Abstract: Stable aqueous dispersions or emulsions can be prepared by merging into a mechanical disperser a stream of a molten or liquid disperse phase with a stream of a molten or liquid continuous phase to form a dispersion or emulsion. The molten or liquid disperse phase stream contains a polymer that is preferably a solid at room temperature, but molten at some advanced temperature. The polymer is formed in a molten state or formed and melted by a continuous reaction process such as an extrusion process, including melt extrusion or compound extrusion. It has been discovered that low polydisperse submicron sized dispersion can be prepared by the method of the present invention.

Abstract: The present invention is a method of preparing a high internal phase ratio emulsion without phase inversion comprising the steps of:a) continuously merging into a disperser and in the presence of an emulsifying and a stabilizing amount of a surfactant, a continuous phase liquid stream having a flow rate R.sub.1, and a disperse phase liquid stream having a flow rate R.sub.2 ; andb) mixing the merged streams with a sufficient amount of shear, and with R.sub.2 :R.sub.1 sufficiently constant, to form the high internal phase ratio emulsion without phase inversion or stepwise distribution of an internal phase into an external phase;wherein R.sub.2 :R.sub.1 encompasses a range, the lower limit of which range being defined by a point where the volume average particle size of the high internal phase ratio emulsion begins to show an inverse dependence on R.sub.2 :R.sub.1, and wherein the upper limit of which range is just less than an R.sub.2 :R.sub.

Abstract: The present invention is a method of preparing a high internal phase ratio emulsion without phase inversion comprising the steps of:a) continuously merging into a disperser and in the presence of an emulsifying and a stabilizing amount of a surfactant, a continuous phase liquid stream having a flow rate R.sub.1, and a disperse phase liquid stream having a flow rate R.sub.2 ; andb) mixing the merged streams with a sufficient amount of shear, and with R.sub.2 :R.sub.1 sufficiently constant, to form the high internal phase ratio emulsion without phase inversion or stepwise distribution of an internal phase into an external phase;wherein R.sub.2 :R.sub.1 encompasses a range, the lower limit of which range being defined by a point where the volume average particle size of the high internal phase ratio emulsion begins to show an inverse dependence on R.sub.2 :R.sub.1, and wherein the upper limit of which range is just less than an R.sub.2 :R.sub.