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| United States Patent | 5443761 |
| Link to this page | http://www.wikipatents.com/5443761.html |
| Inventor(s) | Burba, III; John L. (Lake Jackson, TX);
Christenson; Christopher P. (Lake Jackson, TX) |
| Abstract | Elastic solids having reversible stress-induced fluidity are prepared,
e.g., by combining liquid formulations with a crystalline mixed metal
hydroxide conforming substantially to the formula
Li.sub.m D.sub.d T(OH).sub.(m+2d+3+n.a) (A.sup.n).sub.a.xH.sub.2 O
where m is amount of Li, d is amount of divalent metal D, T is a trivalent
metal, A represents at least one anion or negative-valence radical of
valence n and a is the amount of A, and xH.sub.2 O represents excess
waters of hydration, if any. These make useful coatings.
The instantly reversible fluidization of these unique elastic solids may be
expressed as:
.tau.=ka.epsilon.,
When .epsilon.<F, for the solid phase; and
.epsilon.=f(d.epsilon.'/dt)
when .epsilon.'<F, (this equation represents a generalized form for the
usual rheological equations); for a cycle of .epsilon., -xF<.epsilon.<xF,
and when .epsilon.' equals 0 the liquid phase changes back to the solid
phase, and
where the symbol .sigma. represents stress; k.sub.a represents an elastic
spring constant for the solid phase, .epsilon. and .epsilon.' are strain
and F is critical strain. |
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Title Information  |
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Drawing from US Patent 5443761 |
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Elastic solids having reversible strain-induced fluidity |
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| Publication Date |
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August 22, 1995 |
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| Filing Date |
October 11, 1991 |
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| Parent Case |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part application of application Ser. No.
07/698,428, filed May 10, 1991, now U.S. Pat. No. 5,196,143 and of
application Ser. No. 07/686,098 filed Apr. 16, 1991, now U.S. Pat. No.
5,232,627, and of continuation-in-part of pending application Ser. No.
07/526,970 filed May 16, 1990, now U.S. Pat. No. 5,094,778 which is a
continuing application under 37 CFR 1.62 of Ser. No. 07/282,445 filed Dec.
9, 1988 (now abandoned) which is a continuing application of Ser. No.
07/047,800 filed May 7, 1987, now U.S. Pat. No. 4,790,954, which is a
continuing application of Ser. No. 06/752,326 filed Jul. 5, 1985, now U.S.
Pat. No. 4,664,843. All of these are incorporated by reference herein in
their entirety.
This is also a continuation-in-part of pending application Ser. No. 577,825
filed Sep. 4, 1990, now U.S. Pat. No. 5,154,932 which is a continuation of
Ser. No. 252,281 filed Sep. 4, 1990 (abandoned), which itself is a
continuation-in-part of application Ser. No. 060,133 filed Jun. 9, 1987,
now U.S. Pat. No. 4,990,268, which is a continuation of application Ser.
No. 752,325 filed Jul. 5, 1985, (now abandoned). The above pending parent
application Ser. No. 577,825 filed Sep. 4, 1990, now U.S. Pat. No.
5,754,932, is also a continuation-in-part of application Ser. No.
07/698,428 filed May 10, 1991, now U.S. Pat. No. 5,196,143 and of pending
application Ser. No. 07/686,098 filed Apr. 16, 1991, now U.S. Pat. No.
5,232,627, and of continuation-in-part of application Ser. No. 07/526,970
filed May 16, 1990, now U.S. Pat. No. 5,094,778 which is a continuing
application under 37 CFR 1.62 of Ser. No. 07/282,445 filed Dec. 9, 1988
(now abandoned) which is a continuing application of Ser. No. 07/047,800,
filed May 7, 1987, now U.S. Pat. No. 4,790,954, which is a continuing
application of Ser. No. 06/752,326, filed Jul. 5, 1985, now U.S. Pat. No.
4,664,843. All of these are incorporated by reference herein in their
entirety.
This is also a continuation-in-part of application Ser. No. 07/568,450
filed Aug. 15, 1990 (abandoned), and of application Ser. No. 07/577,405
filed Sep. 4, 1990 (abandoned), and of pending application Ser. No.
07/609,966, filed Nov. 6, 1990 now U.S. Pat. No. 5,084,209.
Other patents containing related subject matter are U.S. Pat. Nos.
4,822,421; 4,999,025; and 5,015,409, this latter patent being a
continuation-in-part of above said Ser. No. 060,133 filed Jun. 9, 1987.
(now U.S. Pat. No. 4,990,268), which is a continuation of Ser. No. 752,325
filed Jul. 5, 1985, now abandoned. |
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Title Information  |
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Claims  |
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What is claimed is:
1. An elastic solid composition which instantly undergoes a phase change to
a fluid phase upon application of a stress force, and which instantly
reverts back to its elastic solid phase upon cessation of the stress
force, said composition comprising
(a) a fluid having distributed throughout finely-divided particles having
surface ionic charge sites, in admixture with
(b) an amount of colloidal, monodispersed particles having counter-ionic
surface charges effective to form an elastic solid when at rest, and which
is fluid under stress.
2. The composition of claim 1 wherein the ionic properties distributed
throughout the fluid are cationic charges and the opposite ionic charges
are anionic.
3. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is an aqueous medium.
4. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is an organic medium.
5. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is predominantly an organic medium
containing a non-dominant amount of aqueous fluid.
6. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is predominantly an aqueous medium
containing a non-dominant amount of organic fluid.
7. The composition of claim 1 wherein the fluid containing the particles
having ionic charge dispersed therein is a polymeric material.
8. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is a resinous material.
9. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is a resinous material selected
from the group consisting of epoxy resin, novolac resin, urethane resin,
vinyl resin, acrylate resin, acrylic polymer, polycarbonate, polyester
resin, polyalkylene oxide, and polyolefin.
10. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is a solvent for a resinous or
polymeric material and which contains a resinous or polymeric material.
11. The composition of claim 1 wherein the fluid containing the particles
having ionic charges dispersed therein is an aqueous fluid having
dispersed therein a finely divided polymeric or resinous material.
12. An elastic solid composition exhibiting stress-dependent fluidity, said
composition comprising
a fluid containing an amount, sufficient to cause the fluid to be an
elastic solid exhibiting stress-dependent fluidity, of
a crystalline mixed metal hydroxide conforming essentially to the empirical
formula
Li.sub.m D.sub.d T(OH).sub.(m+2d+3+na) (A.sup.n).sub.a.xH.sub.2 O
where m is an amount, in the range of zero to about 1, of Li cations,
D represents divalent metal cations, d is an amount of D and is in the
range of zero to about 4,
T represents a unit amount of trivalent metal cations,
A represents monovalent or polyvalent anions or negative-valent radicals of
valence -n, with a being the amount of A anions;
m+d is greater than zero and (m+2d+3+na) is equal to or greater than 3,
and x is zero or more if there are excess waters of hydration,
said discontinuous phase being essentially uniformly distributed in the
fluid system in an amount which produces a gel which has the
characteristics of an elastic solid having stress-dependent fluidity.
13. The composition of claim 12 wherein the fluid system comprise, an
organic material.
14. The composition of claim 12 wherein the fluid system comprises at least
one organic material selected from the group consisting of polyols,
resins, oils, greases, epoxy resin, novolac resin, urethane resin, vinyl
resin, acrylate resin, acrylic polymer, polycarbonate polyester resin,
polyalkylene oxide, and polyolefin.
15. The composition of claim 12 wherein the fluid system comprises an
aqueous material.
16. The composition of claim 12 wherein the fluid system comprises at least
one aqueous material selected from the group consisting of solutions,
dispersions, suspensions, colloids, emulsions, and water.
17. The composition of claim 12 wherein the fluid system comprises at least
one liquid silicon compound of the group consisting of, silicones,
silicate compounds, polysilane compounds, polysilicates, siloxanes,
silylamino compounds, silylene compounds, silylidene compounds, and
silylthio compounds.
18. The composition of claim 12 wherein the fluid system comprises a fluid
system which contains, in the continuous phase, at least one dispersed
material, colloidal material, suspended material, or emulsified material.
19. The composition of claim 12 wherein the D metal is at least one
selected from the group consisting of Mg and Ca, the T metal is selected
from the group consisting of Al, Fe, and Ga, and A is at least one
selected from the group consisting of hydroxy, oxyhydroxy, alkoxy, and
aryloxy negative valence radicals.
20. The composition of claim 12 wherein the value of m is in the range of
about zero to about 1. the value of d is in the range of about 0.5 to
about 2, and the amount of A is in the range of zero to about 2.
21. The composition of claim 12 wherein the mixed metal hydroxide comprises
monolayered, monodispersed crystals.
22. The composition of claim 12 wherein the mixed metal hydroxide comprises
Mg.sub.d Al(OH).sub.(d+3+na) (A.sup.n).sub.a.xH.sub.2 O,
where d is an amount in the range of about 0.5 to about 2, n.a is a
negative amount in the range of about zero to about 1, and x is an amount
of from zero to about 6.
23. The composition of claim 12 wherein the mixed metal metal hydroxide
essentially comprises MgAl(OH).sub.5.
24. The composition of claim 12 wherein the mixed metal compound comprises
Mg.sub.d Al(OH).sub.(d+3+na) (A.sup.n).sub.a.xH.sub.2 O,
where d is an amount in the range of about 1 to about 2, n.a is a negative
amount in the range of about zero to about 0.5, and x is an amount of from
zero to about 2, and is of the monolayered, monodispersed variety.
25. A process for converting a fluid to an elastic solid having reversible
stress-induced fluidity,
said process comprising adding to the fluid an effective amount of a
crystalline mixed metal hydroxide of the formula
Li.sub.m D.sub.d T(OH).sub.(m+2d+3+na) (A.sup.n).sub.a.xH.sub.2 O
where m is an amount, in the range of zero to about 1, of Li cations,
D represents divalent metal cations, d is an amount of D and is in the
range of zero to about 4,
T represents a unit amount of trivalent metal cations,
A represents monovalent or polyvalent anions or negative-valent radicals of
valence -n, with a being the amount of A anions;
m+d is greater than zero and (m+2d+3+na) is equal to or greater than 3,
and x is zero or more if there are excess waters of hydration,
thereby obtaining an elastic solid composition having stress-induced
fluidity and having the property of instantly reverting to its elastic
solid state after being induced to flow by the the application of stress.
26. The process of claim 25 wherein the numerical value of m is zero: of d
is about 0.5 to about 2, of n.a is zero to about 2, and of x is zero to
about 6.
27. The process of claim 25 wherein the crystalline mixed metal hydroxide
comprises MgAl(OH).sub.( 5+na)(A.sup.n).sub.a with little or no excess
waters of hydration. |
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Claims  |
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Description  |
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BACKGROUND OF THE INVENTION
It has been disclosed in the above-identified applications and patents that
certain crystalline layered mixed metal hydroxides and activated mixed
metal hydroxides can be used in the modification of the viscosity of
various fluid formulations. In some of the disclosures, the said mixed
metal hydroxides are combined with clay, e.g. bentonite and others, and
with fine-particle silica, to form adducts which are useful for viscosity
modification of drilling fluids and other fluids. In some cases, the
viscosity is said to be thixotropic, and in other cases the viscosity is
merely said to be thickened or modified. Also, some of the
above-identified pending applications disclose that fluids gelled by use
of the crystalline layered mixed metal hydroxides will quickly re-gel
after being subjected to shear.
In a paper prepared for presentation at the 1990 Drilling Conference of the
International Association of Drilling Contractors/Society of Petroleum
Engineers in Houston, Tex., Feb. 27-Mar. 2, 1990 , the efficacy of using
MMH (Mixed Metal Hydroxides) in a drilling mud are disclosed. The paper,
in its References section on page 5, refers to other papers about the use
of MMH in drilling muds at meetings of the IAPC/SPE and SPE Symposium on
Oilfield Chemistry in February-March 1989. These publications are
cumulative to the information disclosed in U.S. Pat. Nos. 4,664,843 and
4,790,954, the publication of which pre-dates these papers.
None of the patents identified above disclose any recognition of an
entirely novel type of viscosity effect which is not of the forms
previously known, i.e, those known to rheologists as dilatant,
thixotropic, Newtonian, non-Newtonian, psuedo-plastic, Bingham plastic, or
rheopexic.
Other related patents are U.S. Pat. Nos. 4,822,421; 4,990,268; 4,999,025;
and 5,015,409, this latter patent being a continuation-in-part of the
above-cited Ser. No. 060,133, now U.S. Pat. No. 4,990,268, which is a
continuation of application Ser. No. 7,52,325, field Jul. 5, 1985, now
abandoned.
We have now discovered more about some of these reported compounds and
formulations containing them and have discovered some which undergo a
phase change from an elastic solid state to a fluid state under the force
of stress, rather than shear, and which immediately revert to an elastic
solid state upon cessation of the stress: this is an unexpected
phenomenon, which we believe has not been previously recognized or
reported by others, and is believed to be unique. In a manner of speaking,
it is a phase metamorphosis, not a chemical metamorphosis.
The phase change of going from an elastic solid phase to a fluid phase by
the applying a fluidizing amount of stress, and then reversion back to the
elastic solid phase upon cessation of the stress, is not perceived as a
viscosity modification in the ordinary sense of the term "viscosity
modification".
For example, changing of a Newtonian liquid to a non-Newtonian liquid, or
vice-versa, is one form of a viscosity modification. Changing the degree
or extent of thixotropicity or dilatancy of a liquid is a form of
viscosity modification. These viscosity modifications are not perceived as
being a phase change from an elastic solid phase to a fluid phase.
Instead, our new discovery is perceived as a reversible phase change of an
elastic solid composition having high energy, short range ionic
interactions with a very low degree of reinforcement. Because of this a
stress-induced fluidization of the elastic solid is reversible, since the
high energy, short range interactions are not destroyed, and the low
degree of reinforcement permits the fluidization until reversion back to
an elastic solid.
These elastic solids having reversible stress-induced fluidity are
perceived as being analogous, in their response to a critical stress, to a
solid-state diode in response to a flow of electrons and the cessation of
the flow of electrons.
This novel phase change effect is herein given the name of
"stress-dependent fluidity" as a means of identifying the effect on an
elastic solid which instantly becomes a relatively low-viscosity fluid
under a critical stress. The change from an elastic solid phase to a fluid
phase begins as soon as the critical stress is applied and the reversion
to an elastic solid phase is immediate upon ceasing the stress; by
"immediate" it is meant that the reversion to the elastic solid state is a
fraction of a second, essentially too fast for visual perception or for
measurement using state of the art measuring devices. It is not the same
effect as is obtained using shearing forces to break up a gel or a sol
since those do not immediately return to the form of a gel or sol, (such
as hydrogel, alcogel, organogel, or electrosol) though many will return,
at least to some degree, to a gel or sol over a detectable period of time.
Some of the various previously known forms of gels or sols may even
undergo changes under shearing forces which interfere with, or even
prevent a complete return to their previous form upon cessation of the
shearing forces.
SUMMARY OF THE INVENTION
It has now been found that novel elastic solids having stress-induced
fluidity are prepared by creating a fluid having distributed therein ionic
charge sites and also having distributed therein counter-ionic charge
sites, the charge sites being present in the fluid in sufficient quantity
to produce an elastic solid having stress-induced fluidity. Preferably,
the ionic charge sites are anionic, the counter-ionic charge sites are
cationic, and the chemical moieties containing the ionic sites comprise
about 0.1 to about 50 percent of the total weight of the elastic solid.
When stress is applied to the elastic solid, the elastic solid is strained
until it suddenly becomes fluidized. The point at which fluidization
occurs is referred to here as the critical stress/strain relationship,
which is computed as the critical strain point.
The instantly reversible fluidization of these unique elastic solids may be
expressed as:
.sigma.=ka.epsilon.,
when .epsilon.<F, for the solid phase; and
.sigma.=f(d.epsilon.'/dt)
when .epsilon.'<F, (this equation represents a generalized form for the
usual rheological equations); for a cycle of .epsilon., -xF<.epsilon.<xF,
and when .epsilon.' equals 0 the liquid phase changes back to the solid
phase, and
where the symbol .sigma. represents stress; k.sub.a represents an elastic
spring constant for the solid phase, .epsilon. and .epsilon.' are strain
and F is critical strain.
Compositions comprising elastic solids having stress-dependent fluidity are
found to be useful in a variety of applications for obtaining useful
effects of the unique properties of the compositions. Such compositions
which benefit from the properties include a variety of coatings,
adhesives, gels, resins, and fluids. The fluids comprise aqueous and
organic fluids, such as paints, sealers, fillers, glues, protective
coatings, temporary coatings, and the like, The fluids can be latex,
dispersions, emulsions, solutions, acrylics, acrylates, resins, epoxies,
urethanes, rubbers, polyolefins, polyglycols, polyesters, polycarbonates,
condensation polymers, polyethers, and the like. Temporary coatings, such
as de-icing formulations for airplane wings awaiting take-off, can be
formulated as elastic solids which can be blown off the wings by the total
stress placed on the formulation by air currents during flight.
Notable among the compounds which are used in preparing these elastic
solids, by being added to the desired fluid, are crystalline layered mixed
metal hydroxides, including those prepared in aqueous systems, those
prepared in non-aqueous systems, and those prepared in a combination of
aqueous/non-aqueous systems. Also, adducts of the mixed metal hydroxides
are found to be useful in preparing the elastic solids having
stress-dependent fluidity by being added to the desired fluid. Preferably
the mixed metal hydroxides include aluminum as one of the metals, along
with a divalent metal, especially magnesium, and, in some cases, including
a monovalent metal, especially lithium. Furthermore, the crystalline
layered mixed metal hydroxides may, at times, be called mixed metal
oxyhydroxides or mixed metal hydrous oxides. The expression refers to a
crystalline structure which contains at least two metals, not to a mere
mixture of metal compounds. Most preferable are the crystalline mixed
metal hydroxides, crystalline mixed metal oxides, and crystalline mixed
metal oxy-hydroxides of Mg and Al. One can begin with anhydrous forms, if
desired, and high-temperature activated forms of the mixed metal compounds
can be used.
We have found that there are many compositions or formulations which become
elastic solids exhibiting stress-dependent fluidity when combined with an
effective amount of at least one of the crystalline, layered mixed metal
compounds disclosed herein. There are so many permutations of combinations
of the mixed metal compounds and the fluids to which they are added to
achieve stress-dependent fluidity, that absolute numerical ranges are
difficult to define. The amount of a given mixed metal compound of this
present invention needed to produce an elastic solid having
stress-dependent fluidity can be easily determined by testing a few
concentrations, usually less than about 10% by weight of the mixed metal
compound in the total weight of the combined ingredients. A person skilled
in these relevant arts of adjusting the properties of a fluid, and being
informed of the present invention, will recognize when a formulation has
taken on the appearance of an elastic solid which undergoes a phase change
to a low viscosity fluid under the influence of stress and which
immediately reverts to the elastic solid phase upon cessation of the
fluidizing stress.
DETAILED DESCRIPTIONS INCLUDING BEST MODE KNOWN
As used herein, the term "stress-dependent fluidity" refers to the
fluidization of an elastic solid, which is in contact with a substrate,
upon application of a force which induces the elastic solid to undergo a
phase change to a fluid state, rather than plastic deformation, and flow
along. or upon the substrate. It immediately recovers its elastic solid
state upon cessation of the stress, though the shape and/or position on
the substrate has been changed. Considering that a new concept of
obtaining stress-dependent liquid flow phase in an elastic solid is
encountered here as a reversible phase change, then appropriate means of
describing this unique phenomenon are attempted here.
The term "plug flow" is used in the customary manner to indicate that flow
is not turbulent flow, but is substantially uniform and monolithic along a
flow path, even though there may be some laminar flow due to friction
along the interface of the substrate on which there is flow and which
tends to hold back ("drag") the fluid.
As used herein, the term "activated" (a term often used in the field of
minerals and inorganic chemistry) refers to the heating (thermal
activation) of metal hydroxides or hydrous metal oxides, sometimes in the
presence of CO.sub.2, to a temperature high enough to drive off the waters
of hydration, leaving the metals as "active" metal oxides or
oxy-hydroxides. Activation of hydrous mixed metal oxides and the like is
illustrated in pending application Ser. No. 686,098 filed Apr. 16, 1991
now U.S. Pat. No. 5,232,627, which is incorporated herein by reference as
shown hereinbefore. The activated MMOH (hereinafter sometimes referred to
as an AHMMO) and other AHMMO compounds, which are arid, are very friable
(easily decrepitated), and easily disperse in water as very small
crystals, generally of colloidal size. While one may encounter a chemical
method for creating activated metal oxides or oxy-hydroxides, the thermal
method would be expected to be the easiest and least expensive method.
In one aspect the present invention embodies the making of clay adducts
with activated MMOH of the monolayer and the multi-layer variety as well
as natural and synthetic hydrotalcites (expressed here simply as
MgO.Al.sub.2 O.sub.3 or MgAl.sub.2 O.sub.4 since those are the principal
components) and other forms of activated mixed metal oxides or mixed metal
oxy-hydroxides including AHMMO.
For example, hydrotalcite is a naturally-occurring mineral (that contains
some CO.sub.2 in its structure) which, when thermally dehydrated, yields
an active magnesium aluminum oxide compound or oxyhydroxide compound. Also
for example, magnesium hydroxide and aluminum hydroxide can be combined
(especially in the presence of some CO.sub.2) and heated to yield mixed
metal oxides conforming essentially to the formula (MgO).sub.x.Al.sub.2
O.sub.3, where the ratio of Mg/Al can vary over the range of about 0.01/1
to about 6/1, preferably about 0.5/1 to 4/1. Below that range the amount
of MgO may not be sufficient to yield a mixed metal oxide which behaves
efficiently in the present invention. Above about 4/1, the amount of
excess MgO is likely to form a single metal oxide which is present with
the mixed metal oxide structure, but as a separate phase.
U.S. Pat. No. 4,748,139 discloses the thermal activation of mixed metal
hydroxides at about 500.degree. C. These activated mixed metal oxides were
then made into dense spinel structures at above 1000.degree. C. Examples
are shown starting with Mg(OH).sub.2 mixed with NaAlO.sub.2 and digested
at 105.degree. C. to form a layered magnesium hydroxide/aluminum hydroxide
which forms MgAl.sub.2 O.sub.4 when heated above 500.degree. C. While this
patent teaches the making of some activated mixed metal oxides, it does
not each the formation of an adduct of clay with the activated mixed metal
oxides. Neither does it disclose the making of an elastic solid which can
undergo a reversible phase change and be caused to flow by the force of
stress and recover its elastic solid state upon cessation of stress.
Other than the AHMMO compounds, the MMOH compounds may be prepared in
accordance with the procedures in parent applications and progeny of this
application listed on pages 1 and 2, especially U.S. Pat. No. 4,990,268
where they are prepared in aqueous media and U.S. Pat. No. 5,084,209 where
they are made in a non-aqueous media so as to be subsequently free of
excess waters of hydration.
Natural clays and refined natural clays may vary from one mining location
to another and the performance obtained with one batch may not exactly
match the performance of another batch; the color may not match and the
effect on viscosity may not match. The natural clays, and even refined
natural clays, may contain impurities which can produce non-uniformity
among batches and may create side-reactions with other ingredients in a
formulation to which the clay is added. Clays are normally anionic and can
react with ingredients which are cationic, such as cationic surfactants
used in hair conditioners or in cleansers and the like.
We have found that activated mono-layered and multi-layered mixed metal
hydroxides (MMOH) and other activated hydrous mixed metal oxides, all of
which are referred to here as "AHMMO", especially those which are of
layered crystalline structures exhibiting cationic surface charges, are
beneficially employed as adducts with clay and with other compounds or
materials which are anionic.
For purposes of conciseness, the expression "MMOH" will be used in this
disclosure to refer to the crystalline mixed metal hydroxides which are
described in detail below and the expression "AHMMO" will be used in
reference to activated forms of the MMOH and activated forms of other
hydrous metal oxides. The AHMMO compounds which are made from
synthetically produced mixed metal compounds can be of substantially
consistent quality and purity. AHMMO compounds made from
naturally-occurring minerals, especially hydrotalcites, which can contain
small or trace amounts of metal impurities besides the Mg and Al
components, are particularly useful in the present invention.
The crystalline mixed metal hydroxides (MMOH) used in the present
invention, to create activated mixed metal oxides or oxy-hydroxides,
AHMMO, conform substantially to the empirical formula
Li.sub.m D.sub.d T(OH).sub.(m+2d+3+n.a) (A.sup.n).sub.a.xH.sub.2 O
where m is an amount of Li of from zero to one,
where D represents at least one divalent metal cation and d is an amount of
from about zero to about 4,
where T represents at least one trivalent metal cation,
where A represents at least one monovalent or polyvalent anion or
negative-valence radical,
a is an amount of A ions of valence n, with n.a being an amount of from
about zero to about -3,
where (m+2d+3+n.a) is equal to or more than 3,
where (m+d) is not zero,
and where xH.sub.2 O represents excess waters of hydration, with x being
zero or more.
In the above generic empirical formula, "excess waters of hydration" means
that there is more water associated with the compound than is needed to
supply the amount of hydroxyl ions in the crystal structure. When there is
no excess water and x is essentially zero, the compounds, AHMMO, are very
fine "activated" crystals having a cationic charge which are found to have
a high affinity for forming adducts with anionic compositions such as clay
when dispersed in an aqueous liquid.
In the above formula, it should be noted that n, being the valence of the
anion, is a negative number; thus n.a is a negative number.
The AHMMO compounds are found to be beneficial as thickeners or
viscosity-modifiers for aqueous-based functional products, such as
cleansers, commercial products, household products, and personal care
products when incorporated therein, as well as forming useful adducts with
clay.
In one aspects, the present invention is perceived as being a formulation
of the type described having incorporated therein the MMOH or AHMMO
compounds.
In another aspect, the present invention is perceived as a means, method,
or process for providing viscosity-modifiers or thickeners to the
described formulations by incorporating therein the MMOH or AHMMO
compounds, especially as adducts with clay.
A further aspect is that AHMMO compounds provide a thickened, elastic solid
product which flows readily under even slight stress, but which rethickens
rapidly to an elastic solid state when the stress is ceased. The
re-thickening or gelling rate is perceived as being immediate. Liquid
dispersions of clay adducts prepared in accordance with the present
invention exhibit the novel and unique behaviour of exhibiting fluidity
which is stress dependent. That is, the liquid dispersion is essentially
of a gelled consistency in the absence of any stress placed on it, but
becomes quite fluid upon application of a stress. It exhibits neither
Newtonian activity, nor thixotropic activity, nor dilatant activity, but
instead it responds to a stress placed upon it by instantly becoming very
fluid, then when the stress is removed it returns to its previous gelled
consistency, which we refer to as an elastic solid.
Though there are many forms of clays, the clays preferred for use in the
present adducts comprise the smectite clays, especially the
bentonite-type, and montmorillonite clays. Even though this disclosure is
based largely on the bentonite forms of clay, other forms and classes of
clay are within the ambit of this invention, such as amorphous clay (e.g.
of the allophane group) and crystalline clay (e.g. 2-layer, 3-layer
expanding-type, non-expanding type, elongate-type, regular mixed layer
type, and chain structure type). For example, a non-exhaustive listing of
the clays is as follows:
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bentonite vermiculite kaolinite
chlorite halloysite attapulgite
smectite sepiolite montmorillonite
polygorskite illite Fuller's earth
saconite and the like
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The activated MMOH and AHMMO compounds useful in the present invention are
preferably those of the monodispersed, monolayer variety such as described
in parent parents U.S. Pat. No. 4,664,843 and 4,990,268 identified above.
Compounds which are not of the monolayer varieties, but are of the
multi-layer varieties, are shown, e.g., in U.S. Pat. Nos. 4,326,961;
4,333,846; 4,347,327; 4,348,295; 4,392,979; 4,446,201; 4,461,714; and
4,477,367. These multi-layered varieties in the activated form can be used
in the present invention.
The process, in general, for making the multi-layered varieties of mixed
metal hydroxides involves starting with a soluble compound of a tri-valent
metal and then reacting that with the desired soluble monovalent metal(s)
and/or divalent metal(s) and converting the said compounds with a source
of OH- ions, e.g., NH.sub.4 OH, at a temperature sufficient to create the
multi-layered (generally 2-layer or 3-layer) crystalline mixed metal
hydroxide. In contradistinction thereto, the crystalline monolayer mixed
metal hydroxides are prepared by combining the desired metal compounds in
solution in the desired ratio and then reacting the combination of metal
compounds with a source of OH-- ions at an appropriate temperature for
producing the mixed metal hydroxide crystals.
Thus, for the most part, the MMOH compounds are prepared by the general
process of forming a solution of compounds of the desired metals under
appropriate conditions whereby a source of hydroxyl ions, e.g. ammonium
hydroxide or caustic, reacts with the soluble metal compounds to produce
the layered crystals of mixed metal hydroxides. In some instances, it is
often best to avoid having residual ammonia in the product, in which case
another hydroxy material, especially NaOH or KOH is used.
The process of using activated MMOH and AHMMO compounds to thicken
aqueous-based functional products can be achieved in at least two general
ways. One method, in general, involves the activation of the MMOH and
AHMMO particles by an electrolyte. In this process, the MMOH and AHMMO is
first dispersed by using high shear, sonic waves or other methods known in
the art to produce a high degree of dispersion of agglomerated particles.
Once the material is dispersed in aqueous or partially aqueous media, a
salt (electrolyte) is added either predissolved or dry and mixing/or
shearing is continued until a smooth, thickened system is obtained. Other
ingredients may be blended into the prethickened material. Often, one or
more of the ingredients is a salt and a separate activator is not needed.
The salt used for activation can be almost any ionic substance but
components containing organic anions or multivalent anions such as
CO.sub.3.sup.-2, PO.sub.4.sup.-3, P.sub.3 O.sub.10.sup.-5 and the like are
usually more effective.
The other general method involves interaction with other colloidal
particles in such a manner that they are linked together through bridges
or bonds formed by the MMOH and AHMMO. In these cases, it can be
interpreted as forming an adduct with the other particles. This can
produce an "extension" effect. This can happen, for instance, when fumed
silica or a clay is also an ingredient and less material is needed for
thickening. This can also occur when a normally soluble material is
included in the formulation beyond the point of saturation such that very
small or colloidal particles are present as crystals or agglomerates. In
this case, the thickening occurs when the MMOH or AHMMO and other
particles are sheared together and agglomerates are broken, exposing fresh
faces which react. Adducts of MMOH and fumed silica, a very fine particle
form of silica, are disclosed in pending application Ser. No. 825,794
filed Feb. 10, 1992, now U.S. Pat. No. 5,273,728, which is incorporated
herein by reference.
The expression "mixed metal hydroxide" implies that there are at least two
different metals in the hydrous oxide crystals. In the present invention,
it is preferred that at least one of the metals is a trivalent metal,
along with at least one other metal which can be either, or both, of the
divalent or monovalent (Li) varieties, preferably the divalent variety.
The amount of the A anion (or negative-valence radical) is that which,
with the OH.sup.- ions, substantially satisfies the valence requirements
of the cations in the crystalline material.
In the above described formula, the trivalent metal cation is preferably
Al, Fe, or Ga, and can be mixtures of any of these; Al is most preferred
as the trivalent metal.
The divalent metal cation is preferably Mg, Ca, Mn, Fe, Co, Ni, Cu, or Zn
and can be mixtures of any of these; Ca or Mg, especially Mg, is most
preferred as the divalent metal.
The contents of the numerous formulations that can be thickened or modified
by the addition of AHMMO compounds can be varied widely. Generally, the
ingredients and levels of the ingredients which are in a given formulation
have more to do with a desired effect other than that of thickening or
viscosity-modification. The versatility of the AHMMO compounds is
beneficial in that it can be added to so many formulations for viscosity
purposes without interfering with the other ingredients in their intended
purpose. Substitutions, replacements, and/or eliminations of one or more
of the components (other than the AHMMO compound) often has little effect
on thickening or viscosity-modification.
In the following examples the expression "MMOH" is in reference to certain
compounds within the generic formula shown above and which conform
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