Synthetic organo- and polymer–clays: preparation, characterization, and materials applications

Abstract We have over the years developed and patented a general technique for the hydrothermal synthesis of clay minerals in the presence of organic, organometallic, and polymeric intercalants. This review will summarize the details for crystallization of modified hectorites along with their characterization and materials applications. Among the several potential uses of these synthetic materials, there are two important applications concerning catalysis and composites. The fate of the template dictates which of these applications is pertinent. First, if the organic molecule or polymer is used with the intention of acting as templates of pore structure, then the organic template is removed after the modified clay has been crystallized. Upon template removal, the now porous materials are examined for their use as potential catalysts and catalyst supports. We have recently proven a correlation between catalyst pore size in the mesoporous range and the size and concentration of a polymeric template that is used. Preliminary hydrodesulfurization catalytic results have been obtained using these materials. If, on the other hand, intercalants are allowed to remain as a part of the structure, then a distinctive class of organic–inorganic composites becomes possible. When polymeric intercalants are used, especially at high concentrations, the materials have relevance to nanocomposite applications. Work in this area has focused on incorporating polymers at higher than 85 wt.% of the nanocomposite.