| CPC B29C 44/3461 (2013.01) [B01J 13/20 (2013.01); B29K 2101/12 (2013.01); B29K 2105/0076 (2013.01)] | 17 Claims |

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1. A device for expanding unexpanded, thermally expandable, thermoplastic microspheres, comprising:
a heating zone having an inlet, and an outlet;
a pump upstream of and in fluid communication with the heating zone for feeding a slurry of unexpanded, thermally expandable, thermoplastic microspheres into the heating zone, wherein the pump is capable of generating above-atmospheric pressure in the heating zone;
an element for heating the heating zone to soften the microspheres fed into the heating zone;
an expansion zone with an inlet and an outlet, said inlet of the expansion zone being connected to the outlet of the heating zone in such a way that a pressure drop is created across the expansion zone inlet, such that a pressure in the expansion zone is at a lower pressure than the heating zone for expanding the microspheres in the expansion zone;
a distribution pipe located downstream of the expansion zone with a first inlet in fluid communication with the outlet of the expansion zone, a second inlet configured to be fluidly coupled to a cooling medium source and an outlet; and
an adjustable back pressure generator disposed in the distribution pipe for creating a variable counter pressure to influence the pressure in the expansion zone.
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