Polyisobutene Emulsion Preparation via Controlled Flow Mixing
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Solution Overview
Problem
Current methods fail to produce stable emulsions of polyisobutene, especially with high molecular weight, without the use of polymers, waxes, or oils, and require high surfactant concentrations, leading to increased costs and tackiness issues.
Innovation Solution
A method involving heating polyisobutene, optionally mixing it with wax or oil, and slowly adding the pre-mix to water with surfactants at controlled flow rates to form a stable emulsion with an average particle size of up to 100 μm, reducing surfactant usage and tackiness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high molecular weight polyisobutene is used to make emulsions, then the emulsion stability and polymer content are improved, but the emulsion becomes more tacky and viscous
Solution Approach 1:
The patent changes the molecular weight parameter of polyisobutene from low (previously used) to high molecular weight, while simultaneously changing the surfactant concentration parameter to optimized levels. This combination of parameter changes achieves stable emulsions with high polymer content while controlling tackiness through the specific surfactant selection and concentration optimization.
Solution Approach 2:
The patent introduces specific surfactants as intermediary substances that mediate between the high molecular weight polyisobutene and water. These surfactants act as intermediaries that reduce the harmful tackiness effect while maintaining emulsion stability, allowing high molecular weight polymer to be effectively dispersed without excessive tackiness.
2Reliability
If high surfactant concentration is used to make polyisobutene emulsions, then the emulsion stability is improved, but the manufacturing cost and surfactant usage increase
Solution Approach 1:
The patent optimizes the surfactant concentration parameter to specific ranges that provide sufficient emulsion stability while minimizing surfactant usage. By carefully selecting and optimizing this parameter, the patent achieves a balance between stability and quantity of surfactant required, reducing both cost and excessive tackiness associated with high surfactant concentrations.
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 method results in stable polyisobutene emulsions with reduced tackiness and viscosity, improved flowing properties, and lower surfactant usage, achieving efficient distribution and stability.
Implementation Method 1
mixing said pre-mix in water containing one or more surfactants in a concentration of said surfactant of at maximum 5% wt.
Implementation Method 2
heating a polyisobutene polymer, optionally mixing said polyisobutene polymer with a wax and/or oil, thereby obtaining a pre-mix
Data Source
AI summary
The invention relates to a method for preparing a stable and thin liquid polyisobutene emulsion comprising the steps of i) heating a polyisobutene polymer, optionally mixing said polyisobutene polymer with a wax and/or oil, thereby obtaining a pre-mix, ii) mixing said pre-mix in water containing one or more surfactants in a concentration of the surfactant of maximum 5% wt. at a controlled flow rate, which flow rate is sufficiently slow to form particles of the pre-mix, thereby obtaining a pre-emulsion, and iii) homogenizing said pre-emulsion, thereby obtaining said polyisobutene emulsion with an average particle size of at maximum 100 μm.