The rheology of aqueous emulsions prepared by direct emulsification and phase inversion from a high viscosity alkyd resin

A comparison of the rheological properties of dispersions of an alkyd resin in water prepared by direct emulsification and phase inversion has been conducted. These dispersions have application as the base dispersion in the manufacture of the new generation of water based gloss paints. An experimental investigation of the effect of dispersed phase fraction, droplet size and dispersion age on the rheological properties of dispersions produced by each emulsification route has been carried out. The droplet size distributions of the dispersions are also characterised. It was found that phase inversion always gave a smaller droplet size distribution than direct emulsification. Surprisingly it was found that for a given dispersed phase fraction, the dispersions with a smaller droplet size, produced by the phase inversion route, have a lower zero shear rate viscosity than those produced by the direct emulsification route. The rheology of the direct emulsification samples was also observed to change with age, whilst with phase inversion samples the rheology was stable. It is proposed that this and other differences observed between the two methods of manufacture can be associated to the presence, or otherwise, of excess surfactant in the aqueous phase.