Abstract: A method for generating a thermoplastic foam from an aqueous dispersion, the aqueous dispersion comprising a thermoplastic resin, water, and a dispersion stabilizing agent, the method including: adding at least one froth stabilizing surfactant to the aqueous dispersion to form a mixture; adding a fiber to the mixture; and frothing the mixture to create a froth, removing at least a portion of the water in the froth to create a foam, wherein the foam generated has a non-cellular fibrillated morphology. In another aspect, embodiments disclosed herein relate to a foam having a thermoplastic-based, fibrillated, non-cellular structure, wherein the foam has an average density of about 0.02 g/cm3 to about 0.07 g/cm3. In certain embodiments, the foam may be used in an absorbent article.

Abstract: A method for generating a thermoplastic foam from an aqueous dispersion, the aqueous dispersion comprising a thermoplastic resin, water, and a dispersion stabilizing agent, the method including: adding at least one froth stabilizing surfactant to the aqueous dispersion to form a mixture; adding a fiber to the mixture; and frothing the mixture to create a froth, removing at least a portion of the water in the froth to create a foam, wherein the foam generated has a non-cellular fibrillated morphology. In another aspect, embodiments disclosed herein relate to a foam having a thermoplastic-based, fibrillated, non-cellular structure, wherein the foam has an average density of about 0.02 g/cm3 to about 0.07 g/cm3. In certain embodiments, the foam may be used in an absorbent article.