Thermoplastic polymer foams having sound deadening properties satisfactory
for demanding applications are provided which have mechanical strength, which are
economical to manufacture, and which are hydrolytically stable. Methods of preparing
these foams are also provided. The foams are useful in sound management, cushion
packaging, filtering, and fluid absorption and exhibit one or more of the following
properties: 1) average cell size greater than about 2 mm; 2) substantially open-cell
structure and 3) relatively large pores connecting the cells. In order that the
foam be acoustically active, the foam should possess a substantially open-cell
structure and a relatively low airflow resistivity. Foams with substantially open-cell
structure and relatively low airflow resistivity are prepared by mechanically opening
a foam having an average cell size greater than about 2 mm. In most cases, such
mechanical opening creates relatively large pores connecting the cells.