Fibrillated polyolefin foam

A method for generating a thermoplastic non-cellular fibrillated foam, the method comprising:

• melting a thermoplastic resin and a dispersion stabilizing agent in a first part of an extruder to form a polymer melt in a second part of the extruder;
• adding water to the polymer melt to form an aqueous dispersion;
• adjusting the pH of the aqueous dispersion to between 8 and 11;
• adding at least one froth stabilizing surfactant to the aqueous dispersion to form a mixture;
• adding fiber to the mixture,
• wherein the fiber comprises at least one of a polyethylene homopolymer, copolymer, or multiblock interpolymer, a polypropylene homopolymer, copolymer, or multiblock interpolymer, and combinations thereof;
• and
• wherein the fiber has an average length in the range from about 0.2 to about 30 mm;
• and
• wherein the fiber is present in the range from about 30 wt. % to about 60 wt. % based on a total weight of the thermoplastic resin and the fiber;
• frothing the mixture to create a froth;
• and
• removing at least a portion of the water in the froth to create a foam;
• wherein the foam created comprises 20 weight percent or less residual water;
• and
• wherein the foam generated has a non-cellular fibrillated morphology.