Method of producing a foam from a radiation-curable composition

Claim 2

A process for producing a cured foamed polymeric composition comprising: (a) homogeneously and uniformly dispersing a frothing gas into a photocurable liquid composition by mechanical means to form a dispersion and; (b) exposing the dispersion to a source of actinic radiation.

Claim 3

The process of claim 1 wherein the photocurable composition is comprised of an oligomer and a reactive diluent.

Claim 4

The process of claim 2 wherein the photocurable composition is further comprised of a surfactant.

Claim 5

The process of claim 3 wherein the photocurable composition is further comprised of a photoinitiator.

Claim 6

The process of claim 4 wherein the photocurable composition is further comprised of a plasticizer.

Claim 7

The process of claim 2 wherein the frothing gas is selected from the group consisting of air and an inert gas.

Claim 8

The process of claim 6 wherein the frothing gas is air.

Claim 9

The process of claim 6 wherein the frothing gas is nitrogen.

Claim 10

The process of claim 6 wherein the amount of frothing gas dispersed in the liquid composition is such as to produce a dispersion having a specific gravity from about 0.450 to about 0.875.

Claim 11

The process of claim 1 wherein the mechanical means is a continuous mechanical frothing machine in a closed system.

Claim 12

The process of claim 10 wherein the frothing gas is injected into the liquid composition upstream of the mechanical frothing machine.

Claim 13

The process of claim 10 wherein the frothing gas is injected into the liquid composition in the mechanical frothing machine.

Claim 14

The process of claim 11 wherein the mechanical frothing machine homogeneously and uniformly distributes the frothing gas in the form of small bubbles throughout the liquid composition by a cutting and shearing action imparted by concentric rows of blades projecting from a rotating rotor which are interposed between similar concentric rows of blades which project from a stationary stator.

Claim 15

A process for producing a cured foamed polymeric composition comprising the steps of: (a) blending together ingredients to form a liquid photocurable composition; (b) transferring the liquid photocurable composition in a closed system to a continuous mechanical frothing machine; (c) injecting into the liquid photocurable composition a frothing gas selected from the group consisting of air and an inert gas at such a rate to produce a froth having a specific gravity from about 0.450 to about 0.875; (d) mechanically frothing the liquid/gas mixture in the mechanical frothing machine to form a froth; (e) discharging the froth from the mechanical frothing machine; and (f) exposing the froth to actinic radiation to form a cured foam.

Claim 16

A process for producing a cured foamed polymeric composition comprising the steps of: (a) blending together ingredients to form a liquid photocurable composition; (b) transferring the liquid photocurable composition in a closed system to a continuous mechanical frothing machine; (c) injecting into the liquid photocurable composition a frothing gas selected from the group consisting of air and an inert gas at such a rate to produce a froth having a specific gravity from about 0.450 to about 0.875; (d) mechanically frothing the liquid/gas mixture in the mechanical frothing machine to form a froth; (e) discharging the froth from the mechanical frothing machine; and (f) exposing the froth to actinic radiation to form a cured foam.

Claim 17

The process of claim 14 wherein the liquid photocurable polymeric composition is formed by: (a) dissolving a photosensitizer in a reactive diluent to form a solution; (b) mixing a surfactant and a plasticizer into the solution of step (a) to form a mix; and (c) blending the mix from step (b) with an oligomer to form a liquid photocurable composition.

Claim 18

The process of claim 15 further comprising the step of deaerating the liquid photocurable composition prior to the transferring step.