An instrumented mixer setup for making tackifier dispersions used to make pressure-sensitive adhesives

Abstract

Water-based pressure-sensitive adhesives (PSAs) are made by combining a tackifier dispersion and a polymer latex. During the process of making the tackifier dispersion, the system initially forms a water-in-oil emulsion, and then inverts to an oil-in-water one as more water is continuously added with constant agitation. To better understand the process, an instrumented mixer setup was constructed to simulate the manufacturing process, and agitation was provided by an inner impeller and an outer impeller. Several variables were monitored in situ. They are the electrical resistance of the emulsion, torque exerted on the inner impeller, agitation speeds of both impellers, power consumption of both impellers and the flow rate of feeding water. Our measurements showed that torque reached a maximum at phase inversion, and this was verified by direct measurements of viscosity during the process. Simultaneously electrical resistance measurements monitored the chemical changes as well as phase inversion. Experiments showed that under a certain low water feeding flow rate, there appeared to be an intermediate agitation speed at which the phase inversion occurred the earliest. This, from the industrial standpoint, is really favorable due to both time and energy efficiency. Furthermore, this intermediate agitation speed also corresponded to a better quality product. All this information may be used for optimizing this process in the future.