Process for the production of high internal phase emulsion foams

1. A method for reducing the adherence of a High Internal Phase Emulsion to a belt surface comprising the steps of:

forming a High Internal Phase Emulsion from

an oil phase comprising monomer, cross-linking agent, emulsifier;

an aqueous phase;

photoinitiator;

depositing the High Internal Phase Emulsion on an extrusion belt having a surface, such that the High Internal Phase Emulsion has a top surface and a bottom surface, and the bottom surface is in contact with the extrusion belt;

exposing the High Internal Phase Emulsion to an Ultraviolet light source;

partially polymerizing the top surface of the High Internal Phase Emulsion;

moving the High Internal Phase Emulsion having partially polymerized top surface to a multi-tiered curing oven;

contacting the partially polymerized top surface of the High Internal Phase Emulsion with a curing oven belt surface in the multi-tiered curing oven; and

polymerizing the monomer component in the oil phase of the High Internal Phase Emulsion using a polymerization reaction that is conducted at a temperature of from about 20° C. to about 150° C. for a time sufficient to from a High Internal Phase Emulsion foam;

wherein the High Internal Phase Emulsion foam exhibits a Z-stick measurement between the top surface of the High Internal Phase Emulsion foam and a glass-lined upper platen of less than 0.64 N.

2. The method of claim 1 , wherein the UV light is in the wavelength range of from about 200 nm to about 400 nm.

3. The method of claim 1 , wherein the source of UV light is a UV lamp.

4. The method of claim 1 , wherein the High Internal Phase Emulsion foam is exposed to the UV light for less than about 1 minute.

5. The method of claim 1 , wherein the photoinitiator is at least one of benzyl ketals, α-hydroxyalkyl phenones, α-amino alkyl phenones, or acylphospine oxides.

6. The method of claim 1 wherein the multi-tiered curing oven comprises at least three curing oven belts.

7. The method of claim 1 , wherein the aqueous phase and oil phase of the High Internal Phase Emulsion are combined in a ratio between about 24:1 and about 140:1.

8. The method of claim 1 , wherein the High Internal Phase Emulsion is formed by subjecting the aqueous and oil phases to shear agitation.

9. The method of claim 8 , wherein the shear agitation is provided by a static mixer.

10. The method of claim 1 , wherein the High Internal Phase Emulsion is deposited on the extrusion belt using at least one of a die, sprayer, or caster.

11. The method of claim 1 , wherein the extrusion belt is an endless belt.

12. The method of claim 1 , wherein the endless belt comprises at least one of films, non-woven materials, or woven materials.

13. A method for reducing the adherence of a High Internal Phase Emulsion to a belt surface comprising the steps of:

forming a High Internal Phase Emulsion from

an oil phase comprising monomer, cross-linking agent, emulsifier;

an aqueous phase;

photoinitiator;

depositing the High Internal Phase Emulsion on an extrusion belt having a surface, such that the High Internal Phase Emulsion has a top surface and a bottom surface, and the bottom surface is in contact with the extrusion belt;

exposing the High Internal Phase Emulsion to an Ultraviolet light source;

partially polymerizing the top surface of the High Internal Phase Emulsion;

moving the High Internal Phase Emulsion having partially polymerized top surface to a multi-tiered curing oven;

transferring the High Internal Phase Emulsion from the extrusion belt to a first curing oven belt such that the partially polymerized top surface of the HIPE is in contact with the first curing oven belt surface;

transferring the High Internal Phase Emulsion from the first curing oven belt to a second curing oven belt such that the bottom surface of the HIPE is in contact with the second curing oven belt surface; and

polymerizing the monomer component in the oil phase of the High Internal Phase Emulsion using a polymerization reaction that is conducted at a temperature of from about 20° C. to about 150° C. for a time sufficient to from a High Internal Phase Emulsion foam;

wherein the High Internal Phase Emulsion foam exhibits a Z-stick measurement between the top surface of the High Internal Phase Emulsion foam and a glass-lined upper platen of less than 0.64 N.

14. The method of claim 13 , wherein the UV light is in the wavelength range of from about 20 nm to about 400 nm.

15. The method of claim 13 , wherein the source of UV light is a UV lamp.

16. The method of claim 13 , wherein the High Internal Phase Emulsion foam is exposed to the UV light for less than about 1 minute.

17. The method of claim 13 , wherein the extrusion belt, first curing oven belt, and second curing oven belt are endless belts.

18. The method of claim 17 , wherein the extrusion belt, first curing oven belt, and second curing oven belt comprise at least one of films, non-woven materials, or woven materials.

19. The method of claim 13 , wherein the extrusion belt comprises at least one of fluorine resins, silicone resins, polyimides, polyphenylene sulfides, polysulfones, polyether sulfones, polyether imides, polyether ether ketones, para type aramid resins; thermoplastic polyester resins, or thermoplastic polyester type elastomer resins.