The application relates to a method and apparatus for producing a solid foam continuously. A homogeneous suspension is formed from a raw material in which the suspension comprises a solidifying agent, and a foam mixture which comprises bubbles is formed by mixing air bubbles into the suspension. The foam mixture is injected via at least one nozzle to form a foam pattern and the foam pattern is laid on a moving surface and the foam mixture of the foam pattern is solidified in order to form a solid foam such that the bubbles of the foam mixture shrink in off-length directions to form the shaped bubbles. Further, the application relates to the product and the use of the method.

A nozzle and a process suitable for dispensing liquid foamable products, particularly useful with carbon dioxide blowing agents, the nozzle comprising a tubular exit zone having an inlet and an outlet; the tubular exit zone having an inner wall surface defining a passageway for dispensing having a centerline axis; the tubular exit zone further having a plurality of vanes attached to the inner wall surface parallel to the centerline axis with the vanes extending radially into the passageway for dispensing; the vanes having a length dimension, a thickness dimension, and a width dimension; and wherein the vanes do not connect or touch at the centerline of the passageway for dispensing.