Syntactic foams with reinforced large inclusions

Abstract

A syntactic foam is comprised of a polymer infusing matrix, a plurality of polymer beads or matrix cavities, and a plurality of interstitial microspheres. The polymer beads and matrix cavities have a width of 0.5-50 mm and are distributed throughout the infusing matrix. Each of the polymer beads or matrix cavities is surrounded by a polymer reinforcing binder containing bead-covering microspheres, and each of the matrix cavities is partially occupied by a polymer particle. The interstitial microspheres are distributed within the infusing matrix amongst the polymer beads or matrix cavities. The bead-covering microspheres have a size distribution of ±20 um or less. ±20 um or less. 20 25 27 15 30 28 N ov 2 02 5 S Y N T A C T I C F O A M S W I T H R E I N F O R C E D L A R G E I N C L U S I O N S 2 0 2 5 2 7 1 5 3 0 2 8 N o v 2 0 2 5 ± 2 0 u m o r l e s s .

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