Patent ID: 9637607
Date: 2017-05-02
CPC Classifications: C08F,C08J

Claim:
1. A method of making a foam from a polymerizable resin, the method comprising: (i) providing a thermally-activated initiator having a given initiation temperature and a given promoted temperature, wherein the temperature of the initiator is below the initiation temperature; (ii) providing an elevated-temperature solution comprising a given amount of the polymerizable resin and carbon dioxide, and optionally promoter, wherein the temperature of the elevated-temperature solution is above the promoted temperature; (iii) combining at a mixing pressure the initiator of step (i) with the solution of step (ii) to form a mixture having a temperature above the promoted temperature; (iv) expanding the mixture by decreasing the pressure of the mixture to below the mixing pressure to create a froth comprising a plurality of cells formed by carbon dioxide that expanded out of solution; and (v) curing the polymerizable resin within the froth to create a solidified matrix encasing the plurality of cells.