4 #1 -acetyltri-n-butyl citrate *2 -acetyltri-n-hexyl citrate *3 -n-butyryltri-n-hexyl citrate *4 -acetyltri-n-(hexyl/octyl/decyl) citrate #5 -acetyitri-n-(octylidecyl) citrate The plasticizer performance data in Figure 6 demonstrates the results of tests with citric esters expoxidized soybean oil (ESO) blends. ESO is commonly used in conjunction with DEHP at levels in the range of 1-5% based on DEHP as an aid in stabilization. The ratio of 2.5197.5 ESO/citrate was used as a base point in the studies.Test results on this combination are shown in column 1. A significant improvement in properties, particularly soapy water extraction is noted.

Figure 6 (Plasticizerperfqrmance data) PLASTICIZER 2.5 ESQ 20 ESO 40 ESO 40 ESO 40 ESO PERCENTAGES: 97.5 k2 80 *2 60 *2 60 *3 60 *5- HARDNESS, Durometer A,10 Sec. 81 80 80 81 85 TENSILE, psi 2907 3010 3079 3165 3097 ULTIMATE ELONGATION, % 422 424 420 428 395 100% MODULUS, psi 1415 1429 1491 1514 1779 ' T4 (10,000 psi) "C. -9.5 -7.8 -7.7 -8.2 -5.4 T4 (i00,000 psi) "C. -41.8 -41.3 -39.3 -41.8 -50.3 BRITTLE POINT, "C. -26.5 -25.5 -20.5 -24.5 -26.5 VOLATILE LOSS, (Air),% 2.4 2.1 1.5 .8 .5 VOLATILE LOSS, (AiC),% 1.3 1.6 1.4 .9 1.1 WATER EXTRACTION, % 1.3 .9 .6 .8 1.0 SOAPY WATER EXTRACTION, % 2.9 2.9 6.4 4.8 3.8 OIL EXTRACTION, % 13.0 11.6 10.1 10.0 12.9 SILICA GEL MIGRATION, % 5.7 5.3 4.7 4.0 2.5 ESO-Esterlepoxidized Soybean Oil *2 -acetyltri-n-hexyl citrate *3 -n-butyryltri-n-hexyl citrate *5 -acetyltri-n-(octyl/dec"'l) citrate Since ESO is less expensive than citrates, a reduction in plasticizer cost results if ESO can be substituted for part of the citrates. Results of tests with higher ESOicitrate ratios as shown in columns 2-5 of Figure 6 and a significant improvement in properties up to and perhaps beyond the ratio of 20/80 ESO/ citrate ratio as shown.

Various other PVC compositions can be formulated and the examples and illustrations shown herein are for illustrative purposes and are not intended to limit the scope of the invention.

Claims (12)

1. A method of producing citrate esters of the general formula:

wherein the groups R1, R2 and Ra are the same or different straight or branched chain alkyl groups having from 1 to 18carbon atoms and R4 is a straight or branched chain alkyl group having from 1 to 7 carbon atoms, which method comprises the steps of: heating citric acid with one or more of the alcohols q,OH, R2OH and/or R3OH, wherein R1, R2 and R3 are as defined above, in the presence of an organic titanate for esterification; removing the excess alcohol; and acylating the citrate by adding thereto the appropriate acid anhydride and sulfuric acid while maintaining the temperature below approximately 110"C until the acylation reaction is complete.

2. A method according to claim 1, wherein R1, R2 and R3 are n-hexyl and R4 is methyl.

-

3. A method according to claim 1, wherein R1, R2 and R3 are n-hexyl and R4 is n-propyl.

4. A method according to claim 3, wherein excess n- hexyl alcohol is removed after the esterification reaction is complete by vacuum steam stripping.

5. A method according to claim 1, wherein the citric acid is esterified using a mixture of alcohols having the general formula: C6.10 H13.2, OH.

6. A method according to claim 5, wherein the mixture of alcohols comprises a mixture of n-hexanol, n-octanol and n-decanol.

7. A method according to claim 1, wherein the citric acid is esterified using a mixture of alcohols having the general formula:- C8-10H17-21OH.

8. A method according to claim 7, wherein the mixture of alcohols comprises a mixture of n-octanol and n- decanol.

9. A method according to any one of claims 5 to 8, wherein the acylating agent is acetic anhydride.

10. A method according to any one of claims 1 to 9, wherein the organic titanate is tetra-n-butyl titanate.

11. A method as hereinbefore described with reference to Examples 1 and 2.

12. Citrate esters when produced by a method claimed in any one of claims 1 to 11.