Recyclable, biodegradable, and industrially compostable foams, and methods of manufacturing the same

Abstract

A method for producing a foam includes subjecting a polymer pre-form to a first foaming stage within an autoclave chamber to form a pre-expanded polymer pre-form and subjecting the pre-expanded polymer pre-form to a second foaming stage within an autoclave chamber to form an expanded polymer pre-form. The first and second foaming stages may occur at different autoclave temperatures, pressures, and hold times. The expanded polymer pre-from may be further subjected to a compression molding process to produce a final foam product. The polymer pre-form may include one or more thermoplastic polymers that are not cross-linked. The one or more thermoplastic polymers may be biodegradable and / or recyclable.