Patent ID: 7138436

Claim:
A process for making an uncrosslinked polymeric foam comprising: a) mixing a reactive phase comprising at least one polymerizable material comprising a monomer containing a reactive functional group, the polymerizable material having an effective glass transition temperature sufficient to permit the formation of a stable foam upon polymerization of the material and subsequent removal of an immiscible phase with no effective amount of crosslinking agent and at least one emulsifier with at least one photoinitiator system and a liquid immiscible with the reactive phase to form an emulsion wherein the immiscible liquid forms a discontinuous or co-continuous phase with the continuous reactive phase; b) shaping the emulsion; and c) irradiating the emulsion with actinic radiation having a wavelength of about 200 to about 800 nanometers, thereby causing the emulsion to polymerize such that it forms a stable foam.