Apparatus and method for producing foam

Abstract

An apparatus and method for producing foam whereby said apparatus comprises a solution chamber, a gas inlet, a perforated membrane, a foam formation chamber and an exit port.

1 . An apparatus for producing foam comprising: 
 a. a solution chamber;    b. a gas inlet in said solution chamber; and    c. perforated membrane.    
   
   
       2 . The apparatus of  claim 1  further comprising a foam formation chamber.  
   
   
       3 . The apparatus of  claim 2  further comprising an exit port.  
   
   
       4 . The apparatus of  claim 1  wherein said solution chamber retains a solution comprising at least one solvent.  
   
   
       5 . The apparatus of  claim 4  wherein said solvent in said solution chamber is organic or aqueous.  
   
   
       6 . The apparatus of  claim 4  wherein said solvent in said solution chamber is aqueous.  
   
   
       7 . The apparatus of  claim 4  wherein said solvent in said solution chamber is a cosolvent comprising at least one aqueous and at least one organic solvent.  
   
   
       8 . The apparatus of  claim 4  wherein said solvent in said solution chamber further comprises at least one surfactant.  
   
   
       9 . The apparatus of  claim 8  wherein said surfactant is an ionic or non-ionic surfactant.  
   
   
       10 . The apparatus of  claim 1  wherein said gas inlet supplies gas from outside the apparatus to the interior of the apparatus.  
   
   
       11 . The apparatus of  claim 10  wherein said gas is supplied through said gas inlet at a pressure between 0.1-60 psi.  
   
   
       12 . The apparatus of  claim 10  wherein said gas is supplied through said gas inlet at a pressure between 0.1-40 psi.  
   
   
       13 . The apparatus of  claim 10  wherein said gas is supplied through said gas inlet at a pressure between 0.1-20 psi.  
   
   
       14 . The apparatus of  claim 1  wherein said perforated membrane is formed with a plurality of perforations along opposing surfaces of said membrane.  
   
   
       15 . The apparatus of  claim 1  wherein said perforated membrane is formed of rubber, plastic, polymer or metal.  
   
   
       16 . The apparatus of  claim 1  wherein said exit port is substantially round.  
   
   
       17 . The apparatus of  claim 1  wherein said exit port is covered with a cover wherein said cover comprises at least one opening to produce foam extruded into a desired shape.  
   
   
       18 . A process for producing foam comprising: 
 a. filling a solution chamber with a solution formulated to produce foam;    b. attaching a perforated membrane to the open end of the solution chamber;    c. attaching a foam formation chamber to the solution chamber such that said perforated membrane is positioned between said solution chamber and said foam formation chamber;    d. introducing gas into said solution chamber through a gas inlet;    e. continued application of gas until foam exits the foam producing chamber.    
   
   
       19 . The process of  claim 18  wherein said solution chamber retains a solution comprising at least one solvent  
   
   
       20 . The process of  claim 18  wherein said solvent in said solution chamber is organic or aqueous.  
   
   
       21 . The process of  claim 18  wherein said solvent in said solution chamber is aqueous.  
   
   
       22 . The process of  claim 18  wherein said solvent in said solution chamber is a cosolvent comprising at least one aqueous and at least one organic solvent.  
   
   
       23 . The process of  claim 18  wherein said solvent in said solution chamber further comprises at least one surfactant.  
   
   
       24 . The process of  claim 23  wherein said surfactant is an ionic or non-ionic surfactant.  
   
   
       25 . The process of  claim 18  wherein said gas inlet supplies gas from outside the apparatus to the interior of the apparatus.  
   
   
       26 . The process of  claim 25  wherein said gas is supplied through said gas inlet at a pressure between 0.1-60 psi.  
   
   
       27 . The process of  claim 25  wherein said gas is supplied through said gas inlet at a pressure between 0.1-40 psi.  
   
   
       28 . The process of  claim 25  wherein said gas is supplied through said gas inlet at a pressure between 0. 1-20 psi.  
   
   
       29 . The process of  claim 18  wherein said perforated membrane is formed with a plurality of perforations along opposing surfaces of said membrane.  
   
   
       30 . The process of  claim 18  wherein said perforated membrane is formed of rubber, plastic, polymer or metal.  
   
   
       31 . The process of  claim 18  wherein said exit port is substantially round.  
   
   
       32 . The process of  claim 18  wherein said exit port is covered with a cover wherein said cover comprises at least one opening to produce foam extruded into a desired shape.  
   
   
       33 . Foam produced by the process of  claim 18.