The invention provides systems, methods, and articles useful in the
production of foams, and, in particular microcellular foams. The systems
include a restriction element that reduces the backflow of polymer melt in
an extruder while polymeric material is injected into a mold or ejected
from a die. The restriction element is positioned upstream of a blowing
agent injection port to maintain the solution of polymer and blowing agent
in the extruder above a minimum pressure throughout an injection or
ejection cycle, and preferably above the critical pressure required for
the maintenance of a single-phase solution of polymer and blowing agent.
The systems can be used in injection molding, blow molding, or in any
other processing techniques that include injection or ejection cycles. In
some embodiments, the systems utilize reciprocating screws for injection
or ejection. In other embodiments, the systems include an accumulator
connected to an outlet of the extruder, in which a plunger moves to inject
polymeric material into a mold or eject polymeric material from a die.