WO2006063730A1

WO2006063730A1 - Manufacture of stable silicone emulsion

Info

Publication number: WO2006063730A1
Application number: PCT/EP2005/013174
Authority: WO
Inventors: Amit Kumar Paul
Original assignee: Wacker Chemie Ag
Priority date: 2004-12-15
Filing date: 2005-12-08
Publication date: 2006-06-22
Also published as: KR20070097503A; EP1838761A1; KR100896723B1; JP2008523229A; CN101080440A; US20070238829A1

Abstract

A simple and cost-effective process for making stable and high particle size silicone emulsion especially in the range of 1- 100 micron involving a selective combination of organopolysiloxanes, emulsifiers and water in a single process. Importantly apart from the selective use of emulsifier to achieve the desired high particle size emulsion the quantity of the emulsifiers are selective for obtaining the stable emulsion. The process of making high particle organopolysiloxane emulsion makes advantageous use of surfactant / surfactants having a critical HLB value that help to mix oil and water easily without need for complex manipulative steps or precautions while water addition. Moreover, the present invention further identifies the importance of the selective use of thickener which has an important role in achieving a stable high particle emulsion with good shelf life.

Description

Manufacture of Stable Silicone Emulsion

The present invention relates to a process for making stable and high particle size silicone emulsion involving a selective combination of organopolysiloxanes, emulsifiers and water in a single process. The process is directed to be simple and cost- effective and can be easily adapted for large scale production of stable high particle silicone emulsions for diverse beneficial end use and application. Importantly, the silicone emulsion produced by the process of this invention is in the range of average 1-100 micron (D50 value) with a narrow particle size distribution is highly stable and is found to have advantageous and beneficial use in conditioners for shampoo and like applications.

It is well known to provide silicone emulsions with varying particle size to suit different end applications and uses.

EP 0 463 431 A2 discloses a process where a silicone oil-in- water emulsion is formed mechanically by forming initially a thick phase emulsion by combining and shearing the silicone, a non ionic surfactant having HLB value of 10-19 and water. Thereafter, a further non ionic surfactant is added having a selective HLB of 1.8-15.0 with or without other anioninc and cationic surfactants. Subsequent shearing of the mix resulted in reduced particle size of silicone oil of less that 0.35 microns (350 nanometers) . Such silicone emulsions with small particle size are found to have limited application. In particular, the particle size of the silicone emulsion does have an effect on the end application such as in case of hair care applications. For applications such as conditioners and the like for hair care the emulsion is required to be destabilized for beneficial use / application. It is found that higher the particle size, the faster is the breaking or desired destabilization of the emulsion for the increased deposition of the benefit agent silicone on the hair.

US 5,302,658 is directed to a process for the manufacture of silicone emulsions having high particle size of silicone oil in the emulsion of 1-100 microns. In particular the process is stated to involve particular sequence of manipulative steps to achieve the desired high particle size of the emulsion. Importantly, the process suggests the requirement of adding water in numerous small quantities, and gradually, to obtain a single emulsion alongwith the use of different HLB valued emulsifiers, which ultimately made the process complicated. The complex manipulative steps involved include the initial use of high HLB emulsifiers, which are almost water-soluble with the highly insoluble polydimethyl siloxane which suggest a tendency of phase separation of two immiscible components and the need for a high shear mixing system to bring in contact the two immiscible components. This lead to required manipulative steps to disperse silicone in that high HLB emulsifiers together with water which necessarily make the process complex and difficult to control . Thus the said patent teaches that the water addition in number of steps is essential for converting organopolysiloxane-surfactant-water from oil phase to water dispersible phase. The process further requires the use of a second emulsifier having HLB values 1.8-15 for stabilizing and further attention for water addition for achieving desired particle size. Apart from the above complexities in the process for the emulsion with particle size range from 1-100 micron, there is the usual need for further controlling of some distinct physical parameters in intermittent steps in the emulsion process, which usually conform the quality of the final emulsion. In fact it is well known that to control desired parameters in the final emulsion the process should include some physical property based quality checking since it is difficult to rectify the emulsion quality at the end of the process. No such quality control measure appear to be proposed in the above process of emulsion manufacture with high particle size in the range of 1-100 micron and there is thus apart from the complexities in the manufacture discussed above always a chance of quality deviation at the end of the process.

Therefore, there is a continuing need in the art to develop process of making emulsion having particle size from 1-100 micron which would be more simple and can be readily adopted for large scale commercial manufacture of such high particle size silicone emulsions for diverse applications.

It is thus the basic object of the invention to provide a process of making silicone emulsion having particle size from 1-100 micron which would be simple, cost-effective and would not require the complex manipulative steps and thus can be readily adopted for large scale commercial manufacture of such high particle size silicone emulsions for diverse applications such as in hair care products and the like.

Another object of the invention is directed to provide a simple process of making silicone emulsion having particle size from 1-100 micron which would ensure the simplicity of the process involving simple stirring and selective emulsifier and thus avoiding the use of complex and cost-extensive machinery. Yet further object of the present invention is directed to making stable silicone emulsion having particle range from 1- 100 micron following simple steps without any continuous monitoring and adding of components in number of steps with the completion of the process steps controlled by measuring the standard physical parameter of the emulsion like viscosity and not requiring any continuous particle size measurement.

Yet further object of the invention is directed to process of making silicone emulsion having particle size from 1-100 micron which would be storage stable and thus favour its various diverse end uses and applications especially as conditioner in hair care products .

Thus according to the basic aspect of the present invention there is provided a process for the manufacture of stable and high particle silicone emulsion comprising: i) providing (a) silicone oil or blends thereof in an amount of 50 to 70 % by.wt. (b) water in an amount of 10 to 30 % by wt. (c) selective non-ionic emulsifier having HLB in the range of 4.0 to 9.5 in amounts of 1 to 10% by wt . and (d) selective anionic thickener in an amount of 0.1 to 1 % by. Wt.; ii) heating the mix of (i) above in the temperature range of 55 to 70⁰C and stirring to provide a homogenous mix. ; iii) cooling the mix of (ii) above in the temperature range of 20-40⁰C and continuing mixing till a desired viscosity in the range of 70,000-1,50,000 cps is attained; iv) adding further a non ionic emulsifier having HLB in the range of 4.0 to 9.0 in an amount of 0.5 to 5%, continuing the mixing in the temperature range of 30-35⁰C till a desired viscosity of 20,000 to 65,000 cps is attained and thereafter adding water for final dilution and average particle size in the range of 1 to 100 microns.

Importantly, it is found by way of the invention that one of the critical aspects, which enable obtaining of such high particle size emulsion following a simple process, is the selective use of emulsifier to achieve the desire high particle size emulsion. Also the quantity of the emulsifiers has great role to make the emulsion stable. In particular in the above process of making high particle organopolysiloxane emulsion the emulsion is stabilized by use of surfactant / surfactants having a critical HLB value that help to mix oil and water easily without need for complex manipulative steps or precautions while water addition.

Moreover, the present invention further identifies the importance of the selective use of thickener which has a important role to achieving a stable high particle emulsion. In the process the thickener is selectively used to act as a suspending agent in the emulsion. Anionic thickener is found one of the best thickening agent to stabilize the emulsion in compare to other known conventional thickeners . The selective use of thickener provide for longer self life of the emulsion system of the invention. Since, process use high viscosity blended silicone oil with small quantity of surfactant, it is important to adapt the process in such a way that material can be mixed uniformly.

Also the process advantageously suggests a simple measurement of viscosity (Brookfield) of the emulsion as a physical parameter to confirm the emulsion formation with desired constitution / high particle size.

Thus the above disclosed process of the invention directed to making high particle size emulsion of an organopolysiloxane or a mixture of polysiloxanes having particle size in the range of 1-100 micron involves very simple and selective mix of components and the effective completion of the stages in the emulsion preparation is determined by simple measurement of viscosity of the emulsion system.

In accordance with a preferred aspect of the present invention the above process for the manufacture of stable and high particle size silicone emulsion is a two stage process comprising of:

stage one comprising of providing the silicone oil/blend in a mixing tank in an amount of 50-70 % of the emulsion preferably, in the range of 55-65% of the emulsion, adding 10-30% water preferably 15-25 % of the emulsion, a Non-ionic emulsifier having HLB value 4.0-9.5 in amounts of 1-10% of the emulsion preferably 1-4% of emulsion or emulsifier in ratio of 20-30:1 against fluid to emulsifier ratio is used alongwith 0.1 to 1% thickener of the emulsion, heating all components under mixing condition in the range of 55°C-70°C and continued stirring till the emulsifier and thickener disperse in the system for a period of 0.5-3 hr preferably, 0.5-1.0 hr with stirring, cooling the mixture to 20-40⁰C and most preferably 30-35⁰C continuing mixing, till the desired viscosity of the water-oil- surfactant-thickener in the range of 70,000 to 1,50,000 Cps is achieved in a period of 2-5 hr preferably, 2-4 hr; and

stage two comprising adding emulsifier 0.5% to 5% preferably 0.5 to 2.5% of the emulsion or using emulsifier in ratio of 40- 45:1 against fluid to emulsifier ratio, said emulsifier having a HLB value in-between 4.0 to 9.5., continue the mixing at 30- 35⁰C till the desired viscosity of the water-oil-surfactant- thickener in the range of 20000 to 65000 Cps is achieved in a period of from 1-3 hr preferably, it is 1.0-1.5 hr with the stirring system, after desired viscosity is achieved, adding balance water for final dilution and biocide in the range of 0.01 to 0.05 % of the emulsion to finally obtain the high particle size emulsion of average particle size in the range of 1-100 micron.

According to the present invention, one of the critical parameters include the selection of the right emulsifier to achieve the desired high particle size emulsion. Since, one of the main objectives in the present invention is to produce large particle emulsion in a simple way where emulsifier(s) have a great importance to make the process simple. Quantity of the emulsifiers also has great role to make the emulsion stable. Since, process use high viscosity blended silicone oil with small quantity of surfactant, it is necessary to make the recipe in such a way that material can be mixed uniformly. According to the present invention, it is also important to identify a physical parameter by which it is easy to understand the completion of mixing. Viscosity of the mixture has a great importance to identify the completion of mixing. In particular, the homogeneity of the dispersion ensured completion of first emulsifier and thickener in oil water system.

Importantly, the above process of high particle size emulsion of the invention is not time dependent because particle size of the final emulsion is dependent only on the type of emulsifiers and fluid to emulsifiers' ratios.

The invention thus provides a process for making stable high particle emulsion from an organopolysiloxane (silicone fluid) or a mixture of organopolysiloxane (henceforth refer as blended silicone fluid) . Blended silicone fluid are a mixture of one high viscosity non volatile organopolysiloxane and a low viscosity non volatile organopolysiloxane; functional polysiloxane and mixture thereof. Even though the invention is effective for producing high particle emulsion from a silicone fluid or blended silicone fluid but such limitation is not restricted to the invention since it is found that high particle emulsion can be produced from a silicone of amino functional polysiloxane, carbonyl functional polysiloxane, glycol functional polysiloxane, epoxy functional polysiloxane, carboxy functional polysiloxane and vinyl functional polysiloxane or mixture there off.

The high viscous polysiloxanes used in the present inventions have the following structure of Formula I

where R, which may differ, is a monovalent hydro carbon radical and x is an integer from 1000 to 4000.

Examples of R are alkyl radicals, such as methyl, ethyl, n- propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl, tert pentyl, hexyl such as n-hexyl, heptyl, such as n-heptyl, octyl, such as n-octyl and isooctyl, such as 2,2,4-trimethyl pentyl, nonyl, such as n-nonyl, decyl such as n decyl, dodecyl such as n-dodecyl, octadecyl such as n-octadecyl; alkenyl, such as vinyl and allyl, cycloalkyl, such as cyclopentyl, cyclohexyl, cycloheptyl and methyl cyclohexyl, aryl such as phenyl, naphthyl, anthryl and phenanthryl; alkylaryl, such as o-, m-, p-tolyl, xylyl and ethylphenyl; aralkyl, such as benzyl, α- and β-phenylethyl, of which methyl, ethyl, n-propyl, isopropyl are preferred and methyl is particularly preferred.

The Low viscosity non-volatile polysiloxane having the following Formula II

where R, which may differ, is a monovalent hydro carbon radical and x is an integer from 75 to 700.

Examples of R are alkyl radicals, such as methyl, ethyl, n- propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n-pentyl, isopentyl, neopentyl, tert-pentyl, hexyl such as n-hexyl, heptyl, such as n-heptyl, octyl, such as n-octyl and isooctyl, such as 2,2,4-trimethyl pentyl, nonyl, such as n- nonyl, decyl such as n decyl, dodecyl such as n-dodecyl, octadecyl such as n-octadecyl; alkenyl, such as vinyl and allyl, cycloalkyl, such as cyclopentyl, cyclohexyl, cycloheptyl and methyl cyclohexyl, aryl such as phenyl, naphthyl, anthryl and phenanthryl; alkylaryl, such as o-, m-, p-tolyl, xylyl and ethylphenyl; aralkyl, such as benzyl, α- and β-phenylethyl, of which methyl, ethyl, n-propyl, isopropyl are preferred and methyl is particularly preferred. The high viscosity non-volatile polysiloxane according to structure (I) has a viscosity in-between 60,000 Cps to 1 million cps. Preferably, viscosity of the high viscosity nonvolatile is in-between 100,000 Cps to 600,000 cps. According to the structure (II) of low viscosity polysiloxane, oil viscosity lies in-between 100 cps to 5000 cps. Preferably, viscosity of the low viscosity non-volatile is in-between 350 Cps to 2000 cps.

According to the present invention, ratio of two fluids in the blended silicone has also great important in use as a conditioner in shampoo. Generally, high viscosity to low viscosity ratio in the blended silicones varies from 20:80 to 80:20. Preferably, best effect is achieved as a conditioner when ratio is varies from 50:50 to 70:30. According to the present invention, viscosity of the blended silicone oil varies from 30,000 cps to 100,000 cps imparts optimum conditioning effect in the shampoo.

The functional non-volatile polysiloxane useful according to the present invention has the following Formula III

where Rl is selected from amino functional group containing one or more than one carbon; carbonyl functional group containing one or more than one carbon; glycol functional group containing one or more than one carbon; epoxy functional group containing one or more than one carbon; acryloxy functional group; chloroalkyl functional group; vinyl functional group and other functional group having the formula X — R2 — where X is the functional groups containing one atom which is not a carbon atom or hydrogen atom and R2 is selected from alkylene group having at least one carbon atom, x is the integer from 10-100. Some of the important Rl groups have the following formula but not limited to the following functional groups:

CICH₂CH₂CH₂-

—

O

CH₂- CH - CH₂ - O - CH₂CH₂CH₂

O

CH₃ - CH CO CH₂CH₂CH₂ - H - ( OCH₂ CH₂ J ₁₅ -O- CH₂CH₂CH₂ -

CH₉= CH-

HO - CH₂CH₂CH₂ -

According to the present invention, the process of making high particle size emulsion comprises simple mixing of silicone oil with atleast one primary surfactant, thickener and water. It is preferred to mix silicone oil, surfactant, thickener and water in a SS blender to at least 55⁰C and more preferably 55°C-70°C. After dispersing the thickener, cool the mixture to 20-40⁰C and most preferably 30-35⁰C. Continue stirring with maintaining temperature 30-35⁰C till a desire viscosity of the emulsion reached. Add the second emulsifier and continue stirring with maintaining temperature 30-35⁰C till viscosity of the emulsion drop to desired viscosity. The resulting material is then diluted with rest of the water and biocide to form the high particle size emulsion. Resulting emulsion has an average particle size in-between 1-100 micron (D50) .

It is also preferred that the processing in the first stage of mixing (till first emulsifier and thickener disperse in fluid) can be carried out in at least more than 50⁰C and more preferably at temperature in-between 55-70 ⁰C at atmospheric pressure. Heat can be applied by electrical means or steam or hot oil or hot water or any combination thereof. After disperse of surfactant and thickener in the fluid, mixture cool to 20- 40⁰C and most preferably 30-35⁰C. Rest of the mixing process is carried out at 30-35⁰C at atmospheric pressure.

The components are mixed by simple low shear mixer. Useful low shearing stirring system may be illustrated but not limited to, propeller stirrer, turbine stirrer, pitch blade stirrer, anchor stirrer and others. Also low shearing means, which can mix the components without generating much shear, can be used in the process of this invention. It is not recommended to use any mixing system, which generated high shear like a homogenizer. From the capital investment point of view, it is also clear that the process needs a very economic mixing system unlike the expensive mixing systems used in the prior art.

Total time needed to produce an emulsion having a particle size 1-100 micron from starting to finishing of emulsion process is dependent on the design of the stirrer, loading system of all inputs and efficiency of temperature change. Typically, such emulsion can be produced less than 6 hr. It is important to mix the compositions to achieve desired viscosity and related properties till av. Particle size reaches to 1-100 micron.

The selective emulsifiers used in the formulation of high particle size emulsion in accordance to present emulsion is a non ionic surfactant having HLB value of 4.0-9.5. Most useful surfactants of this category are polyoxyalkylene alkyl ether, polyoxyalkylene alkylphenyl ethers and polyoxyalkylene sorbitan esters. Non-ionic surfactant having HLB value in-between 4.0- 9.5 has a great importance in the present invention to make process more simpler. Non ionic Surfactant within the HLB value 4.0-9.5 help easily to mix two different phase components (silicone oil and water) with each other with a simple stirring since these emulsifiers are dispersible in both the phase. These emulsifiers also help to form emulsion micelles very fast due their dispersibility advantages.

According to the present invention, suitable thickener has a very important role to make a stable high particle emulsion. Main criteria of the thickener are to act as a suspending agent in the emulsion. Choice of the right thickener is also an art according to the present invention, since thickener improves the stability of the emulsion significantly. Anionic Polycarboxylic acid thickener is found one of the best thickening agent to stabilize the emulsion in compare to conventional Xantham gum, Sodium alginate, gum Arabic, all types of guar gum and all types of cellulose derivatives. Carbopol^® 980; Carbopol^® 981; of Noveon are found most useful thickening agent in the present invention to stabilize the emulsion. The quantity of the thickener has also critical effect to endow longer stability of the emulsion. Generally, 0.1 to 10% thickener in the emulsion is useful to make the emulsion stable for longer time. Preferably, 0.1 to 1% thickener is the optimum quantity for longer shelf-life of the emulsion.

Importantly, the atbility of the emulsion system of the invention is confirmed by the fact that after achieving desire viscosity in stage one and stage two, if the material is stirred for more time after achieving the desire viscosity, there is still no effect in the quality of the emulsion.

Further, after making emulsion when it put at the oven in the range of 45 to 60⁰C and most preferably, 55⁰C for one month, no creaming or separation or deformation in the emulsion is observed. It is also made a study of 12 hr freeze / thaw cycles in 10°C / 50⁰C temperature for one month. In this study also, no creaming or separation or deformation in the emulsion is observed.

The details of the invention, its objects and advantages are explained hereunder in greater detail in relation to non- limiting exemplary illustrations of the process:

EXAMPLES ;

Example I

A blended silicone oil containing 40% trimethylsiloxy ended dimethyl polysiloxane having viscosity 350 Cps and 60% trimethylsiloxy ended dimethyl polysiloxane having viscosity 600,000 Cps was mixed together in a mixing tank having anchor stirrer in it. This oil was used for making emulsion in the following emulsions.

Example II

In the first step of the emulsion process, transferred the 4000 gm blended oil from example I, 1370 gm demineralised water (DM water) ; 13.5 gm Carbopol^® 980 and 156 gmSTAL 5 (Grand Organics) . Materials were heated to 60⁰C under stirring and continued stirring till STAL 5 (Grand Organics) and Carbopol^® 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 1,20,000 cps. Generally, 3.5 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 80 gm Laffonics 1340 (Laffans India) and continue mixing till viscosity drop to 40,000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 1057 gm DM water for final dilution of the emulsion and added 3 gm Kathon⁸ CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a very narrow particle size distribution having 2.87 micron DlO; 10.76 micron D50; 23.74 micron D90 and 41.43 micron DlOO.

We also made a study of heat stability of Example II emulsion at 55 ⁰C for one month and didn't observe any deformation of the emulsion even after one month. Emulsion from example II also showed absolutely perfect when the emulsion went for 12 hr freeze / thaw cycles in 10⁰C / 50⁰C temperature for one month. Example: III

In the first step of the emulsion process, transferred the.4000 gm blended oil from example I, 1370 gm demineralised water (DM water) ; 20 gm Carbopol^® 980 and 200 gm STAL 5 (Grand Organics) . Materials were heated to 60⁰C under stirring and continued stirring till STAL 5 (Grand Organics) and Carbopol^® 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35°C till viscosity reach to 1,25,000 cps. Generally, 3.5 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 98 gm Laffonics 1340 (Laffans India) and continue mixing till viscosity drop to 45,000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 975 gm DM water for final dilution of the emulsion and added 3 gm Kathon CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a very narrow particle size distribution having 4.13 micron DlO; 17.59 micron D50; 47.88 micron D90 and 58.94 micron DlOO.

Also study of heat stability of Example III emulsion at 55 ⁰C for one month didn't observe any deformation of the emulsion even after one month. Emulsion from Example III also showed absolutely perfect when the emulsion went for 12 hr freeze/thaw cycles in 10°C/50°C temperature for one month. Example : IV

In the first step of the emulsion process, transferred the 4000 gm blended oil from example I, 1370 gm demineralised water (DM water) ; 10 gm Carbopol^® 980 and 200 gm STAL 5 (Grand Organics) . Materials were heated to 60⁰C under stirring and continued stirring till STAL 5 (Grand Organics) and Carbopol^® 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 1,18,000 cps. Generally, 3.0 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 98 gm Laffonics 1340 (Laffans India) and continue mixing till viscosity drop to 39,000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 985 gm DM water for final dilution of the emulsion and added 3 gm Kathon^® CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a very narrow particle size distribution having 2.5 micron DlO; 10.0 micron D50; 23.61 micron D90 and 35.56 micron DlOO.

Also study of heat stability of Example IV emulsion at 55 ⁰C for one month didn't show any deformation of the emulsion even after one month. Emulsion from Example IV also showed absolutely perfect when the emulsion went for 12 hr freeze/thaw cycles in 10°C/50°C temperature for one month. Example : V

In the first step of the emulsion process, transferred the 4000 gm blended oil from example I, 1370 gm demineralised water (DM water) ; 12 gm Carbopol^® 980 and 200 gm Laffonics 1340 (Laffans India) . Materials were heated to 60⁰C under stirring and continued stirring till Carbopol^® 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 1,50,000 cps. Generally, 2.5 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 98 gm Laffonics 1340 (Laffans India) and continue mixing till viscosity drop to 60,000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 983 gm DM water for final dilution of the emulsion and added 3 gm Kathon^® CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a very narrow particle size distribution having 3.44 micron DlO; 13.43 micron D50; 30.05 micron D90 and 56.23 micron DlOO.

Also study of heat stability of Example V emulsion at 55 ⁰C for one month didn't show any deformation of the emulsion even after one month. Emulsion from Example V also showed absolutely perfect when the emulsion went for 12 hr freeze/thaw cycles in 10°C/50⁰C temperature for one month. Example : VI

In the first step of the emulsion process, transferred the 4000 gm blended oil from example I, 1370 gm demineralised water (DM water) ; 14 gm Carbopol^® 980 and 200 gm STAL 5 (Grand Organics) . Materials were heated to 60⁰C under stirring and continued stirring till STAL 5 (Grand Organics) and Carbopol^® 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 1,30,000 cps. Generally, 3.0 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 326 gm 30% solution of STAL 5 (Grand Organics) and continue mixing till viscosity drop to 44000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 753 gm DM water for final dilution of the emulsion and added 3 gm Kathon^® CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a very narrow particle size distribution having 3.82 micron DlO; 20.51 micron D50; 46.3 micron D90 and 76.32 micron DlOO.

Also study of heat stability of example VI emulsion of at 55 ⁰C for one month didn't observe any deformation of the emulsion even after one month. Emulsion from Example VI also showed absolutely perfect when the emulsion went for 12 hr freeze / thaw cycles in 10⁰C / 50⁰C temperature for one month. Example: VII

In the first step of the emulsion process, transferred the 4000 gm blended oil from example I, 1370 gm demineralised water (DM water); 13.5 gm Rhodopol^® 23 (Xanthum gum) and 156 gm STAL 5

(Grand Organics) . Materials were heated to 60⁰C under stirring and continued stirring till STAL 5 (Grand Organics) and

Rhodopol^® 23 dispersed in fluid and water. Generally, 0.5 hr required for dispersing the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 1,05,000 cps. Generally, 3.5 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 80 gm Laffonics 1340 (Laffans India) and continue mixing till viscosity drop to 37,000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 1057 gm DM water for final dilution of the emulsion and added 3 gm Kathon^® CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a wide particle size distribution having 0.5 micron DlO; 7.88 micron D50; 56.7 micron D90 and 99.4 micron DlOO.

Also study of heat stability at 55 ⁰C showed emulsion was separated after eight days. Emulsion also separated after nine days when the emulsion went for 12 hr freeze/thaw cycles in 10⁰C / 50⁰C temperature. Example VI II-X .

In the examples VIII to X, the same recipe like example II was used but only changed the stirring time in first stage and second stage or both. The particle size of the emulsion for Examples VIII-X were then measured.

Also a study of heat stability of emulsion of Example VIII-X at 55 ⁰C for one month didn't observe any deformation of the emulsion even after one month. Emulsions from Example VIII-X also showed absolutely perfect when the emulsion went for 12 hr freeze / thaw cycles in 10⁰C / 50⁰C temperature for one month.

Example XI

In the first step of the emulsion process, transferred the 4000 gm blended oil from Example I₇ 1370 gm demineralised water (DM water) ; 13.5 gm Carbopol^® 980 and 156 gm Brij 35 (ICI product) . Materials were heated to 60⁰C under stirring and continued stirring till Brij 35 and Carbopol⁰ 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components into water oil mixture. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 70,000 cps . Generally, 3.0 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 98 gm Dehydol LS-2 (Henkel product) and continue mixing till viscosity drop to 35000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level. Added 1057 gm DM water for final dilution of the emulsion and added 3 gm Kathon^® CG as a biocide.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a wide particle size distribution having 0.7 micron DlO; 5.0 micron D50; 65.8 micron D90 and 240.9 micron DlOO.

A study of heat stability at 55 ⁰C showed emulsion was separated after one days. Emulsion also separated after one days when the emulsion went for 12 hr freeze/thaw cycles in 10⁰C/50⁰C temperature.

Example XII

In the first step of the emulsion process, transferred the 4000 gm blended oil from example I, 1370 gm demineralised water (DM water) ; 13.5 gm Carbopol^® 980 and 400 gm STAL 5 (Grand Organics) . Materials were heated to 60⁰C under stirring and continued stirring till STAL 5 (Grand Organics) and Carbopol^® 980 dispersed in fluid and water. Generally, 0.5 hr required to disperse the components in water oil mixtures. Cooled the mixture to 30-35⁰C and continued mixing at 30-35⁰C till viscosity reach to 400,000 cps. Generally, 3.0 hr required to reach the viscosity of the mixture to desire level. In the second stage, Added 200 gm Laffonics 1340 and continue mixing till viscosity drop to 130,000 Cps. Generally, 1.0 hr required to reach the viscosity of the mixture to desire level . Added 680 gm DM water for final dilution of the emulsion and added 3 gm Kathon^® CG as a biocide. Viscosity of the final product was 70000 Cps.

Measured the particle size of the emulsion by Malvern Mastersizer. Result showed a wide particle size distribution having 0.08 micron DlO; 0.75 micron D50; 10 micron D90 and 14 micron DlOO.

Due to high content of emulsifier, particle size of the emulsion obtained was lower than 1 micron.

The above results demonstrate clearly the importance of the selective use of emulsifier to achieve the desire high particle size emulsion. Also the quantity of the emulsifiers also has great role to make the emulsion stable. In particular as demonstrated above in the process of making high particle organopolysiloxane emulsion, the emulsion could be stabilized by use of selective amounts of surfactant/surfactants having a critical HLB value that help to mix oil and water easily without need for complex manipulative steps or much of precautions of water addition. Moreover, the selective use of thickener which has a very important role to achieving a stable high particle emulsion is further demonstrated by the above examples. Use of the Anionic thickener is found to be the best thickening agent to stabilize the emulsion as compared to other known conventional thickeners . The selective use of thickener provide for longer self life of the emulsion system of the invention. It is thus possible by way of the invention to provide a process of making silicone emulsion having particle size from 1-100 micron which would be simple, cost-effective and would not require the complex manipulative steps and thus can be readily adopted for large scale commercial manufacture of such high particle size silicone emulsions for diverse applications such as in hair care products and the like.

It is possible to obtain variety of high particle emulsions based on selective emulsifiers, silicone fluid compositions and ratio of fluid to emulsifiers following the simple two stage process of making high particle emulsion of the invention for diverse end use applications including in hair care products and the like and the scope of the invention may be governed keeping in view such beneficial aspects of the present process.

Claims

Claims :

1. A process for the manufacture of stable and high particle silicone emulsion comprising: i) providing (a) silicone oil or blends thereof in an amount of 50 to 70 % by. wt. (b) water in an amount of 10 to 30 % by wt. (c) selective non- ionic emulsifier having HLB in the range of 4.0 to 9.5 in amounts of 1 to 10% by wt. and (d) selective anionic thickener in an amount of 0.1 to

1 % by. wt.; ii) heating the mix of (i) above in the temperature range of 55 to 70⁰C and stirring to provide a homogenous mix. ; iii) cooling the mix of (ii) above in the temperature range of 20-40⁰C and continuing mixing till a desired viscosity in the range of 70,000-1,50,000 cps is attained; iv) adding further a non ionic emulsifier having HLB in the range of 4.0 to 9.0 in an amount of 0.5 to

5%, continuing the mixing in the temperature range of 30-35⁰C till a desired viscosity of 20,000 to 65,000 cps is attained and thereafter adding water for final dilution and average particle size in the range of 1 to 100 microns.

2. A process as according to claim 1 comprising said steps selectively carried out to produce silicone emulsion in the range of average 1-100 micron (D50 value) with narrow particle size distribution, to obtain an highly stable emulsion. 3. A process as according to anyone of claims 1 or 2 for making high particle organopolysiloxane emulsion wherein said non ionic emulsifiers used comprise surfactant / surfactants having said critical HLB value selectively used to mix oil and water.

4. A process as according to anyone of claims 1 to 3 comprising providing a stable high particle emulsion selected from organopolysiloxane (silicone fluid) and a mixture of organopolysiloxane (blended silicone fluid) .

5. A process as according to anyone of claims 1 to 4 wherein said blended silicone fluid used comprise a mixture of one high viscosity non volatile organopolysiloxane and a low viscosity non volatile organopolysiloxane; functional polysiloxane and mixture thereof.

6. A process as according to anyone of claims 1 to 4 wherein said high particle emulsion is produced from a silicone selected from amino functional polysiloxane, carbonyl functional polysiloxane, glycol functional polysiloxane, epoxy functional polysiloxane, carboxy functional polysiloxane and vinyl functional polysiloxane and mixture thereof.

7. A process as according to anyone of claims 1 to 6 wherein said high viscous polysiloxanes used comprise the structure of Formula I PI V - R ...... (B)

Formula I where R, which may differ, is a monovalent hydro carbon radical and x is an integer from 1000 to 4000.

A process as according to claim 7 wherein in said high viscous polysiloxanes structure of Formula I R comprise alkyl radicals preferably selected from methyl, ethyl, n- propyl, isopropyl, n-butyl, isobutyl, tert-butyl, n- pentyl, isopentyl, neopentyl, tert-pentyl, hexyl preferably n-hexyl, heptyl preferably n-heptyl, octyl, preferably n-octyl and isooctyl preferably 2,2,4-trimethyl pentyl, nonyl preferably n-nonyl, decyl preferably n- decyl, dodecyl preferably n-dodecyl, octadecyl preferably n-octadecyl; alkenyl, preferably vinyl and allyl, cycloalkyl, preferably cyclopentyl, cyclohexyl, cycloheptyl and methyl cyclohexyl, aryl preferably phenyl, naphthyl, anthryl and phenanthryl; alkylaryl, preferably o-, m-, p-tolyl, xylyl and ethylphenyl; aralkyl, preferably benzyl, α- and β-phenylethyl, of which methyl, ethyl, n-propyl, isopropyl are most preferred and methyl is particularly preferred. A process as according to anyone of claims 1 to 6 wherein said anyone of claims 1 to 8 wherein said low viscosity non-volatile polysiloxane used have the structure of following Formula II

Formula II

10. A process as according to claim 9 wherein in said low viscosity non-volatile polysiloxane structure of Formula II R comprise alkyl radicals, preferably methyl, ethyl, n- propyl, iso propyl, n-butyl, isobutyl, tert-butyl, n- pentyl, isopentyl, neopentyl, tert-pentyl, hexyl preferably n-hexyl, heptyl, preferably n-heptyl, octyl, preferably n-octyl and isooctyl, preferably 2,2,4- trimethyl pentyl, nonyl, preferably n-nonyl, decyl preferably n-decyl, dodecyl preferably n-dodecyl, octadecyl preferably n-octadecyl; alkenyl, preferably vinyl and allyl, cycloalkyl, preferably cyclopentyl, cyclohexyl, cycloheptyl and methyl cyclohexyl, aryl preferably phenyl, naphthyl, anthryl and phenanthryl; alkylaryl, preferably o-, m-, p-tolyl, xylyl and ethylphenyl; aralkyl, preferably benzyl, α- and β- phenylethyl, of which methyl, ethyl, n-propyl, isopropyl are most preferred and methyl is particularly preferred.

11. A process according to anyone of claims 1 to 10 wherein the high viscosity non-volatile polysiloxane of Formula I has a viscosity in-between 60,000 Cps to 1 MIO cps preferably, viscosity in-between 100,000 Cps to 600,000 cps.

12. A process according to anyone of claims 1 to 11 wherein the low viscosity polysiloxane oil of Formula II has a viscosity in the range of 100 cps to 5000 cps, preferably, 350 Cps to 2000 cps.

13. A process according to anyone of claims 1 to 12 wherein the ratio of two fluids in the blended silicone in particular high viscosity to low viscosity ratio in the blended silicones varies from 20:80 to 80:20.

14. A process according to claim 13 wherein for the use of the blended silicone varies preferably from 50:50 to 70:30.

15. A process according to anyone of claims 1 to 14 wherein the viscosity of the blended silicone oil varies from 30,000 cps to 100,000 cps. 16. A process according to anyone of claims 1 to 15 wherein the functional non-volatile polysiloxane used have the following Formula III

Formula III

where Rl is selected from amino functional group containing one or more than one carbon; carbonyl functional group containing one or more than one carbon; glycol functional group containing one or more than one carbon; epoxy functional group containing one or more than one carbon; acryloxy functional group; chloroalkyl functional group; vinyl functional group and other functional group having the formula X — R2 — where X is the functional groups containing one atom which is not a carbon atom or hydrogen atom and R2 is selected from alkylene group having at least one carbon atom, x is the integer from 10-100. 17 . A process according to claim 16 wherein in said Formula III Rl groups is selected from the following functional groups :

C ICH₂ CH₂ CH₂-

NH₂ - CH₂CH₂ -NH- C-JTi 2 OrI 2 C- 1I2 ~"

0

CH₂ — CH CH₂ - O - C_-Jτd.2 L_*H.2 L. U2

0

CH₃ - CH CO CH₂CH₂CH₂ - H - (OCH₂ CH_a ) ₁₅ -O- CH₂CH₂CH₂ -

CH,= CH-

HO - CH₂CH₂CH₂ -

18. A process according to anyone of claims 1 to 17 wherein said process preferably comprise mixing said silicone oil, surfactant, thickener and water in a closed SS blender to at least 55⁰C and more preferably 55⁰C -70⁰C, after dispersing the thickener, cooling the mixture to 20-40⁰C and most preferably 30-35⁰C, continue stirring with maintaining temperature 30-35⁰C till a desire viscosity of the emulsion reached, adding the second emulsifier and continue stirring with maintaining temperature 30-35⁰C till viscosity of the emulsion drop to desired viscosity, diluting the resulting material with rest of the water and biocide to form the high particle size emulsion (D50) in the range of 1-100 micron emulsion. 19. A process according to anyone of claims 1 to 18 wherein the processing in steps (i) and (ii) are carried out in at least more than 50⁰C and more preferably at temperature in-between 55-70 ⁰C at atmospheric pressure, said heating is done using selectively electrical means, steam, hot oil, hot water and any combination thereof, after dispersing of surfactant and thickener in the fluid, the mixture is cooled to 20-40⁰C and most preferably 30-35⁰C, the rest of the mixing process being carried out at 30- 35⁰C at atmospheric pressure.

20. A process according to anyone of claims 1 to 19 wherein the components are mixed by simple low shear mixer.

21. A process according to anyone of claims 1 to 20 comprising mixing the compositions to achieve desired viscosity and related properties till av. Particle size reaches to 1-100 micron.

22. A process according to anyone of claims 1 to 21 wherein the non ionic surfactant having HLB value of 4.0-9.5. are selected from polyoxyalkylene alkyl ether, polyoxyalkylene alkylphenyl ethers and polyoxyalkylene sorbitan esters .

23. A process according to anyone of claims 1 to 22 wherein said anionic thickener used is selectively provided to act as suspending agent in the emulsion preferably polycarboxylic acid. 24. A process according to anyone of claims 1 to 23 wherein the quantity of the thickener is 0.1 to 10% in the emulsion preferably, 0.1 to 1%.

25. A process for the manufacture of stable and high particle size silicone emulsion comprising of: stage one comprising of providing the silicone oil/blend in a mixing tank in an amount of 50-70% of the emulsion preferably, in the range of 55-65% of the emulsion, adding 10-30% water preferably 15-25% of the emulsion, a Non- ionic emulsifier having HLB value 4.0-9.5 in amounts of 1- 10% of the emulsion preferably 1-4% of emulsion or emulsifier in ratio of 20-30:1 against fluid to emulsifier ratio is used alongwith 0.1 to 1% thickener of the emulsion, heating all components under mixing condition in the range of 55°C -70⁰C and continued stirring till the emulsifier and thickener disperse in the system for a period of 0.5-3 hr preferably, 0.5-1.0 hr with stirring, cooling the mixture to 20-40°C and most preferably 30-35⁰C continuing mixing, till the desired viscosity of the water-oil-surfactant-thickener in the range of 70,000 to 1,50,000 Cps is achieved in a period of 2-5 hr preferably, 2-4 hr ; and

stage two comprising adding emulsifier 0.5% to 5% preferably 0.5 to 2.5% of the emulsion or using emulsifier in ratio of 40-45:1 against fluid to emulsifier ratio, said emulsifier having a HLB value in-between 4.0 to 9.5., continue the mixing at 30-35°C till the desired viscosity of the water-oil-surfactant-thickener in the range of 20000 to 65000 Cps is achieved in a period of from 1-3 hr preferably, it is 1.0 -1.5 hr with the stirring system, after desired viscosity is achieved, adding balance water for final dilution and biocide in the range of 0.01 to 0.05 % of the emulsion to finally obtain the high particle size emulsion of average particle size in the range of I- 100 micron.

26. A stable high particle silicone emulsion obtained following the processes as claimed in anyone of claims 1 to 25.

27. Use of the stable high particle silicone emulsion obtained following the processes as claimed in anyone of claims 1 to 26 in hair care products such as shampoo conditioners and the like.

28. A process for the manufacture of stable and high particle silicone emulsion substantially as herein described and illustrated with reference to the accompanying examples.