Method for the production of high internal phase emulsion foams

Patent metadata

Field	Value
Publication number	US-9574058-B2
Application number	US-201514730954-A
Country	US
Kind code	B2
Filing date	Jun 4, 2015
Priority date	Jun 6, 2014
Publication date	Feb 21, 2017
Grant date	Feb 21, 2017

Abstract

A method for producing a High Internal Phase Emulsion foam is provided that comprises forming a first High Internal Phase Emulsion from an oil phase comprising monomer, crosslinking agent, emulsifier; and an aqueous phase. The High Internal Phase Emulsion is pumped into a water bath. The High Internal Phase Emulsion cures in the bath.

First claim

What is claimed is:

1. A method for producing a High Internal Phase Emulsion foam comprising the steps of:
forming a High Internal Phase Emulsion from
an oil phase comprising monomer, cross-linking agent, emulsifier,
an aqueous phase, and
an initiator in either the oil or aqueous phase;
pumping the High Internal Phase Emulsion into a water bath;
curing the High Internal Phase Emulsion in the water bath to form a High Internal Phase Emulsion foam.

2. The method of claim 1 , wherein the water bath comprises an electrolyte.

3. The method of claim 2 , wherein the electrolyte is selected from the group consisting of mono-, di-, poly-, or tri-valent inorganics salts of the halides, nitrates and sulfates of alkali metals, and alkaline metals.

4. The method of claim 1 , wherein the electrolyte is NaCl.

5. The method of claim 1 , wherein the water bath comprises an initiator.

6. The method of claim 5 , wherein the initiator is selected from the group consisting of persulfate-bisulfate, persulfate-ascorbic acid, persulfate-thiosulfate, and sodium persulfate (NaPs).

7. The method of claim 1 , wherein the water bath comprises a redox couple capable of reacting with the initiator present in the emulsion.

8. The method of claim 7 , wherein the emulsion comprises persulfate or peroxide and the water bath comprises bisulfate, ascorbic acid, or thiosulfate.

9. The method of claim 1 , wherein the High Internal Phase Emulsion foam exhibits a porosity between 0% and 99.9%.

10. The method of claim 1 , wherein the water bath has a temperature between 70 C and 150 C.

11. A method for producing a High Internal Phase Emulsion foam comprising the steps of:
forming a High Internal Phase Emulsion from
an oil phase comprising monomer, cross-linking agent, emulsifier,
an aqueous phase, and
pumping the High Internal Phase Emulsion into a water bath;
curing the High Internal Phase Emulsion in the water bath to form a High Internal Phase Emulsion foam.

12. The method of claim 11 , wherein the water bath comprises an electrolyte.

13. The method of claim 12 , wherein the electrolyte is selected from the group consisting of mono-, di-, poly-, or tri-valent inorganics salts of the halides, nitrates and sulfates of alkali metals, and alkaline metals.

14. The method of claim 11 , wherein the electrolyte is NaCl.

15. The method of claim 11 , wherein the water bath comprises an initiator.

16. The method of claim 15 , wherein the initiator is selected from the group consisting of persulfate-bisulfate, persulfate-ascorbic acid, persulfate-thiosulfate, and sodium persulfate (NaPs).

17. The method of claim 11 , wherein the High Internal Phase Emulsion foam exhibits a porosity between 0% and 99.9%.

18. The method of claim 11 , wherein the water bath has a temperature between 70 C and 150 C.

19. A method for producing a High Internal Phase Emulsion foam comprising the steps of:
forming a High Internal Phase Emulsion from
an oil phase comprising monomer, cross-linking agent, emulsifier,
an aqueous phase, and
pumping the High Internal Phase Emulsion into a water bath comprising between 0.1% and 5% NaCl;
curing the High Internal Phase Emulsion in the water bath to form a High Internal Phase Emulsion foam.

Assignees

• Procter & Gamble

Inventors

• Foudazi Reza
• Bezik Cody
• Feke Donald L
• Manas-Zloczower Ica
• Merrigan Steven Ray
• Rowan Stuart J

Classifications

• C08J9/0023 Primary

  containing oxygen · CPC title

• C08J2333/08

  Homopolymers or copolymers of acrylic acid esters · CPC title

• C08J9/28

  by elimination of a liquid phase from a macromolecular composition or article, e.g. drying of coagulum · CPC title

• C08F220/1808

  C8-(meth)acrylate, e.g. isooctyl (meth)acrylate or 2-ethylhexyl (meth)acrylate · CPC title

• B29C44/022

  Foaming unrestricted by cavity walls, e.g. without using moulds or using only internal cores · CPC title