Ultrasonic treatment chamber for preparing emulsions

Abstract

An ultrasonic mixing system having a treatment chamber in which at least two separate phases can be mixed to prepare an emulsion is disclosed. Specifically, at least one phase is a dispersed phase and one phase in a continuous phase. The treatment chamber has an elongate housing through which the phases flow longitudinally from a first inlet port and a second inlet port, respectively, to an outlet port thereof. An elongate ultrasonic waveguide assembly extends within the housing and is operable at a predetermined ultrasonic frequency to ultrasonically energize the phases within the housing. An elongate ultrasonic horn of the waveguide assembly is disposed at least in part intermediate the inlet and outlet ports, and has a plurality of discrete agitating members in contact with and extending transversely outward from the horn intermediate the inlet and outlet ports in longitudinally spaced relationship with each other. The horn and agitating members are constructed and arranged for dynamic motion of the agitating members relative to the horn at the predetermined frequency and to operate in an ultrasonic cavitation mode of the agitating members corresponding to the predetermined frequency and the phases being mixed in the chamber.

1 . An ultrasonic mixing system for preparing an emulsion, the mixing system comprising:
 a treatment chamber comprising:
 an elongate housing having longitudinally opposite ends and an interior space, the housing being generally closed at at least one longitudinal end and having at least a first inlet port for receiving a first phase for an emulsion, a second inlet port for receiving a second phase for the emulsion into the interior space of the housing, and at least one outlet port through which the emulsion is exhausted from the housing following ultrasonic mixing of the first and second phases to form the emulsion, the outlet port being spaced longitudinally from the first and second inlet ports such that the first and second phases flow longitudinally within the interior space of the housing from the inlet ports to the outlet port; and 
 an elongate ultrasonic waveguide assembly extending longitudinally within the interior space of the housing and being operable at a predetermined ultrasonic frequency to ultrasonically energize and mix the first and second phases flowing within the housing, the waveguide assembly comprising an elongate ultrasonic horn disposed at least in part intermediate the first and second inlet ports and the outlet port of the housing and having an outer surface located for contact with the first and second phases flowing within the housing from the first and second inlet ports to the outlet port, and a plurality of discrete agitating members in contact with and extending transversely outward from the outer surface of the horn intermediate the first and second inlet ports and the outlet port in longitudinally spaced relationship with each other, the agitating members and the horn being constructed and arranged for dynamic motion of the agitating members relative to the horn upon ultrasonic vibration of the horn at the predetermined frequency and to operate in an ultrasonic cavitation mode of the agitating members corresponding to the predetermined frequency and the first and second phases being mixed in the chamber. 
   
     
     
         2 . The ultrasonic mixing system as set forth in  claim 1  further comprising a first delivery system operable to deliver the first phase to the interior space of the housing of the treatment chamber through the first inlet port and a second delivery system operable to deliver the second phase to the interior space of the housing of the treatment chamber through the second inlet port, wherein the first phase and second phase are independently delivered at a rate of from about 1 gram per minute to about 100,000 grams per minute. 
     
     
         3 . The ultrasonic mixing system as set forth in  claim 1  wherein the emulsion is selected from the group consisting of oil-in-water emulsions, water-in-oil emulsions, water-in-oil-in-water emulsions, oil-in-water-in-oil emulsions, water-in-silicone emulsions, water-in-silicone-in-water emulsions, glycol-in-silicone emulsions, and high internal phase emulsions. 
     
     
         4 . The ultrasonic mixing system as set forth in  claim 3  wherein the first phase and second phase are independently selected from the group consisting of an oil phase, a water phase, a silicone phase, a glycol phase, and combinations thereof. 
     
     
         5 . The ultrasonic mixing system as set forth in  claim 4  wherein at least one of the first phase and second phase further comprise a surfactant. 
     
     
         6 . The ultrasonic mixing system as set forth in  claim 3  further comprising a third inlet port for receiving a third phase for the emulsion into the interior space of the housing, the third phase being selected from the group consisting of an oil phase, a water phase, a silicone phase, a glycol phase, and combinations thereof. 
     
     
         7 . The ultrasonic mixing system as set forth in  claim 1  wherein the predetermined frequency is in a range of from about 20 kHz to about 40 kHz. 
     
     
         8 . The ultrasonic mixing system as set forth in  claim 1  wherein the horn has a terminal end within the interior space of the housing and substantially spaced longitudinally from the inlet port to define an intake zone therebetween within the interior space of the housing. 
     
     
         9 . An ultrasonic mixing system for preparing an oil-in-water emulsion, the mixing system comprising:
 a treatment chamber comprising:
 an elongate housing having longitudinally opposite ends and an interior space, the housing being generally closed at at least one longitudinal end and having at least a first inlet port for receiving an oil phase into the interior space of the housing, a second inlet port for receiving a water phase into the interior space of the housing, and at least one outlet port through which an oil-in-water emulsion is exhausted from the housing following ultrasonic mixing of the oil phase and water phase to form the oil-in-water emulsion, the outlet port being spaced longitudinally from the inlet port such that the oil and water phases flow longitudinally within the interior space of the housing from the inlet port to the outlet port; 
 an elongate ultrasonic waveguide assembly extending longitudinally within the interior space of the housing and being operable at a predetermined ultrasonic frequency to ultrasonically energize and mix the oil and water phases flowing within the housing, the waveguide assembly comprising an elongate ultrasonic horn disposed at least in part intermediate the first and second inlet ports and the outlet port of the housing and having an outer surface located for contact with the oil water phases flowing within the housing from the first and second inlet ports to the outlet port, a plurality of discrete agitating members in contact with and extending transversely outward from the outer surface of the horn intermediate the first and second inlet ports and the outlet port in longitudinally spaced relationship with each other, the agitating members and the horn being constructed and arranged for dynamic motion of the agitating members relative to the horn upon ultrasonic vibration of the horn at the predetermined frequency and to operate in an ultrasonic cavitation mode of the agitating members corresponding to the predetermined frequency and the oil water phases being mixed in the chamber, and a baffle assembly disposed within the interior space of the housing and extending at least in part transversely inward from the housing toward the horn to direct longitudinally flowing oil and water phases in the housing to flow transversely inward into contact with the agitating members. 
   
     
     
         10 . The ultrasonic mixing system as set forth in  claim 9  further comprising a first delivery system operable to deliver the oil phase to the interior space of the housing of the treatment chamber through the first inlet port and a second delivery system operable to deliver the water phase to the interior space of the housing of the treatment chamber through the second inlet port, wherein the oil phase and the water phase are independently delivered to the interior space of the housing at a rate of from about 1 gram per minute to about 100,000 grams per minute. 
     
     
         11 . The ultrasonic mixing system as set forth in  claim 9  wherein the oil phase further comprises a surfactant. 
     
     
         12 . The ultrasonic mixing system as set forth in  claim 9  wherein the predetermined frequency is in a range of from about 20 kHz to about 40 kHz. 
     
     
         13 . The ultrasonic mixing system as set forth in  claim 9  wherein the horn has a terminal end within the interior space of the housing and substantially spaced longitudinally from the inlet port to define an intake zone therebetween within the interior space of the housing. 
     
     
         14 . A method for preparing an emulsion using the ultrasonic mixing system of  claim 1 , the method comprising:
 delivering the first phase via the first inlet port into the interior space of the housing;   delivering the second phase via the second inlet port into the interior space of the housing; and   ultrasonically mixing the first and second phases via the elongate ultrasonic waveguide assembly operating in the predetermined ultrasonic frequency.   
     
     
         15 . The method as set forth in  claim 14  wherein the first phase and the second phase are independently delivered at a rate of from about 1 gram per minute to about 100,000 grams per minute. 
     
     
         16 . The method as set forth in  claim 14  wherein the emulsion is selected from the group consisting of oil-in-water emulsions, water-in-oil emulsions, water-in-oil-in-water emulsions, oil-in-water-in-oil emulsions, water-in-silicone emulsions, water-in-silicone-in-water emulsions, glycol-in-silicone emulsions, and high internal phase emulsions. 
     
     
         17 . The method as set forth in  claim 16  wherein the first phase and second phase are independently selected from the group consisting of an oil phase, a water phase, a silicone phase, a glycol phase, and combinations thereof. 
     
     
         18 . The method as set forth in  claim 16  further comprising delivering a third phase via a third inlet port into the interior space of the housing, the third phase being selected from the group consisting of an oil phase, a water phase, a silicone phase, a glycol phase, and combinations thereof. 
     
     
         19 . The method as set forth in  claim 14  wherein at least one of the first phase and the second phase are heated prior to being delivered to the interior space of the housing. 
     
     
         20 . The method as set forth in  claim 14  wherein the first and second phases are ultrasonically mixed using the predetermined frequency being in a range of from about 20 kHz to about 40 kHz.