Mold process for making nanofoam

1. A process for preparing nanofoam comprising the following steps:

a. providing a mold having a mold cavity defined by mold walls, the mold walls comprising at least three pieces that form a sealed enclosure around the mold cavity while at least one wall is movable with respect to other walls, wherein the at least three pieces are opposing top plate and bottom plate and side plates oriented such that the side plates extend between the top and bottom plates, the mold further having a sealable port which provides access into the mold cavity when open and seals the mold cavity when shut;

b. providing a foamable polymer mixture comprising a polymer and a blowing agent where the polymer is selected from a group consisting of styrene acrylonitrile copolymers and acrylate polymers and where the foamable polymer mixture is at a temperature and pressure where at the temperature the pressure is at least 690 kilopascals above the pressure needed to fully dissolve the blowing agent in the polymer;

c. introducing the foamable polymer mixture into the mold cavity of the mold while maintaining a temperature and pressure where at the temperature the pressure is at least 690 kilopascals above the pressure needed to fully dissolve the blowing agent in the polymer and controlling the pressure by controlling a combined rate of introducing foamable polymer mixture into the mold cavity and movement of a wall of the mold to increase mold cavity volume; and

d. releasing the pressure around the foamable polymer mixture by moving at least one piece of the mold wall at a rate of at least 45 centimeters per second so as to increase the volume within the mold thereby causing the foamable polymer mixture to expand into a nanofoam having a porosity of at least 60 percent, a volume of at least 100 cubic centimeters and at least two orthogonal dimensions of four centimeters or more.

2. The process of claim 1 , wherein the mold in step (a) is further characterized by the side plates being a single piece that sets on top of and seals against the bottom plate and the top plate fit within and seals against the side plates while being movable within the side plates and wherein the top plate moves within the side plates to increase mold cavity volume during introduction of foamable polymer mixture into the mold cavity in step (c).

3. The process of claim 1 , further characterized by releasing the pressure in step (d) by sequentially moving the top plate relative to the side plates and then moving the side plates relative to the bottom plate so as to leave the resulting foam setting on the bottom plate free of the side plates and top plate.

4. The process of claim 1 , further characterized by the blowing agent consisting of carbon dioxide.

5. The process of claim 1 , further characterized by the mold cavity having two orthogonal dimensions prior to step (d) that are each at least four centimeters.

6. The process of claim 1 , where the foamable polymer mixture is provided in step (b) from an extruder that directs the foamable polymer mixture into the mold cavity in step (c) through a gate valve in a semi-continuous manner whereby steps (b), (c) and (d) are repeated in a cycle with an additional step (e) of removing the nanofoam from the mold cavity following step (d) in the cycle.

7. The process of claim 1 , further characterized by having a post-expansion step after step (d) where the resulting foam is exposed to heat and optionally steam to further expand.