Fluoropolymer foams prepared with the use of blowing agents and applications thereof

A process for making an open, semi-open or closed cell fluoropolymer foam comprising the steps of:

• 1a) mixing a fluoropolymer resin and a blowing agent to produce a compound, wherein the blowing agent is in non-gaseous form or a form in which gas is not liberated from the blowing agent
• 1b) forming or shaping an artifact from the compound
• 1c) heating the artifact under pressure to a temperature above the softening point of the resin and above an activation temperature of the blowing agent in order to convert the blowing agent to a gaseous form or to liberate gas from the blowing agent
• 1d) reducing the pressure while maintaining the temperature above the softening point of the resin in order to expand the material
• 1e) cooling the resultant fluoropolymer foam to ambient temperature
• wherein the compound is preferably crosslinked after step (1b).