A fully imidized, solvent-free polyimide foam having excellent mechanical,
acoustic, thermal, and flame resistant properties is produced. A first
solution is provided, which includes one or more aromatic dianhydrides or
derivatives of aromatic dianhydrides, and may include one or more
aromatic diamines, dissolved in one or more polar solvents, along with an
effective amount of one or more blowing agents. This first solution may
also advantageously include effective amounts respectively of one or
mores catalysts, one or more surfactants, and one or more fire
retardants. A second solution is also provided which includes one or more
isocyanates. The first and second solutions are rapidly and thoroughly
mixed to produce an admixture, which is allowed to foam--in an open
container, or in a closed mold--under ambient conditions to completion
produce a foamed product. This foamed product is then cured by high
frequency electromagnetic radiation, thermal energy, or a combination
thereof. Alternatively, the process is adapted for spraying or extrusion.