Process for the production of high internal phase emulsion foams

• US 9,056,412 B2
• Filed: 06/07/2010
• Issued: 06/16/2015
• Est. Priority Date: 12/30/2009
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Merrigan, Steven Ray, Desmarais, Thomas Allen
• Primary Examiner(s): LIGHTFOOT, ELENA TSOY
• Application Number:
  US12/794,993
• Publication Number:
  US 20110159206A1
• Time in Patent Office: 1,835 Days
• Field of Search: 427/493, 427/508, 427/517, 427/519
• US Class Current: 1/1
• CPC Class Codes: B29C 2948/9298 Start-up, shut-down or parameter setting phase; Emergency shut-down; Material change; Test or laboratory equipment or studies
• CPC Class Codes: B29C 33/68 Release sheets
• CPC Class Codes: B29C 41/28 by depositing flowable material on an endless belt
• CPC Class Codes: B29C 44/28 Expanding the moulding material on continuous moving surfaces without restricting the upwards growth of the foam
• CPC Class Codes: B29C 44/60 Measuring, controlling or regulating
• CPC Class Codes: B29C 48/08 flexible, e.g. films
• CPC Class Codes: B29C 48/269 Extrusion in non-steady condition, e.g. start-up or shut-down
• CPC Class Codes: B29C 48/355 Conveyors for extruded articles
• CPC Class Codes: B29C 67/202 comprising elimination of a solid or a liquid ingredient
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: C08F 120/10 Esters
• CPC Class Codes: C08F 2/50 with sensitising agents
• CPC Class Codes: C08J 2201/028 Foaming by preparing of a high internal phase emulsion

Abstract

A method for reducing the adherence of a High Internal Phase Emulsion (HIPE) to belt surfaces in a multi-tiered curing oven is provided. The method comprises forming a High Internal Phase Emulsion from an oil phase comprising monomer, cross-linking agent, emulsifier, an aqueous phase and photoinitiator; depositing the High Internal Phase Emulsion on an extrusion belt; exposing the High Internal Phase Emulsion to an Ultraviolet light source to partially polymerize the top surface of the High Internal Phase Emulsion; moving the High Internal Phase Emulsion to a multi-tiered curing oven such that the partially polymerized top surface of the High Internal Phase Emulsion is contacted with a curing oven belt in the multi-tiered curing oven; and polymerizing the monomer component in the oil phase of the High Internal Phase Emulsion at a temperature of from about 20° C. to about 150° C. for a time sufficient to from a High Internal Phase Emulsion foam.

Claims

1. A method for reducing the adherence of a High Internal Phase Emulsion to a belt surface comprising the steps of:

forming a High Internal Phase Emulsion from

an oil phase comprising monomer, cross-linking agent, emulsifier;

an aqueous phase;

photoinitiator;

depositing the High Internal Phase Emulsion on an extrusion belt having a surface, such that the High Internal Phase Emulsion has a top surface and a bottom surface, and the bottom surface is in contact with the extrusion belt;

exposing the High Internal Phase Emulsion to an Ultraviolet light source;

partially polymerizing the top surface of the High Internal Phase Emulsion;

moving the High Internal Phase Emulsion having partially polymerized top surface to a multi-tiered curing oven;

contacting the partially polymerized top surface of the High Internal Phase Emulsion with a curing oven belt surface in the multi-tiered curing oven; and

polymerizing the monomer component in the oil phase of the High Internal Phase Emulsion using a polymerization reaction that is conducted at a temperature of from about 20°

C. to about 150°

C. for a time sufficient to from a High Internal Phase Emulsion foam;

wherein the High Internal Phase Emulsion foam exhibits a Z-stick measurement between the top surface of the High Internal Phase Emulsion foam and a glass-lined upper platen of less than 0.64 N.

2. The method of claim 1, wherein the UV light is in the wavelength range of from about 200 nm to about 400 nm.

3. The method of claim 1, wherein the source of UV light is a UV lamp.

4. The method of claim 1, wherein the High Internal Phase Emulsion foam is exposed to the UV light for less than about 1 minute.

5. The method of claim 1, wherein the photoinitiator is at least one of benzyl ketals, α

-hydroxyalkyl phenones, α

-amino alkyl phenones, or acylphospine oxides.

6. The method of claim 1 wherein the multi-tiered curing oven comprises at least three curing oven belts.

7. The method of claim 1, wherein the aqueous phase and oil phase of the High Internal Phase Emulsion are combined in a ratio between about 24:

1 and about 140;

1.

8. The method of claim 1, wherein the High Internal Phase Emulsion is formed by subjecting the aqueous and oil phases to shear agitation.

9. The method of claim 8, wherein the shear agitation is provided by a static mixer.

10. The method of claim 1, wherein the High Internal Phase Emulsion is deposited on the extrusion belt using at least one of a die, sprayer, or caster.

11. The method of claim 1, wherein the extrusion belt is an endless belt.

12. The method of claim 1, wherein the endless belt comprises at least one of films, non-woven materials, or woven materials.

13. A method for reducing the adherence of a High Internal Phase Emulsion to a belt surface comprising the steps of:

forming a High Internal Phase Emulsion from

an oil phase comprising monomer, cross-linking agent, emulsifier;

an aqueous phase;

photoinitiator;

depositing the High Internal Phase Emulsion on an extrusion belt having a surface, such that the High Internal Phase Emulsion has a top surface and a bottom surface, and the bottom surface is in contact with the extrusion belt;

exposing the High Internal Phase Emulsion to an Ultraviolet light source;

partially polymerizing the top surface of the High Internal Phase Emulsion;

moving the High Internal Phase Emulsion having partially polymerized top surface to a multi-tiered curing oven;

transferring the High Internal Phase Emulsion from the extrusion belt to a first curing oven belt such that the partially polymerized top surface of the HIPE is in contact with the first curing oven belt surface;

transferring the High Internal Phase Emulsion from the first curing oven belt to a second curing oven belt such that the bottom surface of the HIPE is in contact with the second curing oven belt surface; and

polymerizing the monomer component in the oil phase of the High Internal Phase Emulsion using a polymerization reaction that is conducted at a temperature of from about 20°

C. to about 150°

C. for a time sufficient to from a High Internal Phase Emulsion foam;

wherein the High Internal Phase Emulsion foam exhibits a Z-stick measurement between the top surface of the High Internal Phase Emulsion foam and a glass-lined upper platen of less than 0.64 N.

14. The method of claim 13, wherein the UV light is in the wavelength range of from about 20 nm to about 400 nm.

15. The method of claim 13, wherein the source of UV light is a UV lamp.

16. The method of claim 13, wherein the High Internal Phase Emulsion foam is exposed to the UV light for less than about 1 minute.

17. The method of claim 13, wherein the extrusion belt, first curing oven belt, and second curing oven belt are endless belts.

18. The method of claim 17, wherein the extrusion belt, first curing oven belt, and second curing oven belt comprise at least one of films, non-woven materials, or woven materials.

19. The method of claim 13, wherein the extrusion belt comprises at least one of fluorine resins, silicone resins, polyimides, polyphenylene sulfides, polysulfones, polyether sulfones, polyether imides, polyether ether ketones, para type aramid resins;

thermoplastic polyester resins, or thermoplastic polyester type elastomer resins.