Process for the continuous production of high-internal-phase-ratio emulsions

Claim 1

A process for the production of a stable highly viscous high-internal-phase-ratio emulsion (HIPRE) of at least 75% by volume internal phase comprising the steps of: (a) moving a first liquid having a viscosity substantially lower than the viscosity of the resulting HIPRE product at a first volume flow rate; (b) moving a second liquid having a viscosity substantially lower than the viscosity of the resulting HIPRE product at a second volume flow rate of at least three times that of the volume flow rate of the first liquid, said first liquid and said second liquid being substantially immiscible with each other with at least one of said liquids containing an emulsifying agent; (c) simultaneously and continuously metering the first liquid and the second liquid into a confined emulsion forming zone to form a confluent stream of said liquids; (d) moving the resulting confluent stream undirectionally through the emulsion forming zone; (e) establishing and maintaining within the confined emulsion forming zone a plurality of low shear mixing stages such that the confluent streams being mixed flows substantially unobstructed between the said mixing stages; and (f) removing the resulting HIPRE product from the confined emulsion zone.