Method for optimizing a hegman rating of a diluted emulsion, a diluted emulsion produced thereby, and a coating made

A method for optimizing a Hegman rating of a diluted emulsion comprising:

• (a) feeding a molten polymer resin into a melt kneader;
• (b) feeding an initial water stream into the melt kneader;
• (c) feeding a basic aqueous solution and/or a dispersing agent into the melt kneader to form a concentrated emulsion, wherein the concentrated emulsion comprises from greater than 60 wt % polymer resin solids;
• (d) feeding the concentrated emulsion into a dilution mixer wherein water is continuously or in a single or multi-stage manner added to the concentrated emulsion to dilute the concentrated emulsion to form a diluted emulsion, wherein the diluted emulsion comprises equal to or less than 70 wt % polymer resin solids;
• (e) measuring a first Hegman rating of a first sample of the diluted emulsion;
• (f) adjusting the shear work in the dilution mixer, wherein the adjusting the shear work may comprise raising or lowering the shear work;
• (g) measuring a second Hegman rating of a second sample of the diluted emulsion;
• (h) determining if the second Hegman rating of the second sample is acceptable for the intended end use application;
• (i) adjusting the temperature of the concentrated and/or diluted emulsion;
• (j) measuring a third Hegman rating of a third sample of the diluted emulsion;
• (k) determining if the third Hegman rating of the third sample is acceptable for the intended end use application;
• and
• (l) conducting one or more steps selected from the group consisting of (i) adding a basic aqueous solution and/or surfactant solution into the melt kneader;
• (ii) adjusting the amount of any the basic solution or surfactant solution added into the melt kneader;
• (m) measuring a fourth Hegman rating of a fourth sample of the diluted emulsion;
• (n) determining if the fourth Hegman rating of the third sample is acceptable for the intended end use application;
• (o) if the fourth Hegman rating is not acceptable, repeating any one or more of steps (f), (i) and (l);
• (p) if the fourth Hegman rating is acceptable, collecting the diluted emulsion.