Bi-modal Emulsions for High Solids Pourability
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Solution Overview
Problem
High solids content emulsions become viscous and non-pourable, making them unusable in many applications, and there is a need to reduce surfactant concentration and impurities like cyclosiloxanes in silicone emulsions for compatibility with downstream applications and regulatory compliance.
Innovation Solution
A process for preparing bi-modal water continuous emulsions by forming a mixture of hydrophobic oil and water continuous emulsion with additional water or emulsion to create emulsions with two distinct dispersed phases, allowing for high solids content while maintaining pourability and reducing surfactant and impurity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the percent solids of an emulsion is increased, then the emulsion can be used in applications requiring high solids content, but the viscosity increases and the emulsion becomes non-pourable
Solution Approach 1:
The patent applies segmentation by creating a bi-modal emulsion with two distinct dispersed phases: a first phase containing high solids content (70-90 wt%) and a second phase with different properties. This segmentation allows each phase to contribute differently to the overall emulsion behavior, enabling high solids content while maintaining pourability through the complementary characteristics of the second phase
Solution Approach 2:
The patent uses composite materials by combining two different emulsion phases with distinct properties. The first dispersed phase (high solids) and second dispersed phase (different viscosity/surfactant content) work together as a composite system, where the interaction between phases produces an overall emulsion that achieves both high solids content and acceptable flow characteristics
2Object-affected harmful factors
If the concentration of surfactants in emulsion is reduced, then the coating quality improves with better hydrophobicity and dirt resistance, but the emulsion stability deteriorates
Solution Approach 1:
The patent applies local quality by having different surfactant concentrations in different phases of the bi-modal emulsion. The first dispersed phase contains minimal surfactant (0.1-5 wt%) to ensure coating quality, while the second dispersed phase contains higher surfactant concentrations to provide emulsion stability. Each phase has locally optimized surfactant content for its specific function
Solution Approach 2:
The patent merges the functions of two separate emulsion systems into one bi-modal emulsion. One phase is optimized for coating performance with low surfactant, while the other phase is optimized for stability with higher surfactant. The merging of these two phases into a single emulsion system allows both functions to coexist and work together
3Object-affected harmful factors
If cyclosiloxanes and other impurities are reduced in silicone emulsions, then the emulsion becomes compatible with medical and cosmetic applications, but the manufacturing complexity increases
Solution Approach 1:
The patent applies the extraction principle by separating the high solids content phase containing cyclosiloxane impurities from the second phase. The first dispersed phase can contain up to 90 wt% solids including cyclosiloxanes, while the second phase is formulated to be compatible with sensitive applications. This extraction approach allows the problematic impurities to be isolated in one phase while maintaining overall emulsion compatibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in emulsions with lower viscosities and reduced surfactant concentrations, enabling the production of pourable high solids content emulsions and minimizing cyclosiloxane content, suitable for various applications including coatings and personal care products.
Implementation Method 1
a water continuous emulsion having at least one surfactant
Implementation Method 2
B) 1 to 1000 part by weight of a water continuous emulsion having at least one surfactant
Data Source
AI summary
A process for preparing bi-modal water emulsions is disclosed comprising: I) forming a mixture comprising; A) 100 parts by weight of a hydrophobic oil, B) 1 to 1000 part by weight of a water continuous emulsion having at least one surfactant, II) admixing additional quantities of the water continuous emulsion and/or water to the mixture from step I) to form a bi-modal emulsion.