It is highly desirable to produce elastomeric foams directly from liquid components. Flexible urethanes, the only technologically important elastomeric foams that are commercially available, are enjoying rapid growth. An essential feature of a successful foam system is the ability to attain the appropriate balance between gas generation and cure reaction. We report here a completely new system which allows syrups, consisting of polymer dissolved in free-radically polymerizable monomers, to be foamed directly using certain azo compounds. Our preliminary results show that a number of different azo compounds may be utilized to produce elastomeric foams over a wide density range. The variables which can effectively control the foaming and curing reaction are discussed, but there has been no attempt to optimize the physical properties of the flexible foams. Physical property evaluations will be the subject of future publications. We illustrate the versatility of the system and believe that properties may be easily tailored to end-use needs by appropriate selection of formulation components.
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