Organoclay compositions prepared from ester quats and composites based on the compositions

An organoclay comprising the reaction product of a smectite clay with a quaternary onium compound mixture wherein the quaternary onium compound mixture comprises a diester quaternary ammonium compound mixed with an additional quaternary ammonium compound, wherein the additional quaternary ammonium compound comprises a triester quaternary ammonium compound, a monoester quaternary ammonium compound, or mixtures thereof.

A method for preparing a nanocomposite comprising:

• contacting a smectite clay with a quaternary onium compound mixture comprising a diester quaternary ammonium compound mixed with an additional quaternary ammonium compound, wherein the additional quaternary ammonium compound comprises a triester quaternary ammonium compound, a monoester quaternary ammonium compound, or mixtures thereof;
• and
• intermixing an organoclay with a polymer matrix.

A nanocomposite comprising an organoclay which has been exfoliated into a polymer matrix, the organoclay being the reaction product of a smectite clay with a quaternary ammonium component, the quaternary ammonium component comprising a monoester compound of formula (I), a diester compound of formula (II), and a triester compound of formula (III):

• wherein X, X′ and X″ are the same or different and are selected from straight or branched chain, oxyalkylene or polyoxyalkylene groups having from 2-6 carbon atoms where the oxyalkylene units number from about 1-10, each R group is individually selected from straight or branched chain alkyl or alkylene groups having from 11 to 23 carbon atoms, Y is and alkylphenyl group or a straight or branched chain C1 to C6 alkyl or alkylene group;
• and Z− represents a halogen or sulfate;
• wherein the diester compound comprises greater than 55 wt. % of the quaternary ammonium component and wherein the triester compound comprises less than 25 wt. % of the quaternary ammonium component.

A nanocomposite comprising an organoclay which has been exfoliated into a polymer matrix, the organoclay being the reaction product of a smectite clay with a quaternary ammonium component, the quaternary ammonium component comprising one or more compounds having the general formula (IV):

• wherein n is an integer from 1 to 2, R is a C5 to C23 straight or branched chain alkyl or alkylene group, each X can be the same or different and is selected from straight or branched chain oxyalkylene or polyoxyalkylene groups having from 2-6 carbon atoms;
• each Q can be the same or different and is selected from a oxyalkylene or polyoxyalkylene group, or straight or branched chain alkyl, alkylene, alkyl phenyl, hydroxyalkyl, or hydroxyalkylene group, wherein at least one of the Q groups is a C2 to C6 linear or branched chain oxyalkylene or polyoxyalkylene capped with a C1 to C6 alkyl, or an alkyl phenyl group;
• and Z− is a halogen or sulfate.

An organoclay comprising a reaction product of a smectite clay with a quaternary ammonium component, the quaternary ammonium component comprising a monoester compound of formula (I), a diester compound of formula (II), and a triester compound of formula (III):

• wherein X, X′ and X″ are the same or different and are selected from straight or branched chain oxyalkylene or polyoxyalkylene groups having from 2-6 carbon atoms, where the oxyalkylene units number from about 1-10, each R group is individually selected from straight or branched chain alkyl or alkylene groups having from 11 to 23 carbon atoms, Y is and alkylphenyl group or a straight or branched chain C1 to C6 alkyl or alkylene group;
• and Z− represents a halogen or sulfate;
• wherein the diester compound comprises greater than 55 wt. % of the quaternary ammonium component and wherein the triester compound comprises less than 25 wt. % of the quaternary ammonium component.

An organoclay comprising the reaction product of a smectite clay with a quaternary ammonium component, the quaternary ammonium component comprising one or more compounds having the general formula (IV):

• wherein n is an integer from 1 to 2, R is a C5 to C23 straight or branched chain alkyl or alkylene group, each X can be the same or different and is selected from straight or branched chain oxyalkylene or polyoxyalkylene groups having from 2-6 carbon atoms;
• each Q can be the same or different and is selected from a oxyalkylene or polyoxyalkylene group, or straight or branched chain alkyl, alkylene, alkyl phenyl, hydroxyalkyl, or hydroxyalkylene group, wherein at least one of the Q groups is a C2 to C6 linear or branched chain oxyalkylene or polyoxyalkylene capped with a C1 to C6 alkyl, or an alkyl phenyl group;
• and Z− is a halogen or sulfate.