Silicone Polymer Emulsion Inversion for High-Viscosity Gum Processing
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Solution Overview
Problem
Existing methods for emulsifying high molecular weight silicone polymers, known as silicone gums, face challenges due to their high viscosity, making it difficult to incorporate surfactants and water, and controlling particle size, especially in mechanical emulsification processes.
Innovation Solution
A method involving the polymerization of siloxane-containing monomers and oligomers in the presence of an inert fluid, followed by quenching, introducing surfactants, forming a water-in-oil emulsion, and applying shear to invert it into an oil-in-water emulsion, while optionally diluting, to create stable silicone oil-in-water emulsions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical emulsification is used for high molecular weight silicone polymers, then emulsion can be produced, but the high viscosity makes it difficult to incorporate surfactant and water, and control particle size
Solution Approach 1:
The patent applies preliminary action by first dissolving the surfactant in water to create a surfactant solution, then adding this solution to the silicone polymer. This pre-mixing of surfactant with water before contact with the high viscosity polymer enables easier incorporation compared to adding surfactant directly to the polymer, thereby resolving the operational difficulty caused by high viscosity.
Solution Approach 2:
The patent uses an intermediary approach by introducing a volatile solvent (such as methyl ethyl ketone or toluene) as a medium to dissolve both the silicone polymer and surfactant. This solvent acts as an intermediary that facilitates the mixing of components that would otherwise be difficult to incorporate due to the polymer's high viscosity, enabling subsequent emulsification.
2Ease of manufacture
If emulsion polymerization is used, then high molecular weight silicone gum can be emulsified, but control of particle size is limited and the process is complex
Solution Approach 1:
The patent replaces the complex chemical emulsion polymerization process with a simpler mechanical emulsification method. By using mechanical shear forces in a high-speed mixer or homogenizer to break the polymer-surfactant-solvent solution into fine droplets, the process avoids the complexity of polymerization chemistry while achieving effective emulsification of high molecular weight silicone gum.
Solution Approach 2:
The patent applies parameter changes by adjusting the solvent-to-polymer ratio and surfactant concentration to optimize emulsification. By controlling these parameters and using sufficient shear force during mixing, the process achieves good particle size control without requiring the complex emulsion polymerization methodology.
3Manufacturing precision
If volatile solvent is used in mechanical emulsification, then particle size control is improved, but the solvent must be substantially removed during polymerization
Solution Approach 1:
The patent applies the extraction principle by removing the volatile solvent step from the process. The emulsion is formulated and stabilized such that the volatile solvent is not required to be substantially removed, eliminating the loss of substance issue while maintaining particle size control through the use of surfactant and mechanical shear.
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 allows for the production of stable emulsions with high molecular weight silicone polymers, overcoming viscosity issues and achieving controlled particle sizes, which is not feasible with traditional methods.
Implementation Method 1
polymerization of siloxane-containing monomers and/or oligomers in the presence of an inert fluid
Implementation Method 2
applying shear to the water-in-oil emulsion to cause inversion of the water-in-oil emulsion to an oil-in-water emulsion
Implementation Method 3
introducing one or more surfactants into the polysiloxane containing polymer
Data Source
AI summary
Silicone oil-in-water emulsions containing a polysiloxane containing polymer is prepared by first preparing a polysiloxane containing polymer by the polymerization of siloxane containing monomers and/or oligomers in the presence of an inert organopoly siloxane and/or an organic fluid, a suitable catalyst and optionally an end-blocking agent; and quenching the reaction if required. If required one or more surfactants may be introduced into the polysiloxane containing polymer to form a homogenous oil phase. Water is then added (in an amount of 0.1-10 percent by weight based on total oil phase weight) to the homogenous oil phase to form a water-in-oil emulsion. Shear is applied to the water-in-oil emulsion to cause inversion of the water-in-oil emulsion to an oil-in-water emulsion. Finally, if required the oil-in-water emulsion can be diluted by adding more water.