FORMULATIONS INCLUDING IMPROVED ORGANOCLAY COMPOSITIONS

Abstract: Organoclay compositions which comprise the reaction product of a smectite-type clay having an ion exchange capacity of at least 50 meq. wt. per 100 g. clay (active basis), and an alkoxylated quaternary ammonium compound having one or two alkoxylated chains containing 0-10 moles ethylene oxide and 3-15 moles of propylene or butylene oxide residues are useful thixotropic materials, especially for the preparation of aqueous systems such as latex paint formulations.

Description: FORMULATIONS INCLUDING IMPROVED ORGANOCLAY COMPOSITIONS BACKGROUND OF THE INVENTION This invention relates generally to organoclays, and, more specifically, to improved organoclays which are produced by the reaction of the organoclay with an alkoxylated quaternary ammonium compound. Organoclays, representing the reaction product of a smectite-type clay with a quaternary ammonium compound, have long been known for use in gelling of organic liquids such as lubricating oils, linseed oil, toluene and the like. A large variety of highly useful products, such as lubricating greases, are producible through use of such gelling agents. The procedures and chemical reactions pursuant to which these organoclays are prepared, are well-known. Thus, under appropriate conditions, the organic compound which contains a cation, will react by ion exchange with the clay which contains a negative layer lattice and exchangeable cations to form the organoclay products. Other uses for such modified organoclays are those such as are disclosed in U. S. Patent 5,151,155, wherein organically modified smectite clays are utilized in a process for deinking wastepaper, and in U. S. Patent 4,677,158, wherein smectite-type clays which have been reacted with quaternary ammonium compounds are utilized as thickeners for aqueous suspensions, particularly latex paints and caulks. These modified organoclays differ from those of the present invention in the type of quaternary ammonium compound with which they are reacted. This modification produces organoclays with markedly superior properties than those of the prior art. OBJECTS OF THE INVENTION It is an object of the present invention to prepare organoclay compositions having improved rheological properties, and thus useful as thixotropes in aqueous compositions. It is further an object of the present invention to prepare improved aqueous compositions, especially paint formulations, which possess improved properties by virtue of their inclusion of the organoclay compositions of the present invention. SUMMARY OF THE INVENTION In accordance with the present invention, it has unexpectedly been discovered that the reaction of smectite-type clays with certain alkoxylated quaternary ammonium compounds can produce organoclay products having superior properties when utilized as water-based thixotropes. Thus, the present invention is concerned with an organoclay composition comprising the reaction product of a smectite-type clay having an ion exchange capacity of at least 50 meq. wt. per 100 g. clay (active basis) , and an alkoxylated quaternary ammonium compound having the following formula: wherein R, and R 2 are alike or different, and are selected from the group consisting of C,-C 8 alkyl, benzyl or 2-hydroxyethyl groups; R 3 is a C,-C 8 alkyl, benzyl or 2-hydroxyethyl group, or an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide, and mixtures thereof; and R 4 is an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide, and mixtures thereof; and X is the salt anion. DESCRIPTION OF PREFERRED EMBODIMENTS The smectite clays which are utilized as one of the starting materials of the present invention are those which have been conventionally utilized in the prior art. Suitable smectite-type clays are those which have a cation exchange capacity of at least 50 milliequivalents (meq.) weight (wt.) per 100 grams of clay (active basis). Useful clays for such purposes include the naturally occurring Wyoming variety of swelling bentonite and similar clays, and hectorite, which is a swelling magnesium-lithium silicate clay. The clays are preferably converted to the sodium form if they are not already in this form. This can be effected, again as in known in the art, by a cation exchange reaction, or the clay can be converted via an aqueous reaction with a soluble sodium compound. Smectite-type clays prepared synthetically can also be utilized, such as montmorillonite, bentonite, beidelite, hectoritesaponite, and stevensite. Such clays, and processes for their preparation, are described in U. S. Patents 4,695,402, 3,855,147, 3,852,405, 3,844,979, 3,844,978, 3,671,190, 3,666,407, 3,586,478, and 3,252,757. The alkoxylated quaternary ammonium salts which are reacted with the smectite-type clay are of the formula R 2 I θ θ - R 3 -N-R, X I I R 4 wherein R] and R 2 are alike or different, and are selected from the group consisting of C j -C 8 alkyl, benzyl or 2-hydroxyethyl groups; R 3 is a C^Cg alkyl, benzyl or 2-hydroxyethyl group, or an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtures thereof; and R 4 is an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtures thereof; and X is the salt anion. The salt anion X is methosulfate, ethosulfate, methylcarbonate, ethylcarbonate, chloride, bromide, or mixtureε thereof, and is most preferably a methosulfate ion. The salt anion may also, however, be nitrate, hydroxide, acetate, or mixtures of these. The alkoxylated chains present in the alkoxylated quaternary ammonium compounds of the present invention determine the particularly advantageous properties of the resultant organoclays of the present invention. Thus, the prior art organoclays which contain saturated alkyl groups in the quaternary ammonium compound provide modified organoclays which are too hydrophobic to be useful in aqueous systems. Likewise, the use of the prior art polyethoxylated chain quaternary ammonium compounds provide modified organoclays which are too hydrophilic and which provide organoclays which are difficult to de-water during processing steps. It is thus critical to the present invention to provide quaternary ammonium compounds which, upon reaction with the smectite-type clay, will afford an organoclay composition having the desired hydrophobic/hydrophilic balance, resulting in desirable properties in the end- products. Preferred embodiments of the present invention will utilize quaternary ammonium compounds having one or two alkoxylated chains each containing 1-5 moles ethylene oxide and 4-10 moles propylene oxide and/or butylene oxide residues. Highly preferred embodiments of the present invention are organoclays which comprise the reaction product of smectite-type clays with alkoxylated quaternary ammonium compounds wherein the R 3 and R 4 chains each contain the residue of 5 moles ethylene oxide and 5 moles propylene oxide, and are thus represented by the following formula: (CH 3 ) 2 N [ (CH 2 CH 2 0) x (CH 2 CH(CH 3 )O y ] 2 H wherein x and y = 5 or wherein R 3 and R 4 each contain the residue of 1 mole of ethylene oxide and 4 moles of propylene oxide, represented by the formula: (CH 3 ) 2 N [ (CH,CH 2 0) x (CH 2 CH(CH 3 ) (0) y ] 2 H wherein x and y = 4 or wherein R 3 and R 4 each contain the residue of 1 mole ethylene oxide and 5 moles each of propylene oxide and butylene oxide, represented by the formula: (CH 3 ) 2 N [ (CH 2 CH 2 0) x (CH 2 CH(CH 3 )0) y (CH 2 CH(CH 2 CH 3 )0) z ] 2 H wherein x=l, y=5 and z=2. Other preferred embodiments of the invention involve the reaction product of a smectite-type clay with an alkoxylated quaternary ammonium compound wherein R,, R 2 and R 3 are each a methyl group and R 4 is an alkoxylated chain containing 1 mole ethylene oxide and 9 moles propylene oxide represented by the formula: (CH 3 ) 3 N [(CH 2 CH 2 0) x (CH 2 CH(CH 3 )0) y ] H wherein x=l and y=9 or when R 4 is an alkoxylated chain containing 1 mole ethylene oxide, 5 moles propylene oxide and 5 moles of butylene oxide represented by the formula: (CH 3 ) 3 N [(CH 2 CH 2 0) x (CH 2 CH(CH 3 )0) y (CH 2 CH(CH 2 CH 3 )0) H wherein x=l, y=5 and z=5; x, y and z when employed herein denote relative reactive molar ratios and the reaction products generally represent a product distribution centered around these ratios. Other quaternary ammonium salts which are particularly useful in the present invention are described in the U.S. Patents 3,123,641, 4,144,122, 4,432,833 and 5,296,627. The alkoxylated quaternary ammonium compounds useful in the present invention of the present invention can be prepared by various methods known by those of ordinary skill in the art. In a preferred method, the quaternary ammonium compound is prepared by the reaction of a tertiary amine and an alkylating agent. Some alkylating agents, well known to those practicing the art, include organic halides such as methyl chloride, diorganosulfates such as dimethyl sulfate, or diorgano carbonates, such as dimethyl carbonate. This method of preparation is described in ENCYCLOPEDIA OF CHEMICAL TECHNOLOGY edited by Kirk/Othmer (Third Edition, Vol 19, page 521-531). The tertiary amine, useful in preparing the quaternary ammonium salt, is preferably a polyalkoxylated amine produced by reacting ammonia, a primary amine, or a secondary amine with an alkoxylating agent. Suitable alkoxylating agents include alkyl epoxides such as ethylene oxide, propylene oxide, and butylene oxide. Tertiary polyalkoxylated amines which can also be employed in the present invention are prepared by reacting ammonia, a primary amine, or a secondary amine with a polyalkoxylated alcohol or polyalkoxylated glycol. Especially useful tertiary amines may also be made by alkylating a primary, or secondary alkoxylated amine, such as the available JEFFAMINE® series of alkoxylated amines available from Huntsman Chemicals (JEFFAMINE® is a registered mark of Huntsman Chemicals Inc.) or the available TECTRONIC® series of alkoxylated amines available form BASF Corporation (TECTRONIC® is a registered trademark of BASF Corporation) . Examples of other tertiary amines useful in the present invention can be found in U.S. Patent Nos. 3,654,370, 4,739,094, 4,960,942, 4,967,005, 5,344,984 and 5,347,051. The amount of the alkoxylated quaternary ammonium compound reacted with the smectite-type clay depends upon the specific clay and the desired degree of hydrophobicity. Typically, the amount of cation ranges from about 0.1 to about 150%, preferably from about 100 to about 130% of the cation exchange capacity of the clay. Thus, for example, when bentonite is used, the amount of cation reacted with the clay will range from about 85 to about 143 milliequivalents, preferably from about 95 to about 124 milliequivalents per 100 grams of clay, 100% active basis. A further embodiment of the present invention is the procesε for preparing the organoclay composition comprising the reaction product of a smectite-type clay having an ion exchange capacity of at least 50 meq. wt. per 100 g. clay (active basis) , and an alkoxylated ammonium compound of the formula: Θ θ R 3 -N-R ! X wherein R, and R 2 are alike or different, and are selected from the group consisting of C^Cg alkyl, benzyl or 2-hydroxyethyl groups; R 3 is a C,-Cg alkyl, benzyl or 2-hydroxyethyl group, or an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtures thereof; and R 4 is an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtureε thereof; and X iε the salt anion. Such process comprises the steps of: a) dispersing of a smectite-type clay having an ion exchange capacity of at least 50 meq. wt. per 100 g. clay in an aqueous media; b) heating the dispersion of step (a) to a temperature in excess of 30° C; c) adding the heated dispersion of step (b) to a quaternary ammonium salt of the formula R 7 θ R 3 -N-R, X R 4 wherein R, and R 2 are alike or different, and are selected from the group consisting of Cj-C 8 alkyl, benzyl or 2-hydroxyethyl groups; R 3 is a C^Cg alkyl, benzyl or 2-hydroxyethyl group, or an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consiεting of propylene oxide, butylene oxide and mixtureε thereof; and R, iε an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtures thereof; and X is the salt anion, in the desired milliequivalent ratio; and d) agitating the mixture of step (c) to effect completion of the reaction. The organoclay composition of the present invention is thuε prepared by admixing an aqueous dispersion of the smectite-type clay, warmed to a temperature in excess of 30 °C, with an alkoxylated quaternary ammonium compound of formula I to exchange the metal counterions that are naturally present in the smectite-type clay. The reaction iε typically conducted at a temperature within the range of from about 40 °C. to about 100 °C. for a period of time εufficient for the alkoxylated quaternary ammonium compound to react with the clay particleε. Preferably, the clay iε diεpersed in the water at a concentration from about 3% to about 15% by weight and the slurry iε centrifuged to remove non-clay impuritieε. The εlurry iε then agitated and heated to the deεired temperature, and the quaternary ammonium εalt added in the desired milliequivalent ratio. The alkoxylated quaternary ammonium compounds are typically liquids, but they can be dispersed in water to facilitate the reaction. Agitation is continued to effect completion of the reaction. The amount of the alkoxylated quaternary ammonium compound added to the smectite-type clay for the purposes of thiε invention must be sufficient to impart to the clay the enhanced characteristics desired. The milliequivalent ratio is defined as the number of milliequivalents of the alkoxylated quaternary ammonium compound, per 100 grams of clay, 100% active basis. The typical smectite-type clays of this invention have a milliequivalent ratio of from about 10 to about 150. The preferred milliequivalent ratio will vary depending on the characteristics of the particular alkoxylated quaternary ammonium compound utilized and the end use for the resultant product. When the organoclay composition of the preεent invention is utilized for its rheological properties for application as to control sagging of fluid films and prevent settling and hard packing of pigments preεent in paint compositions, particularly latex paint compositions, it is typically employed in an amount of about 5 lb. to about 95 lb./lOO gallons paint compoεition. The present invention thus contemplates the preparation of latex paint formulations having improved properties which comprise the addition of the improved organoclay composition which is the reaction product of a smectite- type clay having an ion exchange capacity of at leaεt 50 meq. wt. per 100 g. clay and an alkoxylated quaternary ammonium compound of the general formula I. Typically, the latex paint formulation will contain the improved organoclay composition in an amount of about 2 to about 10% by weight of the finished latex paint formulation. Preferred formulations contain the organoclay thixotrope in an amount of about 3 to about 6% by weight of the finished latex paint formulation. Latex paint formulations containing the organoclay composition of the instant invention exhibit superior characteriεticε when bruεh out, roll out and spray out applications were compared with standard commercially available latex paint formulations. The latex paints formulated using the organoclay compositions exhibited a high low-shear viscosity and a low high-shear viscosity in contrast to the commercial paints which exhibited lower low-shear values and higher high-shear values. When sheared, these latex paint formulations thinned out to a flowable and workable viscoεity. The low high-shear viscosity of the these latex paints resultε in excellent atomization in airless spray application. In addition, the presence of the organoclay in the latex paint formulations improved the εag characteristics of these paints to such a degree that sprayouts of thirty mils or higher were common. It haε alεo been diεcovered that it is advantageous to react a high solidε level concentration of the εmectite- type clay with the alkoxylated quaternary ammonium compound of formula I. The reεultant organoclay will thus be present in a concentration of about 14-20% or higher rather than a concentration of 8-10%. The high solids level organoclay has unexpectedly been found to provide advantages in flexibility to the latex paint formulator. Previously, it had been thought that the incorporation of a high solids level organoclay in a latex paint formulation would result in a degradation of the performance of the paint. The latex paint formulator was always seeking to utilize as high a concentration of organoclay as possible since a significant amount of water was present in the latex paint formulation becauεe of other ingredientε present in the formulation. Prior to the instant invention, it was not possible to prepare a satisfactory latex paint formulation utilizing a high solids level organoclay. It has now been found that when the organoclay has been prepared to a high solidε level, latex paints containing such high εolids level organoclay exhibit excellent performance in viscosity, sag resistance, tint strength, hiding power and ease of application of the paint by brush or roller. In order to prepare the high solidε level organoclay, it is necesεary to first prepare a smectite-type clay aqueous εlurry having a high solids level and also having a low viscosity. Processes for preparing such slurries are well known in the prior art, e.g. see United States Patents 5,266,538 and 5,391,228. These processes typically involve the dispersion of a smectite-type clay such as a montmorillonite clay in an aqueous solution containing 1-35 wt.% of one or more dispersant-type salts such aε tetraεodium pyrophosphate or one or more non- dispersant-type εalts such as sodium or potassium chloride, carbonate, nitrate, citrate, sulfate, acetate,low molecular weight sodium acrylate, trisodium or tripotassium phosphate and the like. A useful high εolids level, low viscosity smectite-clay slurry may be prepared by mixing, using a high-shear mixer, the clay with an aqueous solution containing 2-4 wt.% tetrasodiu pyrophosphate. The resultant high solids level clay slurry is then reacted with the alkoxylated quaternary ammonium compound of formula I to produce a high solids level (e.g. about 10-20 wt.%) aqueous organoclay slurry which may then be incorporated into the latex paint formulation. EXAMPLE 1 The preparation of a smectite-type clay composition comprising the reaction product of a smectite-type clay and a quaternary ammonium compound of formula I wherein the R, and R 2 are each a methyl group and the R 3 and R 4 chains each contain the residue of 5 moles ethylene oxide and 5 moles propylene oxide is prepared as follows: 5,000 grams of an aqueous three pass slurry of montmorillonite SCPX 818 containing 3.72 % solidε in a 20 liter tank iε heated to 60 °C. To this heated slurry iε then added 87.19 grams of the alkoxylated quaternary ammonium compound of formula I wherein the R, and R 2 are each a methyl group and the R 3 and R 4 chains each contain the residue of 5 moles ethylene oxide and 5 moles propylene oxide (AKR 94005 Lot #94016RS-T) at 30 MER, which mixture is then stirred in a "Lightning" mixer for 15 minutes until the clay swells and mixing is no longer possible. After transfer to a liter jar, no separation was observed after 24 hours, indicating completion of the reaction. This was calculated 5.03% solids, 255.89 grams dry clay. EXAMPLE 2 The preparation of a smectite-type clay composition comprising the reaction product of a smectite-type clay and a quaternary ammonium compound of formula I wherein the R, and R 2 are each a methyl group and the R 3 and R 4 chains each contain the residue of 1 mole ethylene oxide and 5 moles propylene oxide is prepared as follows: 5,000 grams of an aqueous three pass slurry of montmorillonite SCPX 818 containing 3.72 % solids in a 20 liter tank is heated to 60 "C. To this heated slurry is then added 43.6 grams of the alkoxylated quaternary ammonium of formula I wherein the R, and R 2 are each a methyl group and the R 3 and R 4 chains each contain the residue of 1 mole ethylene oxide and 5 moles propylene oxide (ARK 94006 Lot #94016RS-T) at 20 MER, which mixture is then stirred for 15 minutes using a "Lightning" mixer until the clay swells and mixing is no longer posεible. After transfer to a liter jar, no separation was observed after twenty-four hours, indicating completion of the reaction. This was calculated 4.38% solidε, 220.91 gramε dry clay EXAMPLE 3 A latex paint formulation consisting of: Volume Material Weight 5 5.. .8855 Organoclay as prepared in Example 1 49.70 14. .42 Water 120.30 0. .09 Troysan 142-Bacterioεtat 1.00 0. .65 Tamol 731 6.00 0. .05 Potaεεium Tripolyphoεphate 1.00 0 0.. .3344 Triton N-101 3.00 0. .13 AMP-95 1.00 2. .55 Propylene Glycol 22.00 0. .27 Bubble Breaker 748 2.00 Procedure for preparation: Add together the following and mix: 5.09 Ti0 2 175.00 4.42 No. 1 White 100.00 3.56 Snowflake White 80.00 7.99 ECCA Tex 90 175.00 Diεperse to 5+ Hegman 3400 RPM, 15 m. Dispermat 16.61 Water 138.50 0.27 Bubble Breaker 748 2.00 5.85 Organoclay prepared as in Example 1 49.70 1.14 Texanol 9.00 Then, mix and add: 31.27 UCAR 376 Latex 283.00 Check the following specifications: Viscosity, KU 95 ICI, Poise 0. 8 BF 1 66,800 BF 10 10,520 BF 100 1,904 Leneta Sag 12 Leneta Leveling 3 - Final pH 8.16 Weight/Gallon 11.95 Syneresis 120/10D 1-2% Syneresis Ambient EXAMPLE 4 A latex paint formulation consisting of: Volume Material Weight 8.19 Organoclay prepared as in Example 1 69.58 12.04 Water 100.42 0.09 Troysan 142-Bacteriostat 1.00 0.65 Tamol 731 6.00 0.05 Potassium Tripolyphosphate 1.00 0.34 Triton N-101 3.00 0.13 AMP-95 1.00 2.55 Propylene Glycol 22.00 0.27 Bubble Breaker 748 2.00 Procedure for preparation: Add together and mix the following: 5.09 Ti0 2 175.00 4.42 No. 1 White 100.00 3.56 Snowflake White 80.00 7.99 ECCA Tex 90 175.00 Disperse to 5+ Hegman 3400 RPM, 15 . Dispermat 14.22 Water 118.62 0.27 Bubble Breaker 748 2.00 8.19 Organoclay prepared as in Example 1 69.58 1.14 Texanol 9.00 Then, mix and add: 31.27 UCAR 376 Latex 283.00 Check the following specifications: Viscoεity, KU 126 ICI, Poiεe 1.0 BF 1 82,000 BF 10 28,100 BF 100 5,710 Leneta Sag 724 Leneta Leveling 1 Final pH 8.14 Weight/Gallon 11.96 Syneresis 120/10D 1-2% Syneresis Ambient EXAMPLE 5 A latex paint formulation consisting of : Volume Material Weight 5.40 Organoclay prepared as in Example 2 45.66 14.91 Water 124.34 0.09 Troysan 142-Bacteriostat 1.00 0.65 Tamol 731 6.00 0.05 Potassium Tripolyphosphate 1.00 0.34 Triton N-101 3.00 0.13 AMP-95 1.00 2.55 Propylene Glycol 22.00 0.27 Bubble Breaker 748 2.00 Procedure for preparation: Add the following ingredients together and mix: 5.09 Ti0 2 175 . . 00 4.42 No. 1 White 100 .. 00 3.56 Snowflake White 80 .. 00 7.99 ECCA Tex ,90 175 . , 00 Disperse to 5+ Hegman 3400 RPM, 15 m. Dispermat 17.09 Water 142 , . 54 0.27 Bubble Breaker 748 2 .. 00 5.40 Organoclay prepared as in Example 2 45 .. 66 1.14 Texanol 9 .. 00 Then, mix and add: 31.27 UCAR 376 Latex 283 . . 00 Check the following specifications: Viεcoεity, KU 94 ICI, Poiεe 0.8 BF 1 68,800 BF 10 11,560 BF 100 2,028 Leneta Sag 12 Leneta Leveling 3-4 Final pH 8.19 Weight/Gallon 11.96 Synereεis 120/10D 1-2% Syneresis Ambient EXAMPLE 6 A latex paint formulation consisting of the following: Volume Material Weight 8.11 Organoclay prepared as in Example 2 68.49 12.17 Water 101.51 0.09 Troysan 142-Bacteriostat 1.00 0.65 Tamol 731 6.00 0.05 Potassium Tripolyphosphate 1.00 0.34 Triton N-101 3.00 0.13 AMP-95 1.00 2.55 Propylene Glycol 22.00 0.27 Bubble Breaker 748 2.00 Procedure for preparation: Add the following together and mix: 5 5..0099 T TiiOO,, 175.00 4.42 No. 1 White 100.00 3.56 Snowflake White 80.00 7.99 ECCA Tex 90 175.00 Disperse to 5+ Hegman 3400 RPM, 15 m. Dispermat 14.35 Water 119.71 0.27 Bubble Breaker 748 2.00 8.11 Organoclay prepared as in Example 2 68.49 1.14 Texanol 9.00 Then, mix and add: 31.27 UCAR 376 Latex 283.00 Check the following specifications: Viscosity, KU 102 ICI, Poise 0.9 BF 1 72,400 BF 10 16,400 BF 100 3,076 Leneta Sag 16 Leneta Leveling 2 Final pH 8.17 Weight/Gallon 11.95 Syneresis 120/10D 1-2% Syneresis Ambient EXAMPLE 7 A latex paint formulation consisting of: Volume Material Weight 20.00 Organoclay prepared as in Example 2 170.00 0.09 Troysan 142-Bacteriostat 1.00 0.65 Tamol 731 6.00 0.05 Potassium Tripolyphosphate 1.00 0.23 Triton N-101 2.00 0.13 AMP-95 1.00 2.55 Propylene Glycol 22.00 0.27 Bubble Breaker 748 2.00 Procedure for preparation: Add together the following and mix: 5.47 Ti0 2 175.00 4.42 No. 1 White 100.00 7.99 Satintone white 175.00 3.46 Minex 7 75.00 Disperse to 5+ Hegman 3400 RPM, 15 m. Dispermat 1.73 Water 14.40 0.27 Bubble Breaker 748 2.00 20.00 Organoclay prepared as in Example 2 170.00 1.14 Texanol 9.00 Then, mix and add: 31.27 UCAR 376 Latex 283.00 EXAMPLE 8 A latex paint formulation consisting of: Volume Material Weight 40.00 Organoclay prepared as in Example 2 340.00 adjusted on a dry solids basis (Organoclay + water = 170.0 grams) 0.09 Troysan 142-Bacteriostat 1.00 0.65 Tamol 731 6.00 0.05 Potasεium Tripolyphosphate 1.00 0.34 Triton N-101 3.00 0.13 AMP-95 1.00 2.55 Propylene Glycol 22.00 0.27 Bubble Breaker 748 2.00 Procedure for preparation: Add together the following and mix: 5.09 Ti0 2 175.00 4.42 No. 1 White 100.00 3.56 Snowflake white 80.00 7.99 ECCA TEX 90 175.00 Diεperεe to 5+ Hegman 3400 RPM, 15 m. Dispermat 2.18 Water 18.20 0.27 Bubble Breaker 748 2.00 1.14 Texanol 9.00 Then, mix and add: 31.27 UCAR 376 Latex 283.00 EXAMPLE 9 Comparison of Paint Formulations A. An aqueous slurry of non-exchanged montmorillonite added to paint at a rate of 6 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 94,400 cps. 10 RPM 17,880 cps. 100 RPM 2,884 cps. Krebs Stormer Viscoεity 99 KU ICI Cone and Plate Viscosity 0.9 Leneta Chart Sag Reading 10 Leveling Reading 30 pH 8.55 Temp. C° 23.6 Pounds/Gallons 11.90 Syneresis Settling Rating, 120/10D % 1.63 Scrub rating 94/152 106/152 Brush Drag Rating 2.5-3 Brush Out Rating Good Loading Poor Leveling Roller Splatter Rating 6 Spray Out Rating Good Atomization at 12-14 mil. Roll Out Rating 2 Splatter Fine Texture B. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94005 (prepared as in Example 1, at 30 milliequivalents/100 grams montmorillonite) added to the same paint as A at 7 dry lbs/100 gallons paint was found to have the following characteristicε: Brookfield Viεcosity 1 RPM (rotations per minute) 80,000 cps. 10 RPM 14,400 cps. 100 RPM 2,628 cps. Krebε Stormer Viscosity 97 KU ICI Cone and Plate Viscos:ity 0.8 Leneta Chart Sag Reading 8 Leveling Reading 4 PH 8.57 Temp. C° 23.7 Pounds/Gallons 11.92 Syneresis Settling Rating , 120/10D % 1.2 Scrub Rating 115/188 148/211 Brush Drag Rating 2 Brush Out Rating Good Loading Poor Leveling Roller Splatter Rating 6-7 Spray Out Rating Good Atomization at 20 mils. Roll Out Rating 5 Splatter Med Texture C. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94006 (prepared as in Example 2 at 20 milliequivalents/100 grams montmorillonite added to the same paint as A at 6 dry lbs/100 gallons paint waε found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 92, r 000 cps 10 RPM 19, r 400 cps 100 RPM 3, ,648 cps Krebs Stormer Viscosity 109 KU ICI Cone and Plate Viscosity 0.9 Leneta Chart Sag Reading 10 Leveling Reading 4 pH 8.61 Temp. C° 23.5 Pounds/Gallon 11.95 Syneresis Settling Rating, 120/10D % 1.65 Scrub Rating 101/136 101/152 Brush Drag Rating 3 Brush Out Rating OK Loading Poor Leveling Roller Splatter Rating 8 Spray Out Rating Good Atomization at 18 mils. Roll Out Rating 5 Splatter Coarse Texture D. An aqueous slurry of non-exchanged montmorillonite added to paint at a rate of 6 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 104,000 cps. 10 RPM 28,400 cps. 100 RPM 4,470 cps. Krebs Stormer Viscosity 115 KU ICI Cone and Plate Viscosity 0.9 Leneta Chart Sag Reading 14 Leveling Reading 1-2 pH 8.17 Temp. C° 22.6 Pounds/Gallon 11.77 Syneresis Settling Rating, 120/10D % 1.85 Scrub Rating 166/200 137/216 Brush Drag Rating 2.5 Brush Out Rating Good Loading Roller Splatter Rating 7-8 Spray Out Rating Good Atomization at 16 milε. Roll Out Rating 4 Splatter Fine Texture E. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94005 (prepared as in Example 1, at 30 milliequivalents/100 grams montmorillonite) added to the same paint as D at 7 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 81,600 cps. 10 RPM 16,360 cps. 100 RPM 2,840 cps. Krebs Stormer Viscosity 101 KU ICI Cone and Plate Viscosity 0.8 Leneta Chart Sag Reading 8-9 Leveling Reading 3 pH 8.24 Temp. C° 22.6 Pounds/Gallon 11.95 Synereεis Settling Rating, 120/10D % 1.79 Scrub Rating 154/183 122/159 Brush Drag Rating 2.5-3 Brush Out Rating Good Loading Roller Splatter Rating 8 Spray Out Rating Good Atomization at 17 mils. Roll Out Rating 2 Splatter Fine Texture F. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94005 (prepared as in Example 1, at 30 milliequivalents/100 grams montmorillonite) added to the same paint as D at 8 dry lbs/100 gallonε paint waε found to have the following characteristics: Brookfield Viscoεity 1 RPM (rotationε per minute) 127,000 cps. 10 RPM 34,260 cps. 100 RPM 6,280 cps. Krebs Stormer Viscosity 132 KU ICI Cone and Plate Viscosity 1.1 Leneta Chart Sag Reading 16 Leveling Reading 1 pH 8.21 Temp. C° 22.8 Pounds/Gallon 11.84 Syneresis Settling Rating, 120/10D % 1.32 Scrub Rating 137/154 103/167 Brush Drag Rating 2.5-3 Brush Out Rating Good Loading Roller Splatter Rating 9 Spray Out Rating Good Atomization at 18 mils. Roll Out Rating 5 Splatter Fine Texture G. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94006 (prepared as in Example 2 at 20 milliequivalents/100 grams montmorillonite) added to the paint at 6 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 130,000 cps. 10 RPM 27,000 cps. 100 RPM 4,640 cps. Krebs Stormer Viscosity 118 KU ICI Cone and Plate Viscosity 0.9 Leneta Chart Sag Reading 12-13 Leveling Reading 2 pH 8.18 Temp. C° 22.7 Pounds/Gallon 11.90 Syneresis Settling Rating, 120/10D % 1.67 Scrub Rating 165/197 177/208 Brush Drag Rating 2.5-3 Brush Out Rating Good Loading Roller Splatter Rating 8-9 Spray Out Rating Good Atomization at 20 mils. Roll Out Rating 2 Splatter Medium Texture H. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94006 (prepared as in Example 2 at 20 milliequivalents/100 grams montmorillonite) added to the paint at 6 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 81,000 cps. 10 RPM 23,100 cps. 100 RPM 4,290 cps. Krebε Stormer Viεcoεity 114 KU ICI Cone and Plate Viscosity 0.9 Leneta Chart Sag Reading 12 Leveling Reading 2-3 pH 8.30 Temp. C° 22.6 Pounds/Gallon 11.88 Syneresis Settling Rating, 120/10D % 1.72 Scrub Rating 182/236 170/220 Brush Drag Rating 3 Brush Out Rating OK Loading Roller Splatter Rating 7-8 Spray Out Rating Good Atomization at 25-30 mils. Roll Out Rating 3 Splatter Medium Texture I. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94006 (prepared as in Example 2 at 20 milliequivalents/100 grams montmorillonite) added to the paint at 7 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 121,000 cpε. 10 RPM 37,400 cps. 100 RPM 6,900 cps. Krebs Stormer Viscosity 136 KU ICI Cone and Plate Viscoεity 1.1 Leneta Chart Sag Reading 18 Leveling Reading 1 pH 8.23 Temp. C° 22.5 Pounds/Gallon 11.81 Syneresiε Settling Rating, 120/10D % 1.61 Scrub Rating 145/196 157/196 Bruεh Drag Rating 3.5 Bruεh Out Rating Ex . Loading Roller Splatter Rating 8-9 Spray Out Rating Good Atomization at 18 mils. Roll Out Rating 5 i Splatter Medium Texture J. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94005 (prepared as in Example 1 at 30 milliequivalents/100 grams montmorillonite) added to the paint at 7 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscoεity 1 RPM (rotationε per minute) 86,800 cpε. 10 RPM 17,880 cps. 100 RPM 3,192 cps. Krebs Stormer Viscosity 100 KU ICI Cone and Plate Viscosity 0.8 Leneta Chart Sag Reading 10 Leveling Reading 3 pH 8.48 Temp. C° 23.0 Pounds/Gallon 11.90 Syneresis Settling Rating, 120/10D % 1.61 Scrub Rating 145/190 163/194 Brush Drag Rating 2 Brush Out Rating OK Loading Easy Roller Splatter Rating 9 Spray Out Rating Good Atomization at 16 mils. Roll Out Rating 5 Splatter Rough Texture K. An aqueous slurry of montmorillonite exchanged with the quat ACAR 94006 (prepared as in Example 2 at 20 milliequivalents/100 grams montmorillonite) added to the paint at 5 dry lbs/100 gallons paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 76,000 cps. 10 RPM 15,520 cps. 100 RPM 2,680 cps. Krebs Stormer Viscosity 95 KU ICI Cone and Plate Viscosity 0.8 Leneta Chart Sag Reading 10 Leveling Reading 4 pH 8.32 Temp. C° 22.7 Pounds/Gallon 11.89 Synereεiε Settling Rating, 120/10D % 2.42 Scrub Rating 131/197 160/200 Bruεh Drag Rating 2 Bruεh Out Rating Ex . Loading Eaεy Roller Splatter Rating 8 Spray Out Rating Good Atomization at 19 mils. Roll Out Rating 2 ; Splatter Medium Splatter L. Benjamin Moore Contractor Flat Enhance Vinyl Latex paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 22,000 cps 10 RPM 6,960 cps 100 RPM 2,548 cps Krebs Stormer Viscosity 102 KU ICI Cone and Plate Viscosity 1.1 Leneta Chart Sag Reading 8 Leveling Reading 5 pH 8.50 Temp. C° 23.6 Pounds/Gallon 12.14 Synereεiε Settling Rating, 120/10D % <1 Scrub Rating 30/70 30/70 Bruεh Drag Rating 4 Bruεh Out Rating Good Loading Leveling OK Roller Splatter Rating 9 Spray Out Rating Fair Atomization at 12 milε. Roll Out Rating 5 Splatter Leveling OK M. Benjamin Moore Regal Wall Satin paint was found to have the following characteristics: Brookfield Viscosity 1 RPM (rotations per minute) 20,800 cps. 10 RPM 4,500 cps. 100 RPM 1,420 cps. Krebs Stormer Viscosity 87 KU ICI Cone and Plate Viscosity 1.4 Leneta Chart Sag Reading 15 Leveling Reading 7 pH 7.54 Temp. C° 23.3 Pounds/GalIon 10.82 Syneresis Settling Rating, 120/10D % <1 Scrub Rating 130/180 120/200 Brush Drag Rating 2 Brush Out Rating Good Loading Leveling OK Roller Splatter Rating 7 Spray Out Rating Fair Atomization at 1. I mils. Roll Out Rating 5 Splatter Leveling OK N. Benjamin Moore Contractor Flat with added paint was found to have the following characteriεticε: Krebε Stormer Viεcosity 97 KU ICI Cone and Plate Viscosity 1.5 Leneta Chart Sag Reading 10 Slight color change when comparing sealed Leneta chart drawdown versus unsealed Leneta chart drawdown. 0. Benjamin Moore paint with added tint was found to have the following characteristics: Krebs Stormer Viscosity 100 KU ICI Cone and Plate Viscosity 1.4 Leneta Chart Sag Reading 18 Slight color change when comparing sealed Leneta chart drawdown versus unsealed Leneta chart drawdown. P. Product of Example 2 with commercial antisplattering Associative Thickener (Rohm & Haas) agent added. ICI Cone and Plate Viscosity 1.2 Roller Splatter Rating 8 TEST METHODS Sag and leveling were conducted on Leneta antisag bar and leneta leveling bar on Leneta form 7B.

Claims: WHAT IS CLAIMED IS: 1. An improved latex paint formulation wherein the improvement compriseε the inclusion of about 2 to about 10% by weight of an organoclay composition comprising the reaction product of a ε ectite-type clay having an ion exchange capacity of at least 50 meq. wt. per 100 g. clay (active basis) , and an alkoxylated quaternary ammonium compound having the following formula: R 2 I Θ θ R 3 -N-R, X I ' I R 4 wherein R, and R 2 are alike or different, and are selected from the group consisting of C^C^ alkyl, benzyl and 2-hydroxyethyl groups; R 3 is a C,-C x alkyl, benzyl or 2-hydroxyethyl group, or an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtures thereof; and R 4 is an alkoxylated chain containing 0-10 moles ethylene oxide and 3-15 moles of an alkylene oxide residue selected from the group consisting of propylene oxide, butylene oxide and mixtures thereof; and X is the salt anion. 2. The formulation according to Claim 1 wherein the improvement comprises inclusion of 3 to 6 % by weight of the organoclay composition. 3. The formulation according to Claim 1 wherein the alkoxylated quaternary ammonium compound of formula 1 has the formula wherein R 3 and R 4 are each independently an alkoxylated chain containing 1-5 moles ethylene oxide and 4-10 moles of an alkylene oxide residue selected from the group consiεting of propylene oxide, butylene oxide, and mixtures thereof. 4. The formulation according to Claim 3 wherein the alkoxylated quaternary ammonium compound of formula I has the formula wherein R 3 and R, each contain the reεidue of 5 moleε ethylene oxide and 5 moles propylene oxide. 5. The formulation according to Claim 3 wherein the alkoxylated quaternary ammonium compound of formula I has the formula wherein R 3 and R 4 each contain the residue of 1 mole of ethylene oxide and 4 moles of propylene oxide. 6. The formulation according to Claim 3 wherein the alkoxylated quaternary ammonium compound of formula I haε the formula wherein R 3 and R 4 each contain the residue of 1 mole ethylene oxide and 5 moleε each of propylene oxide and butylene oxide. 7. The formulation according to Claim 1 wherein the alkoxylated quaternary ammonium compound of formula I haε the formula wherein R,, R 2 , and R 3 are each a methyl group and R 4 is an alkoxylated chain. 8. The formulation according to Claim 7 wherein the alkoxylated quaternary ammonium compound of formula I has the formula wherein R 4 is an alkoxylated chain containing 1 mole ethylene oxide and 9 moles propylene oxide. 9. The formulation according to Claim 7 wherein the alkoxylated quaternary ammonium compound of formula I has the formula wherein R 4 is an alkoxylated chain containing 1 mole ethylene oxide, 5 moles propylene oxide, and 5 moles butylene oxide. 10. The formulation according to Claim 1 wherein the organoclay composition is incorporated into the paint formulation in the form of an aqueous slurry in which the organoclay solids level in the slurry ranges from about 10 to 20 wt.%.

Inventors: BAUER CARL J, BOOTHE JOHN D, DENNIS HARRY RYAN, ORTIZ JOE A, POWELL CLOIS E, BAUER, CARL, J., BOOTHE, JOHN, D., DENNIS, HARRY, RYAN, ORTIZ, JOE. A., POWELL, CLOIS, E.
Applicants: SOUTHERN CLAY PROD INC, SOUTHERN CLAY PRODUCTS, INC.
Application year: 1996
Main classification: C08K3
IPC codes: C01B33, C09C1, C09D5, C09D7, C09D201