Many polymers are used in a cellular form in which the polymer matrix is filled with gas-filled cells which

may or may not be intercommunicating. Over the years many methods have been devised for producing
cellular polymers of which the most important are the following:

(1) Incorporation of a chemical compound which decomposes at some stage of the processing operation
to yield volatile reaction products. These are known as chemical blowing agents.

(2) Incorporation of low boiling liquids which volatilise during processing. Such volatile blowing agents
are important with polystyrene and polyurethanes and will be dealt with in the appropriate chapters.

(3) Diffusion of gases into the polymer under pressure with subsequent expansion of the composition at
elevated temperatures after decompression. Such a process can be employed with a wide variety of
polymers.

(4) Incorporation of powdered solid carbon dioxide which volatilises at elevated temperatures. This
process has been used in conjunction with PVC pastes.

(5) Chemical reactions of polymer intermediate during polymerisation and/or cross-linking. This is
important with polyurethanes.

(6) Mechanical whipping of polymers in a liquid form and subsequent ‘setting’ in the whipped state. The
manufacture of latex rubber foam is the best-known example of this approach.

(7) Incorporation of hollow or expandable spheres of resin or of glass (microballoons).

(8) Leaching out of soluble additives.