Emulsifying method and apparatus

Abstract: An emulsifying device and method for obtaining emulsion to agitating mixed liquid both dispersion liquid and disperse medium, comprising an emulsifying body consisting of an outer cylinder (3) and an inner cylinder (4) positioned at an uniform clearance therebetween. The mixed liquid is applied to the clearance from an inlet positioned at one end of the circumference side of the outer cylinder, and discharged from an outlet positioned at another end of the circumference side of the outer cylinder. The inner cylinder is rotated around the same axis of the fixed outer cylinder, in which the mixed liquid is sufficiently emulsified by an uniform shearing force along the longitudinal direction of the inner cylinder.

Description: BACK GROUND OF THE INVENTION Field of the Invention This invention relates to a method and an apparatus for producing emulsion in which dispersion liquid is dispersed to a fine particle size in disperse medium, and more particularly to a method and an apparatus for producing emulsion having an uniform distribution. Discussion of the Related Art In the conventional method and apparatus for producing the emulsion, disperse medium and dispersion liquid are mixed by a preferable rate as a preliminary emulsion which is agitated by an emulsifying means, e.g. a high-speed agitator (dissolver), a homogenizer, an inline-mixer or the like, so that the stable emulsion which is emulsified to more fine particle size is produced. When the emulsifying is performed by the above apparatus, required shearing force for the emulsifying is different between far from and near by an emulsifying blade, because a region to which the shearing force affects is limited around the emulsifying blades. Accordingly, there was a problem that the distribution of the particle size in the dispersion liquid broadens. Hereupon, devices which perform the uniform distribution of the particle size in the dispersion liquid are disclosed, e.g. a producing device of the dispersion liquid in which the shearing force supplying to the emulsion is increased continuously or stepwisely (Japanese Patent Application Laid-Open No.59-26129); or a device which rotates an inner tube in the double tubes and supplies a preliminarily vibrated liquid into the body, in order to obtain an uniform liquid (Japanese Patent Application Laid-Open No.56-139122). There is a colloid-mill as the representative device of the former emulsifying device. In this device, however, the width (depth) of the emulsifying chamber is narrow as compared with the diameter of the chamber, and the supply of the mixed liquid to the device and the position of the outlet are not paid attention. As the result, the region which is effected by the uniform shearing force becomes narrow. The coarse particles, therefore, not to become small are discharged, the so-called short-pass phenomenon occurs. Specifically, when the flux is increased, the phenomenon is remarkable and causes the average size of the particles to be large and the distribution of the particles to broaden, in which the coarse particles remain. Accordingly, there is a defect that the device should be operated by a little flux in order to obtain the emulsion having a narrow distribution of the particle size. Regarding the latter, the device is used for producing a dispersion liquid including the large particles in 500 µm degree size. Generally, this device is not adapted to produce the fine particle dispersion liquid so-called emulsion. Furthermore, the vortex in the liquid current between the inner cylinder and the outer cylinder causes the distribution of the shearing force to be uneven and the distribution of the particle size to broaden. Moreover, the supplying inlet and outlet of the liquid are disposed on the header at the both sides of the double tubes. The liquid current, therefore, is apt to flow along the most short distance between the inlet and the outlet. In this case, namely, when the flux is increased, the short-pass phenomenon occurs and causes the distribution of the particles to broaden, in which the coarse particles remain. In the both conventional devices, the defects are that the distribution of the particles of the dispersion liquid broaden and a large quantity treatment cannot be performed. From GB-A-2192558 an emulsifying device is known which comprises two coaxial cylinders with an annular gap therebetween. Liquids to be emulsified are subjected to a shear force inside the gap by maintaining a relative rotation between the cylinders. SUMMARY OF THE INVENTION Accordingly, an object of the invention is to provide an emulsifying device and method in which the above-described problems have been solved, and in which in a simple way a small particle size, a uniform distribution of the particle size and a large quantity treatment are obtained. The foregoing object of the invention has been achieved by the provision of an emulsifying method according to claim 1 and of an emulsifying device according to claim 5. Namely, the present invention in which the inner cylinder of the double cylinder formed by the outer cylinder and the inner cylinder is rotated, in which the clearance between the outer cylinder and the inner cylinder is determined to be narrow, include the method for obtaining the emulsion, wherein the mixed liquid of dispersion liquid and disperse medium is passed through the clearance. In the method, the inner cylinder length is determined more than 0.6 times as the inner cylinder diameter so as to be supplied the uniform shearing force to the mixed liquid. The clearance is supplied the preliminary emulsion, which is preliminarily emulsified, along the tangent direction of the circumference of one side of the outer cylinder, so that the preliminary emulsion is affected by the uniform shearing force more than the stationary time extending over the inner cylinder length. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a summary side view showing one example of a device using a method according to this invention. Figs. 2 and 4 are sectional views of a portion showing other example of inner and outer cylinders of the device according to this invention. Fig. 5 is a plane view of one example of a device of this invention. Figs. 6 and 7 are graphical representations indicating a relationship between a flux and an average particle size comparing concrete example 1 with comparison examples 1 and 2, respectively. Figs. 8 and 9 are graphical representations indicating a relationship between a flux and a particle size distribution comparing concrete example 1 with comparison examples 1 and 2, respectively. Figs. 10 and 11 are sectional views showing conventional colloid-mills. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Embodiments of this invention will be described with reference to Figures in detail. Fig. 1 is a side view showing one example of a device performing a method of the present invention. Figs. 2 - 4 are sectional views showing other examples of the inner and outer cylinders of the present invention. Fig. 5 is a plane view showing a summary of one example of a device of the present invention. In Fig. 1, the dispersion liquid and the disperse medium are compounded to a preferable rate in a preliminary emulsifying tank 1, in which the agitating machine 6 prepares a mixed liquid comprising uniform ingredients, so-called preliminary emulsion. Hereupon, the preliminary emulsion is supplied to the clearance between an outer cylinder 3 and an inner cylinder 4 from an inlet 7a on the circumference surface of the under side of the outer cylinder 3. The inner cylinder 4 is rotated by a motor 5. The liquid supplied between the outer cylinder 3 and the inner cylinder 4 is subjected to the uniform shearing force extending over the inner cylinder length while rotating in the clearance between the outer cylinder and the inner cylinder. After that, the liquid move toward an outlet 7b disposed on the circumference surface of the upper side of the outer cylinder 3. Finally, the liquid is sent to the next other treatment device, as the emulsion having the uniform particle size, through the outlet 7b. On the other hand, the preliminary emulsion is, as shown in Fig. 5, supplied from the under side of the outer cylinder 3 and from the tangent direction along the circumference of the rotating direction of the inner cylinder 4, wherein the preliminary emulsion moves to the upper portion with circling. Hereupon, it is effective for obtaining the uniform emulsion to be discharged along the tangent direction from the outlet disposed on the circumference of the upper side. Accordingly, the preliminary emulsion passing through between the outer cylinder 3 and the inner cylinder 4 is affected by the uniform shearing force during the stationary time without the short-pass so as not to remain the uneven particle and to progress the fine emulsifying, wherein the very uniform distribution of the particle size is realized in the emulsion. In the method and device of the present invention, as the clearance between the outer cylinder 3 and the inner cylinder 4 is determined by the desired particle size and etc., the value is not prescribed. In generally, however, the value of 0.05 - 5 mm is preferable, and more preferable value is 0.1 - 2 mm. When the clearance is narrow more than the above value, the finish of the surfaces of the inner cylinder and the outer cylinder and the distortion of the inner cylinder become important. Therefore, the distribution of the particle size is broadened by the uneven shearing force while increasing the rotation speed of the inner cylinder. Furthermore, there is anxiety that the inner cylinder contacts with the outer cylinder so as to occur troubles during a long time operation. Alternately, when the clearance is broad, in order to supply the shearing force to obtain the fine particle size, the rotation speed of the inner cylinder should be increased. However, the distribution of the particle size is broadened, because the fine particle is produced only adjacent to the circumference surface of the inner cylinder. On the other hand, the stationary time for sufficiently emulsifying the supplied liquid within the clearance is preferably equal or more than 0.02 seconds, more preferably, equal or more than 0.2 seconds. If the time is shorter than the above time, the short-pass phenomenon occurs, and the distribution broadens. The length of the inner cylinder is determined corresponding to the stationary time, preferably, equal or more than 0.6 times as the inner cylinder diameter D , more preferably, equal or more than 1.0 times. The gist of the present invention is that the mixed liquid (both the dispersion liquid and the disperse medium) is treated by the uniform shearing force during equal or more than a stationary time, so that the emulsion having an uniform distribution of the particle size is obtained. Furthermore, in the device of the present invention, by means of adjusting the clearance between the inner cylinder and the outer cylinder and the rotating speed of the inner cylinder, the emulsified liquid comprising the desired particle size is obtained in one time passing, therefore, the emulsion can be continuously produced. In Fig. 2 shown an example of the enlarged diameter cylinders, the same result is obtained such that the emulsified liquid comprising an uniform distribution of the particle size is produced. In Fig. 3 shown an example laying down the cylinders, and in Fig. 4 shown a construction receiving at only one side of the inner cylinder, the same result is obtained such that the emulsified liquid comprising an uniform distribution of the particle size is produced. As described above, in accordance with the emulsifying device of the present invention, the emulsion is treated by the uniform shearing force during equal or more than a stationary time. As the result, the emulsion comprising the small particle size and an uniform distribution of the particle size is produced in large quantities. And the emulsion can be continuously produced. Embodiments of this invention will be described with reference to the examples in detail. However, the present invention is not restricted by the examples. Namely, it may be used to produce other micro-capsules, toner, medicine, chemicals and cosmetics. Examples Concrete Example 1 As the dispersion liquid, 10 parts by weight of Crystal violet lactone, 1 parts by weight of Benzoyl leucomethylene Blue and 4 parts by weight of 3-[4-(dimethylamine)-2-ethoxyphenyl]-3-(2-methyl-1-ethyl 3-indolyl)-4-azaphthalide are dissolved in 200 parts by weight of diisopropylnaphthalene. Further, in this oily liquid, as polyvalent isocyanate, 16 parts by weight of carbodiimide-modified diphenyl methane-diisocyanate (commercial name [MILLIONATE MTL] manufactured by Nippon Polyurethane Co., Ltd.), 14 parts by weight of biuret (commercial name [SUMIDULE N-3200] manufactured by Sumitomo Beyel Urethane Co., Ltd.) of hexamethylene diisocyanate and 6 parts by weight of alkyleneoxide additive (the additive mole number of butylenoxide to ethylenediamine; 16.8 mol, molecular weight 1267) of amine are dissolved for execution. Nextly, as the disperse medium, in 135 parts by weight of water, 15 parts by weight of poly(vinyl alcohol) is dissolved for execution. In the device shown in Fig. 1, while the disperse medium is agitated at 800 rpm by a propeller agitator having a 70 mm diameter blade of an agitator 6, the above dispersion liquid is poured thereto so as to prepare an oil drop in water type emulsion as a preliminary emulsion liquid, being mixture. Further, in the device shown in Fig. 1, this preliminary emulsion liquid is treated for obtaining a desired emulsion by passing through the emulsifying device in one time on conditions of; 0.3 - 3 ℓ/min flux, 0.5 mm clearance between the cylinders, the inner cylinder length L= 200 mm and 2000 rpm revolving speed of a motor 5. Hereupon, the average particle size and the particle size distribution are measured by Coulter counter type TA-II. The average particle size is shown in Fig. 6 and Fig. 7 as line a , and the particle size distribution D90/D10 is shown in Fig. 8 and Fig. 9 as line a . Comparison Example 1 The preliminary emulsion of the above Concrete Example 1 is treated for obtaining a desired emulsion by a colloid-mill A (manufactured by Tokushu Kika Kogyo Co., Ltd.) comprising the rotor blade diameter d 1 = 95 mm and the depth length ℓ 1 = 13 mm, in which the shearing force gradually or continuously change as shown in Fig. 10 in conditions of the flux of 0.3 - 0.9 ℓ/min, the clearance between a rotor and a stator of 0.5 mm, the revolving speed of 1500 rpm and one time passing. Hereupon, the average particle size and the particle size distribution are measured by Coulter counter type TA-II. The average particle size is shown in Fig. 6 as line b , and the particle size distribution D90/D10 is shown in Fig. 8 as line b . Comparison Example 2 The preliminary emulsion of the above Concrete Example 1 is treated for obtaining a desired emulsion by a colloid-mill B (manufactured by Nihon Seiki Seisakusho Co., Ltd.) comprising the rotor blade diameter d 2 = 70 mm and the depth length ℓ 2 = 40 mm as shown in Fig. 11, in conditions of the flux of 1.0 - 3.0 ℓ/min, the clarence between a rotor and a stator of 0.5 mm, the revolving speed of 1500 rpm and one time passing. Hereupon, the average particle size and the particle size distribution are measured by Coulter counter type TA-II. The average particle size is shown in Fig. 7 as line c , and the particle size distribution is shown in Fig. 9 as line c . Alternately, d in each Figure indicates an arithmetical average particle size. D10 and D90 indicate the particle sizes to 10% and 90%, respectively, calculated from an accumulated volume distribution. Furthermore, D90/D10 indicate a sharpness of the particle size distribution such that the particle size distribution is sharp in proportion to the low value of D90/D10. As being shown in Figs. 6 and 7, the average particle size of the present invention is stable at 7 µm between the supplied flux of 0.3 ℓ/m and 3.0 ℓ/m, comparably, the average particle size of the colloid-mills A and B fluctuate between the values of 6.4 - 8.6 µm relative to the supplied flux. Furthermore, the particle size distribution relative to the percent particle size calculated from the accumulated volume distribution is stable at D90/D10 = 1.7, comparably in the conventional colloid-mills, the value of D90/D10 fluctuate between 1.7 - 2.5. Accordingly, in view of total, on the conventional colloid-mill, the uniform average particle size and distribution is obtain during only a small quantity of the flux. As was described above, the emulsifying method and the device according to the invention realize to continuously produce the large quantity of emulsion comprising the more uniform particle size distribution, as compared with the device continuously increasing the shearing force such as the conventional colloid-mill.

Claims: An emulsifying method for producing emulsion from dispersion liquid and disperse medium comprising the steps of mixing together said dispersion liquid and said disperse medium and forcing the mixed dispersion liquid and disperse medium to flow together through a stress field of substantially uniform shearing force in a uniform clearance between two coaxial cylinders (3, 4) with an inner cylinder (4) thereof rotating relative to a fixed outer cylinder (3) thereof, so the dispersion liquid and the disperse medium are sufficiently emulsified, characterised in that , said dispersion liquid and said disperse medium are supplied to said shear stress field between said two cylinders (3, 4) at one end of the cylinder jacket of the outer cylinder (3) in a tangential direction (7a) along the circumference of the rotating inner cylinder, and the emulsion is discharged from said shear stress field at the opposite end of the cylinder jacket of the outer cylinder (3) in a tangential direction (7b), the mixed dispersion liquid and disperse medium being treated by the uniform shearing force for a time at least equal to the stationary time. An emulsifying method according to claim 1, characterised in that , said dispersion liquid and said disperse medium are agitated to prepare a homogeneous mixed liquid comprising uniform ingredients before supplying said dispersion liquid and disperse medium to said shear stress field. An emulsifying method according to at least one of the claims 1 and 2, characterised in that , the dispersion liquid and disperse medium to be emulsified are subjected to the shear stress field between said two coaxial cylinders (3, 4) for a period equal or more than 0.02 seconds. An emulsifying method according to at least one of the claims 1 to 3, characterised in that , said dispersion liquid and said disperse medium are supplied to said stress field from a lower end (7a) thereof, and are forced to flow through said stress field against gravity and discharged at an upper end (7b) of said stress field. Emulsifying device for producing emulsion from dispersion liquid and disperse medium, comprising an inner cylinder (4) and an outer cylinder (3) with coincident longitudinal axes and a uniform clearance defined between each other, the inner cylinder being rotatable relative to the outer fixed cylinder, an inlet (7a) for introducing said dispersion liquid and disperse medium into said clearance and an outlet (7b) for discharging the emulsion therefrom, characterised in that said inlet (7a) and outlet (7b) are formed in the cylinder jacket of said outer cylinder (3) at opposite ends thereof, both the inlet (7a) and the outlet (7b) being tangential to said cylinder jacket and perpendicular to the direction of the longitudinal axis thereof, and the length L of said inner cylinder is equal or more than 0.6 times as the diameter D of said inner cylinder. An emulsifying device according to claim 5, characterised in that said inner cylinder (4) is rotatably supported at both of its ends. An emulsifying device according to claim 5 or 6, characterised by a preliminary emulsifying means (1, 6) for preparing a uniform preliminary emulsion, said preliminary emulsifying means (1, 6) comprising a preliminary emulsifying tank (1) and an agitating means (6) for provisionally mixing said dispersion liquid and said disperse medium. An emulsifying device according to claim 7, characterised in that , a pump (2) is provided between said preliminary emulsifying means (1, 6) and said inlet (7a). An emulsifying device according to at least one of the claims 6 to 8, characterised in that , the value of said clearance is 0.05 to 5 mm. An emulsifying device according to at least one of the claims 6 to 9, characterised in that , the stationary time sufficient for emulsifying the supplied liquid within the clearance is equal or more than 0.02 seconds. An emulsifying device according to at least one of the claims 6 to 10, characterised in that , the longitudinal axis of said inner cylinder (4) and said outer cylinder (3) is vertical, said inlet (7a) being disposed at the bottom end of said outer cylinder and said outlet (7b) being disposed at the top end of said outer cylinder (3).

Inventors: ISHIGAMI YOSHIMI, NAGANO HIDEO, ISHIGAMI, YOSHIMI, NAGANO, HIDEO, Ishigami, Yoshimi, c/o Fuji Photo Film Co., Ltd., Nagano, Hideo, c/o Fuji Photo Film Co., Ltd.
Applicants: FUJI PHOTO FILM CO LTD, FUJI PHOTO FILM CO., LTD.
Application year: 1991
Main classification: B01F5
IPC codes: B01F3, B01F5, B01F7