Process for preparing an acryloyloxysilane

1. A process for preparing an acryloyloxysilane, the process comprising: reacting a metal salt of a carboxylic acid having the formula [CR 2 2 ═CR 1 COO − ] a− M a+ (I), with a haloorganoalkoxysilane having the formula XR 3 Si(OR 4 ) n R 5 3-n (II) in the presence of mineral spirits, wherein the mineral spirits are petroleum distillates comprising a mixture of isoalkane, alkane, and cycloalkane, and a phase transfer catalyst at a temperature of from 50 to 160° C. to form a mixture comprising an acryloyloxysilane and a metal halide having the formula M a+ X − a (III), wherein R 1 is H or C 1 -C 6 hydrocarbyl, each R 2 is independently R 1 or [COO − ] a M a+ , M a+ is an alkali metal cation or alkaline earth metal cation, a is 1 or 2, X is halo, R 3 is C 1 -C 6 hydrocarbylene, each R 4 is independently C 1 -C 10 hydrocarbyl, each R 5 is independently R 1 and n is an integer from 1 to 3.

2. The process of claim 1 , wherein the acryloyloxysilane has the formula CR 6 2 ═CR 1 COOR 3 Si(OR 4 ) n R 5 3-n (IV), wherein R 1 , R 3 , R 4 , R 5 , and n are as defined in claim 1 , and wherein each R 6 is independently H, C 1 -C 6 hydrocarbyl, or COOR 3 Si(OR 4 ) n R 5 3-n , wherein R 3 , R 4 , R 5 , and n are as defined in claim 1 .

3. The process of claim 1 , further comprising at least one of the following steps or limitations a) through e)

a) removing at least a portion of the metal halide from the mixture by filtration, decantation, or centrifugation and decantation wherein the mineral spirits are from 30 to 60% (w/w);

b) wherein M a+ is a sodium ion or potassium ion, a is 1, and X is chloro;

c) wherein each R 1 is independently H, methyl, or [CH 2 COO − ]M a+ , each R 2 is independently H, methyl, or [COO + ] a M a+ , R 3 is methylene, ethylene, or propylene, each R 4 is independently methyl or ethyl, each R 5 is independently H, methyl, or ethyl, and n is 3;

d) wherein the phase-transfer catalyst is tetrabutylammonium bromide;

e) recovering the acryloyloxysilane.

4. The process of claim 1 , wherein the metal salt of a carboxylic acid is selected from a metal salt of fumaric acid or a metal salt of acrylic acid.

5. The process of claim 4 wherein the acryloyloxysilane is γ-acryloyloxypropylmethyldimethoxysilane, γ-acryloyloxypropyltrimethoxysilane, γ-acryloyloxypropyltriethoxysilane, bis(γ-trimethoxysilylpropyl) fumarate, or bis(γ-triethoxysilylpropyl) fumarate.

6. The process of claim 1 , further comprising washing the mixture comprising an acryloyloxysilane, a first metal halide, and a non-polar solvent with a solution comprising water and, optionally, a second metal halide, to produce an organic phase comprising the acryloyloxysilane and an aqueous phase comprising at least a portion of the first metal halide.

7. The process of claim 6 , wherein the acryloyloxysilane has the formula CR 6 2 ═CR 1 COOR 3 Si(OR 4 ) n R 5 3-n (IV), wherein R 1 is H or C 1 -C 6 hydrocarbyl, R 3 is C 1 -C 6 hydrocarbylene, each R 4 is independently C 1 -C 10 hydrocarbyl, each R 5 is independently H or C 1 -C 6 hydrocarbyl, each R 6 is independently H, C 1 -C 6 hydrocarbyl, or —COOR 3 Si(OR 4 ) n R 5 3-n , wherein R 3 , R 4 , and R 5 are as defined above, and n is an integer from 1 to 3.

8. The process of claim 6 , wherein the non-polar solvent is from 10 to 90% (w/w).

9. The process of claim 6 , where the first metal halide and second metal halide are according to the formula M a+ X − a (III), wherein M a+ is an alkali metal cation or alkaline earth metal cation, X is halo, and a is 1 or 2.

10. The process of claim 6 , wherein the solution comprises from 0% to a less than saturated concentration of a second metal halide.

11. The process of claim 6 , wherein the mixture is washed with a sufficient amount of the solution so the first metal halide and the second metal halide together are at least 15% (w/w) of the combined weight of the first metal halide, the second metal halide, and the water.

12. The process of claim 6 further comprising forming the mixture by reacting a metal salt of a carboxylic acid having the formula [CR 2 2 ═CR 1 COO − ] a M a+ (I), with a haloorganoalkoxysilane having the formula XR 3 Si(OR 4 ) n R 5 3-n (II) in the presence of the non-polar solvent and a phase transfer catalyst at a temperature of from 50 to 160° C. to form a mixture comprising an acryloyloxysilane and a metal halide having the formula M a+ X − a (III), wherein each R 1 is independently H or C 1 -C 6 hydrocarbyl, each R 2 is independently R 1 or [COO − ] a M a+ , R 3 is C 1 -C 6 hydrocarbylene, each R 4 is independently C 1 -C 10 hydrocarbyl, each R 5 is independently R 1 , each M a+ is an alkali metal cation or alkaline earth metal cation, a is 1 or 2, X is halo, and n is an integer from 1 to 3.

13. The process of claim 12 , wherein each R 2 is independently H, methyl, or [COO − ] a M a+ , R 1 is H or methyl, R 3 is methylene, ethylene, or propylene, R 4 is methyl, ethyl or propyl, R 5 is H, methyl, or ethyl, X is chloro, and n is 2 or 3.

14. The process of claim 12 , wherein M a+ is a potassium cation or a sodium cation, X is chloride, and a is 1.

15. The process of claim 12 , wherein the phase-transfer catalyst is tetrabutylammonium bromide.

16. The process of claim 6 , wherein the mixture comprises from 30 to 60% (w/w) of the non-polar solvent, and wherein the non-polar solvent has a density of less than 1.0 g/ml and a dielectric constant below 10.

17. The process of claim 6 , wherein the non-polar solvent is mineral spirits.

18. The process of claim 6 , wherein the first metal halide and second metal halide are the same.

19. The process of claim 6 , wherein the mixture comprises from 5 to 15% (w/w) of the first metal halide.

20. The process of claim 6 , further comprising recovering the acryloyloxysilane.