Suspension polymerization
First Claim
1. IN A PROCESS OF MAKING SOLID POLYMERIC BODIES IN THE FORM OF SPHEROIDAL GLOBULES HAVING SUBSTANTIALLY UNIFORM SIZE BY FORMING A SUSPENSION OF SMALL DROPLETS OF A POLYMERIZABLE LIQUID COMPRISING STYRENE IN AN AQUEOUS NON-SOLVENT LIQUID MEDIUM, THE APPARENT VISCOSITY OF THE AQUEODS SUSPENDING MEDIUM BEING SUCH THAT MOVEMENT OF THE DISPERSED DROPLETS RELATIVE TO THE SURROUNDING MEDIUM BY ACTION OF GRAVITATIONAL FORCE DUE TO DIFFERENCE IN DENSITY BETWEEN THE DROPLETS AND THE SURROUNDING MEDIUM IS SUBSTANTIALLY PREVENTED, AND POLYMERIZING THE POLYMERIZABLE LIQUID IN SUCH SUSPENSION BY SUBJECTING THE SAME TO CONDITIONS CONDUCTIVE TO POLYMERIZATION WITHOUT TURBULENE WHEREBY THE SUSPENDED DROPLETS OF POLYMERIZABLE LIQUID ARE CONVERTED TO GLOBULES OF POLYMER HAVING APPROXIMATELY THE SAME SIZE AND SHAPE AS THOSE OF THE SUSPENDED DROPLETS, THE IMPROVEMENT THAT COMPRISES MAKING A SUSPENSION OF DROPLETS OF A POLYMERIZABLE LIQUID COMPRISING STYRENE IN AN AQUEOUS NON-SOLVENT MEDIUM BY FORMING IN A FIRST MIXING ZONE A MIXTURE THAT COMPRISES ONE PART BY VOLUME OF A POLYMERIZABLE ORGANIC LIQUID COMPRISING STYRENE AND AT LEAST 0.5 PART BY VOLUME OF AN AQUEOUS NON-SOLVENT LIQUID MEDIUM WHICH COMPRISES A WATER-INSOLUBLE, HYDROPHILIC, COLLOIDAL SOLID PARTICLE EMULSIFIER CAPABLE OF STABILIZING AN OIL-IN-WATER SUSPENSION, THE COLLOIDAL SOLID PARTICLE EMULSIFIER BEING A HYDROUS MINERAL OXIDE PRESENT IN AMOUNT CORRESPONDING TO FROM 0.01 TO 10 GRAMS PER 100 CUBIC CENTIMETERS OF THE POLYMERIZABLE LIQUID, MECHANICALLY AGITATING THE MIXTURE TO DISPERSE THE POLYMERIZABLE LIQUID, AS SMALLER-THAN-STABLE DROPLETS, IN THE NON-SOLVENT LIQUID MEDIUM, CONTINUOUSLY PASSING A STREAM OF THE RESULTING DISPERSION IN NON-TURBULENT FLOW FROM THE FIRST MIXING ZONE TO A SECOND MIXING ZONE THROUGH A CHANNEL, THE NATURE OF THE FLOW THROUGH SUCH CHANNEL BEING SUCH THAT MATERIAL FROM THE SECOND MIXING ZONE IS PREVENTED FROM FLOWING BACK THROUGH THE CHANNEL AND SUCH THAT THE DISPERSED DROPLETS UNDERGO LIMITED COALESCENCE DURING PASSAGE THROUGH THE CHANNEL TO FORM A LESSER NUMBER OF DROPLETS OF LARGER AND SUBSTANTIALLY UNIFORM SIZE AND THAT ARE SUBSTANTIALLY STABLE TO FURTHER COALESCENCE, CONTINUOUSLY FEEDING TO THE SECOND MIXING ZONE A WATERDISPERSIBLE THICKENING AGENT, AND MILDLY AGITATING THE RESULTING MIXTURE TO INCORPORATE THE THICKENING AGENT THROUGHOUT THE SAME WITHOUT BREAKING UP THE DROPLETS OF POLYMERIZABLE LIQUID FORMED BY THE LIMITED COALESCENCE.
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Accused Products
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Citations
1 Claim
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1. IN A PROCESS OF MAKING SOLID POLYMERIC BODIES IN THE FORM OF SPHEROIDAL GLOBULES HAVING SUBSTANTIALLY UNIFORM SIZE BY FORMING A SUSPENSION OF SMALL DROPLETS OF A POLYMERIZABLE LIQUID COMPRISING STYRENE IN AN AQUEOUS NON-SOLVENT LIQUID MEDIUM, THE APPARENT VISCOSITY OF THE AQUEODS SUSPENDING MEDIUM BEING SUCH THAT MOVEMENT OF THE DISPERSED DROPLETS RELATIVE TO THE SURROUNDING MEDIUM BY ACTION OF GRAVITATIONAL FORCE DUE TO DIFFERENCE IN DENSITY BETWEEN THE DROPLETS AND THE SURROUNDING MEDIUM IS SUBSTANTIALLY PREVENTED, AND POLYMERIZING THE POLYMERIZABLE LIQUID IN SUCH SUSPENSION BY SUBJECTING THE SAME TO CONDITIONS CONDUCTIVE TO POLYMERIZATION WITHOUT TURBULENE WHEREBY THE SUSPENDED DROPLETS OF POLYMERIZABLE LIQUID ARE CONVERTED TO GLOBULES OF POLYMER HAVING APPROXIMATELY THE SAME SIZE AND SHAPE AS THOSE OF THE SUSPENDED DROPLETS, THE IMPROVEMENT THAT COMPRISES MAKING A SUSPENSION OF DROPLETS OF A POLYMERIZABLE LIQUID COMPRISING STYRENE IN AN AQUEOUS NON-SOLVENT MEDIUM BY FORMING IN A FIRST MIXING ZONE A MIXTURE THAT COMPRISES ONE PART BY VOLUME OF A POLYMERIZABLE ORGANIC LIQUID COMPRISING STYRENE AND AT LEAST 0.5 PART BY VOLUME OF AN AQUEOUS NON-SOLVENT LIQUID MEDIUM WHICH COMPRISES A WATER-INSOLUBLE, HYDROPHILIC, COLLOIDAL SOLID PARTICLE EMULSIFIER CAPABLE OF STABILIZING AN OIL-IN-WATER SUSPENSION, THE COLLOIDAL SOLID PARTICLE EMULSIFIER BEING A HYDROUS MINERAL OXIDE PRESENT IN AMOUNT CORRESPONDING TO FROM 0.01 TO 10 GRAMS PER 100 CUBIC CENTIMETERS OF THE POLYMERIZABLE LIQUID, MECHANICALLY AGITATING THE MIXTURE TO DISPERSE THE POLYMERIZABLE LIQUID, AS SMALLER-THAN-STABLE DROPLETS, IN THE NON-SOLVENT LIQUID MEDIUM, CONTINUOUSLY PASSING A STREAM OF THE RESULTING DISPERSION IN NON-TURBULENT FLOW FROM THE FIRST MIXING ZONE TO A SECOND MIXING ZONE THROUGH A CHANNEL, THE NATURE OF THE FLOW THROUGH SUCH CHANNEL BEING SUCH THAT MATERIAL FROM THE SECOND MIXING ZONE IS PREVENTED FROM FLOWING BACK THROUGH THE CHANNEL AND SUCH THAT THE DISPERSED DROPLETS UNDERGO LIMITED COALESCENCE DURING PASSAGE THROUGH THE CHANNEL TO FORM A LESSER NUMBER OF DROPLETS OF LARGER AND SUBSTANTIALLY UNIFORM SIZE AND THAT ARE SUBSTANTIALLY STABLE TO FURTHER COALESCENCE, CONTINUOUSLY FEEDING TO THE SECOND MIXING ZONE A WATERDISPERSIBLE THICKENING AGENT, AND MILDLY AGITATING THE RESULTING MIXTURE TO INCORPORATE THE THICKENING AGENT THROUGHOUT THE SAME WITHOUT BREAKING UP THE DROPLETS OF POLYMERIZABLE LIQUID FORMED BY THE LIMITED COALESCENCE.
Specification
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Current AssigneeDonald E. Ballast, Ralph M. Wiley, Stanley M. Englund
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Original AssigneeDonald E. Ballast, Ralph M. Wiley, Stanley M. Englund
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InventorsBallast, Donald E., Englund, Stanley M., Wiley, Ralph M.
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Application NumberUS03/497,450Time in Patent Office1,856 DaysField of SearchUS Class Current526/194CPC Class CodesC08F 12/08 StyreneC08F 2/16 Aqueous mediumC08F 2/18 Suspension polymerisationY10S 526/909 Polymerization characterize...
