Process for preparing a coated, thermosetting plastic foam having improved properties

Claim 1

A process for preparing a foamed thermosetting composition containing at least a surface layer of particulate particles embedded therein including the successive steps of: (1) distributing a foamable thermosetting liquid composition onto an adhering surface; (2) at least partially initiating the foam curing of said thermosetting composition; (3) thereafter evenly distributing on the exposed surface of the partially formed foam of step (2) a thin, continuous layer of inert, initially non-coherent particulate material; and (4) completing the foaming and curing of the thus coated thermosetting composition, whereby the inert, non-coherent particles are applied to the foam in step (3) at a time in which the foam composition is both adhesive to and at least partially penetrated by the contacted particulate material such that the foam, while still foaming, grows up and around the deposited particles, forming a continuous surface continuously having said inert particulate material distributed therethrough and integrally connected to the now-cured foamed structure of said thermosetting composition, said layer containing said particles having a discrete thickness extending within the said foamed structure.