Method and apparatus for the manufacture of cellular solids

An apparatus for the manufacture of cellular solids comprising:

• An internally hollow housing having an internal surface encapsulating and defining an extrusion channel having a first end and a second end and a cross section extending axially along its length from said first end to said second end and terminating into an exit port at the second end;
• said housing having at least a first feeding port between the first end and second end for injecting at least one granular solid into the extrusion channel, at least a second feeding port between the first feeding port and the exit port for injecting at least one liquid into the extrusion channel to form a plasticized matrix by solvating the at least one injected granular solid, and at least one third feeding unit between the second feeding port and an exit port for injecting cell-fluid into the extrusion channel;
• a granular solid feeding unit for injecting at least one granular solid through the first feeding port into the extrusion channel;
• a solvent feeding unit attached to the second feeding port for injecting at least one solvent;
• a cell-fluid feeding unit attached to at least the third feeding port for injecting cell-fluid into the plasticized matrix to form a plasticized foam in the extrusion channel;
• at least one conveying element for extruding the plasticized foam in the extrusion channel through an exit port;
• and
• a mold or a surface for accepting the extruded plasticized foam.

A method of manufacturing cellular solids comprising the steps of:

• injecting one or more granular solids into an extrusion channel having a cross section extending along its length inside a housing, wherein at least one granular solid melts upon heating;
• heating the injected one or more granular solids to form a plasticized matrix;
• conveying the plasticized matrix towards an exit port of the extrusion channel by applying mechanical work on the plasticized matrix;
• injecting cell-fluid into the extrusion channel to charge the plasticized matrix with cell-fluid and form a plasticized foam as the plasticized matrix transits towards an exit port;
• dispensing the plasticized foam through an exit port into a mold or on a solid surface;
• and
• solidifying the plasticized foam in said mold or on said solid surface.
• wherein
• the cell-fluid injection is performed using a cell-fluid injection unit having a cell-fluid injection channel with a first end and at least a second end contiguous with and terminating in the extrusion channel;
• and
• the cell fluid is injected into a flowing plasticized matrix by the application of pressure pulses in the cell-fluid injection channel so as to control the volume of injected cells and the repetition rate of cell injection.

A method of manufacturing cellular solids comprising the steps of:

• injecting one or more granular solids into an extrusion channel having a cross section extending along its length inside a housing;
• heating the injected one or more granular solids to form a plasticized matrix or injecting a solvent to solvate at least one injected granular solid so that the one or more injected granular solids form a plasticized matrix;
• conveying the plasticized matrix towards an exit port of the extrusion channel by applying mechanical work on the plasticized matrix;
• injecting cell-fluid into the extrusion channel to charge the plasticized matrix with cell-fluid and form a plasticized foam as the plasticized matrix transits towards an exit port;
• and
• dispensing the plasticized foam through an exit port into a mold or on a surface.