Patent ID: 6365642
Filing Date: 2002-04-02
Classification: C08F,C08J

Abstract:
A process for the preparation of a polymeric foam material which comprises the steps of:A) forming a water-in-oil emulsion from: 1) an oil phase comprising: a) from about 80 to about 99% by weight of a monomer component capable of rapid curing, the monomer component comprising: i) from about 20 to about 97% by weight of a substantially water-insoluble monomer selected from the group consisting of alkyl acrylates, alkyl methacrylates, and mixtures thereof; ii) from about 2 to about 40% by weight of a substantially water-insoluble polyfunctional crosslinker selected from the group consisting of acrylate polyester, methacrylate polyester, and mixtures thereof; iii) about 0 to about 15% by weight of a third substantially water-insoluble monomer; and b) from about 1 to about 20% by weight of an emulsifier component which is soluble in the oil phase and suitable for forming a stable water-in-oil emulsion; and 2) a water phase comprising an aqueous solution containing from about 0.2 to about 40% by weight of a water-soluble electrolyte; wherein the emulsion has a volume to weight ratio of water phase to oil phase in the range of from about 8:1 to about 140:1; B) curing the monomer component in the oil phase of the water-in-oil emulsion using a polymerization reaction that is conducted at a curing temperature of from about 20Â° C. to about 130Â° C. for a time sufficient to form a saturated polymeric foam material.