Abstract: The present invention relates to porous crosslinked polymeric microbeads having cavities joined by interconnecting pores wherein at least some of the cavities at the interior of each microbead communicate with the surface of the microbead. The present invention also relates to a process for producing a porous, crosslinked polymeric microbead as well as the product of this process. This process involves combining an oil phase with an aqueous discontinuous phase to form an emulsion, adding the emulsion to an aqueous suspension medium to form an oil-in-water suspension of dispersed emulsion droplets, and polymerizing the emulsion droplets to form microbeads. At least 10% of the microbeads produced in accordance with the present invention are substantially spherical or substantially ellipsoidal or a combination of the two.

Abstract: Insecticides, and particularly termiticides, may be dissolved in monomers polymerized to form foamable polymers, such as polystyrene. The resulting monomer and insecticide may then be polymerized in a conventional manner and either impregnated with a blowing agent or expanded using an extrusion process to produce polymeric foam having insecticidal properties. The polymer may also contain a flame retardant. Such polymers and the foam made therefrom may be used in the construction industry, particularly where insect infestation is a concern.

Abstract: Stable high internal phase water-in-oil emulsions containing polymerizable vinyl monomers, crosslinking monomers and initiators are obtained, useful in producing low density porous crosslinked polymeric materials by using a surfactant system containing (a) an anionic surfactant, the anionic surfactant having an oil soluble tail and an anionic functional group and (b) one or more quatemary salts having one or more hydrocarbon groups having greater than or equal to 8 carbon atoms. A water-in-oil emulsion can be formed with lower surfactant concentration than sorbitan fatty acid ester alone and improved surfactant performance at elevated temperatures is obtained.

Abstract: Chemically resistant, strong fluorinated copolymer adsorbent particles for use in carrying out chromatographic separations are prepared by high shear, anaerobic reaction of a di-unsaturated crosslinking agent with a polyfluorinated monomer in the presence of poly(vinyl alcohol) and a porogen.

Abstract: The invention pertains to a foam material for absorption of aqueous liquids, a manufacturing method and an advantageous use of such a foam material, and an absorbent disposable article comprising such a foam material. The foam material is hydrophilic and primarily intended for use in absorbent disposable articles such as baby diapers, incontinence protectors and products for feminine hygiene. However, the foam material according to the invention is also suited for use in other absorbent articles, such as in different wiping materials, bandage materials and other similar products. The chemical structure of a surfactant, which is utilized as a combined emulsifying and hydrophilizing agent when manufacturing the foam material according to the invention, makes it possible to retain a sufficient proportion of the foam surfactant in the foam material even after repeated wettings, something which renders the foam material highly, permanently hydrophilic.

Abstract: An absorbent, microporous foam comprising a crosslinked polymer having interconnected fluid cells distributed throughout its mass, wherein the fluid cells have a diameter of between about 0.1 and about 100 .mu.m, and wherein the foam can rapidly absorb at least about twice its dry weight in fluid, is disclosed. Also disclosed is a method for producing such microporous, absorbent foams. In this method: (a) a crosslinkable polymer and a first solvent are mixed to form a stable solution which can be induced to phase separate; (b) the stable solution is induced to phase separate into a polymer concentrated phase and a polymer dilute phase; (c) the polymer is induced to crosslink in the polymer concentrated phase for a predetermined period of time thereby forming a microporous material; and (d) the microporous material is dried to produce the absorbent foam.

Abstract: Unsupported pressure sensitive adhesive (PSA) films of tacky, polymeric microspheres are provided. The opposite major surfaces of the film provide different levels of peel adhesion, allowing for removability without substrate damage. In addition, the PSA films provide high shear strength and good tensile properties.

Abstract: A composition adapted to form a strengthened gel for treating subterranean formations is described, the composition comprising an aqueous liquid containing an effective amount of a water soluble crosslinkable polymeric gel forming material and a crosslinking agent in an amount sufficient to crosslink said material, and a gel strengthening amount of an inert colloidal particulate material. A method for forming a strengthened gel in at least a portion of a subterranean formation is also disclosed, the method comprising injecting into at least a portion of a formation an aqueous liquid gel forming composition of the type described, and allowing the aqueous liquid composition to form a strengthened gel.

Abstract: A superabsorbent foam material is made by a water-in-oil high internal phase emulsion polymerization comprising the steps of (a) dissolving an organic solvent-soluble surfactant in a water-insoluble monomer to form an organic phase; (b) blending the-organic phase with an aqueous phase using high shear mixing to form an emulsion, said aqueous phase comprising a water-soluble polymer, a cross-linking agent, and water; (c) polymerizing the water-insoluble monomer in the organic phase; (d) cross-linking the water-soluble polymer in the aqueous phase; and (e) final curing and drying the resulting foam.

Abstract: Rapidly dissolving/absorbing free-flowing powders of hydrophilic/superabsorbent (co)polymers, having irregular nonspherical morphology and a particle size distribution ranging from 100 .mu.m to 800 .mu.

Abstract: Process for making polyisocyanate based aerogels by trimerisation of an organic polyisocyanate in an organic solvent in the presence of a (co)polymer containing an isocyanate-reactive group, gellation and supercritically drying of the obtained sol-gel.

Abstract: The present invention is embodied in a ceramic foam made by mixing a liquid pre-ceramic resin and a liquid phenolic resin, allowing the resultant mixture to chemically foam, curing the mixture for a time and at a temperature sufficiently to convert the mixture to a polymeric foam, and then heating the resultant polymeric foam for a time and at a temperature sufficient to break-down polymers of the polymeric foam and convert the polymeric foam to a ceramic foam. The ceramic foam of the present invention contains residual decomposed components of the liquid phenolic resin and/or liquid pre-ceramic resin.

Abstract: A method of producing a polymer packing material for liquid chromatography includes the steps of swelling seed polymer particles to form swelled particles, polymerizing monomers in the swelled particles under existence of diluent, and removing the diluent to form porous polymer particles, wherein the step of polymerizing the monomers is conducted under existence of a compound having a conjugated double bond not reactive with the monomers and having a molecular weight of 100-500. Alternatively, the polymerization process may be conducted by an oxidation reduction polymerization process. Further, the porous polymer particles obtained after removal of the diluent may be subjected to a heat treatment process at a temperature of 100.degree. C. or higher.

Abstract: High internal phase emulsions having an internal aqueous phase of greater than 70 percent by volume and an external oil phase comprising a vinyl polymerizable monomer contain a surfactant capable of chemically binding to the polymerizable monomer. Polymeric foams having a high internal phase emulsion stabilizing surfactant chemically bound to the polymeric material and a liquid capacity of from about 70 to 99 percent of its saturated volume can be prepared from such emulsions.

Abstract: Highly uniform microporous foam suitable for medical applications and methods for preparing these foams. The highly uniform microporous foams are of controlled pore size that may be utilized in a variety of applications. In preparing the foams, an organic crystalline polymer is melted and combined with a selected solid crystalline fugitive compound to produce a substantially isotropic solution. The solution is cooled under controlled conditions, which foster solid-solid phase separation by the simultaneous crystallization of the fugitive compound and the polymer, to produce a foam precursor containing the solidified fugitive compound dispersed through a matrix of the organic polymer. Crystals of fugitive compound are then removed by solvent extraction and/or sublimation, or like process to produce microcellular foams having a continuous, open-cell structure.

Abstract: This pertains to the general field of gels, foams, and aerogels, particularly, to low density open cell organic foams and low density open cell carbon foams, and methods for preparing them. These low density open cell organic foams are derived from organic gels which may be prepared from hydroxylated benzenes (such as phenol, catechol, resorcinol, hydroquinone, and phloroglucinol) and aldehydes (such as formaldehyde and furfural) using lower than conventional catalyst concentrations (e.g, an R/C value of greater than about 1000, yielding an initial room temperature pH typically lower than about 6.0). These organic foams are characterized by relatively large particle and pore sizes, high porosity, and high surface area. Low density open cell carbon foams derived from such organic foams are also shown, as are methods for preparing same. These carbon foams are also characterized by relatively large particle and pore sizes, high porosity, high surface area, and high electrical capacitance.

Abstract: This invention relates to porous polyfluoroethylene (PTFE), shaped articles prepared therefrom, and to methods of preparing said articles.

Abstract: A microporous membrane and method of manufacture is presented utilizing irradiation and thermal induction phase separation techniques. During manufacture, microsphereulites are created by irradiation of curable agents in a casted polyolefin film. The microsphereulites then serve as nucleating agents in a thermally-induced phase separation step, providing a microporous membrane with improved flow and mechanical properties.

Abstract: Stable high internal phase water-in-oil emulsions containing polymerizable vinyl monomers, crosslinking monomers and initiators are obtained useful in producing low density porous crosslinked polymeric materials by using a surfactant system containing (a) one or more sorbitan fatty acid esters or saccharide fatty acid esters or mixtures thereof and (b) one or more quaternary salts having one or more greater than or equal to 8 carbon atom hydrocarbon groups. A water-in-oil emulsion can be formed with lower surfactant concentration than sorbitan fatty acid ester alone and improved surfactant performance at elevated temperatures is obtained. Sludge formation otherwise observed with the use of sorbitan fatty acid ester surfactants is also reduced or eliminated.

Abstract: A method of producing open porous spherical particles by polymerizing monovinyl monomers and divinyl monomers and/or polyvinyl monomers (cross-linkers) in an emulsion with the aid of an initiator. The method is characterized by the steps of (i) preparing a w/o/w emulsion which comprises an aqueous phase having emulsified therein droplets which contain a water-in-oil emulsion, wherein the oil phase in the droplets includes vinyl monomers and an emulsifier which provides an inverse emulsion and the droplets have a diameter smaller than 2,000 .mu.m, and wherein the total amount of water is between 75-99% (w/w); and (ii) thereafter initiating polymerization and isolating the particles, optionally after sieving, from the reaction mixture after the polymerization process. A population of open spherical porous polymer particles which have a diameter within the range of 50 .mu.m-2,000 .mu.

Abstract: A superabsorbent foam material is made by a water-in-oil high internal phase emulsion polymerization comprising the steps of (a) dissolving an organic solvent-soluble surfactant in a water-insoluble monomer to form an organic phase; (b) blending the-organic phase with an aqueous phase using high shear mixing to form an emulsion, said aqueous phase comprising a water-soluble polymer, a cross-linking agent, and water; (c) polymerizing the water-insoluble monomer in the organic phase; (d) cross-linking the water-soluble polymer in the aqueous phase; and (e) final curing and drying the resulting foam.

Abstract: Highly uniform microporous foam suitable for medical applications and methods for preparing these foams. The highly uniform microporous foams are of controlled pore size that may be utilized in a variety of applications. In preparing the foams, an organic crystalline polymer is melted and combined with a selected solid crystalline fugitive compound to produce a substantially isotropic solution. The solution is cooled under controlled conditions, which foster solid-solid phase separation by the simultaneous crystallization of the fugitive compound and the polymer, to produce a foam precursor containing the solidified fugitive compound dispersed through a matrix of the organic polymer. Crystals of fugitive compound are then removed by solvent extraction and/or sublimation, or like process to produce microcellular foams having a continuous, open-cell structure.

Abstract: The present invention relates to a HIPE-derived heterogeneous polymeric foam structure of interconnected open-cells, wherein the foam structure has at least two distinct regions. Such heterogeneous foams have various applications, such as energy and fluid absorption, insulation, and filtration.The invention further relates to a heterogeneous absorbent polymeric foam that, upon contact with aqueous fluids (in particular body fluids such as urine and blood), can acquire, distribute, and store these fluids.The foams of the invention have at least two distinct regions having different density, polymer composition, surface properties, and/or microcellular morphology.The invention further relates to a process for obtaining the heterogeneous foams by polymerizing a high internal phase water-in-oil emulsion, or HIPE. In one aspect, the process utilizes at least two distinct HIPEs, with each emulsion having a relatively small amount of an oil phase and a relatively greater amount of a water phase.

Abstract: The present invention relates to porous crosslinked polymeric microbeads having cavities joined by interconnecting pores wherein at least some of the cavities at the interior of each microbead communicate with the surface of the microbead. The present invention also relates to a process for producing a porous, crosslinked polymeric microbead as well as the product of this process. This process involves combining an oil phase with an aqueous discontinuous phase to form an emulsion, adding the emulsion to an aqueous suspension medium to form an oil-in-water suspension of dispersed emulsion droplets, and polymerizing the emulsion droplets to form microbeads. At least 10% of the microbeads produced in accordance with the present invention are substantially spherical or substantially ellipsoidal or a combination of the two.

Abstract: Polymers are made from 1,3,7-octatriene or like conjugated polyenes and a crosslinking agent having at least 2 activated double bonds such as ethylene glycol dimethacrylate. These polymers can be used to make absorbent foams that are useful in absorbent articles such as diapers, as well as latexes that are useful as binders and adhesives.

Abstract: The present invention relates to a HIPE-derived heterogeneous polymeric foam structure of interconnected open-cells, wherein the foam structure has at least two distinct regions. Such heterogeneous foams have various applications, such as energy and fluid absorption, insulation, and filtration.The invention further relates to a heterogeneous absorbent polymeric foam that, upon contact with aqueous fluids (in particular body fluids such as urine and blood), can acquire, distribute, and store these fluids.The foams of the invention have at least two distinct regions having different density, polymer composition, surface properties, and/or microcellular morphology.The invention further relates to a process for obtaining the heterogeneous foams by polymerizing a high internal phase water-in-oil emulsion, or HIPE. In one aspect, the process utilizes at least two distinct HIPEs, with each emulsion having a relatively small amount of an oil phase and a relatively greater amount of a water phase.

Abstract: Foams capable of absorbing blood and blood-based fluids, especially menses. These absorbent foams have high capillary absorption pressures required of absorbents used in catamenial products, yet have sufficient openness to allow free movement of the insoluble components in blood-based fluids such as menses. These absorbent foams are made by polymerizing high internal phase emulsions (HIPEs) where the volume to weight ratio of the water phase to the oil phase is in the range of from about 20:1 to about 125:1. These foams are particularly useful as absorbent members for catamenial pads.

Abstract: Highly uniform microporous foam suitable for medical applications and methods for preparing these foams. The highly uniform microporous foams are of controlled pore size that may be utilized in a variety of applications. In preparing the foams, an organic crystalline polymer is melted and combined with a selected solid crystalline fugitive compound to produce a substantially isotropic solution. The solution is cooled under controlled conditions, which foster solid--solid phase separation by the simultaneous crystallization of the fugitive compound and the polymer, to produce a foam precursor containing the solidified fugitive compound dispersed through a matrix of the organic polymer. Crystals of fugitive compound are then removed by solvent extraction and/or sublimation, or like process to produce microcellular foams having a continuous, open-cell structure.

Abstract: This invention relates to porous polyfluoroethylene (PTFE), shaped articles prepared therefrom, and to methods of preparing said articles.

Abstract: A syntactic foam-core material and method for its production are disclosed wherein glass microspheres and chopped fiberglass are dispersed within a slurry comprised of a suitable resin such as an epoxy and a suitable solvent such as methyl ethyl ketone. Under carefully controlled vacuum and rate of addition conditions, the microspheres and chopped fiberglass are added to the slurry to form a light weight syntactic foam-core material. The material may either be stored under cold conditions for use at a later time as a B-stage material or it may be shaped and/or molded to conform to a desired configuration which, for example, may correspond with a desired component part. After curing, the material may be machined to final dimensions. The material may be characterized as a tightly packed network of resin-coated microspheres spaced by controlled, yet random voids comprising at least 20%, and more usually, between 23 and 25% by volume, of the fully-cured material.

Abstract: An improvement in a continuous process for making high internal phase emulsions that are typically polymerized to provide microporous, open-celled polymeric foam materials capable of absorbing aqueous fluids, especially aqueous body fluids such as urine. The improvement involves recirculating a portion (about 50% or less) of the emulsion withdrawn from the dynamic mixing zone of this continuous process. This increases the uniformity of the emulsion ultimately obtained from this continuous process in terms of having the water droplets homogeneously dispersed in the oil phase. This also improves the stability of the HIPE and expands the temperature range for pouring and curing this HIPE during subsequent emulsion polymerization. The improvement also eliminates the need for a static mixer outside the dynamic mixing zone, and allows for processing where relatively low pressure drops are required across the mixing zone.

Abstract: The present invention relates to a HIPE-derived heterogeneous polymeric foam structure of interconnected open-cells, wherein the foam structure has at least two distinct regions. Such heterogeneous foams have various applications, such as energy and fluid absorption, insulation, and filtration.The invention further relates to a heterogeneous absorbent polymeric foam that, upon contact with aqueous fluids (in particular body fluids such as urine and blood), can acquire, distribute, and store these fluids.The foams of the invention have at least two distinct regions having different density, polymer composition, surface properties, and/or microcellular morphology.The invention further relates to a process for obtaining the heterogeneous foams by polymerizing a high internal phase water-in-oil emulsion, or HIPE. In one aspect, the process utilizes at least two distinct HIPEs, with each emulsion having a relatively small amount of an oil phase and a relatively greater amount of a water phase.

Abstract: The present invention relates to a process for forming a foamed elastomeric polymer. The process involves forming a reverse emulsion of liquid droplets in a continuous liquid phase of polymer precursor and then polymerizing the precursor to entrap uniformly distributed droplets of the liquid in pores formed in the polymer bulk. The liquid in the pores is then removed under supercritical conditions.

Abstract: Foams capable of absorbing blood and blood-based fluids, especially menses. These absorbent foams have high capillary absorption pressures required of absorbents used in catamenial products, yet have sufficient openness to allow free movement of the insoluble components in blood-based fluids such as menses. These absorbent foams are made by polymerizing high internal phase emulsions (HIPEs) where the volume to weight ratio of the water phase to the oil phase is in the range of from about 20:1 to about 125:1. These foams are particularly useful as absorbent members for catamenial pads.

Abstract: Absorbent foams materials that are capable of acquiring and distributing aqueous fluids, especially discharged body fluids such as urine. These absorbent foams combine relatively high capillary absorption pressures and capacity-per-weight properties that allow them to acquire fluid, with or without the aid of gravity. These absorbent foams also give up this fluid efficiently to higher absorption pressure storage materials, including foam-based absorbent fluid storage components, without collapsing. These absorbent foams are made by polymerizing high internal phase emulsions (HIPEs).

Abstract: A structure of a microporous resin bonded to metal is prepared by a method, comprising, molding a resin composition comprising a polymer alloy consisting of polyether imide and polyphenylene ether and particles of aluminum borate or amorphous silica filler, wherein the particles of aluminum borate and amorphous silica have an aspect ratio of 10 or less and an average diameter of 0.01-100 .mu.m, the aluminum borate having the formula: nAl.sub.2 O.sub.3.mB.sub.2 O.sub.3, wherein n and m individually represent an integer of 1-100, and the amorphous silica having the formula: SiO.sub.2, into a shaped object, treating the molded resin composition with an aqueous alkaline solution to remove the filler, thereby creating micropores within the resin object, and depositing a metal film on a surface of the treated resin object.

Abstract: The present invention relates to compressable polymeric foam materials useful as insulation. These polymeric foams are prepared by polymerization of certain water-in-oil emulsions having a relatively high ratio of water phase to oil phase, commonly known as "HIPEs." The polymeric foam materials comprise a generally hydrophobic, flexible or semi-flexible, nonionic polymeric foam structure of interconnected open-cells. The foam structures have:(a) a specific surface area per foam volume of at least about 0.01 m.sup.2 /cc;(b) an expanded density of less than about 0.05 g/cc; and(c) a ratio of expanded to compressed thickness of at least about 3:1;wherein when the foam is compressed to 33% of its original expanded thickness and is thereafter maintained without artificial restraint on its surface, said foam will reexpand by no more than 50% after 21 days at ambient temperature (22.degree. C.).

Abstract: Biodegradable and/or compostable polymers are made from isoprene, 2,3-dimethyl-1,3-butadiene or like conjugated dienes and a crosslinking agent having a cleavable linking group such as ethylene glycol dimethacrylate. These polymers can be used to make absorbent foams that are useful in absorbent articles such as diapers, as well as other biodegradable articles such as films, and latexes useful as binders and adhesives.

Abstract: Absorbent foam materials that are capable of acquiring and distributing aqueous fluids, especially discharged body fluids such as urine. These absorbent foams combine relatively high capillary absorption pressures and capacity-per-weight properties that allow them to acquire fluid, with or without the aid of gravity. These absorbent foams also give up this fluid efficiently to higher absorption pressure storage materials, including foam-based absorbent fluid storage components, without collapsing. These absorbent foams are made by polymerizing high internal phase emulsions (HIPEs).

Abstract: The present invention relates to porous crosslinked polymeric microbeads having cavities joined by interconnecting pores wherein at least some of the cavities at the interior of each microbead communicate with the surface of the microbead. The present invention also relates to a process for producing a porous, crosslinked polymeric microbead as well as the product of this process. This process involves combining an oil phase with an aqueous discontinuous phase to form an emulsion, adding the emulsion to an aqueous suspension medium to form an oil-in-water suspension of dispersed emulsion droplets, and polymerizing the emulsion droplets to form microbeads. At least 10% of the microbeads produced in accordance with the present invention are substantially spherical or substantially ellipsoidal or a combination of the two.

Abstract: Low density collapsed absorbent foams materials that, upon contact with aqueous fluids, in particular urine, can expand and absorb these fluids. These low density foams typically have an expanded thickness from about 6 to about 10 times the thickness of the foams in their collapsed state. These low density foams are made by polymerizing high internal phase emulsions (HIPEs) where the volume to weight ratio of the water phase to the oil phase is in the range of from about 55:1 to about 100:1.

Abstract: Low density collapsed absorbent foams materials that, upon contact with aqueous fluids, in particular urine, can expand and absorb these fluids. These low density foams typically have an expanded thickness from about 6 to about 10 times the thickness of the foams in their collapsed state. These low density foams are made by polymerizing high internal phase emulsions (HIPEs) where the volume to weight ratio of the water phase to the oil phase is in the range of from about 55:1 to about 100:1.

Abstract: The present invention relates to a process for forming a foamed elastomeric polymer. The process involves forming a reverse emulsion of liquid droplets in a continuous liquid phase of polymer precursor and then polymerizing the precursor to entrap uniformly distributed droplets of the liquid in pores formed in the polymer bulk. The liquid in the pores is then removed under supercritical conditions.

Abstract: An alkanol permeation polymer membrane prepared by dissolving biocompatible, non-allergenic polymer capable of being dissolved in polar organic solvent in methylene chloride to prepare a first solution, dissolving cellulose or glycol type polyol compounds in cosolvent composed of alkanol and methylene chloride to prepare a second solution, and mixing the first solution with the second solution, casting the mixed solution on a glass plate with a controlled thickness and evaporating may control the release of drugs effectively.

Abstract: This invention relates to porous polyfluoroethylene (PTFE), shaped articles prepared therefrom, and to methods of preparing said articles.

Abstract: A polymeric reticulated structure is prepared by mixing an ethylene-propylene copolymer having an ethylene content of at least 60% by weight or a thermoplastic block copolymer terminated with a crystalline ethylene block with a low molecular weight material. The low molecular weight material is trapped in the three-dimensional continuous network the copolymer forms.

Abstract: A novel processing technique is reported to bond non-woven fibers and, thus, prepare structural interconnecting fiber networks with different shapes for organ implants. The fibers are physically joined without any surface or bulk modification and have their initial diameter.

Abstract: Absorbent foam materials that are capable of acquiring and distributing aqueous fluids, especially discharged body fluids such as urine. These absorbent foams combine relatively high capillary absorption pressures and capacity-per-weight properties that allow them to acquire fluid, with or without the aid of gravity. These absorbent foams also give up this fluid efficiently to higher absorption pressure storage materials, including foam-based absorbent fluid storage components, without collapsing. These absorbent foams are made by polymerizing high internal phase emulsions (HIPEs).

Abstract: A polymeric foam with continuous, open-cell pores containing living cells suitable for medical applications and methods for preparing these foams. The microporous foams are of controlled pore size that may be utilized in a variety of applications. In general, the foams are characterized in that the pores are continuous and open-celled. In preparing the foams, an organic polymer is melted and combined with a selected solid crystalline fugitive compound, that melts above about 25.degree. C. and/or that sublimates at above about 25.degree. C. or can be extracted, to produce a substantially isotropic solution. The solution is cooled under controlled conditions to produce a foam precursor containing the solidified fugitive composition dispersed through a matrix of the organic polymer. Crystals of fugitive composition are then removed by solvent extraction and/or sublimation, or a like process to produce microcellular foams having a continuous, open-cell structure.

Abstract: A syntactic foam-core material and method for its production are disclosed wherein glass microspheres and chopped fiberglass are dispersed within a slurry comprised of a suitable resin such as an epoxy and a suitable solvent such as methyl ethyl ketone. Under carefully controlled vacuum and rate of addition conditions, the microspheres and chopped fiberglass are added to the slurry to form a light weight syntactic foam-core material. The material may either be stored under cold conditions for use at a later time or it may be shaped and/or molded to conform to a desired configuration which, for example, may correspond with a desired component part. After curing, the material may be machined to final dimensions.