Abstract:
The invention comprises a fully continuous process for shaping a high internal phase emulsion (HIPE) with a polymerizable continuous phase into dry foam, comprising 1) providing a high internal phase emulsion (HIPE) comprising (a) at least 70 percent by volume of an eternal phase comprising one or more polymerizable monomer; (b) a surfactant in an amount effective to produce a high internal phase emulsion; and (c) an internal phase; 2) depositing the emulsion onto a lower moving support substrate; 3) leveling the emulsion to a desired thickness above the support substrate; 4) polymerizing the monomers by running the emulsion and the lower moving support substrate through a heating zone for a time sufficient to polymerize at least 75 % of the monomer in the HIPE by the end of the heating zone; and 5) drying the polymerized HIPE in a drying zone for a time sufficient to produce a foam having greater than 50 % of the internal phase removed.
Abstract:
The invention comprises a fully continuous process for shaping a high internal phase emulsion (HIPE) with a polymerizable continuous phase into dry foam, comprising 1) providing a high internal phase emulsion (HIPE) comprising (a) at least 70 percent by volume of an eternal phase comprising one or more polymerizable monomer; (b) a surfactant in an amount effective to produce a high internal phase emulsion; and (c) an internal phase; 2) depositing the emulsion onto a lower moving support substrate; 3) leveling the emulsion to a desired thickness above the support substrate; 4) polymerizing the monomers by running the emulsion and the lower moving support substrate through a heating zone for a time sufficient to polymerize at least 75 % of the monomer in the HIPE by the end of the heating zone; and 5) drying the polymerized HIPE in a drying zone for a time sufficient to produce a foam having greater than 50 % of the internal phase removed.
Abstract:
Described is a method of forming and curing high internal phase emulsions (HIPEs) into shaped three dimensional foam implements. In general the method uses the steps of: providing a HIPE, depositing the HIPE into a mold cavity having a predetermined three dimensional shape, curing the HIPE in the mold cavity to form a HIPE foam, and stripping the HIPE foam from the mold cavity to form the three dimensional foam implement. The molded implements are widely useful as components in absorbent articles, toys, insulation, and other uses where a combination of low density and tridimensional shape are desired.
Abstract:
The invention comprises a fully continuous process for shaping a high internal phase emulsion (HIPE) with a polymerizable continuous phase into dry foam, comprising 1) providing a high internal phase emulsion (HIPE) comprising (a) at least 70 percent by volume of an eternal phase comprising one or more polymerizable monomer; (b) a surfactant in an amount effective to produce a high internal phase emulsion; and (c) an internal phase; 20 depositing the emulsion onto a lower moving support substrate; 3) leveling the emulsion to a desired thickness above the support substrate; 4) polymerizing the monomers by running the emulsion and the lower moving support substrate through a heating zone for a time sufficient to polymerize at least 75% of the monomer in the HIPE by the end of the heating zone; and 5) drying the polymerized HIPE in a drying zone for a time sufficient to produce a foam having greater than 50% of the internal phase removed.