Abstract: A molding arrangement and method, such as slush or rotational molding, for forming a thermoplastic shell or skin product. The mold arrangement includes a hollow mold housing provided with a mold shell thereon, which together define an air chamber located within the mold housing. A plurality of air flow control devices, such as centrifugal fans, are mounted within the mold housing and direct heated air into the air chamber through discharge channels defined within the mold housing. The mold arrangement also includes an elongate air supply and heating arrangement which generates heated air within the mold housing and along substantially the entire longitudinal extent thereof to effect uniform heating of the mold shell.

Abstract: A process for producing a hollow rubber article by (1) injecting a slush molding plastisol composition of (a) polyvinyl chloride, (b) from about 40 to about 65 parts of a plasticizer per 100 parts of polyvinyl chloride, (c) from about 1 to about 3 parts of a stabilizer, and (d) from about 10 to about 15 parts of a highly crosslinked nitrile rubber composition per 100 pars of the polyvinyl chloride wherein the highly cross-linked nitrile rubber composition has repeat units derived from (i) 1,3-butadiene, (ii) acrylonitrile, and (iii) a crosslinking agent, and wherein the highly crosslinked nitrile rubber has a Mooney viscosity of about 50 to about 120; a swelling index of less than about 10 percent; a mill shrinkage of less than 10 percent; and a gel content of greater than 90 percent, into a mold; (2) maintaining the mold at an elevated temperature for a period of time which is sufficient for the slush molding composition to be fused into the shape of the desired hollow article; and (3) removing the hollow ru

Abstract: A resilient and flexible base for a two-piece traffic channelizer is provided that does not require external ballasting to stabilize the channelizer against wind forces and vacuum forces created by passing vehicles and minor impacts from a vehicle. The base is formed of a hardenable liquid resin such that the base is resilient and flexible after curing and has a specific gravity greater than about 1.25. The base further includes at least one flexible footpad for generating a restoring moment when the channelizer is subjected to a tipping force, such as a minor impact. The composition of the liquid resin includes at least one off-grade polyvinylchloride (PVC) resin, a plasticizer and a specific gravity increasing agent. A method is also provided for forming the base by slush molding at least a portion of the hardenable liquid resin adjacent the interior surface of a molding cavity. The base formed by the disclosed method is also self-lubricating and resistant to chemical degradation and extreme temperatures.

Abstract: A multi-ply structure which includes a release coating sandwiched between two plies of the structure and present in an amount of about 5 to about 25 g/sq yd., one of the plies of the structure being flexible and in contact with the release coating and removable therefrom by the application of a force of between about 90 to about 600 g/in., as determined by the Keil test procedure, including a composition for forming the release coating and comprising an aqueous coating composition which includes a solids portion and which is effective in forming a coating having release properties, the solids portion of the composition comprising a major amount of resin binder and a minor amount of filler, the filler comprising a major amount of clay and a minor amount of magnesium or calcium hydroxide, and including also a continuous process for forming such multi-ply structure, including particularly a structure comprising a poly(vinyl chloride) ply strippable from a support ply.

Abstract: Apparatus for heating and cooling a mold onto which thermoplastic material is cast and fused to form a finished article includes a plenum having an inlet and an outlet for connection to a fluid heating and cooling system and a mold box having a plurality of cavities for selectively receiving interchangeable tube bundles that are selectively positioned in a movably sealed relationship within the mold box and wherein each tube bundle has a mold and a tube array that are maintained in a fixed relationship during interchange thereof into and out of said mold box so as to maintain individually heat balanced molds.

Abstract: This invention relates to the use of a flexible, heat resistant mold member. The mold member is useful in molding processes such as dip or slush molding. The mold member maintains its structural integrity and may therefore be used as an insert in the article being molded to provide flexible stability at specific locations within the article. The mold member is made of a material which is substantially non-reactive with the molded article. The molded article may be any article made from a plastisol such as a binaural for a stethoscope having single or double lumens.

Abstract: A trim strip which has a thick body portion is formed with a fused outer perimeter. The central portion generally remains in a partially fused or incompletely fused state reducing cost while providing a trim strip with a pleasing aesthetic appearance.

Abstract: An apparatus and method of manufacturing a trim strip with an outer heat settable molding bonded to a base with an adhesive attaching member. The method includes heating and cooling a liquid heat settable material, reheating the material and bonding the outer molding to a base at very low pressures to form a trim strip.

Abstract: An apparatus and method of manufacturing a trim strip with an outer heat settable molding bonded to a base with an adhesive attaching member. The method includes heating a liquid heat settable material to be bonded to a hard base with an adhesive member at very low pressures to form a trim strip.

Abstract: An apparatus and process for manufacturing multiple thin walled hollow shells for parts such as automobile door panels, arm rests, and instrument panels from thermoplastic plastisol includes a pair of plastisol charge boxes each forming a separate compartment and members for joining the charge boxes with an open ended mold. The mold has a divider rib thereon that is inaccessible by straight vertical engagement of a seal assembly on the divider. An indexable divider wall is operatively connected between the charge boxes so that the divider wall can be selectively extended and retracted at an angle with respect to the vertical and against the mold at the divider rib thereon for allowing separation of the casting surfaces having different colors fixed thereon and the subsequent fusing of the casting surfaces to one another at the divider.

Abstract: In the course of producing a multicolored slush skin in accordance with the powder-slush method, individual one-piece slush skins are produced in successive process steps, which extend over the entire mold, which is divided into individual color zones by means of separation fins. After the first slush skin with the first color has been produced, the area assigned to another color is cut off and this part taken out of the mold, the other part of the slush skin remaining in the mold. Subsequently a complete second slush skin is formed in the previously emptied partial area as well as in the area of the remaining first slush skin, etc. A multicolored slush skin, looking from the grain side, then is the result after it is finally taken out of the mold, which is distinguished by an exact and visually tidy separating seam between the individual color areas.

Abstract: A method for forming a hidden tear seam in the cover for a safety air bag assembly comprises the steps of filling a heated open mold with liquid plastisol or dry powder comprised of polyvinyl materials; forming a gel layer of polyvinyl chloride material on the open heated thin metal mold; dumping excess polyvinyl liquid plastisol chloride material from the gel layer; fusing the gel layer; stamping a tear seam in a fused layer while it is still plastic by providing an anvil having a surface thereon of a first predetermined area and including an embossment thereon extending outwardly of said first predetermined area and stamping the tear seam by directing the embossment into the fused layer until the surface engages the fused layer and wherein the first predetermined area is sized to produce a reaction force on the anvil to determine the depth of penetration of the embossment and thereafter finally curing and cooling the fused layer and removing same from said thin metal mold.

Abstract: A method of producing a molded foam article having an integral skin and a backing layer of foam comprising mixing particles of two polyvinyl compounds one of the compounds having a molecular weight less than that of the other compound and a higher solvating plasticizer than that of the other compound and casting the mixture against a heated mold surface and melting the one compound to flood the interstices of the particles of the other compound and float to the surface of the heated mold to form a skin and wherein the other compound includes foaming constituents to simultaneously form a layer of foam material behind the skin.

Abstract: A mold for use in producing a hollow tube component for a dispensing applicator. The mold has a main body portion that defines a forward end from which extends a sloped shoulder portion, a neck portion, and a stem element. Between the stem element and the neck portion, there is a provided a re-entrant surface which forms a sharp edge and an angle with respect to the outer, main surface of the neck portion. The mold is used in a dip-molding process for producing a dispensing container that has a frangible portion that is broken away during first use, which frangible portion is formed by the re-entrant surface.

Abstract: An assembly (10) for molding a two-tone color plastic shell (12) includes a divider wall (42) having first and second sections (42a) and (42b) that are interconnected for lateral adjustment therebetween for controlling the position of a seal gasket (60) with respect to a divider rib or division surface (36) on a heated mold (22).

Abstract: An apparatus for the production of molded shells and bodies of plastic material by a rotational molding procedure within an electroplate mold includes a double-walled hollow body which is heated up and cooled down by a heating and cooling medium. A box which contains plastic material can be fitted on to the mold. The mold and the box are jointly pivotable so that the plastic material can pass into the mold and fuse at the wall of the mold. At its rear wall, which is remote from the internal contour which produces the molding action, the double-walled hollow body has a multiplicity of intake and discharge openings for the heating and cooling medium so that heating and cooling can be effected specifically and quickly. The total discharge cross-section is greater than the total feed cross-section whereby the hollow body remains substantially pressure-less.

Abstract: A two component leadwire system is disclosed for electrical connection between biomedical electrodes and electrical equipment for diagnostic or therapeutic use. One leadwire component has a bayonet terminus and can be rugged for reuse. The second leadwire is an inexpensively-made receptacle for making electrical contact with the bayonet. The receptable has a socket for receiving the bayonet and an electrical conductor surrounded by a resilient, insulative sheath. When the bayonet is inserted into the socket, the sheath resiliently grips the bayonet and holds the bayonet in electrical contact with the conductor. A method for making the receptacle component, involving dip molding of the conductor arrayed on a mandril, is also disclosed.

Abstract: A method of molding utilizes an apparatus (10) for molding a thin-wall plastic shell which includes a powder box (12) and a mold box (14). The powder box (12) is positioned to an operative position wherein an opening (18) in the powder box (12) is brought in proximity to the mold surface (20) of the mold. A bellows member (34) having a gasket (42) about the end thereof is extended from the opening (18) to perfect a sealed passageway between the opening (18) and the periphery (22) of the mold surface (20).

Abstract: A method and apparatus for producing an article, by covering at least a portion of a microwave heatable former with a liquid-containing material, applying microwave radiation to heat the former so as to leave a dry solid coating on the former, and effecting relative separation between the former and the dry solid coating so as to produce the article.

Abstract: A delivery system for dispersing either hot air or water uniformly to the outer surface of a shell mold used for forming a thin molded shell, for the respective fusion and cooling phases thereof. The delivery system includes a plurality of distributors, each having a central water inlet surrounded by an axially adjustable outer shell, with the latter having a frusto-conically shaped upper end which cooperates with the upper edge of the central water inlet to selectively close off or vary the annular opening therebetween for controlling the flow of air at a predetermined temperature form the space intermediate the central water inlet and the surrounding outer shell.

Abstract: A method for molding a thin walled plastic shell utilizes the following apparatus. An apparatus (40) for molding a thin walled plastic shell includes a mold box (42) having an inner mold surface (48). A powder box (52) includes an internal chamber and first divider wall (54) for separating the internal chamber into at least two sections (56,58). A carrier framework (60) is removably mounted on the mold box (42) and includes a peripheral seal for perfecting a seal between the mold box (42) and the powder box (52) when the same are connected thereto. A second divider wall (64) is connectable to the first divider wall (54) separating the inner mold surface into two chambers continuous with the two sections of the powder box (52). The carrier framework (60) further includes a mold surface seal (66) for perfecting a seal between the second divider wall (64) and mold surface (48).

Abstract: An assembly (10) for molding a two-tone, thin-walled plastic shell (12) for parts such as automobile door panels, control and instrument panels and the like includes a charge box (24) for supplying dry thermoplastic material to separate casting surfaces (30, 32) on a heated mold (22) selectively connected to the charge box (24) during the casting process. A pressurized inflatable seal gasket (60) is connected to the charge box (24) for sealing a division surface (36) on the heated mold (22) which surface (36) separates the casting surfaces (30, 32) of the mold (22). The seal gasket (60) is attached to the charge box (24) on a divider wall (42) via a sliding member (80) which positions the seal gasket (60) longitudinally along the divider wall (42). The sliding member (80) is secured to the divider wall (42) via threaded pins (86). The gasket seal (60) may be removed and reinserted in the slider member (80) providing automatic adjustment thereof.

Abstract: An apparatus (40) for molding a thin walled plastic shell includes a mold box (42) having an inner mold surface (48). A powder box (52) includes an internal chamber and first divider wall (54) for separating the internal chamber into at least two sections (56,58). A carrier framework (60) is removably mounted on the mold box (42) and includes a peripheral seal for perfecting a seal between the mold box (42) and the powder box (52) when the same are connected thereto. A second divider wall (64) is connectable to the first divider wall (54) separating the inner mold surface into two chambers continuous with the two sections of the powder box (52). The carrier framework (60) further includes a mold surface seal (66) for perfecting a seal between the second divider wall (64) and mold surface (48).

Abstract: A tool for manufacturing the two tone plastic shell includes an electroformed mold (28) having a first surface (29) for forming a front of a shell; a second surface (32) for forming the side edge portion of a shell; and a third surface segment (34) for forming a return flange on a door shell and the third surface segment has a cut-out opening (36) therein and a runout surface (40) providing for entry and removal of a seal and divider wall assembly to seal against a sealing rib (38) in the mold which separates the first, second and third segments into first and second casting surfaces. The divider rib and runout surface are sprayed with thermoplastic material to form a joint between material cast on the first and second casting surfaces and a skin return flap for sealing the cut-out opening.

Abstract: A mold assembly for molding thermoplastic particles into a solid thin shell includes a metal shell having a cavity and including an outer surface exposed to a heat source and further including an inner surface on which thermoplastic material is cast and fused to form a thin layer thermoplastic shell. The heat transfer area of the metal shell is increased by providing a plurality of heat transfer pins connected to the outer surface; each of the heat transfer pins has an extended outside surface area exposed to the heat source for heating the metal shell and each of the heat transfer pins further includes a large diameter head portion which is joined to the metal shell by a capacitive weld nugget formed solely between the large diameter head portion and the outer surface of the metal shell without disrupting the metal shell at surface portions thereof formed between the heat transfer pins.

Abstract: An apparatus for reflow smoothing a molded article made by first heating a face of a mold at a first station, then applying a fusible synthetic resin to the heated face and thereby melting the resin into a continuous coating covering the heated mold face at a second station spaced angularly from the first station, and cooling the coating and mold at the second station until the coating hardens. To reflow smooth the article, the surface of the cooled coating is then smoothed by confining the mold and hardened coating in a substantially closed chamber at the second station and reheating the confined coating until its surface flows. Thereafter the coating is cooled again at a third station angularly spaced from and downstream of the second station until it hardens and the hardened covering is stripped from the mold at a fourth station angularly spaced downstream of the third station and upstream of the first station.

Abstract: A low-pressure inflatable article, made by rotomolding of polyvinyl chloride materials, featuring a lower weight as compared to similar articles made of the same material as well as improved physical characteristics which permit inflation of the article without the need for any inflation mechanical device, such as inflation with the mouth.

Abstract: A slush molding method including the steps of preparing a mold with a groove provided on the entire periphery of the opening portion thereof, engaging a heating medium guard frame with the groove, charging a resin material into the mold, heating the mold into the heating medium which is contained in a fluidized-bed oven and fluidized by air so as to melt the resin and cause it to adhere to the molding surface and removing the heating medium guard frame to discharge the surplus resin. An apparatus used for the slush molding method is also included.

Abstract: Apparatus for manufacturing thin-walled hollow shells for parts such as automobile door panels, control and instrument panels and the like includes a charge box or powder box for supplying dry thermoplastic material to separate casting surfaces on a heated mold selectively connected to the charge box during a casting process. A selectively pressurizable inflatable seal gasket is connected to the charge box for sealing a division surface on the heated mold which surface separates the casting surfaces of the mold. The inflatable seal gasket includes a base portion fixed to the charge box; an inflatable core with expandable walls to bridge the distance between the charge box and the division surface and a seal bead that sealingly engages the division surface when the seal gasket is inflated to keep the division surface clean for a subsequent application of material to form a connector bond between previously cast two tone colored segments.

Abstract: A rotational molding process for slush casting mold with plastisol includes providing a conveyor having a plurality of spaced reversing arm assemblies, each arm assembly having opposite ends carrying molds thereon; providing first and second conveyor paths for the molds on the opposite ends of each arm assembly and locating one of the first and second conveyor paths inside the outer perimeter of the other of the first and second conveyor paths; preheating a mold on one of the arm assemblies on the first conveyor path and filling the preheated mold with an excessive charge of plastisol to form a gel layer thereon while on the first conveyor path and thereafter dumping plastisol from the preheated mold for return to a supply source of plastisol; and simultaneously curing a gel layer on another of the arm assemblies by directing the mold through the second conveyor path as the preheated mold on the other end of the arm assembly is being filled and dumped whereby the movement of an arm assembly produces simultane

Abstract: An apparatus for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. The powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearance therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell.

Abstract: A method for manufacturing a plastic foam, wherein a plastic compound with chemical foaming agent is charged in molding cavity which is defined by a pair of upper and lower die cavities and wherein the plastic compound is subject to a dielectric heating, so that the chemical foaming agent decomposes. One of the cavity surfaces is movable to vary the volume of the molding cavity in accordance with the expansion of the plastic compound, so that the movable cavity surface is kept in contact with the plastic compound which expands during heating.

Abstract: A process for preparing an artificial biological membrane in which an aqueous solution containing 6 wt % or more of polyvinyl alcohol having a degree of hydrolysis of not less than 95 mol % and an average polymerization degree of not less than 700 and containing a biological substance or a substance which does not hinder the gelation of the polyvinyl alcohol is subjected to a freezing step followed by a thawing step. Then, the mass thus obtained is further subjected to at least one additional cyclic processing step including the freezing and thawing steps. The product hydrogel is hard or not too soft and not swollen in water.

Abstract: A dip molding process for making an integral article having a solid inner surface and a foamed outer cover in which a hot mold is dipped into a solid plastisol which is partially fused before being dipped into a foamable plastisol which is then formed, fused and bonded to the solid plastisol to form an integral article.

Abstract: A process and an apparatus obtain plastic molded objects according to a technique which consists of introducing the plastic into a silicone elastomer mold, then inserting this mold into a high frequency device comprising a turntable "carrousel", a series of high frequency heating presses and a cooling device.The process is characterized by the introduction of plastic into one end of the mold in the form of liquid plastisol under low pressure, i.e., less than 1 Magapascal. The apparatus employs a carrousel, a mold having two male inserts and resting on the carrousel, vacuum-creating means and plastisol injection means.

Abstract: A slush mold for molding film moldings such as surface coverings of interior finishing parts of automotive vehicles. The slush mold comprises a mold body having a molding surface of a predetermined shape formed in the inner surface thereof, a skirt capable of being detachably joined to the mold body so as to cover the marginal portion of the inner surface of the mold body other than the molding surface so that a resin film molding is formed only over the molding surface, and guide members for guiding the skirt so that the skirt is joined correctly to the mold body. Thus, the molding material is distributed only over the molding surface, and thereby the yield rate of film moldings is improved and the work in the subsequent process is facilitated.

Abstract: An apparatus for the production of a synthetic resin skin uses a mold for forming at least two separate skin sections which are then joined prior or after a final heat treatment. The synthetic resin skin sections are produced in at least two separate mold members, and the skin sections are then caused to contact each other along determined faces or margins which are joined under light pressure. Any so-called selvage is easily removed after the joining which intimately bonds the skin sections to each other due to the curing of the synthetic resin.

Abstract: In a slush molding method of making a blood pump for an artificial heart, a heat insulating material is applied to at least a portion of the outer surface of a mold in which the blood chamber formed so that at least a part of the blood chamber is thinned in a tapered form.

Abstract: Apparatus and a process for manufacturing multiple color thin-walled hollow sheels for parts such as automobile door panels, consoles and instrument panels from dry thermoplastic plastisol includes a supply box with a divider to form two or more compartments in the box. The box divider cooperates with selectively positioned split mold parts defining a separation in an open-ended heated mold for separating the mold into two or more sections. Complementary open ends of the charge box and mold are joined. Then the apparatus is rotated so that the powder is distributed into each mold section by gravity flow with the powder from each section flowing to the divider which separates the colors so as to form two or more tones on a resultant shell of cured material; thereafter the powder box is removed and the split mold parts are joined to clamp cast shell segments for fusion at a joint line.

Abstract: Apparatus for reducing the waste area in a mold for an article molded from a heat-fusing material by a powdered vinyl process, has a mold box disposed adjacent the backside of a mold surface for controlling the temperature over respective first and second areas of the mold surface. The waste area elimination is accomplished by isolating and insulating the section of the mold defining the waste area. A kerf is cut into the mold around the waste area to isolate the area. The kerf is filled with castable silicone to insulate the waste area from the heated segments of the mold. To obtain the coating, the mold is filled with powdered vinyl and the excess material is removed from the mold by dumping the plastisol from the mold into a return tank.

Abstract: Gaskets are formed in container closures fabricated from polyolefin resins exhibiting substantially no response to heat activation by radio frequency electrical energy by introducing a vinyl chloride plastisol containing a vinyl chloride polymer resin and a plasticizer having a loss factor in the range of 0.1-12 into the closure. The closure is preheated to 55.degree. to 100.degree. C. by conventional means and then the plastisol is fused in the closure by exposure to a field of radio frequency electrical energy.

Abstract: A method wherein an article is molded of a heat-fusing material or plastisol, either liquid or dry, in a mold having an array of gas impingement jets disposed adjacent the backside of a mold surface for controlling the temperature over respective first and second areas of the mold surface. There is included first and second gas heating and cooling circuits each including a blower and dampers for supplying gas at the gas impingement jets associated with the mold. All of the gas impingement jets are supplied with heated gas to preheat the mold surface to a non-gelling temperature and a liquid plastisol coating is applied to the mold surface. To obtain the coating, the mold is filled and the excess plastisol is removed from the mold by dumping the plastisol from the mold into a dump tank.

Abstract: A molding machine has a valve assembly that includes means for selectively heating or cooling a mold by controlling flow of gas through an array of gas impingement jets disposed adjacent the backside of a mold surface to regulate the temperature over respective first and second areas of the mold surface. Gas heating and cooling circuits include two drive cylinder regulated plate valves for supplying gas at the gas impingement jet nozzles associated with the mold.

Abstract: The present invention relates to superior wear layer-coated embossed surface coverings which are prepared by depositing a cross-linking inhibitor on at least a portion of the surface of a cross-linkable foam formed on a backing and containing a cross-linking initiator. Preferably a wear layer is applied at this point and cross-linking of the affected areas is accomplished by heating the sheet. The sheet of material is either uniformly or differentially heated and then uniformly compressed to a desired embossing depth using a non-patterned press or roll. The noncross-linked regions remain depressed upon removal of the compressing force whereas the cross-linked regions return essentially to their original height. The wear layer remains in contact with all of the foam regions so that the resulting sheet of material has a wear layer which is uniformly adhered to the contour of the foam layer. The surface of the sheet has an embossed or textured finish.

Abstract: Apparatus and a process for manufacturing multiple color thin walled hollow shells for parts such as automobile door panels, controls and instrument panels from thermoplastic plastisol includes a plastisol box divider to form two or more compartments in a plastisol charge box and means for joining the charge box divider end-to-end with a mold separation edge on an open-ended heated mold for separating the mold into two or more sections; each compartment of the charge box has a different color plastisol. The charge box and mold are joined and then are rotated so that the plastisol is distributed into each mold section by gravity flow with the plastisol from each section flowing to the divider which separates the colors so as to form two or more tones on a resultant shell of cured material.

Abstract: A laminate comprises fused adherent layers of plastisol vinyl chloride polymer resins in which a first layer contains Sb.sub.2 O.sub.3 and a second layer contains TiO.sub.2. The flexible laminate is useful as a roofing membrane for the roof of a building wherein the layer containing the Sb.sub.2 O.sub.3 is adjacent a structural or insulation member of the roof of the building while the TiO.sub.2 layer can be exposed to the elements and can protect the Sb.sub.2 O.sub.3 layer from sunlight.

Abstract: Uniformly porous foamed erasers and process for the production thereof, the process comprising continuously mixing air or other gas into a flowable plasticized mixture and gelling the mixture by introducing the same continuously to a heating mean.

Abstract: A process is disclosed for making miniature doll heads. An oversized head is formed of a shrinkable plastisol including a plasticizer, and facial features are applied to the head using a shrinkable paint. Hair is rooted to the scalp of the oversized head. The head is reduced in size by extracting the plasticizer from the plastisol. During the extraction, the head and its facial features shrink simultaneously to form the miniature head.

Abstract: An improvement is disclosed in a process for producing foamed articles of thermo-plastic or thermo-setting compounds. The improvement reduces the number of steps normally followed to make a foamed product and cuts down on the time.

Abstract: A mixture of vinyl plastisol, suspension grade resin and expanded perlite is prepared in a manner such that the particles of perlite are not significantly damaged. The mixture is placed on a substrate and fused, thereby producing a foam-like material which is usable as a decorative covering. Alternatively, the mixture can be cast on a release surface and allowed to stand until the majority of the perlite particles have migrated to the top surface, thus leaving a layer of material containing substantially no perlite along the lower surface which interfaces with the release surface. Upon fusing this stratified mixture and separating the release surface, the fused material is inverted. The layer of material which contains substantially no perlite becomes the protective surface and the remaining portion of the fused material, which is foam-like in nature, becomes the resilient support. Such syntactic foams may be used as replacements or substitutes for mechanically frothed or chemically blown foams.