IMPROVED PROCESS FOR THE PREPARATION OF 2-SUSTITUTED-2-(6-(SUBSTITUTED)-7-METHYLBENZO[D] [l,3]DIOXOL-4-YL)ACETIC ACID DERIVATIVES

FIELD OF INVENTION

Present invention relates to an improved and commercial process for the preparation of 2-sustituted-2-(6-(substituted)-7-methylbenzo[d][l,3]dioxol-4-yl)acetic acid derivatives of formula-I
Wherein R1 is a O-protecting group such as methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran-2-yl, allyl; X is hydroxyl, halogen, mesylate, triflate, tosylate, acetate; Y is oxygen atom, NH or sulfur atom; R2 is C1-C6 alkyl

Compounds of formula-I are key intermediates useful in the synthesis of Ecteinascidins such as Ecteinascidin 743, Ecteinascidin 736, Ecteinascidin 729, Ecteinascidin 722, Ecteinascidin 637, and Ecteinascidin 594. Ecteinascidins are a family of tetrahydroisoquinoline alkaloids isolated from the Caribbean tunicate Ecteinascidia turbinate, which possess potent cytotoxic acitivity against a variety of turners. One of its memebers, Ecteinascidin 743 (Et 743, commercial name Yondelis) is approved in the United States for ovarian, endometrium, and breast cancer. Yondelis has been granted Orphan Drug Designation by the US FDA and Europian Commission for the treatment of cancer. The antiproliferative activity of Et 743 is greater than that of taxol, camptothecin, adriamycin, mitomycin C, cisplatin, and etoposide by 1-3 fold orders of magnitude.

BACKGROUND OF INVENTION
Compound of formula-I wherein R1 is methoxymethyl (MOM), R2 is ethyl, Y is oxygen atom and X is hydroxyl or bromo is used by Jieping Zhu, et al in their synthesis of Ecteinascidin 743 (J. Am. Chem. Soc, 2006,128, pages 87-89). According to the process given in this reference, sesamol is protected with methoxymethyl group and converted to compound of formula-Ill by reacting with n-butyl lithium and trimethyl borate (Scheme-I). Compound of formula-Ill is reacted with ethyl glyoxalate in the presence of hexafluoroisopropanol to get the compound of formula-IV. Triflation of compound of formula-IV followed by reaction with trimethylboroxine in the presence of palladium (tetrakis-triphenylphosphine) gave the compound of formula-VI. Reaction of compound of formula-VI with thionyl bromide gave the compound of formula-VII. Compound of formula-VII is used as a key intermediate in the synthesis of Ecteinascidin 743.

Scheme-I
Main drawback in this process is the handling of costly, toxic, and pyrophoric reagents. Another main drawback in the synthesis is the non-availability of trimethylboroxine on commercial scale.
Keeping in view of the difficulties in commercialization of the above-mentioned process for the preparation of compound of formula-I, we aimed to develop a simple, economical, and commercial process.

We observed that a promising approach for a process for the preparation of compound of formula-I would be to (a) avoid the usage of costly and difficult to handle reagents.

Accordingly, the main objective of the present invention is to provide an improved process for the preparation of compound of formula-I, which is commercially applicable.

PROCESS OF THE PRESENT INVENTION
The present invention has been developed based on our finding that 3-methyl-2,4-dihydroxybenzaldehyde would be a suitable starting material for the synthesis of compound of formula-I than the sesamol (Scheme-II). Hydroxy group present at 4-position in 3-methyl-2,4-dihydroxybenzaldehyde is known to undergo selective etherification (Org. Lett. 2011, 13(17), 4486-89; J. Med. Chem., 1998, 41, 4819-4832; Synthetic Commun. 1996, 26(3), 593-601). Therefore, compound of formula-VIII is reacted with methoxymethyl chloride in the presence of a base to get the compound of formula-IX. During process optimization studies it was observed that along with the required compound of formula-IX (about 75% by GC) about 3% of 4-hydroxy-2-methoxymethoxy-3-methylbenzaldehyde and 20% of 2,4-bis(methoxymethoxy)-3-methylbenzaldehyde were formed. Fortunately, crystallization of crude from a polar solvent like isopropanol removed all the impurities and the purity of required product (compound of formula-IX) was found to be more than 98% by GC. Isolated yield of compound of formula-IX is 55-60%. Alternatively, crude compound of formula-IX was also purified to more than 95% by high vacuum distillation. Compound of formula-IX distilled at 140-150°C (bath temperature) at a vacuum of 1.0 mmHg. Distilled compound of formula-IX contained 2-3% of 2,4-bis(dimethoxymethoxy)-3-methylbenzaldehyde. Mother liquors of crystallization were collected, distilled of IP A partially and treated with IN HC1 at room temperature to form 2,4-dihydroxybenzaldehyde. The formed 2,4-dihydroxybenzaldehyde was collected by filtration of reaction mass. Recovery of 2,4-dihydroxybenzaldehyde is 20-25% of charged quantity. Based on recovery of 2,4-dihydroxybenzaldehyde isolated yield of compound of formula-IX is about 70%.

Scheme-II Compound of foraiula-IX is oxidized under Dakin oxidation conditions (US pat. 4435601) in basic medium to get the compound of formula-X. Dihydroxy compound of formula-X is condensed with ethyl glyoxalate under Casiraghi (Casiraghi, G.; Cornia, M.; Rassu, G. J. Org. Chem. 1988, 53, 4919-4922) conditions to get the compound of formula-XI. Surprisingly, no regio-isomeric condensation product was formed in this reaction. Compound of formula-XI is reacted with dihalomethane such as bromochloromethane in the presence of a base to get the compound of formula-VI. Compound of formula-VI is converted to compound of formula-VII under prior art conditions or by other brominating agents.

Accordingly, process of the present invention provides an improved process for the preparation of compound of formula-I,

Wherein R1 is a O-protecting group such as methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran2-yl, allyl; X is hydroxyl, halogen, mesylate, tosylate, triflate, acetate; Y is oxygen atom, NH or sulfur atom; R2 is C1-C6 alkyl which comprises: (i) Reaction of 2,4-dihydroxy-3-methylbenzaldehyde with an etherification reagent in the presence of a base (or acid in case of tetrahydropyran-2-yl protection) to get the mono-protected derivative of formula-XII,

Wherein R1 = methoxymethyl, ethoxymethyl, trialkylsilyl, tetrahydropyran-2-yl, allyl,
arylmethyl (ii) Oxidation of compound of formula-XII with an oxidizing agent in the presence of a
base to get the dihydroxy compound of formula-XIII,

Wherein R\ = methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran-
2-yl, allyl; (iii)Reaction of dihydroxy compound of formula-XIII with a base and an aldehyde
compound of formula-XIV, XIV Wherein Y and R2 are as defined above to get the compound of formula-

Wherein R1, Y, and R2 are as defined above .

(iv) Reaction of dihydroxy compound of formula-XV with a dihalomethane in the presence of a base to get the methylenedioxy derivative of formula-XVI

Wherein R1, Y, and R2 are as defined above
(v) Conversion of hydroxyl group to X wherein X is as defined above using a suitable reagent to get the compound of formula-I-1 Wherein R1, R2, X, and Y are as defined above

In a preferred embodiment of the present invention in step (i) 2,4-dihydroxy-3-methylbenzaldehyde is reacted with etherification reagents such as alkoxymethyl halides like methoxymethyl chloride, ethoxymethylchloride; silyl halides such as trimethylsilyl chloride, triethylsilyl chloride, tert-butyldimethylsilyl chloride, tert-butyldiphenylsilyl chloride, allyl halide, aryl halide, etc., in the presence of a base such as trialkylamine, sodium or potassium carbonate, bicarbonate, etc. in an organic solvent such as halogenated solvents, ethers, hydrocarbons to get the mono-protected compound of formula-XII. In the case of tetrahydropyran-2-yl derivative an acid catalyst like, p-toluenesulfonic acid is preferred over a base. Temperature of the reaction can be 10°C to the boiling point of the solvent employed in the reaction, preferably 25-30°C.

In step (ii) oxidizing reagent employed in the reaction is hydrogen peroxide, per acids like m-chloroperbenzoic acid, peracetic acid, or any other equivalent. Base employed in step (ii) is selected from sodium or potassium bicarbonate, carbonate, hydroxide, preferably sodium or potassium hydroxide. In step (iii) base employed in the reaction is Cl-C6alkylmagnesium chloride or bromide. Solvent employed in the reaction is a halogenated solvent, ether solvent, hydrocarbon solvent, etc. or a mixture thereof, preferably a mixture of hydrocarbon and ether solvent.

In step (iv) dihalomethane reagent employed in the reaction is bromochloromethane, bromoiodomethane, dibromomethane, dichloromethane, diiodomethane, preferably bromochloromethane. Base employed in the reaction is a carbonate or bicarbonate of sodium, potassium cesium, etc., preferably cesium carbonate. Solvent employed in the reaction is a dipolar aprotic solvent such as dimethylformamide or a polar solvent such as acetonitrile and the temperature of the reaction is 25-120°C.

In step (v) reagents employed for suitable X are thionyl chloride, methanesulfonyl chloride, triflic anhydride, acetyl chloride, acetic anhydride, p-toluenesulfonyl chloride, etc. Additionally, a base such as benzotriazole, diazabicycloundecane, DCC, DBU, etc., may be used do the required conversion. When X is a halide preferred reagents are a combination of carbon tetrahalide with triphenylphosphine and catalytic amount of a base like diisopropylethylamine.

Advantages of present invention:

1. Present process uses all cheap and readily available raw materials.

2. Present process avoids the usage of toxic and costly reagents such as sodium hydride, n-butyl lithium, trimethylboroxine, tetrakis(triphenylphosphine)palladium (0), p-nitro-
phenyltrifluoromethanesulfonate, 1,1,1,3,3,3-hexafluoroisopropanol, thionyl bromide, etc.

3. Present process is short, simple, and free from usage of hazardous reagents.

4. Present process is economically and commercially viable.

The details of the invention are given in the Examples given below which are provided to illustrate the invention only and therefore should not be construed to limit the scope of the present invention.

EXAMPLES
Example 1:

Preparation of 2,4-dihydroxy-3-methylbenzaIdehyde:
Into a clean and dry 2L, 4-Necked RB Flask, charged 600 ml of dichloromethane under nitrogen atmosphere at RT. N,N-Dimethylformamide (324g) was charged to the reaction mass under stirring at RT. Reaction mass was cooled to 0-5°C. Phosphorous oxychloride (568g) was slowly added to the reaction mass at 0-5°C. After completion of the addition, mass was allowed to reach 25°C and maintained at 25-30°C for 1.5h. The reaction mass was cooled 0-5°C. 2-Methylresorcinol (200g) was added in lots maintaining the mass temperature at 0-5°C. Reaction mass was maintained for 16h at RT, poured into chilled water (2500ml). Reaction mass was stirred for 15h at 25-30°C and filtered under suction.

The wet cake was washed with 1000ml water and dried under vacuum at 60-65°C for 6 h to get 210g of title compound as an off-white solid.

Example 2:
(i) Preparation of 2-hydroxy-4-(methoxymethoxy)-3-methylbenzaldehyde:

Into a clean and dry 5L, 4-Necked RB Flask-was charged 2000 ml of dichloromethane under nitrogen atmosphere at RT. 2,4-Dihydroxy-3-methylbenzaldehyde (200g) was added to the reaction mass under stirring at RT. N,N-Diisopropylethylamine (290g) was slowly added to the reaction mass under stirring at RT. The reaction mass was cooled to 0-5°C. Methoxymethyl chloride (prepared from 159.5g of dimethoxymethane, 164.5g of acetyl chloride and 12mg of zinc bromide) was added to the reaction mass at 0-5°C. The reaction mass was allowed to RT and maintained for 15 h under stirring. Aqueous ammonium chloride (200 ml) was added to the reaction mass under stirring and kept under stirring for 0.5h. Organic layer was separated and washed with 600ml of saturated sodium bicarbonate solution. Organic layer was dried with Na2SO4 and distilled of solvent. The residue (232g containing 17% of 2,4-bis(methoxymethoxy)-3-methylbenzaldehyde by GC) was treated with 300 ml of IPA at 40-45°C, cooled to RT, further cooled to 0-5°C and maintained for 3h. The reaction mass filtered under suction and washed the wet cake with 120ml of chilled (0-5°C) IPA. The wet material was dried under vacuum at 40°C for 5h to get 150g of title compound as off-white solid. Purity of title compound by GC is 97%. M.R.: 55.5-57.5°C. IR (KBr): 3289, 3099, 3009, 3003, 2917, 2829, 2743, 1644, 1590, 1495, 1448, 1389, 1308, 1284, 1249, 1208, 1160, 1106, 1071, 1020, 974, 922, 879, 810, 745, 689, 638, and 608 cm"1. 1H-NMR (CDC13, 400MHz): 8 11.39 (s, 1H, exchangeable with D2O, OH), 9.48 (s, 1H, CHO), 7.60 (d, J = 8.8Hz, 1H, Ar. H), 6.82 (d, J = 8.8Hz, 1H, Ar. H), 5.34 (s, 2H, OCH2O), 3.40 (s, 3H, OCH3), 2.05 (s, 3H, ArCH3). 13C-NMR (CDC13, 100MHz): 8 195.81 (CHO), 161.32 (C-4), 160.13 (C-2), 132.93 (C-6), 115.73 (C-l), 112.98 (C-3), 106.06 (C-5), 93.85 (OCH2O), 55.95 (OMe), 7.47 (ArCH3). Mass (EI-MS): 195.4 (M-l).

2,4-bis(methoxymethoxy)-3-methylbenzaldehyde: DSC: 32.95°C (peak). IR (KBr): 2992, 2961, 2944, 2915, 2879, 2833, 1681, 1549, 1482, 1452, 1432, 1404, 1385, 1374, 1313, 1259, 1224, 1205, 1156, 1107, 1053, 1003, 971, 928, 859, 804, 779, 761, 696, and 663cm-1. !H-NMR (CDC13, 400MHz): 5 10.2O (s, 1H, CHO), 7.70 (d, J = 8.8Hz, 1H, H-6), 6.98 (d, J = 8.8Hz, 1H, H-5), 5.27 (s, 2H, OCH2O), 5.08 (s, 2H, OCH2O), 3.61 (s, 3H, OMe), 3.49 (s, 3H, OMe), 2.21 (s, 3H, ArCH3). 13C-NMR (CDC13, 100MHz): δ 189.47 (CHO), 161.27 (C-4), 159.75 (C-2), 127.88 (C-6), 123.97 (C-l), 120.95 (C-3), 109.82 (C-5), 100.92 (OCH2O of C-2), 94.16, (OCH2O of C-4), 57.76 (OCH3), 56.2O (OCH3), 9.34 (ArCH3).
Recovery of 2,4-Dihydroxy-3-metbylbenzaldehyde:

IPA MLs were collected and distilled of IPA under vacuum at 60°C to keep about one volume of IPA to the weight of residual mass. The residue was cooled and treated with 750ml of IN HC1. Reaction mass was stirred for 48 hours at RT and filtered. The wet cake was washed with water, toluene and dried at 60°C under vacuum to get 45g of 2,4-dihydroxy-3 -methylbenzaldehyde.

Example 3:
Preparation of 4-(ethoxymethoxy)-2-hydroxy-3-methylbenzaldehyde:
By following Example 2 procedure, 25.0g of 2,4-dihydroxy-3-methylbenzaldehyde was reacted with 40.0g of ethoxymethyl chloride (prepared from 23g of diethoxymethane and 17.3g of acetyl chloride) and 31.8g of N,N-diisopropylethylamine to get 36.0g of crude title product containing 11.5% of 2,4-bis(ethoxymethoxy)-3-methylbenzaldehyde by GC. Crude product was purified by column chromatography to get the title compound (25. Og) as white solid. DSC: 43.1°C (peak). IR (KBr): 3283, 3095, 3038, 2972,2952,2909,2876, 2807, 2765, 2734, 1641, 1621, 1584, 1492, 1453, 1434, 1396, 1320, 1298, 1242, 1176, 1128, 1094, 1071, 1017, 978, 882, 849, 807, 777, 736, 691, 642, and 617 cm'VH-NMR (CDC13, 400MHz): δ 11.48 (s, 1H, exch. withD2O, OH), 9.73 (s, 1H, CHO), 7.35 (d, J = 8.8Hz, 1H, H-6), 6.78 (d, J = 8.8Hz, 1H, H-5), 5.33 (s, 2H, OCH2O), 3.74 (q, J = 6.8Hz, 2H, OCH2CH3), 2.12 (s, 3H, ArCH3), 1.23 (t, J = 6.8Hz, 3H, OCH2CH3) 13C NMR (CDCI3, 100MHz): δ 194.91 (CHO), 162.11 (C-4), 161.30 (C-2), 132.72 (C-6), 115.72 (C-l), 114.26 (C-3), 105.82 (C-5), 92.81 (OCH20), 64.76 (OCH2CH3), 15.06 (OCH2CH3), 7.47 (ArCH3). Mass (EIMS): 210.17 (M), 209.10 (M-l).

2,4-bis(ethoxymethoxy)-3-methylbenzaldehyde: IR (liquid, neat): 2978, 2931, 2892, 1680, 1593, 1483, 1444, 1385, 1308, 1254, 1233, 1211, 1155, 1117, 1094, 1053, 1020, 992, 943, 859, 815, 779, and 674cm-1. 1H-NMR (CDCI3,400MHz): 810.19 (s, 1H, CHO), 7.71 (d, J - 8.8Hz, 1H, H-6), 7.00 (d, J = 8.8Hz, 1H, H-5), 5.32 (s, 2H, OCH2O), 5.12 (s, 2H, OCH20), 3.84 (q, J = 7.2Hz, 2H, OCH2CH3), 3.74 (q, J = 7.2Hz, 2H, OCH2CH3), 2.19 (s, 3H, ArCH3), 1.25 (t, J = 7.2Hz, 3H, OCH2CH3),1.23 (t, J = 7.2Hz, 3H, OCH2CH3). 13C-NMR (CDC13, 100MHz): δ 189.69 (CHO), 161.53 (C-4), 159.81 (C-2), 127.82 (C-6), 123.99 (C-l), 120.86 (C-3), 109.40 (C-5), 99.40 (OCH20), 92.93 (OCH20), 66.04 (OCH3), 64.69 (OCH3), 15.00 (2 x OCH2CH3), 9.42 (ArCH3). Mass (EI¬MS): 241.1 (M+l).

Example 4:
Preparation of 4-(tert-butyldimethylsilyloxy)-2-hydroxy-3-methylbenzaldehyde:
By following Example 2 procedure, 5.0g of 2,4-Dihydroxy-3-methylbenzaldehyde was reacted with 4.95g of tert-butyldimethylsilyl chloride and 2.15g of N,N-diisopropylethylamine to get 7.9lg of crude title product containing 16.5% of 2,4-bis(tert-butyldimethylsilyloxy)-3-methylbenzaldehyde by GC. Crude product was purified by column chromatography to get the title compound as colorless liquid. IR (neat): 3280, 2956, 2932, 2888, 2859, 1646, 1622, 1582, 1493, 1425, 1388, 1360, 1325, 1296, 1249, 1171, 1103, 1021, 1007, 846, 798, 726, 679, 652, and 610 cm-1. 'H-NMR (CDCI3, 400MHz): δ 11.56 (s, 1H, exch. with D2O, OH), 9.70 (s, 1H, CHO), 7.26 (d, J = 8.4MHz, 1H, aromatic H-6), 6.45 (d, J = 8.4Hz, 1H, aromatic H-5), 2.10 (s, 3H, ArCH3), 1.02 (s, 9H, Si-tert-Bu), 0.27 (s, 6H, SiMe2). 13C NMR (CDCI3, 100MHz): δ 194.73 (CHO), 162.12 (C-2), 161.44 (C-4), 132.26 (C-6), 116.45 (C-l), 115.39 (C-3), 111.26 (C-

5), 25.26 (CMe3. 18.29 (CMe3), 8.15 (ArCH3), 8.19 (SiMe2). Mass (EIMS): 266.26 (M), 265.19 (M-l).

Example 5:
Preparation of 4-allyloxy-2-hydroxy-3-methylbenzaldehyde:
By following Example 2 procedure, 5.0g of 2,4-dihydroxy-3-methylbenzaldehyde was reacted with 8.35g of allyl chloride and 5.1g of N,N-diisopropylethylamine to get 8.41g of crude title product containing 12% of 2,4-bis(allyloxy)-3-methylbenzaldehyde by GC. Crude product was purified by column chromatography to get the title compound as liquid. IR (neat): 3280, 3088, 3024, 2988, 2926, 2838, 2748, 1645, 1585, 1499, 1452, 1427,1388,1353,1330,1290,1250,1182,1110, 1022, 990, 928, 891, 788, 758, 715, and 646cm-1. 'H-NMR (CDC13, 400MHZ): 5 11.45 (s, 1H, exch. with D20, OH), 9.70 (s, 1H, CHO), 7.34 (d, J = 8.8Hz, 1H, H-6), 6.53 (d, J = 8.8Hz, 1H, H-5), 6.06 (m, 1H, CH=CH2), 5.44 (dq, J = 1.6, 19.2Hz, 1H, CH=CH2), 5.32 (dq, J = 1.2, 10.8Hz, 1H, CH=CH2), 4.64 (dt, J = 1.6, 4.8Hz, 2H, CH2=CH2), 2.13 (s, 3H, ArCH3). 13C NMR (CDC13, 100MHz): 5 194.60 (CHO), 163.17 (C-4), 160.99 (C-2), 133.00 (CH2=CH), 132.38 (C-5), 117.55 (CH2=CH), 113.48 (C-l), 103.75 (C-5), 68.90 (OCH2), 7.30 (ArCH3). Mass (EI-MS): 192.1 (M), 191.3 (M-l). Example 6:

Preparation of 2-hydroxy-3-methyl-4-(tetrahydro-2H-pyran-2-yloxy)benzaldehyde: By following Example 2 procedure, lO.Og of 2,4-Dihydroxy-3-methylbenzaldehyde was reacted with 48.3g of 3,4-dihydro-2H-pyran in the presence of 1.6g of pyridinium para-toluenesulfonate to get 15.0g of crude title product. Formation of 3-methyl-2,4-bis(tetrahydro-2H-pyran-2-yloxy)benzaldehyde was not noticed either by GC or TLC of the crude sample. Crude product was purified by column chromatography to get the title compound as white solid. DSC: 58.2°C (peak). IR (KBr): 3125, 2946, 2870, 2747, 1645, 1623, 1585, 1494, 1431, 1388, 1356, 1327, 1288, 1246, 1204, 1181, 1121, 1091, 1036, 1022, 955, 921, 895, 872, 799, 758, 712, and 642 cm-1. *H-NMR (CDC13, 400MHz): 5 11.49 (s, 1H, exch. with D2O, OH), 9.72 (s, 1H, CHO), 7.33 (d, J = 8.8Hz, 1H, H-6), 6.78

(d, J = 8.8Hz, 1H, H-5), 5.58 (t, J = 2.8Hz, 1H, OCHO), 3.81 (dt, J = 2.8Hz, 11.2Hz, 1H, CH20), 3.61-3.66 (m, 1H, CH20), 2.15 (s, 3H, ArCH3), 2.00-2.05 (m, 1H, CH2CHO), 1.89-1.93 (m, 2H, CH2CHO and CH2CH2CHO), 1.62-1.75 (m, 3H, OCH2CH2CH2). 13C NMR (CDCI3, 100MHz): δ 194.80 (CHO), 161.62 (C-4), 161.2O (C-2), 132.71 (C-6), 115.47 (C-l), 114.05 (C-3), 106.17 (C-5), 95.67 (OCHO), 61.89 (C-6'), 30.00 (C-2'), 24.97 (C-5'), 18.36 (C-4'), 7.38 (ArCH3). Mass (EI-MS): 236.24 (M), 235.10 (M-l).

Example 7:
Preparation of 4-(methoxymethoxy)-3-methylbenzene-l,2-diol:
Into a 2.0L, 4-Necked, RB flask equipped with two addition funnels, thermometer socket and a pH meter was charged 800 mL of DM water. The contents were kept under nitrogen atmosphere. 2-Hydroxy-4-(methoxymethoxy)-3-methylbenzaldehyde (100g) was added to the reaction mass under stirring. Aqueous sodium hydroxide (0.5mL, dissolve 24.6g of sodium hydroxide in 82.0mL of DM Water) was added to the reaction mass to get a pH of 7.0-8.0. Reaction mass was heated to 40-45°C. Simultaneous addition of aqueous sodium hydroxide and hydrogen peroxide to the reaction was started using two addition funnels. During the addition pH of the reaction mass was maintained at 7.8-8.4 and the temperature at 40-45°C. After the completion of addition, maintained the reaction mass at 40-45°C for 4.0 h. The reaction mass was cooled to 25-30°C and extracted with 3 x 500mL of ethyl acetate. Combined organic layer was washed with 500mL of saturated NaCl solution, treated with 20g of activated carbon, dried with sodium sulphate, and distilled of solvent under vacuum to get 90g of crude 4-(methoxymethoxy)-3-methylbenzene-l,2-diol as thick syrup. HPLC purity of sample is about 85%. The material is directly used in next stage. A small sample is purified by column chromatography for characterization purpose. M.R.: 60.5-61.5°C. IR (neat): 3487, 3200, 2969, 2942, 1630, 1621, 1488, 1443, 1405, 1378, 1307, 1290, 1242, 1150, 1086,1042, 1007, 987, 904, 881, 806, 735, 660, 606 cm"1. 1H-NMR (CDCI3,400MHz): 5 8.79 (s, 1H, exchangeable with D2O, OH), 8.19 (s, 1H, exchangeable with D2O, OH), 6.51 (d, J = 8.4Hz, 1H, Ar. H), 6.34 (d, J = 8.8Hz, 1H, Ar. H), 5.02 (s, 2H, OCH2O), 3.36 (s, 3H, OMe), 2.01 (s, 3H, ArCH3). 13C-NMR (CDC13,100MHz): δ 148.45 (C-4), 143.92 (C-2), 139.95 (C-l), 114.64 (C-3), 111.77 (C-6), 105.60 (C-5), 95.16 (OCH20), 55.49 (OMe), 9.17 (ArCH3). Mass (EI-MS): 184.46 (M), 183.3 (M-l)

Example 8:
Preparation of ethyl 2-(2,3-dihydroxy-5-(methoxymethoxy)-4-methylphenyl)-2- hydroxyacetate:
Into a clean and dry 3.0L 4-necked flask, is charged 500mL of THF and 90g of 4-(methoxymethoxy)-3-methylbenzene-l,2-diol under N2 atmosphere. The reaction mass was cooled to 2O-25°C and slowly added a solution of n-butylmagnesium chloride (560ml, 2.0M in THF) in THF. After completion of the addition, mass temperature was raised to 40-45°C and maintained for 90 minutes. THF was distilled under reduced pressure keeping the mass temperature 40-45°C. The reaction mass was cooled to 25-30°C and slowly added 500mL of toluene. The reaction mass was stirred for 15 min to get a clear solution. Ethyl glyoxalate (130 ml, 50% in toluene) was added to the reaction mixture with stirring. After completion of the addition, the reaction mixture was stirred at room temperature for 15h. The reaction mass temperature was raised to 45-50°C and maintained for 3h under stirring. Reaction mass was cooled to 15-2O°C and slowly added aqueous acetic acid (100mL of acetic acid dissolved in 1.3 L of DM Water) and stirred for 0.5h. Reaction mass was transferred into a separating funnel and separated the top organic layer. Aqueous layer is extracted with 200mL of toluene. The combined organic layer is washed with 2 x 200mL of brine, treated with 9.0g of activated carbon, dried with sodium sulphate, and distilled of solvent at 50-55°C under vacuum. Isopropyl ether (150mL) was added to the residue and heated to 50-55°C. Reaction mass was cooled to RT and maintained for 3h, further cooled to 0-5°C and maintained for 2h. Reaction mass was filtered and washed the cake with 100 ml of chilled (0-5°C) IPE. The wet solid was dried under vacuum at 50-55°C for 6.0h. Dry weight of title compound is 75g. HPLC purity is 98%. M.R.: 81.0-83.0°C. IR (KBr): 3458, 3432, 2988, 2954, 2900, 2828, 1726, 1603, 1506, 1467, 1382, 1364, 1334, 1291, 1231, 1205, 1153, 1120, 1100, 1068, 1050, 994, 921, 895, 856, 834, 782, 749, 717, 677, and 622 cm _1. *H-NMR (CDC13, 400MHz): δ 8.37 (s, 1H, exchangeable with D20, OH), 8.07 (s, 1H, exchangeable with D20, OH), 6.48 (s, 1H, Ar-H)), 5.76 (br. s, 1H, exchangeable with D20, OH), 5.29 (s, 1H, ArCHOH)), 5.02 (s, 2H, OCH2O), 4.06 (q, J = 7.2Hz, OCH2CH3), 3.36 (s, 3H, OMe), 2.02 (s, 3H, ArCH3), 1.13 (t, J = 6.8Hz, OCH2CH3). 13C-NMR (CDC13, 100MHz): δ 172.78 (OO), 148.23 (C-5), 143.99 (C-3), 138.16 (C-2), 123.93 (C-l), 114.81 (C-4), 104.99 (C-6), 95.12 (OCH2O), 67.73 (ArCHOH), 60.11 (OCH2CH3), 55.53 OMe), 14.01 (OCH2CH3), 9.32 (ArCH3). Mass (EI-MS): 286.64 (M), 285.47 (M-l).

Example 9:
Preparation of ethyl 2-hydroxy-2-(6-(methoxymethoxy)-7-methyIbenzo[d][l,3]
dioxol-4-yl)acetate Into a clean and dry 2L, 4-necked RB flask was charged 400 ml of N,N-
dimethylformamide under nitrogen atmosphere at RT. Cesium carbonate (171g) was
added to the reaction mass under stirring at room temperature. Bromochloromethane
(226g) was added to the reaction mass under stirring at RT. Reaction mass was heated to
30-35°C. Ethyl 2-(2,3-dihydroxy-5-(methoxymethoxy)-4-methylphenyl)-2-
hydroxyacetate (50g) was dissolved in 100ml of DMF and slowly added to the reaction mass under stirring at 30-35°C. Reaction mass was maintained at 30-35°C for 2.5h under stirring. Reaction mass was poured into 1L toluene and stirred for l.Oh at RT. Reaction mass was filtered through hyflow bed, and the bed washed with 600mL of toluene. Filtrate was washed with 2.0L of DM water. Aqueous layer was extracted with 2 x 500mL of toluene. Combined organic layer was washed with 2 x 600mL of saturated sodium chloride solution and treated with 7.5g of activated carbon at 45-50°C. Reaction mass was filtered and distilled of solvent under vacuum at 45-55°C to get 40g of crude title compound as syrup. HPLC purity of the crude compound is 92.5%. The crude compound was directly used in next step. A small sample was purified by column chromatography to compare its spectral data with the literature values.

Example 10:
Preparation of ethyl 2-bromo-2-(6-(methoxymethoxy)-7-methylbenzo[d][l,3]dioxol-
4-yl)acetate:
Into a clean and dry 5.0L, three-necked RB flask, is charged 163.0g of ethyl 2-hydroxy-2-(6-(methoxymethoxy)-7-methylbenzo[d][l,3]dioxol-4-yl)acetate and 1500mL of methylene chloride under nitrogen atmosphere. Carbon tetrabromide (218.4g) was added to the reaction mass under stirring at 25-30°C. N,N-Diisopropylethylamine (37.8g) was added to the reaction mass under stirring at 25-30°C. Reaction mass was cooled to -45 to -50°C. Triphenylphosphine (157.0g, dissolved in 300mL of methylene chloride) was added to the reaction mass under stirring at -45 to -50°C. Reaction mass was maintained for 1.5h at -45 to -50°C and allowed to reach 10°C over a period of 18h. Solvent was distilled of from the reaction mass under vacuum at 25-30°C. Ethyl acetate/hexane (1:9, 1300ml) was added to the residue and stirred for l.Oh. The reaction mass was filtered and the solids washed with 500mL of (Ethyl acetate/Hexane, 1:9) solvent mixture under stirring. Filtrate was transferred into a RB flask and distilled of solvent under vacuum keeping the temperature at 25-30°C. The crude compound was purified by column chromatography to get 120g of pure ethyl 2-bromo-2-(6-(methoxymethoxy)-7-methylbenzo[d][l,3]dioxol-4-yl)acetate as light yellow colored liquid. HPLC purity of title compound is 99.5%.

Example 11:
Preparation of 4-(ethoxymethoxy)-3-methylbenzene-l,2-diol:
Into a clean and dry 100mL, 4-Necked RB Flask, charge 40ml of Water and 5.0g of 4-(ethoxymethoxy)-2-hydroxy-3-methylbenzaldehyde under nitrogen atmosphere. pH of the reaction mass was adjusted to 7.8-8.4 by using NaOH solution. Reaction mass temperature was raised to 40-45°C. Slowly added 48% hydrogen peroxide (2.0g) and aqueous sodium hydroxide (1.15g in 30mL of DM water) to the reaction mass maintaining the pH at 7.8-8.4 and temperature at 40-45°C. Reaction was maintained for 3h at 45-0°C for 3h. Another 2.0g of 48% hydrogen peroxide and sodium hydroxide (1.15g in 30mL DM Water) was added to the reaction mass and maintained for 2h. The reaction mass was cooled to RT and extracted with ethyl acetate. Organic layer was washed with brine and distilled of solvent to get 3.2g of crude title compound. The crude compound was purified by column chromatography to get pure compound as syrup. IR (neat): 3395, 2978, 2931, 1604, 1490, 1391, 1314, 1289, 1245, 1201, 1155, 1093, 1055, 984, 882, 841, 797, 730, 688, and 655 cm-1. 1H-NMR (CDC13, 400MHz): 6 6.51-6.61 (m, 2H, ar. H), 5.35 (br. s., exch. with D20, 1H, OH), 5.17 (s, 2H, OCH2O), 5.01 (br s, 1H, exch. with D2O, OH), 3.76 (q, J = 7.2Hz, 2H, OCH2CH3), 2.16 (s, 3H, ArCH3), 1.25 (t, J = 6.8Hz, 3H, OCH2CH3). 13C NMR (CDC13, 100MHz): δ 149.81 (C-4), 143.14 (C-2), 138.17 (C-l), 115.19 (C-3), 112.01 (C-6), 106.82 (C-5), 94.21 (OCH2O), 64.36 (OCH2CH3), 14.95 (OCH2CH3), 8.76 (ArCH3). Mass (EI-MS): 198.24 (M), 197.10 (M-1).

Example 12:
Preparation of ethyl 2-(2,3-dihydroxy-5-(ethoxymethoxy)-4-methylphenyl)-2- hydroxyacetate:
Into a clean and dry lOOmL flask, were charged lOmL of THF and 1.0 g of 4-(ethoxymethoxy)-3-methylbenzene-l,2-diol under nitrogen atmosphere. A 3M solution of methylmagnesium chloride in THF (3.6ml) was slowly added to the reaction mass at 2O-25°C. The reaction mass was heated to 40-45°C, maintained for lh and distilled of THF under vacuum. Toluene (10ml) was added to the reaction mass and cooled to 25°C. Ethyl glyoxalate (1.3g, 50% in toluene) was added to the reaction mass. Temperature was raised to 40-45°C and maintained for 3h. Reaction mass was cooled to 15-2O°C and quenched with saturated aqueous ammonium chloride. Reaction mass was extracted with toluene and the combined toluene layer was dried, distilled, the residue purified by column to get the title compound as solid. DSC: 74.17°C (peak). IR (KBr): 3405, 2980, 2933, 1801, 1739, 1630, 1599, 1502, 1470, 1371, 1300, 1213, 1095, 1061, 1019, 857, 819, and 726 cm"1. 1H-NMR (CDC13, 400MHz): δ 6.54 (s, 1H, Ar. H), 5.26 (s, 1H, CHOH), 5.16 (d, J = 3.8Hz, 2H, OCH2O), 4.21-4.32 (m, 2H, COOCH2CH3), 3.74 (q, J =.2Hz, 2H, OCH2CH3), 2.14 (s, 3H, ArCH3), 1.28 (t, J = 7.2Hz, 3H, OCH2CH3), 1.23 (t, J = 7.2Hz, 3H, OCH2CH3). 13C NMR (CDCI3, 100MHz): δ 173.21 (CO), 149.68 (C-5), 144.41 (C-3), 136.80 (C-2), 119.75 (C-l), 115.25 (C-4), 105.26 (C-6), 94.09 (OCH20), 72.10 (CHOH), 64.19 (OCH2CH3), 62.58 (OCH2CH3), 15.02 (OCH2CH3), 13.88 (OCH2CH3), 8.72 (ArCH3). Mass (EI-MS): 300.19 (M), 299.18 (M-l).

Example 13:
Preparation of ethyl 2-(6-(ethoxymethoxy)-7-methylbenzo[d][l,3]dioxol-4-yl)-2-hydroxyacetate:

By following Example 9 procedure, 0.19g of ethyl 2-(2,3-dihydroxy-5-(ethoxymethoxy)-4-methylphenyl)-2-hydroxyacetate is reacted with l.Og of bromochloromethane and 0.65g of cesium carbonate in DMF medium to get 0.086g of title compound as syrup. IR (neat): 3481, 2978, 2928, 1739, 1492, 1435, 1397, 1365, 1255, 1209, 1117, 1058, 984, 936, 847, and 718 cm'VH-NMR (CDC13, 400MHz): δ 6.51 (s, 1H, Ar. H), 5.96 (d, J = 1.2Hz, 1H, OCH20), 5.92 (d, J = 1.2Hz, 1H, PCH20), 5.17 (br. s., exch. with D20, 1H, OH), 5.15 (d, J = 1.6Hz, 2H, ArOCHjjO), 4.19-4.30 (m, 2H, OCH2OCH2CH3), 3.72 (q, J = 6.8Hz, 2H, COOCH2CH3), 2.10 (s, 3H, ArCHj), 1.25 (t, J - 7.2Hz, 3H, OC^CHj), 1.23 (t, J = 7.2Hz, 3H, OCHzCHj). 13C NMR (CDC13, 100MHz): δ 173.04 (CO), 151.26 (C-6), 146.70 (C-la), 139.58 (C-3a), 116.38 (C-4), 110.94 (C-7), 105.55 (C-5), 101.30 (C-2), 94.43 (OCH20), 68.83 (CHOH), 64.29 (OCH2CH3), 62.17 (OCH2CH3), 15.09 (OCH2CH3), 14.04 (OCH2CH3), 8.96 (ArCH3)

Claims We claim

1. A novel and improved process for the preparation of 2-sustituted-2-(6-(substituted)-7-methylbenzo[d][l,3]dioxol-4-yl)acetic acid derivatives of formula-I,

Wherein R1 is a O-protecting group such as methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran-2-yl, allyl; X is hydroxyl, halogen, mesylate, triflate, tosylate, acetate; Y is oxygen atom, NH or sulfur atom; R2 is C1-C6 alkyl
which comprises:

(i) Reaction of 2,4-dihydroxy-3-methylbenzaldehyde with an etherification reagent in the presence of a base (or acid in case of tetrahydropyran-2-yl protection) and a solvent at 0-100°C to get the mono-protected derivative of formula-XII,

XII Wherein Ri = methoxymethyl, ethoxymethyl, trialkylsilyl, tetrahydropyran-2-yl, allyl, arylmethyl (ii) Oxidation of compound of formula-XII with an oxidizing agent in the presence of a base and a solvent at pH 7-14 to get the dihydroxy compound of formula-XIII,

XIII Wherein R1 = methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran-2-yl, allyl; (iii) Reaction of dihydroxy compound of formula-XIII with a base and an aldehyde compound of formula-XIV,

Wherein Y and R2 are as defined above
in the presence of a solvent at 0-100°C to get the compound of formula-XV,

Wherein R1, Y, and R2 are as defined above (iv) Reaction of dihydroxy compound of formula-XV with a dihalomethane in the presence of a base and a solvent at 15-120°C to get the methylenedioxy derivative of formula-XVI

Wherein R1, Y, and R2 are as defined above (v) Conversion of hydroxyl group to X wherein X is as defined above using a suitable reagent in the presence of a base at -78 to 40°C to get the compound offormula-I

Wherein R1, R2, X, and Y are as defined above.

2. An improved process as claimed in claim 1 wherein the base used in step (i) is selected from trialkylamine, sodium or potassium carbonate, bicarbonate, preferably trialkylamine, more preferably N,N-diisopropylethylamine.

3. An improved process as claimed in claims 1 and 2 wherein the solvent used in step (i) is selected from halogenated solvents, ethers, and hydrocarbons, preferably halogenated solvents, more preferably methylene chloride.

4. An improved process as claimed in claims 1-3 wherein the preferred temperature of reaction in step (i) is 10-40°C, more preferably 10-25°C.

5. An improved process as claimed in claims 1-4 wherein the oxidizing agent used in step (ii) is hydrogen peroxide, meta-chloroperbenzoic acid, peracid such as peracetic acid, preferably hydrogen peroxide.

6. An improved process as claimed in claims 1-5 wherein the preferred pH of reaction mass during oxidation in step (ii) is 7.5-8.5, more preferably 7.8-8.3.

7. An improved process as claimed in claims 1-6 wherein the solvent used in step (ii) is water or aqueous alcohols, preferably water.

8. An improved process as claimed in claims 1-7 wherein the base used in step (ii) is selected from sodium or potassium bicarbonate, carbonate, hydroxide, preferably sodium or potassium hydroxide, more preferably sodium hydroxide.

9. An improved process as claimed in claims 1-8 wherein the base used in step (iii) is Cl-C6 alkylmagnesium chloride or bromide, magnesium C1-C6 alkoxide, preferably C1-C6 alkylmagnesium chloride, more preferably methylmagnesium chloride or n-butylmagnesium chloride.

10. An improved process as claimed in claims 1-9 wherein the preferred temperature of the reaction in step (iii) is 0-45°C.

11. An improved process as claimed in claims 1-10 wherein the solvent used in step (iii) is selected from a halogenated solvent such as dichloromethane, a hydrocarbon solvent such as pentane, hexane, heptane, cyclohexane, toluene, xylene, and an ether solvent such as diethyl ether, tetrahydrofuran (THF), diisopropyl ether, methyl tert-butyl ether, or a combination thereof, preferably a combination of toluene and THF.

12. An improved process as claimed in claims 1-11 wherein the base used in step (iv) is selected from sodium, potassium or cesium carbonate, preferably cesium carbonate.

13. An improved process as claimed in claims 1-12 wherein the solvent used in step (iv) is selected from a hydrocarbon solvent such as pentane, hexane, heptane, cyclohexane, toluene, xylene, a dipolar aprotic solvent such as N,N-dimethylformamide, N,N-dimethylacetamide, an ether solvent such as THF, a nitrile such as acetonitrile, preferably N.N-dimethylformamide and / or toluene.

14. An improved process as claimed in claims 1-13 wherein the preferred temperature of the reaction in step (iv) is 25-50°C, more preferably 25-35°C.

15. An improved process as claimed in claims 1-14 wherein the dihalomethane used in step (iv) is bromochloromethane, bromoiodomethane, dibromomethane, dichloromethane, diiodomethane, preferably bromochloromethane.

16. An improved process as claimed in claims 1-15 wherein the reagent used for conversion of hydroxyl to X in step (v) is thionyl chloride, methanesulfonyl chloride, triflic anhydride, acetyl chloride, acetic anhydride, p-toluenesulfonyl chloride, benzenesulfonyl chloride, carbon tetrachloride/triphenylphosphine, carbon tetrabromide/triphenylphosphine, preferably thionyl chloride or carbon tetrabromide/triphenylphosphine.

17. An improved process as earned in Cairns ,-,6 wherein the base used for conven»n of hydroxyl to X in step (v) is selected front benzotriazoie, diazabicycloundecane (DBU), «ropy,et»y>anri»e, trietnylantine, prefer* diisopropyietHyiarnme or benzotriazole.

18. An improved process as claimed in claims 1-17 wherein the preferred temperature of the reaction for conversion of hydroxyl to X in'step (v) is -40 to 25°C.

19. Compounds of formula-XIII,
Wherein R1 = methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran-2-yl, allyl.

20. Compounds of formula XV,

Wherein R1 = methoxymethyl, ethoxymethyl, trialkylsilyl, arylmethyl, tetrahydropyran-2-yl, allyl.