Process for the production of high internal phase emulsion foams

1. A method for polymerizing a High Internal Phase Emulsion foam comprising:

exposing High Internal Phase Emulsion comprising a photoinitiator to an Ultraviolet light source;

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

2. The method of claim 1 , wherein the High Internal Phase Emulsion is moved to a curing oven.

3. The method of claim 1 , wherein the High Internal Phase Emulsion is moved to a multi-tiered curing oven.

4. The method of claim 1 , wherein the High Internal Phase Emulsion further comprises an oil phase, a monomer, a cross-linking agent, an emulsifier and an aqueous phase.

5. The method of claim 1 , wherein the UV light is in the wavelength range of from about 200 nm to about 800 nm.

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

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

8. 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.

9. The method of claim 3 wherein the multi-tiered curing oven-comprises at least three curing oven belts.

10. The method of claim 1 wherein the emulsion has top surface has a z-stick measurement of less than 0.70N.

11. The method of claim 1 , wherein an aqueous phase and an oil phase of the High Internal Phase Emulsion are combined in a ratio between about 8:1 and about 140:1.

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

13. The method of claim 12 , wherein the shear agitation is provided by a static mixer.

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

15. The method of claim 14 , wherein the extrusion belt is an endless belt.

16. A method for polymerizing a High Internal Phase Emulsion foam comprising:

depositing a High Internal Phase Emulsion comprising a photoinitiator on an extrusion belt;

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

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

17. The method of claim 16 , wherein the extrusion belt comprises at least one material from the group including films, non-woven materials, woven materials, and combinations thereof.

18. The method of claim 16 , wherein the extrusion belt comprises depressions, protuberances, or combinations thereof.

19. The method of claim 16 , wherein the aqueous phase and oil phase of the High Internal Phase Emulsion are combined in a ratio between about 8:1 and about 140:1.

20. The method of claim 16 , wherein the High Internal Phase Emulsion is formed by subjecting the aqueous and oil phases to shear agitation.