Syntactic foam component with elongate members

Abstract

To provide a lightweight foam, particularly a syntactic foam component having an elongated member.SOLUTION: Examples of the present disclosure include an apparatus including a syntactic foam component. The syntactic foam component includes low density spheres at least partially embedded in a resin. The syntactic foam component includes an elongate member partially embedded in the resin and including a first end and a second end. At least the first end is disposed against the syntactic foam component. The first end is thereby exposed to the exterior of the syntactic foam component at the outer surface of the syntactic foam component.SELECTED DRAWING: Figure 5B

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE

[0001] This disclosure relates generally to buoyancy foam, and more particularly to syntactic foam components having elongated members. [Background technology]

[0002]

[0002] Lightweight foams are incorporated into components to facilitate their lightweight nature in higher density fluids. Some components that incorporate lightweight foams include, but are not limited to, submarines, ships, oil rigs and their components, and other marine-based systems. Typical lightweight foams are compression resistant and, in some cases, water resistant, durable, and reliable. Producing lightweight foams with these properties in an efficient, cost-effective, and reliable manufacturing process can be difficult. Summary of the Invention

[0003]

[0003] The subject matter of the present application was developed in response to the current state of the art, and in particular in response to the shortcomings of conventional lightweight foams and conventional methods of making such lightweight foams. These shortcomings have not yet been fully addressed by currently available technology. Accordingly, the subject matter of the present application was developed to provide syntactic foam parts and corresponding methods of making such parts, which overcome at least some of the above-mentioned shortcomings of the prior art.

[0004]

[0004] Below is a non-exhaustive list of several examples of the subject matter disclosed in this specification, which may or may not be claimed.

[0005] The subject matter of the following paragraphs constitutes Example 1 of the present disclosure. According to Example 1, an apparatus includes a syntactic foam component. The syntactic foam component includes low-density spheres at least partially embedded in a resin. The syntactic foam component includes an elongate member partially embedded in the resin and including a first end and a second end. At least the first end is positioned relative to the syntactic foam component, such that the first end is exposed to the exterior of the syntactic foam component at an outer surface of the syntactic foam component.

[0006]

[0006] The subject matter of the following paragraphs constitutes Example 2 of the present disclosure. According to Example 2, which encompasses Example 1 above, the low-density spheres are substantially hollow.

[0007]

[0007] The subject matter of the following paragraphs constitutes Example 3 of the present disclosure. According to Example 3, which includes Example 1 or 2 above, the first end is flush with the outer surface or protrudes from the outer surface.

[0008] The subject matter of the following paragraphs constitutes Example 4 of the present disclosure. According to Example 4, which can include any one of Examples 1 to 3 above, the outer surface is a first outer surface. The second end is positioned relative to the syntactic foam component, such that the second end is exposed to the exterior of the syntactic foam component at the second outer surface of the syntactic foam component.

[0009]

[0009] The subject matter of the following paragraphs constitutes Example 5 of the present disclosure. According to Example 5, which can include any one of Examples 1 to 4 above, the first outer surface and the second outer surface are on the same side of the syntactic foam component.

[0010]

[0010] The subject matter of the following paragraphs constitutes Example 6 of the present disclosure. According to Example 6, which encompasses Examples 1 through 4 above, the first exterior surface is opposite the second exterior surface of the syntactic foam component.

[0011] The subject matter of the following paragraphs constitutes Example 7 of the present disclosure. According to Example 7, which can include any one of Examples 1 to 6 above, the elongated member is made of at least one of a metallic material, a ceramic material, or a composite material.

[0012] The subject matter of the following paragraphs constitutes Example 8 of the present disclosure. According to Example 8, which can include any one of Examples 1 to 7 above, the elongated member is substantially hollow, thereby allowing a thermally conductive fluid to flow through the elongated member between the first end and the second end.

[0013]

[0013] The subject matter of the following paragraphs constitutes Example 9 of the present disclosure. According to Example 9, which can include any one of Examples 1 to 8 above, the elongated member is made of a conductive material.

[0014] The subject matter of the following paragraphs constitutes Example 10 of the present disclosure. According to Example 10, which includes any one of Examples 1 to 9 above, the elongate member is a first member. The device further includes a second elongate member including a first second member end 105 and a second second member end 107. The first second member end 105 is positioned relative to the syntactic foam component 142. Thereby, the first second member end 105 is exposed to the exterior casing 110 of the syntactic foam component 142.

[0015]

[0015] The subject matter of the following paragraphs constitutes Example 11 of the present disclosure. According to Example 11, which includes any one of Examples 1 to 10 above, the elongate member extends throughout the syntactic foam component.

[0016] The subject matter of the following paragraphs constitutes Example 12 of the present disclosure. According to Example 12, a system includes a first syntactic foam component. The first syntactic foam component includes a first set of low-density spheres at least partially embedded in a first resin. The system includes a first elongated member partially embedded in the first resin. The first elongated member includes a first first-member end and a second first-member end. At least the first first-member end is positioned relative to the first syntactic foam component, thereby exposing the first first-member end to the exterior of the first syntactic foam component at an outer surface of the first syntactic foam component. The system includes a second syntactic foam component including a second set of low-density spheres at least partially embedded in a second resin. The second elongated member is at least partially embedded in the second resin and includes a first second-member end and a second second-member end. The second elongated member is coupled to the first elongated member.

[0017] The subject matter of the following paragraphs constitutes Example 13 of the present disclosure. According to Example 13, which encompasses Example 12 above, an end of the second second member is selectively directly coupled to an end of the first first member.

[0018]

[0018] The subject matter of the following paragraphs constitutes Example 14 of the present disclosure. According to Example 14, which includes Example 12 or 13 above, a system includes a connector. An end of a second second member is indirectly coupled to the first first member via the connector. The connector engages between and extends between the end of the second second member and the end of the first first member.

[0019]

[0019] The subject matter of the following paragraphs constitutes Example 15 of the present disclosure. According to Example 15, which includes any one of Examples 12 to 14 above, the connector is at least partially embedded in the first resin.

[0020]

[0020] The subject matter of the following paragraphs constitutes Example 16 of the present disclosure. According to Example 16, a method of making a syntactic foam part includes loading low-density spheres into a mold. The method includes introducing an elongated member into the mold, whereby the elongated member is at least partially embedded within the low-density spheres. The method includes introducing a resin into the mold. The method includes embedding the low-density spheres and a portion of the elongated member embedded within the low-density spheres in the resin. The method includes solidifying the resin after embedding the low-density spheres and a portion of the elongated member embedded within the low-density spheres in the resin. The method includes removing the low-density spheres (120) and the elongated member from the mold.

[0021] The subject matter of the following paragraphs constitutes Example 17 of the present disclosure. According to Example 17, which encompasses Example 16 above, a method includes removing an elongated member from a syntactic foam part after the resin has solidified.

[0022] The subject matter of the following paragraphs constitutes Example 18 of the present disclosure. According to Example 18, which includes Example 16 or 17 above, the elongate member is substantially hollow and includes a first end and a second end. The first end and the second end are open ends. The method further includes covering at least one of the first end and the second end after the resin has solidified.

[0023] The subject matter of the following paragraphs constitutes Example 19 of the present disclosure. According to Example 19, which can include any one of Examples 16 to 18 above, a method includes forming a foam within the elongate member before covering at least one of the first end and the second end.

[0024] The subject matter of the following paragraphs constitutes Example 20 of the present disclosure. According to Example 20, including any one of Examples 16 to 19 above, the elongated member is substantially hollow. The method further includes flowing a thermally conductive fluid through the elongated member while the resin is solidifying.

[0025] The described features, structures, advantages, and / or characteristics of the presently disclosed subject matter may be combined in any suitable manner in one or more examples and / or embodiments. In the following description, numerous specific details are presented to facilitate a comprehensive understanding of the embodiments of the presently disclosed subject matter. Those skilled in the art will recognize that the presently disclosed subject matter can be practiced without one or more of the specific features, details, components, materials, and / or methods of a particular example or implementation. In other cases, additional features and advantages may be recognized in particular examples and / or implementations, but may not be present in all examples or implementations. Furthermore, in some instances, well-known structures, materials, or steps have not been described or shown in detail so as not to obscure aspects of the presently disclosed subject matter. The features and advantages of the presently disclosed subject matter will become more apparent from the following description and appended claims, or may be learned by practicing the subject matter as described below.

[0026]

[0026] So that the advantages of the present subject matter may be more readily understood, a more detailed description of the subject matter outlined above will be given by reference to specific embodiments illustrated in the accompanying drawings. It will be understood that these drawings, which are not necessarily drawn to scale, depict only certain examples of the subject matter and therefore should not be considered limiting of its scope, and that the subject matter will be described with added specificity and detail using the drawings. [Brief explanation of the drawings]

[0027] [Figure 1A]

[0027] FIG. 1 is a top perspective view of a device having a syntactic foam component and an elongated member according to one or more embodiments of the present disclosure. [Figure 1B]

[0028] FIG. 1 is a transparent top perspective view of a device having a syntactic foam component and an elongated member according to one or more embodiments of the present disclosure. [Figure 2]

[0029] FIG. 1 is a top perspective view of a device having a syntactic foam component and an elongated member extending only partially through the syntactic foam component, according to one or more embodiments of the present disclosure. [Figure 3]

[0030] FIG. 1 is a front elevation view of a system according to one or more embodiments of the present disclosure. [Figure 4A]

[0031] FIG. 1 is a front elevation view of a system having a connector according to one or more embodiments of the present disclosure. [Figure 4B]

[0032] FIG. 1 is an expanded view of a system having a connector according to one or more embodiments of the present disclosure. [Figure 5A]

[0033] FIG. 1 is a top view of a low density sphere in a mold according to one or more embodiments of the present disclosure. [Figure 5B]

[0034] FIG. 10 is a top view of an elongated member extending through a low-density sphere, according to one or more embodiments of the present disclosure. [Figure 5C]

[0035] FIG. 1 illustrates a top view of a low-density sphere coated with resin in a mold in accordance with one or more embodiments of the present disclosure. [Figure 5D]

[0036] FIG. 1 is a top view of material flowing through an elongate member in accordance with one or more embodiments of the present disclosure. [Figure 5E]

[0037] FIG. 10 is a top view of a resin-coated low-density sphere in a mold with the elongated member removed from the mold, in accordance with one or more embodiments of the present disclosure. [Figure 6]

[0038] FIG. 1 is a front elevation view of an apparatus having a syntactic foam component and a capped elongate member according to one or more embodiments of the present disclosure. [Figure 7]

[0039] FIG. 1 is a front elevation view of an apparatus having a syntactic foam component and a capped elongated member filled with foam material according to one or more embodiments of the present disclosure. [Figure 8]

[0040] FIG. 1 is a top perspective view of a device having a syntactic foam component and several elongated members according to one or more embodiments of the present disclosure. [Figure 9]

[0041] FIG. 1 is a side elevation view of a device having a syntactic foam component and several elongated members extending through the syntactic foam component, according to one or more embodiments of the present disclosure. [Figure 10]

[0042] FIG. 1 is a side elevation view of a device having a syntactic foam component and an elongate member having multiple components, according to one or more embodiments of the present disclosure. [Figure 11]

[0043] 1 is a side elevation view of a device having a syntactic foam component and a plurality of elongated members extending from a first surface to a second surface according to one or more embodiments of the present disclosure. FIG. [Figure 12]

[0044] FIG. 1 is a side elevational view of a device having a plurality of elongate members extending from a first side of a syntactic foam component to a second side of the syntactic foam component adjacent the first side. [Figure 13]

[0045] FIG. 1 is a schematic flow diagram of a method of making a syntactic foam part according to one or more embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0028]

[0046] When reference is made herein to "one embodiment," "an embodiment," or similar phrases, it means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The phrases "one embodiment," "an embodiment," and similar phrases appearing throughout this specification may, but do not necessarily, all refer to the same embodiment. Similarly, the term "embodiment" means an embodiment having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, but the embodiment may be associated with one or more embodiments unless there is a clear correlation suggesting otherwise.

[0029]

[0047] Some conventional methods for making syntactic foam parts involve stacking low-density spheres in contact with one another into a mold. The mold is then infused with resin, which embeds the spheres. As the resin cures, heat is released, which increases the temperature within the mold. Such temperatures can be dangerous and can reduce the quality of the foam by introducing residual stresses or degrading the resin or the spheres.

[0030]

[0048] Described herein are several examples of methods for making syntactic foam parts made with low-density spheres embedded in resin. These examples provide the ability to more precisely control temperature throughout the syntactic foam part. Examples of the present disclosure may also help speed the curing process for syntactic foam parts without sacrificing quality. Examples of the present disclosure may help reduce costs and facilitate the creation of larger syntactic foam parts. Certain examples of the method include introducing an elongated member into the mold prior to injecting the resin into the mold and embedding the spheres in the resin. The elongated member may help conduct heat throughout the mold, reducing overheating and overall residual stress.

[0031]

[0049] In some embodiments, the method results in a device and / or system including a foam component having elongate members suitable for connection with components of other foam components. Connecting separate foam components can be useful for facilitating connection of electrical components housed within the foam components, allowing multiple foam components to move as a unit, and / or allowing electricity and / or heat to be conducted through multiple separate foam components.

[0032]

[0050] According to some embodiments, a method 1300 for fabricating a device such as the device 100 of FIGS. 1A-1B is shown in FIG. 13. Referring generally to FIG. 13 and particularly to FIG. 5A, the method 1300 includes loading low-density spheres 120 into a mold 102 (block 1302). In some embodiments, the mold 102 includes a selectively openable lid that selectively covers an opening in the mold 102 through which the low-density spheres 120 can be loaded into the mold 102. In some embodiments, the low-density spheres 120 are loaded such that they form a lattice arrangement within the mold 102. In some embodiments, in the lattice arrangement, each one of the low-density spheres 120 contacts each one of at least two other low-density spheres 120 at a single contact point to form either a bimodal or trimodal sphere. In some embodiments, the low-density spheres 120 include low-density spheres of several different sizes, such as five differently sized spheres.

[0033]

[0051] 5C-5E, 6, and 7, in some embodiments, the mold 102 forms part of a molding tool. The molding tool further includes a resin introduction system. The resin introduction system is operable to introduce resin 138 into the internal cavity 124 of the mold 102. In some embodiments, the resin introduction system includes an inlet and / or an outlet, such as an inlet operable to introduce resin 138 from a supply into the internal cavity 124. In some embodiments, the outlet is operable to evacuate excess resin 138 from the internal cavity 124.

[0034]

[0052] The size and shape of the internal cavity 124 of the mold 102 defines the size and shape of the syntactic foam part 142. Furthermore, in certain embodiments, the size and shape of the internal cavity 124 is configured to ensure that the low-density spheres 120 form a particular configuration when loaded into the mold 102. Thus, the size and shape of the internal cavity 124 may depend on the size of the low-density spheres 120, or vice versa. Note that the low-density spheres 120 and the mold 102 are not necessarily drawn to scale. For example, in the depicted representation, the size of the low-density spheres 120 is abnormally large relative to the size of the mold 102 to more clearly illustrate and explain the present invention. In practice, the size of the low-density spheres 120 will be significantly smaller relative to the size of the mold 102 than depicted. In some embodiments, the maximum diameter D of the low-density spheres 120 is between 5 microns and 153 millimeters (mm), inclusive, for example, in one embodiment, between 20 microns and 10,000 microns, inclusive, in another embodiment, between 25 microns and 5,000 microns, inclusive, for example, in another embodiment, between 250 microns and 35,000 microns, inclusive, and in yet another embodiment, between 500 microns and 1,000 microns, inclusive.

[0035]

[0053] According to some embodiments, as shown in FIG. 5C , each or at least one of the low-density spheres 120 is a hollow sphere. A hollow sphere has a hollow interior defined by the inner surface of a sidewall that also defines the outer surface of the low-density sphere 120. A hollow sphere has a thin-walled structure. In other words, the thickness of the sidewall of the hollow sphere is less than the diameter of the hollow sphere. In some embodiments, the ratio of thickness to diameter is between 0.001 and 0.1, inclusive, for example, between 0.01 and 0.1, inclusive, in one embodiment, and between 0.02 and 0.08, inclusive, in another embodiment. The hollow spheres can be made of any of a variety of materials, including, but not limited to, glass, ceramic, polymer, and metal.

[0036]

[0054] In alternative embodiments, each or at least one of the low-density spheres 120 is a solid foam sphere. The foam sphere does not have a single hollow space, such as a hollow sphere. Rather, the foam sphere is made of a solid piece of foam having multiple hollow spaces in the form of multiple open or closed cells. In some embodiments, the foam of the foam sphere is one or more of polystyrene foam, expanded polystyrene (EPS) foam, expanded polypropylene (EPP) foam, polyethylene foam, polyurethane foam, and / or any of a variety of other types of foam.

[0037]

[0055] As used herein, in certain embodiments, low density spheres 120 have a density of 0.005 g / cm3, inclusive. 3 and 0.6 g / cm 3 For example, in one embodiment, 0.05 g / cm 3 and 0.4 g / cm 3 and in another embodiment, 0.1 g / cm 3 and 0.3 g / cm 3 and in yet another embodiment, 0.02 g / cm 3 and 0.15 g / cm 3 and in a further embodiment, 0.015 g / cm 3 and 0.03 g / cm 3 The low-density spheres 120 are hollow or solid spheres having a density between 0.01 and 0.01. While not shown, in some embodiments, the low-density spheres 120 may be pre-coated with a uniform coating before being loaded into the mold 102 at block 1302. The uniform coating may be made of any of a variety of materials, including, but not limited to, preceramic materials, polymers, ceramics, foam materials (e.g., resins containing portions of the low-density spheres 120), and reinforced resins (e.g., resins containing milled fiber and / or particle reinforcement). In some cases, such as when the low-density spheres 120 are solid foam spheres, the uniform coating may provide strength and / or a thermal barrier to the underlying spheres. In some embodiments, the uniform coating is resin 138.

[0038]

[0056] 5A, all of the low-density spheres 120 loaded into the mold 102 at block 1302 have the same size. However, in other embodiments, the low-density spheres loaded into the mold 102 at block 1302 may have different sizes and may be loaded into the mold 102 at different times corresponding to their sizes.

[0039]

[0057] As shown generally in FIG. 13 and particularly in FIG. 5B , after the low-density spheres 120 are loaded into the mold 102 at block 1302, the method 1300 further includes introducing the elongated members 104 into the mold (block 1304). In some embodiments, the method 1300 includes introducing the elongated members 104 into the mold before introducing the low-density spheres 120. In various embodiments, the method 1300 includes introducing at least a portion of the low-density spheres 120 into the mold 102 after introducing the elongated members 104. In some embodiments, introducing the elongated members 104 includes introducing the elongated members 104 such that the elongated members 104 are at least partially embedded within the low-density spheres 120.

[0040]

[0058] 5B , in some embodiments, the elongated member 104 is introduced into the mold 102 through one or more passages 126 formed therethrough. In some embodiments, the elongated member 104 has dimensions that allow it to be introduced into the mold 102 without forming passages 126 in the mold 102. For example, the elongated member 104 is introduced through an open top and / or an open side of the mold 102. In various embodiments, the elongated member 104 is introduced into the mold 102 after the low-density spheres 120 are introduced. In other embodiments, the elongated member 104 is first introduced into the mold 102, and then the low-density spheres 120 are introduced to at least partially embed the elongated member 104.

[0041]

[0059] In some embodiments, elongate member 104 has a first end 106 and a second end 108 opposite first end 106. Referring to FIG. 1B , in some embodiments, elongate member 104 has a length L2 from first end 106 to second end 108. Length L2 is greater than width w1 of elongate member 104. In some embodiments, elongate member 104 has length L2 from first end 106 to second end 108. Length L2 extends completely through syntactic foam component 142. In some embodiments, length L2 of elongate member 104 is greater than or equal to length L1 of syntactic foam component 142.

[0042]

[0060] In some embodiments, introducing 1304 the elongate member 104 into the mold includes introducing the elongate member 104 into the mold 102 such that at least one of the first end 106 and the second end 108 is exposed to the exterior 110 of the mold 102. With reference to FIGS. 5B-5D , in some embodiments, the first end 106 of the elongate member 104 protrudes from the mold 102. Thus, with reference to FIGS. 1A-3 , 6-10 , and 12 , in some embodiments, the elongate member 104 protrudes from the outer surface 112A of the resulting syntactic foam part 142. In some embodiments, the first end 106 is flush with the mold 102. Thus, with reference to FIGS. 4A-4B and 11 , in some embodiments, the first end 106 of the elongate member 104 is flush with the outer surface 112A of the resulting syntactic foam part 142.

[0043]

[0061] In some embodiments, the second end 108 is also exposed to the exterior 110 of the mold 102. With reference to FIGS. 5B-5D, in some embodiments, the second end 108 protrudes from the mold 102. In other embodiments, with reference to the system 1100 of FIG. 11, the second end 108 is flush with the mold 102 and, therefore, flush with the outer surface 112C of the resulting syntactic foam part 142. In some embodiments, the outer surface 112C is opposite the outer surface 112A with which the first end 106 is flush. With reference to FIG. 12, in other embodiments, the second end 108 is flush with and / or protrudes from the adjacent surface 112B of the resulting syntactic foam part 142. Referring to FIG. 9, in some embodiments, second end 108 protrudes from an outer surface 112C of syntactic foam piece 142 opposite outer surface 112A from which first end 106 protrudes.

[0044]

[0062] In various embodiments, the second end 108 protrudes from the mold 102 on the same side as the first end 106; with reference to FIG. 10 , the second end 108 protrudes from the same surface 112A of the syntactic foam part 142 from which the first end 106 protrudes. In other embodiments, the second end 108 is within the mold 102. With reference to FIG. 2 , in system 200, the second end 108 is completely contained within the resulting syntactic foam part 142.

[0045]

[0063] In some embodiments, elongated member 104 is made of a thermally conductive material to help promote heat flow through mold 102 as syntactic foam part 142 is formed. Thermally conductive materials include, for example, metallic materials. In some embodiments, elongated member 104 is a rod of metallic material. In some embodiments, elongated member 104 is made of an electrically conductive material in addition to or instead of a thermally conductive material. In some embodiments, elongated member 104 is made of a material that conducts both heat and electricity. Possible materials include, for example, titanium, semiconductors, carbon, carbon nanotube composites, carbon fiber composites, ceramics, silicon carbide, aluminum, copper, silver, gold, graphite, doped silicon, and / or any combination thereof. In various embodiments, the material from which elongated member 104 is made is selected based at least in part on its compatibility with resin 138.

[0046]

[0064] In some embodiments, the elongated member 104 resembles at least one of the following shapes: a strip, a rod, a rectangular prism, a tube, a cylinder, an elliptical tube, and / or any combination thereof. In some embodiments, the elongated member 104 extends in a manner that creates at least one of the following shapes: a semicircular shape, a U-shape, a triangular shape, a semi-rectangular shape, a semi-square shape, a straight shape, an L-shape, an extruded shape, a bent shape, an E-shape, and / or any combination thereof.

[0047]

[0065] As shown generally in FIG. 13 and particularly in FIG. 5C , the method 1300 further includes introducing resin 138 into the mold (block 1306). In some embodiments, the resin 138 is introduced into the mold 102 through an inlet in the mold 102. In some embodiments, the resin 138 is introduced through an inlet in the bottom of the mold 102 and allowed to flow from the bottom of the mold 102 to the top of the mold 102 in a generally bottom-to-top direction. In some embodiments, the resin 138 is actively pushed and / or actively pulled (e.g., via a vacuum) to urge the resin 138 to flow through the mold 102 in a generally bottom-to-top direction. In other embodiments, the resin 138 is passively gravity-fed through the mold 102 from top to bottom.

[0048]

[0066] According to one embodiment, resin 138 may be actively pushed via positive pressure introduced at the bottom of mold 102, such as via a positive pressure device (e.g., a blower, a compressor, etc.). In a further embodiment, resin 138 may be actively pulled via negative pressure introduced at the top of mold 102, such as via a negative pressure device (e.g., a vacuum device).

[0049]

[0067] 13 generally and FIG. 5C in particular, the method 1300 further includes embedding (block 1308) the low-density spheres 120 and a portion of the elongated member 104 in the resin 138 introduced into the mold 102 in block 1306. In some embodiments, embedding the low-density spheres 120 in the resin 138 includes coating the low-density spheres 120 with the resin 138. Coating the low-density spheres 120 in block 230 forms a coating made of the resin 138 entirely around each one of the low-density spheres 120. The low-density spheres 120 are coated when the resin 138 flows through the mold 102 and contacts and adheres to the exterior surfaces of the low-density spheres 120. The method of introducing the resin 138 may facilitate the adhesion and coating of the resin 138 onto the low-density spheres 120. According to some embodiments, to promote adhesion of the resin 138 to the low-density spheres 120 (particularly when the low-density spheres 120 are made of a material with relatively low adhesion properties, such as polystyrene), the method 1300 may also include applying an adhesion promoter onto the exterior surfaces of the low-density spheres 120 before the resin 138 is introduced into the mold 102. The adhesion promoter or wetting agent may be any of a variety of agents configured to promote adhesion, including, but not limited to, silanes. In one embodiment, the adhesion promoter is aspirated or vaporized and sprayed into the mold 102.

[0050]

[0068] As the resin 138 flows through the mold 102 and coats the entire low-density spheres 120, the narrow spaces between adjacent low-density spheres 120 (i.e., the points between adjacent low-density spheres 120 that are closest to each other or immediately adjacent or around the closest points) induce wicking or capillary action of the resin 138 into the narrow spaces.

[0051]

[0069] As defined herein, the entire low-density sphere 120 is coated with resin 138 when substantially all of the low-density sphere 120 is coated with resin 138, or substantially all of the low-density sphere 120 is coated with resin 138 except for the single contact point when a single contact point between adjacent low-density spheres 120 is maintained.

[0052]

[0070] The first resin 138 can be any of a variety of resins that facilitate coating the low-density spheres. According to some embodiments, the first resin 138 is one or more of a preceramic resin (e.g., a silane preceramic resin), a resin matrix composite (i.e., a reinforcing material embedded in a matrix material), a nanoscale material introduced via a slip-casting process, glass, water glass (e.g., sodium silicate), a highly elastic polymer (e.g., a highly cross-linked rigid-chain polymer, a polymer loaded with nanoparticles, a polymer loaded with colloidal silica nanoparticles, and / or a crystalline polymer), a vinyl ester resin, a polyester resin, etc. The reinforcing material of the resin matrix composite can be any of a variety of materials, such as fumed silica, nanoparticles, crushed carbon fiber, etc. In certain embodiments, the first resin 138 includes a solvent that helps thin the first resin 138 and facilitates thin coating of the low-density spheres.

[0053]

[0071] 5C , resin 138 is shown coating individual low-density spheres 120, although embodiments of the present disclosure are not so limited. In some embodiments, resin 138 fills or substantially fills gaps between the low-density spheres 120 within internal cavity 124. In some embodiments, method 1300 includes coating the low-density spheres 120 with a first resin and introducing a second resin into internal cavity 124, where the first resin coats individual low-density spheres 120 and the second resin fills gaps between the coated low-density spheres 120. The second resin is introduced into and / or expelled from internal cavity 124 of mold 102 via any of the methods described above with reference to resin 138.

[0054]

[0072] The second resin can be any of a variety of resins that help embed and immobilize the low-density spheres 120. According to some embodiments, the second resin is one or more of a thermosetting resin (e.g., an epoxy resin), a resin matrix composite (i.e., a reinforcing material embedded in a matrix material), a high-modulus polymer (e.g., a polymer loaded with nanoparticles), etc. The reinforcing material of a resin matrix composite can be any of a variety of materials, such as fumed silica, nanoparticles, crushed carbon fiber, etc. According to some embodiments, the second resin includes a density-reducing component, such as smaller low-density spheres (e.g., hollow polymer or glass spheres), which helps reduce the density of the second resin without compromising the strength of the second resin.

[0055]

[0073] In some embodiments, the elongated member 104 is in thermal contact with a thermally conductive medium, such as a thermally conductive medium layer. In some embodiments, the thermally conductive medium layer is porous and has sufficient coarse porosity to allow the low-density spheres 120 to pass through when the spheres 120 are loaded into the mold 102. In other words, the thermally conductive medium layer has at least some voids larger than each one of the low-density spheres 120. In this embodiment, the thermally conductive medium layer may be angled (e.g., perpendicular) relative to the loading direction of the low-density spheres 120 so that the low-density spheres 120 can pass through the thermally conductive medium layer. In the illustrated embodiment, the loading of the low-density spheres 120 is gravity-assisted, whereby the loading direction of the low-density spheres 120 is substantially vertical or from top to bottom.

[0056]

[0074] In other embodiments, the thermally conductive medium layers of the tool die 102B do not have sufficient coarse porosity to allow the low-density spheres 120 to pass through. Instead, the thermally conductive medium layers may act as a barrier to prevent the low-density spheres 120 from passing through. Because the thermally conductive medium layers are not porous to the low-density spheres 120, the thermally conductive medium layers may be substantially parallel to each other and to the loading direction of the low-density spheres 120. The low-density spheres 120 are thereby stacked vertically between adjacent ones of the thermally conductive medium layers. Embedding a portion of the elongated member 104 in the resin 138 includes embedding a portion of the elongated member 104 in the low-density spheres 120 coated with the resin 138. While Figures 5B-5D show the elongated member 104 visible from a top view for simplicity, in some embodiments, the elongated member 104 is radially surrounded on all sides by low-density spheres 120 and / or resin 138.

[0057]

[0075] 13 , after embedding the low-density spheres 120 and portions of the elongated members 104 within the low-density spheres 120 in the resin 138 in block 1308, the method 1300 also includes solidifying the resin 138 (block 1310). Solidifying the resin 138 includes changing the state of the resin 138 from one state to a harder state (e.g., from a flowable or semi-flowable state to a non-flowable state), where such a change transforms the resin 138 from a fluid to a solid. According to one embodiment, solidifying the resin 138 includes partially or fully curing or drying the resin 138. Fully curing the resin 138 may include increasing the temperature of the resin 138 to a first cure temperature of the resin 138. Pressurization may be applied to the interior cavity 124 of the mold 102 to promote void-free curing of the resin 138. In alternative embodiments, resin 138 is partially or fully cured via alternative methods, such as radiation treatment of resin 138 (e.g., ultraviolet treatment, electron beam treatment, x-ray treatment, etc.). The curing of resin 138 can be irreversible (e.g., resin 138 is a thermosetting material) or reversible (e.g., resin 138 is a thermoplastic material). When resin 138 is a pre-ceramic resin, solidifying resin 138 in block 1310 can include converting the pre-ceramic resin to a ceramic resin. According to one embodiment, resin 138, and therefore the coating formed from resin 138, can be an electrically and / or thermally conductive resin, thereby allowing electrical and / or thermal connectivity to be established from coating to coating through part 142, if desired.

[0058]

[0076] In some embodiments, method 1300 includes introducing a first resin and a second resin into the mold. In some such embodiments, method 1300 includes solidifying the second resin after the second resin is introduced into mold 102 and fills mold 102. According to one embodiment, solidifying the second resin includes solidifying the second resin according to any of the methods described above with respect to first resin 138.

[0059]

[0077] 5D , method 1300 includes flowing fluid 114 through elongate member 104 while introducing and / or solidifying resin 138. In some such embodiments, elongate member 104 is substantially hollow. First end 106 and second end 108 of elongate member 104 are open-ended and / or include inlets and / or outlets. Fluid 114 may thereby be introduced into elongate member 104 at first end 106 and pass through length L2 of elongate member 104. In some embodiments, fluid 114 may flow out of elongate member 104 via second end 108. Fluid 114 may also flow in the opposite direction through elongate member 104, i.e., from second end 108 to first end 106.

[0060]

[0078] In some embodiments, fluid 114 is a material selected to control and / or vary the temperature within mold 102. Fluid 114 includes, for example, a thermally conductive material. In some embodiments, fluid 114 includes a cooling material, such as water, air, ethylene glycol, propylene glycol, a dielectric, and / or any combination thereof. In some embodiments, when fluid 114 is introduced into elongate member 104, fluid 114 has a temperature of 15° C. or more and 230° C. or less, e.g., 15° C. or more and 180° C. or less. In some embodiments, fluid 114 includes a thermally conductive material and may help dissipate heat throughout mold 102 as it flows through elongate member 104. In some embodiments, the temperature of fluid 114 may be varied during curing of resin 138 to provide specific time and temperature cycles.

[0061]

[0079] In some embodiments, rather than flowing fluid 114 through elongate member 104, method 1300 includes disposing a thermally conductive solid within elongate member 104 during processing of syntactic foam part 142. In various embodiments, the thermally conductive solid includes sand, a cooling device, a frozen substance, and / or a rod of thermally conductive material such as aluminum. In some embodiments, method 1300 includes removing the thermally conductive solid and / or fluid 114 from elongate member 104 after resin 138 has solidified 1310.

[0062]

[0080] In some embodiments, elongate member 104 is substantially hollow and serves as a conduit for electrical connections, wires, hoses, and / or any combination thereof. Referring to Figures 3-4B, in some embodiments, wires may be routed from first syntactic foam piece 142A, through hollow elongate members 104A and 104B, and through second syntactic foam piece 142B.

[0063]

[0081] According to some embodiments, after the resin 138 solidifies at block 1310, the low-density spheres 120 and the resin 138 form the syntactic foam component 142, and the syntactic foam component 142 and the elongated member 104 form the device 100. As shown in FIG. 13 , the method 1300 may further include removing the syntactic foam component 142 from the mold 102 (block 1312). In some embodiments, the method 1300 also includes removing the elongated member 104 from the mold 102 (block 1312), as shown in FIG. 5E . In some embodiments, the method 1300 includes removing the elongated member 104 from the mold 102 before removing the syntactic foam component 142. In some embodiments, the method 1300 includes filling any space within the syntactic foam component 142 previously occupied by the elongated member 104 with another material, such as foam. In other embodiments, the method 1300 includes removing 1312 the elongate member 104 and the syntactic foam part 142 from the mold 102, such that the apparatus 100 includes the syntactic foam part 142 and the elongate member 104 partially embedded within the syntactic foam part 142, as shown in Figures 1A-4B and 6-12. In certain embodiments, any resin 138 that coated the interior surface of the mold 102 may be removed along with the syntactic foam part 142, which may then be removed from the part or form part of the part.

[0064]

[0082] Referring back to FIG. 6 , in some embodiments, a device 600 includes an elongated member 104 at least partially embedded within low-density spheres 120. In some embodiments, the device 600 includes one or more caps 118 configured to cover and / or seal the first end 106 and the second end 108 of the elongated member 104. In some embodiments, the cap 118 is not removable from the elongated member 104. For example, the cap 118 is welded onto the elongated member 104. In other embodiments, the cap 118 is removable from the elongated member 104. The cap 118 and / or the ends 106 and 108 include portions configured to mate with each other, such as threaded portions. The elongated member 104 is substantially hollow, and the ends 106 and 108 are open-ended. Thus, the caps 118 serve to seal the ends 106 and 108 from the outer casing 110 and / or prevent the fluid 114 from flowing out of the elongated member 104. In some embodiments, the method 1300 includes covering the first end 106 and the second end 108 with the cap 118 after the resin 138 has solidified.

[0065]

[0083] 7 , in some embodiments, an apparatus 700 includes an elongated member 104 at least partially embedded within low-density spheres 120. In some embodiments, the elongated member 104 is substantially hollow, and a method 1300 includes forming a foam within the elongated member 104 by introducing additional low-density spheres 120 and / or resin into the elongated member 104. In some embodiments, the method 1300 also includes covering the first end 106 and / or the second end 108 with a cap 118 after forming the foam.

[0066]

[0084] 3-4B, several embodiments of the present disclosure include systems 300 and 400 having multiple devices 100A, 100B having syntactic foam components 142A, 142B connected via elongate members 104A, 104B.

[0067]

[0085] Referring to Figure 3, system 300 includes a first device 100A and a second device 100B. First device 100A includes a first syntactic foam component 142A and a first elongated member 104A. Second device 100B includes a second syntactic foam component 142B and a second elongated member 104B. Each of first elongated member 104A and second elongated member 104B is at least partially embedded within their respective syntactic foam components 142A and 142B. Second elongated member 104B is coupled to first elongated member 104A.

[0068]

[0086] In various embodiments, method 1300 includes placing first elongate member 104A in mold 102 during the formation of device 100A, and placing second elongate member 104B in mold 102 or an additional mold during the formation of device 100B. This is done such that when first syntactic foam piece 142A is substantially aligned with second syntactic foam piece 142B, first elongate member 104A is substantially aligned with second elongate member 104B.

[0069]

[0087] In one or more embodiments, the first elongate member end 106A is coupled to the second elongate member end 108B within the sheath 110 of the first syntactic foam piece 142A and the second syntactic foam piece 142B. The first elongate member 104A and the second elongate member 104B are directly coupled to one another. In some embodiments, the first elongate member 104A and the second elongate member 104B include portions at their ends 106A and 108B, such as threaded portions, configured to mate with one another.

[0070]

[0088] In some embodiments, first elongate member 104A also extends at least partially into second elongate member 142B and is coupled to second elongate member 104B within second syntactic foam piece 142B.

[0071]

[0089] 4A , in system 400, first elongate member 104A is not directly joined to second elongate member 104B, but instead is indirectly coupled to second elongate member 104B via connector 116. Connector 116 engages and extends between second second member end 108B and first first member end 106A, indirectly coupling second second member end 108B and first first member end 106A. In some embodiments, connector 116 is received by both first elongate member 104A and second elongate member 104B. When first syntactic foam component 142A and second syntactic foam component 142B do not contact each other, connector 116 is exposed to exterior sheath 110 of first syntactic foam component 142A and second syntactic foam component 142B.

[0072]

[0090] The connector 116 includes portions configured to mate with the first elongate member 104A and the second elongate member 104B. The mating portions include, for example, threaded portions. In some embodiments, the connector 116 has a tubular shape. In various embodiments, the connector 116 has a diameter smaller than the diameters of the first elongate member 104A and the second elongate member 104B. This allows the connector 116 to fit within the first elongate member 104A and the second elongate member 104B. Referring to FIG. 4B , in some embodiments, the connector 116 is at least partially embedded within the resin 138A of the first part and at least partially embedded within the resin 138B of the second part. In one or more embodiments, the connector 116 is substantially hollow. This allows fluids, wires, and / or hoses to be routed from the first elongate member 104A through the connector 116 and into the second elongate member 104B.

[0073]

[0091] In some embodiments, the connector 116 is removably coupled to the first elongate member 104A and the second elongate member 104B. In other embodiments, the connector 116 is fixed to the first elongate member 104A and the second elongate member 104B. The connector is fixed to the first elongate member 104A and the second elongate member 104B via, for example, adhesives, welding, soldering, brazing, crimping, and / or any combination thereof.

[0074]

[0092] In some embodiments, connector 116 is made of and / or includes foam. In other embodiments, connector 116 is made of the same material as first elongate member 104A and / or second elongate member 104B.

[0075]

[0093] Referring to FIG. 8 , in some embodiments, an apparatus 800 includes a syntactic foam component 142 and a plurality of elongate members 104A, 104C, 104D, 104E, and 104F. In some embodiments, first ends 106 of elongate members 104A, 104C, 104D, 104E, and 104F are exposed to exterior 110 of syntactic foam component 142. Elongate members 104A, 104C, 104D, 104E, and 104F each protrude from an outer surface 112A of the syntactic foam component. Referring to FIG. 10 , in a system 1000, each of elongate members 104A, 104C, 104D, 104E, and 104F are connected to one another within syntactic foam component 142 to form a single elongate member 104. In such embodiments, elongate member 104 includes not only first end 106 and second end 108, but potentially also third end 109. First end 106, second end 108, and third end 109 may, in some embodiments, be flush with and / or protrude from the same outer surface 112A. In other embodiments, first end 106 and second end 108 may be flush with and / or protrude from the same outer surface 112A, while third end 109 may be embedded within a syntactic foam piece and / or may be flush with or protrude from a different outer surface.

[0076]

[0094] 8 , in various embodiments, exposed end 106 includes inlets and / or outlets for introducing material into syntactic foam part 142 via elongate strips 104A, 104C, 104D, 104E, and 104F. The number of elongate strips 104A, 104C, 104D, 104E, and 104F is proportional to the volume of syntactic foam part 142. For syntactic foam part 142 with a larger volume, a greater number of elongate strips 104A, 104C, 104D, 104E, and 104F can help dissipate heat and control the temperature within part 142.

[0077]

[0095] 9 , in some embodiments, a device 900 includes a syntactic foam piece 142 having a plurality of elongate members 104A, 104C, 104D at least partially embedded therein. In some embodiments, the plurality of elongate members 104A, 104C, 104D each extend in directions substantially parallel to one another from a first end 106 to a second end 108. As used herein, "substantially parallel" includes directions within 5 degrees of one another.

[0078]

[0096] 12 , in some embodiments, a device 1200 includes a syntactic foam component 142, a first elongate member 104A, and a second elongate member 104C. Each of the first elongate member 104A and the second elongate member 104C is at least partially embedded within the syntactic foam component 142. In some embodiments, a first end 106A of the first member and a first end 106C of the second member protrude from the same first outer surface 112A, and a second end 108A of the first member and a second end 108C of the second member protrude from the first surface 112A and the adjacent second surface 112B. In various embodiments, the first elongate member 104A and / or the second elongate member 104C each include components that extend substantially perpendicular to one another within the syntactic foam component 142. In various embodiments, syntactic foam element 142 is the first foam element of the plurality of foam elements and is positioned centrally in the arrangement of the plurality of foam elements.

[0079]

[0097] In the above description, certain terms may be used, such as "up," "down," "upper," "lower," "horizontal," "vertical," "left," "right," "over," "under," etc. These terms are used where appropriate to provide some clarity to the description when referring to interrelationships. However, these terms are not intended to imply absolute relationships, positions, and / or orientations. For example, with respect to an object, the "upper" surface may become the "lower" surface simply by turning the object upside down. It is still the same object. Furthermore, the words "including," "comprising," "having," and variations thereof mean "including, but not limited to" (unless expressly stated otherwise). Listed items do not imply that any or all of the items are mutually exclusive and / or inclusive, unless expressly stated otherwise. Terms such as "a," "an," and "the" also refer to "one or more," unless expressly stated otherwise. Additionally, the term "plurality" may be defined as "at least two." Furthermore, unless expressly stated otherwise, as made clear herein, a plurality of a particular feature does not necessarily refer to every particular feature of a particular set or class.

[0080]

[0098] While in some embodiments, the terms "about" or "substantially" are defined to mean within + / - 5% of a given value, in further embodiments, any disclosure of "about" can be further narrowed and claimed to mean within + / - 4% of a given value, within + / - 3% of a given value, within + / - 2% of a given value, within + / - 1% of a given value, or the exact given value. Furthermore, when at least two values ​​of a variable are disclosed, such disclosure is specifically intended to include a range between the two values, whether or not disclosed in terms of separate embodiments or examples thereof, and is specifically intended to include a range up to and including at least the lower of the two values ​​and / or a range up to and including the higher of the two values. Furthermore, when at least three values ​​of a variable are disclosed, such disclosure is specifically intended to include ranges between any two of the values, whether or not they are disclosed with respect to separate embodiments or examples, and is specifically intended to include ranges up to and including at least value A and / or value B, where A can be any of the disclosed values ​​other than the maximum disclosed value, and B can be any of the disclosed values ​​other than the minimum disclosed value.

[0081]

[0099] Furthermore, in this specification, an instance where one element is "coupled" to another element may include direct and indirect coupling. A direct coupling may be defined as one element being connected to another element and being in some contact with the other element. An indirect coupling may be defined as a coupling between two elements that are not in direct contact with each other but have one or more additional elements between the coupled elements. Furthermore, in this specification, fixing one element to another element may include direct fixing and indirect fixing. Additionally, in this specification, "adjacent" does not necessarily mean contact. For example, one element may be adjacent to another element without touching the other element.

[0082]

[0100] As used herein, the phrase "at least one of" when used in conjunction with a list of items means that various combinations of one or more of the listed items can be used, and that only one of the listed items may be required. An item may be a specific object, article, or category. In other words, "at least one of" means that any combination or number of items from the list can be used, but not all of the listed items are required. For example, "at least one of item A, item B, and item C" may mean, for example, "item A," "item A and item B," "item B," "item A, item B, and item C," or "item B and item C." In some cases, "at least one of item A, item B, and item C" may mean, by way of example and not limitation, "two item A, one item B, and ten item C," "four item B, and seven item C," or other suitable combinations.

[0083]

[0101] Unless otherwise indicated, the terms "first," "second," etc. are used herein merely as designators and are not intended to impose any sequential, positional, or hierarchical requirements on the items they refer to. Furthermore, a reference to, e.g., a "second" item does not require or exclude the presence of, e.g., a "first" or lower numbered item and / or, e.g., a "third" or higher numbered item.

[0084]

[0102] As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function does not mean that it is, in fact, capable of performing the specified function without any modification and is merely likely to perform the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, the phrase "configured to" means that there are characteristics of the system, device, structure, article, element, component, or hardware that enable the system, device, structure, article, element, component, or hardware to perform a particular function without further modification. In this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being "configured to" perform a particular function may additionally or alternatively be described as being "adapted to" and / or "operative to" perform that function.

[0085]

[0103] The schematic flow diagrams included herein are generally defined as logical flow diagrams. As such, the depicted order and labeled steps represent one embodiment of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the depicted method. Furthermore, it is understood that the format and symbols employed are provided to illustrate the logical steps of the method and do not limit the scope of the method. While various types of arrows and lines may be used in the flow diagrams, it is understood that these do not limit the scope of the corresponding method. In fact, some arrows or other connectors may be used only to indicate the logical flow of the method. For example, arrows may indicate an indefinite amount of waiting or monitoring time between listed steps of the depicted method. Furthermore, the order in which a particular method is performed may or may not strictly follow the order of the corresponding steps depicted.

[0086]

[0104] The subject matter herein may be embodied in other specific forms without departing from its spirit and essential characteristics. The above-described embodiments are to be construed in all respects as merely illustrative and not restrictive. All changes that come within the meaning and range of equivalency of the claims are to be embraced therein.

Claims

1. An apparatus (100) comprising: a syntactic foam component (142) comprising low-density spheres (120) at least partially embedded in a resin (138); and an elongated member (104) partially embedded within said resin (138) and including a first end (106) and a second end (108); The device (100) has at least the first end (106) positioned relative to the syntactic foam component (142) so that the first end (106) is exposed to the exterior (110) of the syntactic foam component (142) at the outer surface (112A) of the syntactic foam component (142).

2. The apparatus (100) of claim 1, wherein the low density sphere (120) is substantially hollow.

3. 2. The apparatus (100) of claim 1, wherein the first end (106) is flush with or protrudes from the outer surface (112A).

4. the outer surface (112A) is a first outer surface; 4. The apparatus (100) of claim 3, wherein the second end (108) is positioned relative to the syntactic foam component (142) so that the second end (108) is exposed to the exterior (110) of the syntactic foam component (142) at a second outer surface (112B) of the syntactic foam component (142).

5. The apparatus (100) of claim 4, wherein the first outer surface (112A) and the second outer surface (112B) are on the same side of the syntactic foam component (142).

6. The apparatus (100) of claim 4, wherein the first outer surface (112A) is opposite the second outer surface (112B) of the syntactic foam component (142).

7. The apparatus (100) of claim 1, wherein the elongated member (104) is made of at least one of a metallic material, a ceramic material, or a composite material.

8. 2. The apparatus (100) of claim 1, wherein the elongated member (104) is substantially hollow such that a thermally conductive fluid can flow through the elongated member (104) between the first end (106) and the second end (108).

9. The apparatus (100) of claim 1, wherein the elongated member (104) is made of an electrically conductive material.

10. The elongated member (104) is a first member (104A), The device (900) further includes a second elongate member (104B) including a first second member end (105) and a second second member end (107); 2. The apparatus (900) of claim 1, wherein the end (105) of the first second member is positioned relative to the syntactic foam component (142) so that the end (105) of the first second member is exposed to the exterior (110) of the syntactic foam component (142).

11. The apparatus (100) of claim 1, wherein the elongated member (104) extends entirely through the syntactic foam component (142).

12. A system (300), comprising: a first syntactic foam component (142A) comprising a first set of low-density spheres (120) at least partially embedded in a first resin (138A); a first elongated member (104A) partially embedded within the first resin (138A) and including a first first member end (106A) and a second first member end (108A), wherein at least the first first member end (106A) is positioned relative to the first syntactic foam piece (142A) such that the first first member end (106A) is exposed to the exterior sheath (110) of the first syntactic foam piece (142A) at an outer surface (112A) of the first syntactic foam piece (142A); a second syntactic foam component (142B) comprising a second set of low-density spheres (120) at least partially embedded in a second resin (138B); and A system (300) comprising a second elongated member (104B) partially embedded within the second resin (138B) and including a first second member end (106B) and a second second member end (108B), the second elongated member (104B) being coupled to the first elongated member (104A).

13. 13. The system (300) of claim 12, wherein the second second member end (108B) is selectively directly coupled to the first first member end (106A).

14. The system (400) further comprises a connector (116); 13. The system (400) of claim 12, wherein the second second member end (108B) is indirectly coupled to the first first member (106A) via the connector (116), the connector (116) engaging and extending between the second second member end (108B) and the first first member end (106A).

15. 15. The system (400) of claim 14, wherein the connector (116) is at least partially embedded within the first resin (138A).

16. A method (1300) of making a syntactic foam component (142), comprising: Loading low density spheres (120) into a mold (102); introducing an elongated member (104) into the mold (102) such that the elongated member (104) is at least partially embedded within the low-density spheres (120); introducing a resin (138) into said mold (102); embedding the low-density spheres (120) and a portion of the elongated member (104) embedded within the low-density spheres (120) in the resin (138); after embedding the low-density spheres (120) and the portions of the elongated members (104) embedded within the low-density spheres (120) in the resin (138), solidifying the resin (138); and removing the low density spheres (120) and the elongated member (104) from the mold (102).

17. The method of claim 16, further comprising removing the elongated member (104) from the syntactic foam component (142) after the resin (138) has solidified.

18. the elongated member (104) is substantially hollow and includes a first end (106) and a second end (108), the first end (106) and the second end (108) being open-ended; 17. The method of claim 16, further comprising covering at least one of the first end (106) and the second end (108) after the resin (138) has solidified.

19. 20. The method of claim 18, further comprising forming foam (122) within the elongated member (104) prior to covering the at least one of the first end (106) and the second end (108).

20. the elongated member (104) is substantially hollow; The method of claim 16, further comprising flowing a thermally conductive fluid (114) through the elongated member (104) while the resin (138) solidifies.

Images