# US 8,770,956 B2 · System for producing high internal phase emulsion foam

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- Number: US 8,770,956 B2
- Document ID: US8770956B2
- Status: Granted
- Kind: B2
- Application number: 12/795,010
- Filed: 2010-06-07
- Published: 2011-06-30
- Granted: 2014-07-08
- Earliest claimed: 2009-12-30
- Assignees: The Procter & Gamble Company
- Applicants: Thomas Allen Desmarais
- Inventors: Thomas Allen Desmarais
- Web page: https://patentgrep.com/patent/US8770956B2

## CPC

- C08F 120/10: Esters
- B29C 33/68: Release sheets
- B29C 41/28: by depositing flowable material on an endless belt
- B29C 44/28: Expanding the moulding material on continuous moving surfaces {without restricting the upwards growth of the foam}
- B29C 44/60: Measuring, controlling or regulating
- B29C 48/08: flexible, e.g. films
- B29C 48/269: {Extrusion in non-steady condition, e.g. start-up or shut-down}
- B29C 48/355: Conveyors for extruded articles
- B29C 67/202: {comprising elimination of a solid or a liquid ingredient}
- C08F 2/50: with sensitising agents
- B29C 2948/9298: Start-up, shut-down or parameter setting phase; Emergency shut-down; Material change; Test or laboratory equipment or studies
- B29K 2105/04: cellular or porous
- C08J 2201/028: Foaming by preparing of a high internal phase emulsion
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)

## Abstract

A system for continuous High Internal Phase Emulsion (HIPE) foam production. A (HIPE) is produced then extruded onto a carrier sheet positioned on a belt surface.

## Claims

### Claim 1

A High Internal Phase Emulsion foam producing system comprising:
a High Internal Phase Emulsion extruding device that extrudes a High Internal Phase Emulsion;
a belt;
a carrier sheet, wherein at least a portion of the carrier sheet is in contact with the belt and is configured to provide a releasable surface for the produced High Internal Phase Emulsion foam to be substantially free from surface irregularities and to reduce formation of defects in the produced High Internal Phase Emulsion foam; and
a retractable piston assembly, wherein the retractable piston assembly is in operable association with the carrier sheet; wherein the retractable piston assembly is capable of positioning the carrier sheet directly under the extrusion device or away from and not under the extrusion device;
wherein the extruding device is configured to extrude the High Internal Phase Emulsion onto the carrier sheet and
wherein the carrier sheet is configured to rest upon the belt and to move in a horizontal direction along with the belt to transport the High Internal Phase Emulsion from the extruding device to a following stage of High Internal Phase Emulsion foam production.

### Claim 2 (depends on 1)

The system of claim 1, wherein the retractable piston assembly comprises:
a bearing adapted to rotatably receive a shaft in a first direction, the bearing being movable in a second direction substantially perpendicular to the first direction;
a fluid cylinder in operative association with a movable piston, said piston being interconnected with said bearing, said fluid cylinder including a fluid inlet for receiving a pressurized fluid, wherein, when a pressurized fluid is introduced into said cylinder, said piston applies a force to said bearing in said second direction; and
a fluid regulator in communication with said fluid inlet for controlling and regulating the pressure of a fluid within said cylinder, said fluid regulator controlling the amount of fluid entering and exiting said fluid cylinder from a pressurized fluid source, wherein said fluid regulator is configured to adjust the fluid pressure within the cylinder to either retract or extend the piston.

### Claim 3 (depends on 2)

The system of claim 2, wherein the fluid cylinder is a pneumatic cylinder.

### Claim 4 (depends on 1)

The system of claim 1, wherein the retractable piston assembly comprises:
a block having a bearing adapted to rotatably receive a shaft in a first direction, the bearing being movable in a second direction substantially perpendicular to the first direction;
a motion transmission screw connected to the block at one end and extending therefrom through and in threaded engagement with a nut.

### Claim 5 (depends on 1)

The system of claim 1, wherein the carrier sheet comprises at least one of fluorine resins, silicone resins, polyimides, polyphenylene sulfides, polysulfones, polyether sulfones, polyether imides, polyether ether ketones, para type aramid resins; thermoplastic polyester resins, or thermoplastic polyester type elastomer resins.

### Claim 6 (depends on 5)

The system of claim 5, wherein the endless belt comprises at least one of polytetrafluoroethylene, tetrafluoroethylene-perfluoroalkylvinyl ether copolymers, tetrafluoroethylene-hexafluoropropylene copolymers, tetrafluoroethylene-ethylene copolymers, dimethyl polysiloxanes, dimethylsiloxane-diphenyl siloxane copolymers, polyethylene terephthalates, polybutylene terephthalates, polyethylene naphthalates, polybutylene naphthalates, polycyclohexane terephthalates, polyether block copolymers, or polyester block copolymers.

### Claim 7 (depends on 1)

The system of claim 1, wherein the belt is an endless belt.

### Claim 8 (depends on 7)

The system of claim 7, wherein the endless belt comprises at least one of films, non-woven materials, or woven materials.

### Claim 9 (depends on 1)

The system of claim 1, wherein the High Internal Phase Emulsion extruder is at least one of a die, sprayer, or caster.

### Claim 10

A High Internal Phase Emulsion foam producing system comprising:
an extruding device that extrudes a High Internal Phase Emulsion;
a belt;
a carrier sheet, wherein at least a portion of the carrier sheet is in contact with the belt and is configured to provide a releasable surface for the produced High Internal Phase Emulsion foam to be substantially free from surface irregularities and to reduce formation of defects in the produced High Internal Phase Emulsion foam; and
a rotatable shaft adapted to support and rotate with the carrier sheet, the rotatable shaft having a first end and a second end;
a retractable piston assembly, mounted to the first end and second end of the rotatable shaft; wherein the retractable piston assembly is capable of positioning the carrier sheet directly under the extrusion device or away from and not under the extrusion device; wherein the carrier sheet is configured to rest upon the belt and to move in a horizontal direction along with the belt to transport the High Internal Phase Emulsion from the extruding device to a following stage of High Internal Phase Emulsion foam production.

### Claim 11 (depends on 10)

The system of claim 10, wherein the retractable piston assembly comprises:
a bearing adapted to rotatably receive the shaft in a first direction, the bearing being movable in a second direction substantially perpendicular to the first direction;
a fluid cylinder in operative association with a movable piston, said piston being interconnected with said bearing, said fluid cylinder including a fluid inlet for receiving a pressurized fluid, wherein, when a pressurized fluid is introduced into said cylinder, said piston applies a force to said bearing in said second direction; and
a fluid regulator in communication with said fluid inlet for controlling and regulating the pressure of a fluid within said cylinder, said fluid regulator controlling the amount of fluid entering and exiting said fluid cylinder from a pressurized fluid source, wherein said fluid regulator is configured to adjust the fluid pressure within the cylinder to either retract or extend the piston.

### Claim 12 (depends on 11)

The system of claim 11, wherein the fluid cylinder is a pneumatic cylinder.

### Claim 13 (depends on 10)

The system of claim 10, wherein the retractable piston assembly comprises:
a block having a bearing adapted to rotatably receive the shaft in a first direction, the bearing being movable in a second direction substantially perpendicular to the first direction;
a motion transmission screw connected to the block at one end and extending therefrom through and in threaded engagement with a nut.

### Claim 14 (depends on 10)

The system of claim 10, wherein the carrier sheet comprises at least one of fluorine resins, silicone resins, polyimides, polyphenylene sulfides, polysulfones, polyether sulfones, polyether imides, polyether ether ketones, para type aramid resins; thermoplastic polyester resins, or thermoplastic polyester type elastomer resins.

### Claim 15 (depends on 14)

The system of claim 14, wherein the endless belt comprises at least one of polytetrafluoroethylene, tetrafluoroethylene-perfluoroalkylvinyl ether copolymers, tetrafluoroethylene-hexafluoropropylene copolymers, tetrafluoroethylene-ethylene copolymers, dimethyl polysiloxanes, dimethylsiloxane-diphenyl siloxane copolymers, polyethylene terephthalates, polybutylene terephthalates, polyethylene naphthalates, polybutylene naphthalates, polycyclohexane terephthalates, polyether block copolymers, or polyester block copolymers.

### Claim 16 (depends on 10)

The system of claim 10, wherein the belt is an endless belt.

### Claim 17 (depends on 16)

The system of claim 16, wherein the endless belt comprises at least one of films, non-woven materials, or woven materials.

### Claim 18 (depends on 10)

The system of claim 10, wherein the High Internal Phase Emulsion extruder is at least one of a die, sprayer, or caster.

### Claim 19 (depends on 1)

The High Internal Phase Emulsion foam producing system of claim 1, wherein the carrier sheet has a thickness between 0.005 mm to 0.1 mm.

### Claim 20 (depends on 1)

The apparatus of claim 1, wherein the carrier sheet is discardable.