Phase inversion emulsification process for controlling latex particle size

Abstract

A phase inversion emulsification process for controlling latex particle size including a) combining a resin, an organic solvent, an optional neutralizing agent, and a first portion of water in a reactor; wherein said reactor is equipped with a jacket, a vacuum, a condenser connected to the reactor by a distillate conduit, and a receiver connected to the condenser by a condensate conduit, to form a water-in-oil dispersion mixture; b) adding a second portion of water to the reactor to convert the water-in-oil dispersion mixture into an oil-in-water dispersion comprising a latex emulsion of latex particles; c) forming a distillate and controlling the distillate temperature by at least one of: adjusting the jacket temperature, adjusting the vacuum level, or a combination thereof; wherein controlling the distillate temperature controls a particle size distribution change of the latex particles during solvent removal; wherein the distillate temperature is from about 30 to about 80° C.; d) performing solvent removal wherein volatile organic compounds are pulled out of the liquid phase in the reactor to a vapor phase and transferred to the condenser via the distillate conduit; e) cooling distillate vapor in the condenser to a liquid phase; and f) collecting the liquid condensate in the receiver.