CA1105636A

CA1105636A - Thixotropic polyester compositions containing an organophilic clay gellant

Info

Publication number: CA1105636A
Application number: CA298,980A
Authority: CA
Inventors: Claude M. Finlayson
Original assignee: NL Industries Inc
Current assignee: NL Industries Inc
Priority date: 1977-06-27
Filing date: 1978-03-15
Publication date: 1981-07-21
Also published as: AU3508178A; NL174736C; JPS5543002B2; IT1094871B; NZ186737A; NO149392B; AR228835A1; BR7804049A; US4081496A; SE437845B; PH13992A; IT7823942A0; NO780923L; DE2813294C2; FR2396042A1; NO149392C; FR2396042B1; FI780887A; SE7803317L; BE865266A

Abstract

TITLE:
THIXOTROPIC POLYESTER COMPOSITIONS CONTAINING AN
ORGANOPHILIC CLAY GELLANT
ABSTRACT:

Thixotropic cross-linkable polyester compositions are provided comprising an unsaturated polyester and an unsaturated aromatic monomer such as styrene having dispersed therein an organophilic clay gellant comprising the reaction product of a smectite-type clay having a cation exchange capacity of at least 75 milliequivalents per 100 grams of clay and a methyl benzyl dialkyl ammonium compound or a dibenzyl dialkyl ammonium com-pound, said alkyl groups comprising a mixture of long chain alkyl radicals having from 14 to 22 carbon atoms, preferably 16 or 18 and most preferably wherein 20% to 35% of said long chain radicals contain 16 carbon atoms and 10% to 75% of said long chain radicals contain 18 carbon atoms, the amount of said ammonium compound reacted with said clay being from 100 to 120 milliequivalents per 100 grams of clay based on 100% active clay.
The polyester compositions are prepared by a pregel method in which the organophilic clay gellant is mixed with the un-saturated aromatic monomer under high shear to form a pregel and the pregel is then combined with an unsaturated polyester to form the thixotropic compositions.

Description

:~10~i636

2 Lhis invention is concerned with thixotropic polyester

3 compositions containing as a gelling agent an organophilic clay

4 comprising the reaction product of a smectite-type clay and a ~ methyl benzyl dialkyl ammonium compound or a dibenzyl dialkyl 6 ammonium compound and the preparation of said compositions from 7 a pregel of an unsaturated aromatic monomer containing said 8 organophilic clay.
g Unsaturated polyester compositions comprising polyesters 0 based on unsaturated acids or acid anhydrides and diols in ad-~1 mixture with unsaturated aromatic monomers such as styrene have 12 been described heretofore for the productlon of cross-linked 13 polymers ini~lated by peroxicles. In the preparation of glass fi.ber relnforllled lamlnates of these. cross-linkecl polymers, thixo-tropic gelling agents are employed which decrease the viscosity of 16 the uncross-linked polyester at high shear such as is developed lq in mixing and spraying but which increase their viscosity at low 8 or no shear to prevent drainage of the composition along the lg vertical surfaces to which they are applied.
In the past, asbestos and fine particle size silica have 21 acted as efficient gelling agents for such polyester compositions.
22 ilowever, both asbestos and silica, especially fibrous silica, 23 present health hazards; also, silica often reduces the clarity 24 and shelflife of compositions in which it is contained.
In an effort to depart from the use of silica and asbestos ~6 as gelling agents, certain organophilic clays, which have hereto-27 fore been effective gellants for liquid hydrocarbon systems~
have been employed as gellants for unsaturated polyester composi-28tions. Such organophilic clays can be described as the ~ ¦ reaction product of a natural or synthetic clay and a higher 31 alkyl-containing quaternary ammonium compound. For purposes o~

~2 ~ 6~
l . .,., .1, 1 ¦ brevity, these organophilic clays are often named as compounds 2 ¦ rather than reaction products, e.g. dimethyl dioctadecyl am-¦monium bentonite or benzyl methyl ditallow ammonium hectorite.
~ ¦ In U. S. Patent 3,014,001 to E. J. ~lurray for example, 6 1 glossy air-cured and non-inhibited polyester coatings are des-6 ¦ cribed WhiCIl are prepared from a polymerizable unsaturated ¦ polyester composition which includes an allcyl resin derive~
~ ¦ from a mixture of maleic anhydride, phthalic anhydride and a ¦ diol and a copolymerizable unsaturated monomer such as styrene.
0 ¦ The composition also contains an organic peroxide catalyst, a metallic salt drier, a crystalline wax, and an organic onium 12 bentonite such as dimethyl dloctadecyl ammonlum bentonite or other organic on:ium bentonLte fiold under the registerecl traciemarlc "BENTONI" of N L Industries, Inc. The pol.yester compositions of this patent are prepared by first dispersing the bentonite in ~6 the unsaturated aromatic monomer and the dispersion is then lq added to a polyester composition also containing the wax, drier ~8 and peroxide catalyst.
19 ¦ In U. S. Patent 3,974,125 to Oswald and Barnum, thixotropic 20 gelling agents for liquid unsaturated polyester compositions ¦
2~ are described comprising higher dialkyl dimethyl ammonium clays 22 which are incorporated into the polyester by a pregel process.
23 The pregel process comprises mixing the quaternary ammonium clay 24 with an unsaturated aromatic monomer such as styrene under high shear to form a pregel and then mixing the pregel with a major 26 amount of an unsaturated polyester which may also contain ad-~7 ditional monomers to produce a clear and stable gelled polyester 28 having thixotropic properties. The higher dialkyl groups of the ~9 dialkyl dimetilyl ammonium clays contain from 14 to 24 carbon atoms, ~0 preferably 16 to 18 carbon atoms. Dioctadecyl and ditallow groups ~2 -3-`
~ i;3~ I

1 are cited as most effectivc. The clays include the natural and 2 synthetic metal and ammonium alumino silicates with the three-layered montmorillonites being preferred. The unsaturated 4 polyester comprises from 50% to 95% by weight of the total 6 composition with the unsaturated aromatic monomer constituting 6 the remainder. The gelling agent concentration in the final polyester composition ranges from 0.25% to ]0% by weigllt oE the 8 total composition. In preparlng the pregels, the amount of clay 9 gellant can range from 0.5% to 25% and preferably 2% to :l2% by ~0 weight of the pregel.
11 Although the organophilic clay gellants such as the dimethyl 12 higher dialkyl ammonium montmorillonites as described in tllc 13 above patents provide thixotropic properties to the final poly-ester compositions in wllicll they are incorporated, these gellants 16 do not form handleable pregels at high concentration of organo-6 philic clay, i.e., the pregels are not flowable and are not homogenous mixtures. The pregels of U. S. Patent 3,974,125 18 containing about 6% clay gellant for example, are grease-like in 19 consistency and cannot be handled further for addition to the polyester without special equipment and cost to the user. At 1 concentrations of gellant greater than 6%, these pregels are so 22 stiff they are virtually unhandleable for further use. Pregels 28 formed from hectorite derivatives of such compounds form accept-able pregels but do not impart tlle desired rheology to the final polyester composition. This is not only true for the clay gel-26 lants of the above patents, but also of other organophilic clays 27 such as trimethyl higher alkyl and dimethyl benzyl higher alkyl ~8 bentonites. This restriction on the amount of clay gellant which 29 can be used to form handleable pregels, in turn limics the amount of clay gellant which can be incorporated into the final 3~

- ' f~ 6~B6 ~

polyester composition because the maximum amount of unsaturated aromatic monomer which carl be combined with the polyester is 3 also 'limited. ~or example, if a polyester formulation comprlsing 4 70~ unsaturated polyester and 30~ styrene by weight is combined ~ with additional styrene and a thicker.er, the maximum amount of 6 styrene which can be added is limited by a ratio of 58 parts by 7 weigl!t of ester to 42 parts by weight of styrene. Therefore the 8 gellant concentration in the styrene pregel dictates the gellant concentration in the final polyester composition; it cannot be 0 increased by attempts to increase the styrene.
In U. S. Patent 3,97~,125, the 6~ concentration of gellant 2 in the styrene pregel llmited the amount of gellant which could 3 be incor~orated in the unsaturated polyester compositions of the ~ ¦ examples to about 1.5%. When it was desired to prepare thixotropic 15 l unsaturated polyester compositions containing greater than 1.5%
6 ¦ gellant, resort was made to the direct addition of gellant to ¦an unsaturated polyester resin ,as in Example 7.
18 ¦ The present invention on the other hand provides thixotropic 19 ¦polyester compositions prepared by the pregel method containing ~
20 ¦novel organophilic clay gellants whicll when mixed with unsaturated ~1 ¦aromatic monomer at high concentrations form soft and handleable 22 ¦pregels and at the same time impart excellent rheology to the ~3 ¦polyester compositions in which they are incorporated. The 24 ¦polyester compositions and pregels formed with these gellants 25 ¦ are characterized by high viscosities at low shear rates and 26 ¦high thixotropic indices. Thixotropic Index as defined herein is 27 the ratio of the Brookfield viscosity in cps at lO r.p.m (numera-28 tor) and 100 r.p.m. (denominator); each measurement taken after 29 the same time of stirring~ at the same temperature and using the same spindle.

82 _5_ l~
~ 3ç~

2The present invention provides a thixotropic cross-linkable polyester composition and process for preparing said composition 8 by the pregel method wherein the polyester composition comprises 4 an unsaturaLed polyester and an unsaturated aromatic monomer having dispersed therein an organophilic clay gellant comprising the reaction product of a smectite-type clay having a cation exchange capacity of at least 75 milliequivalents per lO0 g of 8 clay and a methyl benzyl dialkyl ammonium compound or a dibenzyl . 9 dialkyl ammonium compound, wherein the alkyl groups contain i4 0 to 22 carbon atoms, and the amount of said ammonium compound 11 ¦reacted with said clay being from 100 to 120 milliequivalents 12 ¦per lO0 g of clay based upon 100% active clay.
,13 ¦ 'l'he polyester composition of thls invention is prepared by ~14 ¦the pregel method which comprlses mixing the organophilic clay lS ¦gellant with the unsaturated aromatic monomer under high shear 16 to form a thixotropic pregel and combining this pregel with a 17 iquid unsaturated polyester which may also contain additional 18 unsaturated aromatic monomer under low shear to form the thixotropic 19 polyester composition. The final polyester composition can then 20 be cross-linked to producè coatings or glass fiber-reinforced 21 laminates as well known ln the art.
22 In a typical procedure, clay gellant and an unsaturated ~3 aromatic monomer such as styrene are mixed in a Cowles dispersator 24 or other high shear apparatus and stirred for ten minutes at 25 2000 r.p.m. to form a soft and handleable pregel. This pregel 26 is then added to an unsaturated polyester and additional styrene 27 under low shear to form a polyester composition having a high thixotropic index and excellent rheology.

ll 3~

The clays used to prepare the organophilic clay gellants of this invention are smectite-type clays which have a cation exchange capacity of at least 75 milliequivalents per 100 grams of clay. Particularly desirable types of clay are the naturally-occurring Wyoming varieties of swelling bentonites and like clays, and hectorite, a swelling magnesium-lithium silicate clay.
The clays, especially the bentonite type clays, are pre-ferably converted to the sodium form if they are not already in this form. This can conveniently be done by preparing an aqueous clay slurry and passing the slurry through a bed of cation exchange resin in the sodium form. Alternatively, the clay can be mixed with water and a soluble sodium compound such as sodium carbonate, sodium hydroxide and the like and shearing the mixture with a pugmill or extruder.
Smectite-type clays prepared synthetically by either a pneumatolytic or, preferably a hydrothermal synthesis process can also be used to prepare the present organophilic clays.
Representative of such clays are Montmorillonite, Bentonite, Beidelllte, Hectorite, Saponite and~Stevensite. These clays may be~synthesi~ed hydrothermally by forming an aqueous reaction mixture in the form of a slurry containing mixed hydrous oxides or hydroxides of the desired metals with or without, as the case may be, sodium (or alternate exchangeable cation of mixture thereof) fluoride in the proportions for the particular synthetic smectite desired. The slurry is then placed in an autoclave and heated under autogenous pressure to a temperature within the range of approximately 100 to 325C, preferably 27~ to 300C, for a sufficient period of time to form the desired product.
~epresentative hydrothemal processes for preparing synthetic smectites are described in the following U.S. patents, ' ..

63~

1 U. S. Patents 3,252,757 to ~ranquist; 3,586,478 to Neumann;
2 3,666,407 to Orlemann; 3,671~190 to Neumann; 3,844,978 and 3 3,844,979 to Hickson; and 3,852,405 and 3,855,147 to Granquist.
4 The cation exchange capacity of the smectite clay.s can ~ be determined by the well-known ammonium acetate method.
6 The quaternary ammonium compounds which are reacted Witil q these.smectite-type clays are methyl benzyl dialkyl or dibenzyl 8 dialkyl ammonium salts, the alkyl groups comprising a mixture of 9 alkyl radicals having from 14 to 22 carbon atoms, preferably i~ 16 or 18 carbon atoms and most preferably 20% to 35% of the alkyl radicals contain 16 carbon atoms and 60% to 75% contain 12 18 carbon atoms. The salt anion is preferably selected from the 13 group consisting of chloride and bromide, and mixtures thereof, 14 and is more preEerably chloride, although other anions such as acetate, hydroxide, nitrite, etc., may be present in the quaternary 16 ammonium salt to neutralize the quaternary ammonium cation. These quaternary ammonium salts can be represented by the formula;

~ ~R~-W- R ~ ~l 23 ~ ¦whe ein R~ is Cll3 or C~ll5C~I:; R2 is CG~I~C~IZ; and R3 and R~ are 24 lalkyl groups containing long chain alkyl radicals having 14 to 25 122 carbon atoms, and most preferably wherein 20 to 35% of said 26 ¦long chain alkyl radicals contain 16 carbon atoms and 60% to 27 175% f said long chain alkyl radicals contain 18 carbon atoms; and 28 ¦wherein M is selected from the group consisting of chloride, 29 ¦bromide, nitrite, hydroxyl, acetate,methyl sulfate and mixtures thereof.

. . .

~ The preferred quaternary ammonium salt is metllyl benzyl 8 dihydrogenated tallow ammontum chloride. Commercially prepared hydrogenated tallow typically analyzes 2.0% Cl", 0.5~ C~5, 4 29.0% Cl6, 1.5% Cl,; 66.0~ ClOand 1.0~ C20alkyl radicals.
The organophilic clays of this invention can be prepared by 6 admixing the clay, quaternary ammonium compound and water together, ; 7 prefer~bly at a temperature within the range of from 100F (38C) 8 to 180F (82C), more preferably from 1~0F ~60C) to 170 F (77 C) 0 for a period of time sufficient for the organic quaternary ammonium compound to coat the clay particles, followed by fil-tering, washing, dryin~, and grinding. If using the organopllilic 13 clays in emulsions, the drying and grin(llng steps may be eliminated .. When admixing the clay, quaternary ammonium compound and water 14 in such concentrations that a slurry is not formed, then the filtration and washing steps can be eliminated.

lq Preferably the clay is dispersed in water at a concentration 18 ¦from about 3% to 7% by weight, the slurry optionally centrifuged ¦to remove non-clay impurities which constitute about 10% to 19 ¦about 50% by weight of the starting clay composit:lon; the slurry 20 ¦agitated and heated to a temperature in the ran~e of ~rom 140F
2~ ~(60C) to 170 F (77 C); the quaternary amine salt added in the 22 ¦desired milliequivalen-t ratio, preferably as a liquid in iso-2~ ¦propanol or dispersed in water; and the agitation continued to 25 ¦effect the reaction.
26 The amount of the quaternary ammonium compound added to the 27 clay for purposes of this invention must be sufEicient to impart ¦to the clay the enhanced dispersion characteristics desired. The 2~ ¦milliequivalent ratio is defined as the number of milliequivalents ¦of the quaternary ammonium compound in the organophilic clay, per 100 grams of clay, 100% active basis. The organophilic clays ~2 _9_ ~ ~ 3~

2 oE this inven~io~ ave a mi}.liequivalent ratio Or from 100 to 120.
3 ~t lower milliequivalent ratios the organophilic clays are in-effective gellants even though they may be eEfective gellants 4 when dispcrsed in a conventional manner with a polar additive. ~t ~ higller milliequivalent ratios the organophilic clays are poor 6 gellants. Ilowever, the preferred milliequivalent ratio within the range of from 100 to 120 will vary depending on the charac-8 teristics o~ the organic system to be gelled by the organopllilic 9 clay.
0 The unsaturated aromatic monomers of this invention are aromatic compounds to which is bonded one or more ethylenically 13 unsaturated radicals such as a vinyl radical, substituted vinyl radical or an allylic rad:ical. Su:ltable monomers include styrene, ~-;nethyl styrene, divlnyl bsnzene and allyl benzene. Styrene is preferred due to its effectiveness, wide use and availability.
6 Such monomers are used in cross-linking the polyesters and also act as diluents to reduce viscosity.
18 The unsaturated polyesters useful in preparing the thixotropic 19 ¦compositions of this invention are polyesters of a dicarboxylic 21 ¦acid and a diol having a major amount oE olefinic unsaturation, yreferably 10 to 75 olefin groups per 100 ester groups. The a2 olefinic unsaturation is preferably derived from the carboxylic ~4 acid although the diol may also be unsaturated. Typical diols are ethylene glycol and propylene glycol. Typical unsaturated 26 acids include maleic acid, fumaric acid and phthalic acid. An-27 llydrides of these acids are also commonly used. Such polyesters 28 are made by conventional techniques of esterification as well known 29 in the art. 5enerally, polyesters having molecular weights of from about 400 to 10,000 and acid numbers in the range of from ~0 35 to 45 mg ~0l~ per gram of resin are useful for preparing ~hixo-a2 tropic compositions of this invention.

.

. , ' ~, . . ..
1-e amounts of organop11ilic clay gellant used in forming the pregels oE this invention can range from 0.25% to 40% by weight 3 of the pregel. In the case of styrene, the upper limit is about 4 20% by weight of the pregel. Preferably, the amount of clay ~ gellant comprises from 6% to l~l% by weight of the pregel. Within 6 these ranges, soft pregels are formed which can be easily handled q for f-urther addition to the unsaturated polyester. By attaining such hig11 gellant concen~rations in the pregels, amounts of clay gellant in the polyester compositions can be up to 4% by l~ weight of the total composition or more while providing excellent ll rheologies to the system.
12 The amounts oE unsaturated polyester in the final polyester 13 composition can range from at least ~0% and preferably from about 14 50% to 95% by weight with the remainder being unsaturclted aromatic monomer.
6 ¦ Pregels based on organophilic bentonite clays, parti~eularly ~7 ¦dimethyl ben~yl dihydrogenated tallow ammonium bentonite, provide 18 ¦excellent pregels and impart the best rheologies to the polyester 19 ¦compositions. Organophilic clays based on l1ectorite give soft 21 ¦pregels but rheologies are somewhat poorer than ti1e bentonite-l based clay gellants.
22 ¦ In order to more completely describe the present invention, 23 the ~ollowing examples are given. All percentages given are 24 based upon weight unless otherwise indicated.
.

~28 ~0 31 ~
~21 .

1 I ~ rl r L 1~ 1 l ¦ ~bout 350 gallons of a 3% slurry of l~yoming bentonite in 8 ¦water ~hich had been previously treated by centrifugation to remove ¦all non-clay impurities and ion-exchanged lo provi~e the clay in ~ ¦the sodium form was heated to about 150F and combined with 74 lbs.
6 ¦ of 77.8% active methyl benzyl dihydrogenated tallow ammonium 7 ¦ chloride. The mixture was stirred for ~l5 minutes, filtered to 8 ¦ remove solids, dried at 150F and finally ground to yield an .9 ¦ organophilic clay gellant containing llO.8 milliequivalents of ¦ quaternary ammonium compound per lO0 grams of clay.
il ¦ ~ styrene pregel was prepared by mixing 1.8 paLts by weight ~2 ¦ of the metllyl ben~yl dihydrogenated tallow ammonlum ~ell~:on:L~e 3 ¦ prepared above (~I~DTA ~entonite) withl62 parts by weight of styrene ¦ in a Cowles dispersator at 2000 r.p.m. for ten minutes. The ¦ resulting pregel was a soft past contai.ning 10% by weight of the 6 ¦ clay gellant. Sixty grams of this pregel were added to 240 grams 7 ¦ of an unsaturated polyester formulation comprising 70% of an un-18 ¦saturated polyester resin and 30% styrene (Polyester 32-125) in 19 la Cowles dispersator and stirred for ten minutes at 2000 r.p.m.
20 ¦The resulting polyester compos:ition contained 58% polyester and 21 ¦ 42% styrene having dispersed therein 2~. of the clay gellant.
22¦ For comparison purposes, 6 grams of fine particle size ~3 ¦silica was added to 219 grams of the above 70% polyester-30%
24 ¦styrene formulation and 75 grams of styrene in a Cowles dispersator 25 land stirred at 2000r.p.m. for ten mlnutes to form a thickened 26 polyester composition containing 2% silica. The silica could ~7 ¦not be added to styrene alone to form -a pregel because of its 28 ¦bulk.
29 ¦ Viscosity data for both polyester compositions are given $0 ~elow in Ta~le I. The viscosity determinatiolls were ma~le U';illg 31 a 13roolcfield I~V'L viscometer using a No. 5 spindle.

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~:1 (~) a2 ~ -13-1 The table shows that tile polyester eomposition made.with MBDTA Uentonite using the pregel method had a higller thixotropic 8 index than the standard silica gell~d composition.
4 In addition, the MBDTA Bentonite gelled styrene was sof.t and easily handled. The polyester compon-;ition in which it was incorporated had excellent rheology.

8 In this example, the polyester composition of Example l, 9 made by the pregel method using methyl benzyl diliydrogenated tallo ~0 ammonium bentonite (~tBDTA Bentonite) was compared to seven other polyesters also made by the pregel method but containing as the organopllilic clay gellant:
13 (a) trimethyl hycirogenated ta:llow ammonium bentonite.
, 1~ (T~ITA BeIltonite) (b) trimethyl hydrogenated tallow ammonium bentonite and 6 a polar additive. (TMTA Bentonite-P.A.) (c) dimethyl dihydro~enated tallow ammonium bentonite.
(DMDTA Bentonite) 9 (d) dimethyl dihydrogenated tallow ammonium hectorite.

21 (DMDTA llectorite) ~2 (e) dimethyl dihydrogenatecl tallow ammon:ium bentonite and a polar additive. (DMDTA Bentonite-P.A.) 23 (f) dimettlyl benzyl hydrogenated tallow ammonium bentonite.
24 (DMBTA Bentonite) (g) dimethyl benzyl hydrogenated tallow ammonium hectorite.
26 (DMBTA ~lectorite) ~9 ~0 !
~ ~ ~$~ ~ ~

1 In each of the comparison polyester coulpositlons, a 7.4%
2 pregel of styrene was prepared by mixing 18.5 g of clay gellant ~ with 231.5 g of styrene (or 229.5 g of styrene and 2.5 g of 95%
4 methanol as the polar additive where applicable) in a Cowles ~ dispersator and stirring at 2000 r.p.m. for ten minutes. To 7 219 g of the 70% polyester-30% styrene formulation of Example 1 in .a Cowles dispersator was added 81 g of the pregel followed by 8 stirring at 2000 r.p.m. for ten minutes to form a polyester composition containing 58~ polyester and 42% styrene having dis-~0 persed therein 2~ of clay gellant. Viscosity measurements, 11 Thixotropic Indices, pregel charactcristicq iln(l rheologies oE ~hc 12 polyester compositions are summarl~ed in Ta~le 2 below. Vis-13 cosity cleterminations were made with a Brookfield RVT viscometer 14 using a No. S spindle.

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1 Table II shows that tl~e organophilic clay gellant of this 2 invention (~IBDTA Bentonite) imparts higller viscosities to the 3 polyester compositions, a higher Thixotropic Index and a better 4 rheology than the comparison examples. ~loreover, Lile pregels formed using tile clay gellant of this invention are softer and moro easily llandled than any of the other gellants which are 7 either too stiEf, too difficult to form by mixing or cavitate durillg mixing thus renclering them unhandeable or preparing the final polyester compositions.

In this example, another organophilic clay gellant according 2 to the invention, methyl benzyl dihydrogenated tallow ammonium 13 llectori~e clay (~ll3DT~ llectorite), was usecl to prepare a 7.4%
styrene pregel wllich was tilen added to a polyester-styrene 15 formulation to form a polyester composition containing 2~ ;' 16 gellant. The gellant was prepared using a similar procedure 17 as set forth in Example 1 from a hectorite clay having a cation 18 exchange capacity of at least 75 milliequivalents per 100 g of 9 clay.
Exactly 18.5 g of this clay gellant was mixed with 231.5 of 21 styrene in a Cowles d:ispersator for ten minutes at 2000 r.p.m.
22 Tlle Brookield viscosities of the resulting pregel was determined at various r.p.m.'s with a Brookfield RVT viscometer using a 24 No. 5 spindle and the condition of tile pregel noted. Then 81 g 25 ¦o this pregel was added to 219 g of the 70% polyester-30~
26 styrene formulation of Example 1 in a Cowles dispersator and ~7 stirred for ten minutes at 2000 r.p.m. Viscosities o the poly-28 ester composition so formed was determined as above. The results 29 are given in Table III below.
~0 ~2 -17-~ S~3~

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~ The pregel was as soft and handleable aS the pregel of MB~TA
2 IBentonite. Rheology of the 2% polyester composition was good.

3 I LX~MPLE ~

4 ¦ In this example, two other organophilic clay gellants ¦according to the invention, dibenzyl dihydrogenated tallow am-6 ¦ monium hectorite (DBDTA llectorite) and dibenzyl dillydrogenated q ¦tallow ammonium bentonite (DBDTA I3entonite), were used to preparc 8 17.4% styrene pregels, each of which were combined with po:Lyester 9 ¦formulations to form polyester compositions containing 2% gellant.
0 ¦ . ~xactly 18.5 g of each clay gellant was mixed with 231.5 g -¦of styrene in a Cowles dispersator Eor ten minutes at 2000 r.p.m.
12 I T~c BrookEield viscosities oE each pregel was determined at 13 ¦various r.p.m. 's witll a 13roolcEield I~VT viscometer using a ~o. 5 14 ¦spindle and the condition of the pregel noted.

5 ¦ ~xactly 81 g of this pregel was added to 219 g of the 70%16 ¦polyester-30% styrene formulation of ~xample 1 in a Cowles dis-17 ¦persator and stirred at 2000 r.p.m. for ten minutes. The vis-18 ¦cosities of the polyester compositions were determined as above.

19 ¦The results are summarized in Table IV.

21 l ~2 I

~5 I

2~ I

3~
a2; -19-:

~ D '.

t~ 1 t~
W O t~ W rt O
t~ ~ 3 ~ 3 ' ~

6 ~ o - :I: W rt ~ ~~1~ ~ .
~ 111Il)11~ Il) rr

7 n ~~o ~ ~ ~.
rt rt , rt rt '1 O ' O O O O rD ~

8 ~
rt rt rt rt ,-- .

13 ~ w CO O O ~ O rt ~
Cl~ O C~ ~ O
14 oo oo ~
~t '-h l--3 or~ ~.
~ l- ~ ~ r~ ~ u, ~ ~ . ,.
16 co ~ o O ~ O ~ ~ C~ C H
17 o o o rt :'~ C
~t O
18 w rs~ ~_, r~ Ul 0~ rt 19 o o ~ ~ o ~ D ~
~ ~ o ~ .
2~ o ~ co oo o I . ~
221 . ' ~.

. 23 1 p~, ~J
rt 26 1-- rt X
O I'~ O
27 w ~ ~D CO O rt r w ~ ~n w ~
co ~ ~ ~ o ~-o c: ~
1~.
~9 r~ n ~
~ O CL
3 ~- X
rt ~2 ~ s~

2 Botll pregels were acceptable as to soLtness and handleabili Ly .
The Iheology oE the polyester composition macle with DBDTA BentoniL
3 was very good; the rheology of the polyester made with DBDT~
4 Hectorite was poorer.
The invention being thus described, it will be obvious that 6 the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of ~he 8 invention and all such modifications ale intended to be included within the scope of the following claims.
' ~0 ~ ' :

' 15 1~

Ig ~4 ~8 2~

Claims

WHAT IS CLAIMED IS:

1. A thixotropic cross-linkable polyester composition com-prising an unsaturated polyester and an unsaturated aromatic monomer having dispersed therein an organophilic clay gellant comprising the reaction product of a smectite-type clay having a cation exchange capacity of at least 75 milliequivalents per 100 grams of clay and a methyl benzyl dialkyl ammonium compound or a dibenzyl dialkyl ammonium compound, wherein the alkyl groups contain 14 to 22 carbon atoms and the amount of said ammonium compound reacted with said clay being from 100 to 120 milli-equivalents per 100 grams of clay based upon 100% active clay.

2. The polyester composition of Claim 1 wherein said un-saturated aromatic monomer is styrene.

3. The polyester composition of Claim 1 wherein said clay is hectorite or sodium bentonite.

4. The polyester composition of Claim 1 wherein said alkyl groups are 16 or 18 carbon atoms.

5. The polyester composition of Claim 1 wherein said un-saturated polyester comprises at least 40% of said composition.

6. The polyester composition of Claim l wherein said organo-philic clay gellant comprises up to 4% by weight of said compo-sition.

7. A thixotropic cross-linkable polyester composition com-prising an unsaturated polyester and an unsaturated aromatic monomer having dispersed therein an organophilic clay gellant comprising the reaction product of a smectite-type clay selected from the group consisting of hectorite and sodium bentonite, and a methyl benzyl dialkyl ammonium compound or a dibenzyl dialkyl ammonium compound, said dialkyl groups comprising a mixture of long chain alkyl radicals, wherein 20% to 35% of said long chain alkyl radicals contain 16 carbon atoms and 60% to 75% of said long chain alkyl radicals contain 18 carbon atoms, the amount of said ammonium compound reacted with said clay being from 100 to 120 milliequivalents per 100 grams of clay based upon 100% active clay, wherein said unsaturated polyester comprises at least 40% of said composition and wherein said organophilic clay gellant comprises up to 4% by weight of said composition.

8. A thixotropic polyester composition comprising an un-saturated polyester and styrene having dispersed therein an organophilic clay gellant comprising the reaction product of a hectorite or sodium bentonite clay having a cation exchange capa-city of at least 75 milliequivalents per 100 grams of clay and a quaternary ammonium compound represented by the formula;

wherein R1 is CH3 or C6H5CH2 ; R2 is C6H5CH2; and R3 and R4 are each a hydrogenated tallow group; and M is selected from the group consisting of chloride, bromide, nitrite, hydroxyl, acetate, methyl sulfate and mixtures thereof; and wherein the amount of ammonium compound reacted with said clay is from 100 to 120 milli-equivalents per 100 grams of clay based on 100% active clay.

9. The polyester composition of Claim 8 wherein said organo-philic clay comprises the reaction product of a sodium bentonite and methyl benzyl dihydrogenated tallow ammonium chloride.

10. The polyester of Claim 8 wherein said organophilic clay comprises the reaction product of a sodium bentonite and dibenzyl dihydrogenated tallow ammonium chloride.

11. The polyester of Claim 8 wherein said organophilic clay comprises the reaction product of hectorite with methyl benzyl dihydrogenated tallow ammonium chloride.

12. The polyester composition of Claim 8 wherein said organophilic clay comprises the reaction product of hectorite with dibenzyl dihydrogenated tallow ammonium chloride.

13. The polyester composition of Claim 8 wherein said organophilic clay gellant comprises up to 4% by weight of said total composition.

14. A process for preparing thixotropic unsaturated polyester composition comprising;
(a) forming a pregel of an aromatic unsaturated monomer with an organophilic clay gellant comprising the reaction product of a smectite-type clay having a cation exchange capacity of at least 75 milliequivalents per 100 grams of clay and a methyl benzyl dialkyl ammonium compound or a dibenzyl dialkyl ammonium compound, wherein the alkyl groups contain 14 to 20 carbon atoms, the amount of said ammonium compound reacted with said clay being from 100 to 120 milliequivalents per 100 grams of clay based on 100% active clay; and (b) combining said pregel with a liquid unsaturated polyester to form a thixotropic composition.

15. The process of Claim 14 wherein the clay gellant com-prises from 0.25% to 40% by weight of said pregel.

16. The process of Claim 15 wherein the clay gellant com-prises form 6% to 14% of said pregel.

17. The process of Claim 14 wherein said pregel is added to said liquid unsaturated polyester.

18. The process of Claim 14 wherein said alkyl groups contain a mixture of long chain alkyl radicals, wherein 20% to 35% of said long chain alkyl radicals contain 16 carbon atoms and 60% to 75% of said long chain alkyl radicals contain 18 carbon atoms.

19. A process for preparing thixotropic unsaturated polyester composition comprising;
(a) forming a pregel of an aromatic unsaturated monomer with an organophilic clay gellant comprising the reaction pro-duct of a smectite-type clay having a cation exchange capacity of at least 75 milliequivalents per 100 grams of clay and a methyl benzyl dialkyl ammonium compound or a dibenzyl dialkyl ammonium compound, said dialkyl groups comprising a mixture of long chain alkyl radicals, wherein 20% to 35% of said long chain alkyl radicals contain 16 carbon atoms and 60% to 75% of said long chain alkyl radicals contain 18 carbon atoms, the amount of said ammonium compound reacted with said clay being from 100 to 120 milliequivalents per 100 grams of clay based on 100% active clay; and (b) combining said pregel with a liquid unsaturated poly-ester to form a thixotropic composition.

20. The process of Claim 19 wherein the clay gellant comprises from 0.25% to 40% by weight of said pregel.

21. The process of Claim 20 wherein the clay gellant comprises from 6% to 14% of said pregel.

22. The process of Claim 19 wherein said pregel is added to said liquid unsaturated polyester.

23. A process for preparing a thixotropic unsaturated polyester composition comprising;
(a) mixing styrene under high shear with an organophilic clay gellant comprising the reaction product of a hectorite or sodium bentonite clay having a cation exchange capacity of at least 75 milliequivalents per 100 grams of clay and a quaternary ammonium compound represented by the formula;

wherein R1 is CH3 or C6H5CH2; K2 is C6H5CH2; and R3 and R4, are each a hydrogenated tallow group; and M is selected from the group consisting of chloride, bromide, nitrite, hydroxyl, acetate, methyl sulfate and mixtures thereof; and wherein the amount of ammonium compound reacted with said clay is from 100 to 120 milli-equivalents per 100 grams of clay, based on 100% active clay, to form a pregel; and (b) adding said pregel to a liquid unsaturated polyester under low shear to form said thixotropic polyester composition.

24. The process of Claim 23 wherein the amount of clay gellant in the pregel is from 0.25 to 40% by weight of said pregel

25. The process of Claim 24 wherein the amount of clay gellant in the pregel is from 6% to 14% by weight of said pregel.