Method of dewatering in a continuous high internal phase emulsion foam forming process

• US 9,809,693 B2
• Filed: 10/20/2016
• Issued: 11/07/2017
• Est. Priority Date: 03/30/2012
• Status: Active Grant

• Current Assignee: The Procter & Gamble Company
• Original Assignee: The Procter & Gamble Company
• Inventors: Siew, Wei-ling, Zhang, Jiajie, Garg, Aditya
• Primary Examiner(s): Johnson, Christina
• Assistant Examiner(s): LIU, XUE H
• Application Number:
  US15/298,909
• Publication Number:
  US 20170037213A1
• Time in Patent Office: 383 Days
• Field of Search: 264 53
• CPC Class Codes: B29C 67/202 comprising elimination of a solid or a liquid ingredient
• CPC Class Codes: C08J 2201/028 Foaming by preparing of a high internal phase emulsion
• CPC Class Codes: C08J 2205/05 Open cells, i.e. more than 50% of the pores are open
• CPC Class Codes: C08J 2300/00 Characterised by the use of unspecified polymers
• CPC Class Codes: C08J 9/228 Forming foamed products
• CPC Class Codes: C08J 9/283 a discontinuous liquid phase emulsified in a continuous macromolecular phase

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.

Claims

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.

2. The method of claim 1, wherein the vacuum box comprises a plurality of nip inserts, wherein each of the plurality of nip inserts impacts an individual vacuum box.

3. The method of claim 1 wherein the nip insert is selected from the group consisting of one or more layers of tape, a bolt, a washer, a screw, a piece of wood, and/or combinations thereof.

4. The method of claim 2, wherein the nip inserts are located at intervals along the belt cross directional width, wherein the intervals between nip inserts are between about 0.5 inch to about 5 inches.

5. The method of claim 2, wherein the nip inserts are located at intervals along the belt cross directional width, wherein the intervals between nip inserts are between about 1 inch to about 3 inches.

6. The method of claim 2, wherein the nip inserts raise the vacuum box by about 0.01 inch to about 0.1 inch.

7. The method of claim 2, wherein the nip inserts raise the vacuum box by about 0.02 inch to about 0.05 inch.

8. A method for removing an aqueous phase from an open-celled foam, the method comprising:

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.

9. The method of claim 8, wherein the vacuum box comprises a plurality of nip inserts, wherein each of the plurality of nip inserts impacts an individual vacuum box.

10. The method of claim 8, wherein the nip insert is selected from the group consisting of one or more layers of tape, a bolt, a washer, a screw, a piece of wood, and/or combinations thereof.

11. The method of claim 9, wherein the nip inserts are located at intervals along the belt cross directional width, wherein the intervals between nip inserts are between about 0.5 inch to about 5 inches.

12. The method of claim 9, wherein the nip inserts are located at intervals along the belt cross directional width, wherein the intervals between nip inserts are between about 1 inch to about 3 inches.

13. The method of claim 9, wherein the nip inserts raise the vacuum box by about 0.01 inch to about 0.1 inch.

14. The method of claim 9, wherein the nip inserts raise the vacuum box by about 0.02 inch to about 0.05 inch.

15. A method for producing a High Internal Phase Emulsion foam, the method comprising:

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.

16. The method of claim 15, 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.

17. The method of claim 15, wherein the vacuum box comprises a plurality of nip inserts, wherein each of the plurality of nip inserts impacts an individual vacuum box.

18. The method of claim 16, wherein the nip insert is selected from the group consisting of one or more layers of tape, a bolt, a washer, a screw, a piece of wood, and/or combinations thereof.

19. The method of claim 17, wherein the nip inserts are located at intervals along the belt cross directional width, wherein the intervals between nip inserts are between about 0.5 inch to about 5 inches.

20. The method of claim 17, wherein the nip inserts raise the vacuum box by about 0.01 inch to about 0.1 inch.