Gasket having foamed sealant

A process for preparing a gasket having a compressible, resilient sealant coating, comprising:

• (a) comminuting to a particulate form a partially cured dry resin selected from the group consisting of epoxy, polyester, and polyurethane thermosetting resins, said resin being sufficiently cured to be solid and dry at room temperatures but capable of further cure at a temperature within an elevated, predetermined temperature range,
• (b) admixing a blowing amount of a dry blowing agent with said resin particles to form a substantially dry admixture, said blowing agent having a temperature of activation within said elevated, predetermined temperature range,
• (c) electrostatically directing said substantially dry admixture of resin particles and blowing agents toward and onto a base sheet,
• (d) heating the base sheet and applied admixture to a temperature within said predetermined temperature range to further cure the resin of said particles,
• (e) activating substantially all of the blowing agent during said heating step within said predetermined temperature range to foam the resin and form a compressible, resilient, foamed sealant coating on said base sheet, and
• (f) adhering the sealant coating to said base sheet to prepare said gasket, said sealant coating being adapted to effect a fluid-type seal for said gasket without resort to permanent deformation of the sealant coating by excessive pressure or by plastic flow.