Curing High Internal Phase Emulsions in Saturated Steam
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Solution Overview
Problem
The process of creating high internal phase emulsions (HIPE) for microporous foams is inefficient, leading to significant monomer loss during curing, which affects the economic viability and quality of the final product.
Innovation Solution
A method involving the formation of a water-in-oil emulsion that is cured in a saturated steam environment with a quiescent atmospheric layer, minimizing monomer loss by maintaining equilibrium between the steam and the emulsion, and using a serpentine oven design to optimize space and reduce steam loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional curing methods are used for HIPE, then the curing process can be completed, but significant monomer loss occurs during the process
Solution Approach 1:
The patent applies an inert atmosphere principle by using a quiescent atmospheric layer (inert gas or steam environment) during the curing process. This prevents monomer evaporation and loss by creating a controlled environment that minimizes harmful interactions between the monomer and the surrounding atmosphere, thereby reducing monomer loss while maintaining curing efficiency
Solution Approach 2:
The patent changes the physical and chemical parameters of the curing environment by introducing saturated steam and maintaining specific temperature and pressure conditions. This creates a controlled atmosphere that reduces monomer volatility and loss while enabling efficient curing of the HIPE
2Loss of energy
If conventional curing equipment is used, then the process can be completed, but equipment buildup occurs and steam is lost
Solution Approach 1:
The patent employs a serpentine oven design with controlled atmospheric layers that act as flexible containment structures. This design allows for efficient steam utilization and reduces steam loss by creating a controlled environment that prevents unnecessary evaporation while maintaining the curing process
Solution Approach 2:
The serpentine oven design introduces dynamic elements to the curing process, allowing for optimized steam flow and heat distribution. The design enables the system to adapt steam and heat delivery to the specific needs of the curing process, reducing waste while maintaining effectiveness
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
This approach reduces monomer loss to less than 10%, preferably less than 5%, and more preferably less than 3.5%, while also improving the efficiency of the curing process and reducing equipment buildup, thus enhancing the cost-effectiveness and quality of the HIPE foams.
Implementation Method 1
curing the monomer component in the emulsion in a saturated steam environment
Implementation Method 2
curing the monomer component in the emulsion in a saturated steam environment
Implementation Method 3
the evaporation or disruption of the emulsion is prevented
Data Source
AI summary
The present invention is directed to a method for reducing monomer loss during curing of a high internal phase emulsion. The method has the steps of: forming a water-in-oil emulsion, curing the monomer component in the emulsion in a saturated steam environment, and forming a saturated polymeric foam material. The water-in-oil emulsion has an aqueous phase and an oil phase comprising a monomer component.