Method of dewatering in a continuous high internal phase emulsion foam forming process
First Claim
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1. A method for removing an aqueous phase from an open-celled foam, the method comprising:
- providing a belt comprising a cross directional width;
providing an open-celled foam;
providing a vacuum box, wherein the vacuum box comprises a nip insert, wherein the nip insert is located below the vacuum box and is in direct contact with the vacuum box;
placing the open-celled foam on the belt; and
passing the open-celled foam over the vacuum box to remove a saturated aqueous phase.
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Abstract
A method for continuous High Internal Phase Emulsion (HIPE) foam production. A HIPE is produced then extruded onto a belt. After polymerization, a portion of the saturated aqueous phase is removed using a vacuum box. A nip insert is inserted under the vacuum box to raise the vacuum box leading to improved uniformity of the HIPE in the cross direction along the belt.
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Citations
20 Claims
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1. A method for removing an aqueous phase from an open-celled foam, the method comprising:
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providing a belt comprising a cross directional width; providing an open-celled foam; providing a vacuum box, wherein the vacuum box comprises a nip insert, wherein the nip insert is located below the vacuum box and is in direct contact with the vacuum box; placing the open-celled foam on the belt; and passing the open-celled foam over the vacuum box to remove a saturated aqueous phase. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for removing an aqueous phase from an open-celled foam, the method comprising:
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forming an emulsion from an oil phase comprising a monomer, a cross-linking agent, an emulsifier, and an aqueous phase; providing an extrusion device; providing a belt comprising a cross directional width; providing a vacuum box, wherein the vacuum box comprises a nip insert, wherein the nip insert is located below the vacuum box and is in direct contact with the vacuum box; extruding the emulsion on the belt; polymerizing the monomer in the oil phase of the emulsion; and passing the polymerized emulsion over the vacuum box to remove a saturated aqueous phase. - View Dependent Claims (9, 10, 11, 12, 13, 14)
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15. A method for producing a High Internal Phase Emulsion foam, the method comprising:
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forming a High Internal Phase Emulsion from an oil phase comprising a monomer, a cross-linking agent, an emulsifier, and an aqueous phase; providing an extrusion device; providing a belt comprising a cross directional width and a material positioned on the belt and moving therewith; providing a vacuum box; extruding the High Internal Phase Emulsion on the belt; polymerizing the monomer in the oil phase of the High Internal Phase Emulsion; and passing the High Internal Phase Emulsion over the vacuum box to remove a saturated aqueous phase. - View Dependent Claims (16, 17, 18, 19, 20)
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Specification