Syntactic foam parts made with prefabricated syntactic foam components

Abstract

To provide a syntactic foam component and a corresponding method of making such a component.SOLUTION: A method of making a syntactic foam part includes loading a first prefabricated component into a mold. Thereby, a gap is defined between the first prefabricated component and at least one of the second prefabricated component in the mold and the inner circumference of the mold. The first prefabricated component comprises low density spheres embedded in a solidified first resin. The method also includes introducing a second resin into the gap. The method further includes solidifying the second resin after the second resin is introduced into the gap.SELECTED DRAWING: Figure 1E

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE

[0001] This disclosure relates generally to buoyancy foam, and more particularly to foam parts having prefabricated components. [Background technology]

[0002]

[0002] Lightweight foams are incorporated into components to facilitate their lightweight nature in higher density fluids. Some components incorporating lightweight foams include, but are not limited to, submarines, ships, oil rigs and their components, and other marine-based applications. Typical lightweight foams are water resistant, durable, reliable, and in some cases, pressure resistant. 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. Example 1 includes a method of making a syntactic foam part. The method includes loading a first prefabricated component into a mold, thereby defining a gap between the first prefabricated component and at least one of a second prefabricated component within the mold and an inner periphery of the mold. The first prefabricated component includes low-density spheres embedded in a solidified first resin. The method also includes introducing a second resin into the gap. The method further includes solidifying the second resin after the second resin is introduced into the gap.

[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 method includes depositing and solidifying a material along an inner periphery of a mold before loading a first prefabricated component into the mold, and forming an opening through the material. Introducing a second resin into the gap includes inserting the second resin through the opening.

[0007] The subject matter of the following paragraphs constitutes Example 3 of the present disclosure. According to Example 3, which encompasses Example 1 or 2 above, the second resin and the first prefabricated component after solidification form an intermediate part. The mold is a first mold, and the method further includes removing the intermediate part from the first mold. The method includes inserting the intermediate part into a second mold, depositing material in the second mold, and solidifying the material.

[0008] The subject matter of the following paragraphs constitutes Example 4 of the present disclosure. According to Example 4, which includes any one of Examples 1 to 3, the method includes introducing second low-density spheres into the gap together with a second resin. The second low-density spheres are thereby embedded in the second resin. Solidifying the second resin includes solidifying the second resin with the second low-density spheres embedded in the second resin.

[0009]

[0009] The subject matter of the following paragraphs constitutes Example 5 of the present disclosure. According to Example 5, which encompasses any one of Examples 1 to 4 above, the first prefabricated component includes a spacer extending from a side of the first prefabricated component by a distance corresponding to a desired gap between the first prefabricated component and at least one of the second prefabricated component and the inner periphery of the mold. The spacer engages with the corresponding one of the second prefabricated components and the inner periphery of the mold to maintain the first prefabricated component at the desired gap from the corresponding one of the second prefabricated components and the inner periphery of the mold.

[0010]

[0010] The subject matter of the following paragraphs constitutes Example 6 of the present disclosure. According to Example 6, which encompasses Example 5 above, the desired gap is between 0.1 centimeters (cm) and 1.5 cm, inclusive.

[0011] The subject matter of the following paragraphs constitutes Example 7 of the present disclosure. According to Example 7, which includes any one of Examples 1 to 6 above, the second resin fills gaps when introduced into a mold.

[0012] The subject matter of the following paragraphs constitutes Example 8 of the present disclosure. According to Example 8, which includes any one of Examples 1 to 7 above, the first pre-fabricated component and the second pre-fabricated component are pre-fabricated components of a plurality of pre-fabricated components. Loading the first pre-fabricated component into the mold includes loading the plurality of pre-fabricated components into an internal cavity of the mold. When loaded into the internal cavity of the mold, the pre-fabricated components occupy at least 25% of a total volume of the internal cavity.

[0013] The subject matter of the following paragraphs constitutes Example 9 of the present disclosure. According to Example 9, which includes any one of Examples 1 to 8 above, the method includes forming a third prefabricated component. The third prefabricated component has at least one of the following: a density greater than the densities of the first prefabricated component and the second prefabricated component, a strength greater than the strengths of the first prefabricated component and the second prefabricated component, or a durability greater than the durability of the first prefabricated component and the second prefabricated component. The method includes loading the third prefabricated component into a mold. A gap is further defined between the third prefabricated component and at least one of the first prefabricated component and the second prefabricated component.

[0014] The subject matter of the following paragraphs constitutes Example 10 of the present disclosure. According to Example 10, which encompasses Example 9 above, the third prefabricated component includes a plurality of third prefabricated components. The plurality of third prefabricated components are loaded into a mold. The plurality of third prefabricated components are thereby closer to the inner periphery of the mold than the first prefabricated component and the second prefabricated component are to the inner periphery of the mold.

[0015] The subject matter of the following paragraphs constitutes Example 11 of the present disclosure. Multiple examples of the present disclosure include a syntactic foam part. The syntactic foam part includes prefabricated components. Each prefabricated component has low-density spheres at least partially embedded in a first resin. The prefabricated components are arranged such that a gap is defined between at least two adjacent ones of the prefabricated components. The syntactic foam part also includes a second resin disposed within the gap.

[0016]

[0016] The subject matter of the following paragraphs constitutes Example 12 of the present disclosure. According to Example 12, which encompasses Example 11 above, a second resin bonds pre-fabricated components together.

[0017] The subject matter of the following paragraphs constitutes Example 13 of the present disclosure. According to Example 13, which encompasses Examples 11 or 12 above, the syntactic foam part includes second low-density spheres embedded in a second resin within a void space. The second resin and the second low-density spheres thereby fill the void space.

[0018] The subject matter of the following paragraphs constitutes Example 14 of the present disclosure. According to Example 14, which can include any one of Examples 11 to 13, the syntactic foam part includes a spacer extending from a side of a first one of the prefabricated components and contacting a side of a second one of the prefabricated components.

[0019] The subject matter of the following paragraphs constitutes Example 15 of the present disclosure. According to Example 15, which encompasses Example 14, a spacer provides at least one of thermal conductivity or electrical conductivity between the first prefabricated component and the second prefabricated component.

[0020] The subject matter of the following paragraphs constitutes Example 16 of the present disclosure. According to Example 16, which can include any one of Examples 11 to 15, the foam part includes several additional prefabricated components. Each one of the several additional prefabricated components has at least one of a density greater than the density of the prefabricated component, a strength greater than the strength of the prefabricated component, or a durability greater than the durability of the prefabricated component. A distance between each one of the several additional prefabricated components and an outer surface of the syntactic foam part is less than a distance between any one of the prefabricated components and the outer surface of the syntactic foam part.

[0021] The subject matter of the following paragraphs constitutes Example 17 of the present disclosure. According to Example 17, which encompasses Examples 11 to 16 above, each one of the prefabricated components has a shape that is the same as or substantially similar to one of a triangular prism, a pyramid, a rectangular-based prism, a rod, a cylinder, a sphere, a dodecahedron, a hexagonal prism, or a cube.

[0022]

[0022] The subject matter of the following paragraphs constitutes Example 18 of the present disclosure. According to Example 18, which includes any one of Examples 11 to 17 above, at least one of the prefabricated components includes an electronic component.

[0023]

[0023] The subject matter of the following paragraphs constitutes Example 19 of the present disclosure. According to Example 19, which includes any one of Examples 11 to 18 above, the low-density spheres are substantially hollow.

[0024] The subject matter of the following paragraphs constitutes Example 20 of the present disclosure. According to Example 20, which includes any one of Examples 11 to 19 above, at least one of the prefabricated components has a shape that is different from the overall shape of the syntactic foam part.

[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 front elevation cross-sectional view of a prefabricated component according to one or more embodiments of the present disclosure. [Figure 1B]

[0028] FIG. 1 is a front elevation cross-sectional view of a mold according to one or more embodiments of the present disclosure. [Figure 1C]

[0029] FIG. 1 is a cross-sectional front elevation view of a prefabricated component loaded into a mold in accordance with one or more embodiments of the present disclosure. [Figure 1D]

[0030] FIG. 1 is a front elevation cross-sectional view of resin being introduced into a mold in accordance with one or more embodiments of the present disclosure. [Figure 1E]

[0031] FIG. 1 is a cross-sectional front elevation view of a foam component according to one or more embodiments of the present disclosure. [Figure 1F]

[0032] FIG. 1 is a cross-sectional front elevation view of a foam component being introduced into a mold in accordance with one or more embodiments of the present disclosure. [Figure 1G]

[0033] FIG. 1 is a cross-sectional front elevation view of a foam component including a solidifying material according to one or more embodiments of the present disclosure. [Figure 2]

[0034] FIG. 1 is a top perspective view of a foam component according to one or more embodiments of the present disclosure. [Figure 3]

[0035] FIG. 1 is a cross-sectional front elevation view of a foam part having a pre-fabricated component in the shape of a triangular prism, according to one or more embodiments of the present disclosure. [Figure 4]

[0036] FIG. 1 is a cross-sectional front elevation view of a foam part having a spherically shaped pre-fabricated component according to one or more embodiments of the present disclosure. [Figure 5A]

[0037] 1A-1C are schematic diagrams illustrating steps in a method for forming a foam part with prefabricated components according to one or more embodiments of the present disclosure. [Figure 5B]

[0038] 10 is a schematic diagram illustrating another step of a method for forming a foam part with prefabricated components according to one or more embodiments of the present disclosure. FIG. [Figure 5C]

[0039] 10 is a schematic diagram illustrating yet another step of a method for forming a foam part with prefabricated components according to one or more embodiments of the present disclosure. FIG. [Figure 5D]

[0040] 10 is a schematic diagram illustrating a further step of a method for forming a foam part with prefabricated components according to one or more embodiments of the present disclosure. FIG. [Figure 5E]

[0041] FIG. 10 is a schematic diagram illustrating an additional step of a method for forming a foam part with prefabricated components, according to one or more embodiments of the present disclosure. [Figure 5F]

[0042] 10 is a schematic diagram illustrating another step of a method for forming a foam part with prefabricated components according to one or more embodiments of the present disclosure. FIG. [Figure 5G]

[0043] 10 is a schematic diagram illustrating yet another step of a method for forming a foam part with prefabricated components according to one or more embodiments of the present disclosure. FIG. [Figure 6]

[0044] FIG. 1 is a front elevation schematic diagram of a foam component having prefabricated components and electronic components according to one or more embodiments of the present disclosure. [Figure 7]

[0045] 1 is a schematic flow chart of a method of making a 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. The resin is then cured. As the resin cures, it releases heat. If the size of the syntactic foam part is too large, the released heat cannot easily escape from the syntactic foam part because foam has poor thermal conductivity. This localized temperature increase increases the cure rate and accelerates heat generation by the resin. Therefore, current methods are limited in the size of the syntactic foam part that can be produced.

[0030]

[0048] Described herein are several examples of methods for making syntactic foam parts made of low-density spheres embedded in resin. These examples mitigate thermal issues without the size limitations of conventional methods. By implementing the methods, the syntactic foam parts are not subject to the same size limitations as conventional syntactic foam parts. The methods can also result in syntactic foam parts with components having different chemical or physical properties. Certain examples of the methods include loading pre-fabricated components into a mold. The pre-fabricated components include a syntactic foam part. Certain methods include introducing resin into gaps between the pre-fabricated components in the mold and allowing the resin to solidify.

[0031]

[0049] According to some embodiments, a method 700 for making a syntactic foam part, such as intermediate syntactic foam part 141 of FIG. 1E , syntactic foam part 142 of FIG. 1G , syntactic foam part 242 of FIG. 2 , syntactic foam part 342 of FIG. 3 , and / or syntactic foam part 642 of FIG. 6 , is shown in FIG. 7 . Referring generally to FIG. 7 and particularly to FIGS. 1C and 5E , method 700 includes loading pre-fabricated components 104 into a first mold 102A (block 702). In some embodiments, each one of the pre-fabricated components 104 includes low-density spheres 120 (see, e.g., FIGS. 1A and 2 ) embedded in a first resin 138. The first resin 138 has been cured. While FIGS. 1C and 5E depict multiple pre-fabricated components 104, embodiments of the present disclosure are not limited thereto. In some embodiments, only the first pre-fabricated component 104A is loaded into the mold 102, and the syntactic foam parts 141 and / or 142 only include a single pre-fabricated component 104A.

[0032]

[0050] In various embodiments, the method 700 includes forming each of the prefabricated components 104 by loading the low-density spheres 120 into a smaller mold. In some embodiments, the method 700 includes introducing a first resin 138 into the smaller mold and curing the first resin 138. In some further embodiments, the method 700 includes introducing the first resin 138 into the smaller mold so that the first resin 138 coats the low-density spheres 120. In certain embodiments, the prefabricated components 104 are then cured, removed from the smaller mold, and introduced into the first mold 102A along with the other prefabricated components 104.

[0033]

[0051] 1A and 5A, in some embodiments, one or more of the prefabricated components 104 have a shape substantially similar to a rectangular-based prism. In some embodiments, one or more of the prefabricated components 104 have a shape that is the same as or substantially similar to at least one of the following: a triangular prism, a pyramid, a rectangular-based prism, a rod, a cylinder, a sphere, a dodecahedron, a hexagonal prism, a cube, and / or combinations thereof. In some embodiments, the prefabricated components 104 have a shape that at least partially surrounds a portion of a cylinder. At least one prefabricated component 104 includes a surface with a curvature that substantially corresponds to the circumference of a cylinder, such as the circumference of a cylindrically shaped prefabricated component 104. In various embodiments, at least one prefabricated component has a shape substantially similar to a rectangular-based prism and / or a triangular prism, except for the portion that is curved to correspond to the curvature of the cylinder. In some embodiments, at least one prefabricated component 104 includes a portion having a shape corresponding to the exterior surface of a sphere. At least one prefabricated component 104 may include a prefabricated component 104 in the shape of a rectangular base prism having a portion configured to at least partially surround a portion of a sphere, such as another prefabricated component 104 having a shape substantially similar to a sphere. The prefabricated components 104 may each have a substantially similar shape to one another. In other embodiments, the prefabricated components 104 have a variety of different shapes.

[0034]

[0052] Each one of the prefabricated components 104, in some embodiments, includes a component made of syntactic foam. In some embodiments, each one of the prefabricated components 104 has similar physical and / or chemical properties. In other embodiments, the prefabricated components 104 have different physical and / or chemical properties. In various embodiments, the prefabricated components 104 are made of a material selected to attenuate noise and / or absorb specific frequencies. In some embodiments, the prefabricated components 104 are coated with a material, such as a thermally and / or electrically conductive material.

[0035]

[0053] The first resin 138 can be any of a variety of resins that help coat, embed, and / or adhere the low-density spheres. According to some embodiments, the first resin 138 is one or more of a pure resin material (e.g., epoxy resin), a preceramic resin (e.g., 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 coating of the low-density spheres.

[0036]

[0054] In some embodiments, the mold 102 includes a selectively openable and closable lid that selectively covers an opening in the mold 102 through which a pre-fabricated component 104 can be loaded into the mold 102. With reference to FIGS. 1B and 1C, the mold 102 can be a first mold 102A that includes an internal cavity 124 and an inner periphery 106 that surrounds the internal cavity 124. With reference to FIG. 5D, in some embodiments, the first mold 102A includes one or more openings 110 through which the pre-fabricated component 104 can be introduced into the first mold 102A. With reference to FIG. 5C, in some embodiments, a method 700 includes depositing and solidifying a pre-hardened material 109 along the inner periphery 106 of the first mold 102A before loading the pre-fabricated component 104 into the first mold 102A. Method 700 may also include forming openings 110 through pre-cured material 109. In various embodiments, pre-cured material 109 becomes part of the final syntactic foam part 142 product. In these embodiments, method 700 includes removing pre-cured material 109 from first mold 102A along with pre-fabricated component 104 and solidified second resin 140 (such as the solidified second resin 140 shown in FIG. 1D ). In some embodiments, pre-cured material 109 is a pre-cured foam material.

[0037]

[0055] 1C , a gap 132 is defined between a first prefabricated component 104A of the prefabricated components 104 and at least one of (1) a second prefabricated component 104B of the prefabricated components 104, and (2) the inner periphery 106 of the mold 102. Because the drawing shows the prefabricated components 104 in two-dimensional space, each gap 132 is shown as being defined by only two of the prefabricated components 104. However, as can be appreciated, the arrangement of the prefabricated components 104, when considered in three-dimensional space, may have prefabricated components 104 entering and / or exiting the page. Thus, in three-dimensional space, each gap 132 may be further defined by one or two additional prefabricated components 104.

[0038]

[0056] 1B-1D and 5B-5E, in some embodiments, the first mold 102A forms part of a molding tool. The molding tool further includes a resin introduction system operable to introduce a second resin 140 (see, for example, FIG. 1D) into the internal cavity 124 of the first mold 102A. In some embodiments, the first resin introduction system includes an inlet and / or an outlet. The inlet is operable to introduce the second resin 140 from a supply of the introduction system into the internal cavity 124. The outlet is operable to evacuate excess resin from the internal cavity 124. Each one of the inlets and outlets may include a valve selectively operable to regulate the flow of the second resin 140 into and out of the internal cavity 124, respectively.

[0039]

[0057] The size and shape of the internal cavity 124 of the first mold 102A defines the size and shape of the intermediate syntactic foam part 141. In some embodiments, the size and shape of the internal cavity 124 may depend on the size of the prefabricated component 104, or vice versa. Note that the prefabricated component 104, low-density spheres 120, and first mold 102A are not necessarily drawn to scale. For example, in the depicted representation, the size of the low-density spheres 120 is exaggerated relative to the size of the prefabricated component 104 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 prefabricated component 104 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.

[0040]

[0058] According to some embodiments, each or at least one of the low-density spheres 120 is a hollow sphere. A hollow sphere has a thin-walled structure. In other words, the thickness of the sidewall is less than the diameter of the low-density sphere 120. In some embodiments, the ratio of thickness to diameter is between 0.001 and 0.1, inclusive, such as between 0.01 and 0.1, inclusive, in one embodiment, and between 0.02 and 0.08, inclusive, in another embodiment. The hollow sphere may be made of any of a variety of materials, including, but not limited to, glass, ceramic, or polymer. In alternative embodiments, each or at least one of the low-density spheres 120 is a solid foam sphere. This 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 spheres is one or more of polystyrene foam, expanded polystyrene (EPS) foam, polyethylene foam, polyurethane foam, and / or any of a variety of other types of foam.

[0041]

[0059] 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 A hollow or solid sphere having a density between .

[0042]

[0060] Although not shown, in some embodiments, the low-density spheres 120 may be pre-coated with a uniform coating before being loaded into a smaller mold. The uniform coating has a consistent (i.e., non-varying) thickness throughout the sphere. The uniform coating may be made of any of a variety of materials, including, but not limited to, preceramic materials, polymers, ceramics, etc. In some cases, such as when the low-density spheres 120 are solid foam spheres, the uniform coating may provide strength and / or enhanced thermal stability to the underlying spheres.

[0043]

[0061] In some embodiments, all of the prefabricated components 104 loaded into the first mold 102A in block 702 have the same size. However, in other embodiments, such as shown in FIG. 1C, the prefabricated components 104 loaded into the first mold 102A in block 702 may have different sizes and be loaded into the mold 102 at different times corresponding to their sizes.

[0044]

[0062] In some embodiments, when the prefabricated component 104 is introduced into the internal cavity 124 of the first mold 102A, it occupies at least 25% of the total volume of the internal cavity 124. In some embodiments, the prefabricated component 104 occupies 25% or more and 99% or less of the total volume of the internal cavity 124. In some embodiments, the prefabricated component 104 occupies 50% or more and 99% or less of the total volume of the internal cavity 124.

[0045]

[0063] 7 generally and 1D and 5F specifically, the method 700 further includes introducing (block 704) the second resin 140 into the first mold 102A. In some embodiments, the method 700 includes introducing 704 the second resin 140 into the first mold 102A after the prefabricated component 104 is loaded into the first mold 102A in block 702. In other embodiments, the method 700 includes loading 702 the prefabricated component 104 and simultaneously introducing the second resin 140 into the first mold 102A.

[0046]

[0064] In some embodiments, the second resin 140 is passively gravity-fed through the first mold 102A in a generally top-to-bottom direction. However, in other embodiments, the flow of the second resin 140 through the first mold 102A is actively pushed and / or actively pulled to urge the second resin 140 to flow in a generally top-to-bottom direction from the top of the first mold 102A to the bottom of the first mold 102A. According to one embodiment, the second resin 140 may be actively pushed via positive pressure introduced at the bottom of the first mold 102A, such as via a positive pressure device (e.g., a blower, a compressor, etc.). In a further embodiment, the second resin 140 may be actively pulled via negative pressure introduced at the top of the first mold 102A, such as via a negative pressure device (e.g., a vacuum device). In some embodiments, rather than flowing from the bottom to the top of the first mold 102A, the second resin 140 flows and / or is actively pushed from the side of the first mold 102A into the internal cavity 124, such as through the opening 110 shown in FIG. 5F.

[0047]

[0065] The second resin 140 can be any of a variety of resins that help encapsulate and immobilize the low-density spheres 120. According to some embodiments, the second resin 140 is one or more of a pure resin material (e.g., an epoxy resin), a resin matrix composite (i.e., a reinforcing material embedded within a matrix material), a high modulus polymer (e.g., a nanoceramic-loaded polymer), a colloidal silica nanoparticle-loaded resin, a vinyl ester resin, a polyester resin, 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 140 includes a density-reducing component, such as smaller, low-density spheres (e.g., glass spheres), which helps reduce the density of the second resin 140 without compromising its strength.

[0048]

[0066] In some embodiments, second resin 140 is made of the same and / or similar material as first resin 138. In other embodiments, second resin 140 is different from first resin 138. For example, second resin 140 is a different type of resin than first resin 138 or is configured differently from first resin 138. For example, first resin 138 may be stronger, denser, and / or more durable than second resin 140. In other embodiments, second resin 140 is stronger, denser, and / or more durable than first resin 138. According to some embodiments, the curing temperature of first resin 138 is lower than the curing temperature of second resin 140. This configuration allows first resin 138 to be cured at a temperature that does not damage low-density spheres 120. When cured, first resin 138 may be stronger, denser, and / or more durable than low-density spheres 120, protecting the integrity of low-density spheres 120 when second resin 140 is infused and / or cured at a higher temperature, such as a temperature that would otherwise soften or damage low-density spheres 120. Thus, in certain embodiments, the first curing temperature is below the softening temperature of low-density spheres 120, and the second curing temperature is above the softening temperature of low-density spheres 120. The softening temperature may be the temperature at which the spheres soften to the point where they can no longer support a mechanical load.

[0049]

[0067] In one or more embodiments, prefabricated components 104 have a stiffness and / or strain capacity that matches the stiffness and / or strain capacity of other prefabricated components 104. In various embodiments, prefabricated components 104 have a stiffness and / or strain capacity that matches the stiffness and / or strain capacity of second resin 140. These embodiments improve the overall strength of syntactic foam part 142 and help prevent fracture during compression.

[0050]

[0068] In various embodiments, introducing 704 the second resin 140 into the gap 132 (see, for example, FIG. 1D ) includes introducing an additional number of low-density spheres 128 into the gap 132 along with the second resin 140. The additional number of low-density spheres 128 are embedded within the second resin 140. The additional number of low-density spheres 128 fill the gap 132 along with the second resin 140. In various embodiments, solidifying the second resin 140 includes forming a foam material made of the second resin 140 and the additional number of low-density spheres 128.

[0051]

[0069] In some embodiments, the method 700 includes introducing an additional number of low-density spheres 128 into the first mold 102A before introducing the second resin 140 into the first mold 102A. An additional number of low-density spheres 128 may also be introduced into the first mold 102A before the pre-fabricated component 104 is introduced into the first mold 102A.

[0052]

[0070] 1C, 1D, 5E, and 5F, the second resin 140 fills the gap 132 when introduced into the mold 102. In various embodiments, the second resin 140 surrounds at least a portion of the prefabricated component 104, filling the gap 132 between the inner periphery 106 and the prefabricated component 104. In some embodiments, the prefabricated component 104 is coated with the second resin 140 as the second resin 140 flows through the first mold 102A and contacts the side surface 118 of the prefabricated component 104. When the second resin 140 is introduced into the first mold 102A, the second resin 140, the additional low-density spheres 128, and the prefabricated component 104 together occupy 95% or more of the volume of the internal cavity 124. In some embodiments, second resin 140, additional low-density spheres 128, and pre-fabricated components 104 together occupy 100% of the volume of interior cavity 124. Second resin 140 bonds pre-fabricated components 104 together to form the final product (e.g., intermediate syntactic foam part 141 and / or syntactic foam part 142).

[0053]

[0071] The method of introducing the second resin 140 may promote adhesion of the second resin 140 to the prefabricated component 104 and coating of the second resin 140 onto the prefabricated component 104. Referring to FIG. 6 , according to some embodiments, to promote adhesion of the second resin 140 to the exterior surface, the method 700 may also include applying an adhesion promoter onto the side 118 of the prefabricated component 104 before the second resin 140 is introduced into the first mold 102A. In some embodiments, the adhesion promoter is aspirated or vaporized and sprayed into the first mold 102A. The adhesion promoter or wetting agent may be any of a variety of agents configured to promote adhesion, including, but not limited to, silanes.

[0054]

[0072] In some embodiments, the method 700 includes introducing a non-foaming material into the first mold 102A before solidifying the second resin 140. The non-foaming material includes, for example, a composite material that is added to the edges of the prefabricated component 104 to help reinforce the prefabricated component 104 and prevent damage.

[0055]

[0073] 7 and 1E and 5G in particular, the method 700 further includes solidifying the second resin 140 (block 706) as part of a solidification process (e.g., a curing process) of the second resin 140. In certain embodiments, the second resin 140 solidifies at room temperature without additional external heat. However, in other embodiments, the tool includes one or more heaters configured to generate and direct heat into the mold 102. Solidifying 706 the second resin 140 includes changing the state of the second resin 140 from one state to a harder state (e.g., from a flowable or semi-flowable state to a non-flowable state), for example, changing the second resin 140 from a fluid to a solid. According to one embodiment, solidifying 706 the second resin 140 includes partially or fully curing or drying the second resin 140. Fully curing the second resin 140 may include raising the temperature of the second resin 140 to the curing temperature of the second resin 140. The internal cavity 124 of the first mold 102A may be pressurized to facilitate complete filling of the internal cavity 124 with the second resin 140. In alternative embodiments, the second resin 140 is partially or fully cured via alternative methods, such as radiation treatment of the second resin 140 (e.g., ultraviolet treatment, electron beam treatment, X-ray treatment, etc.). The solidification of the second resin 140 may be irreversible (e.g., the second resin 140 is a thermosetting material) or irreversible (e.g., the second resin 140 is a thermoplastic material). When the second resin 140 is a pre-ceramic resin, solidifying the second resin 140 in block 706 may include converting the pre-ceramic resin to a ceramic resin. According to one embodiment, the second resin 140 may be an electrically and / or thermally conductive resin, whereby electrical and / or thermal connectivity may be established through the components if desired.

[0056]

[0074] In some embodiments, without limitation, the solidification temperature of second resin 140 is between 21° C. (i.e., room temperature) and 232° C., inclusive, such as between 21° C. and 180° C., inclusive, in one particular embodiment, between 21° C. and 125° C., inclusive, in another particular embodiment, and between 21° C. and 65° C., inclusive, in yet another particular embodiment. Second resin 140 is held at the solidification temperature for a predetermined period of time (and / or second resin 140 may undergo multiple identical or different cure cycles associated with particular temperatures and ramp rates) to effect solidification of second resin 140.

[0057]

[0075] According to some embodiments, after second resin 140 solidifies in block 706, prefabricated component 104 and second resin 140 form an intermediate syntactic foam part 141, an example of which is shown in FIG. 1E. Intermediate syntactic foam part 141 includes multiple layers of prefabricated component 104. As shown in FIG. 1E, method 700 may further include removing intermediate syntactic foam part 141 from first mold 102A. After being removed from first mold 102A, intermediate syntactic foam part 141 may form a stand-alone part or may be combined with one or more other parts or components to form a larger or more complex part.

[0058]

[0076] In some embodiments, the intermediate syntactic foam piece 141 is a three-dimensional piece, such as the syntactic foam piece 242 shown in Figure 2. In various embodiments, the intermediate syntactic foam piece 141 has a volume of 0.0023 cubic meters (m 3 ) and 0.4m 3 and one or more of the prefabricated components 104 has a volume between 0.00001 and 0.003 m, inclusive. 3 For example, in one particular embodiment, 0.00015 m inclusive. 3 and 0.002m 3 It has a volume between

[0059]

[0077] As shown in FIG. 1F , the mold 102 can be a second mold 102B. After the intermediate syntactic foam component 141 is removed from the first mold 102A, the intermediate syntactic foam component 141 can be introduced into the second mold 102B. In some embodiments, the method 700 includes placing the first mold 102A with the intermediate syntactic foam component 141 into the second mold 102B and then removing the first mold 102A. In some embodiments, multiple intermediate syntactic foam components 141 are introduced into the second mold 102B. The method, in certain embodiments, includes depositing a reinforcing material 108 into the second mold 102B, such that the reinforcing material 108 fills the space between the outer surface 112 of the intermediate syntactic foam component 141 and the second mold 102B. The reinforcing material 108 solidifies. The reinforcing material 108 and intermediate syntactic foam part 141 comprise the final syntactic foam part 142. The method includes removing the syntactic foam part 142 from the second mold 102B. In some embodiments, the reinforcing material 108 comprises a foam material. The reinforcing material 108 may be stronger, more durable, and / or denser than the pre-fabricated component 104 and / or the second resin 140.

[0060]

[0078] In some embodiments, the first mold 102A and the second mold 102B are different molds, but in other embodiments, the first mold 102A and the second mold 102B are the same mold.

[0061]

[0079] 1F-4, 5E-5G, and 6, in some embodiments, pre-fabricated components 104 include first pre-fabricated component 104A, second pre-fabricated component 104B, third pre-fabricated component 104C, and fourth pre-fabricated component 104D. In these embodiments, method 700 includes forming third pre-fabricated component 104C.

[0062]

[0080] In some embodiments, a third pre-fabricated component 104C and a fourth pre-fabricated component 104D are loaded into the first mold 102A, such that the third pre-fabricated component 104C and the fourth pre-fabricated component 104D are peripheral pre-fabricated components. A distance 134 between the third pre-fabricated component 104C and the inner periphery 106 of the first mold 102A is less than a distance 135 or 136 between the second pre-fabricated component 104B and the inner periphery 106 of the first mold 102A and / or the outer surface 112 of the syntactic foam part 142.

[0063]

[0081] In some embodiments, the third pre-fabricated component 104C has a higher density than another pre-fabricated component 104 disposed further from the inner periphery 106 of the first mold 102A, such as the first pre-fabricated component 104A. The third pre-fabricated component 104C is made of a different material than the first pre-fabricated component 104A. In certain embodiments, the third pre-fabricated component 104C has a higher strength than the first pre-fabricated component 104A. The third pre-fabricated component 104C, in some embodiments, is more durable, tougher, more resistant to ultraviolet (UV) radiation, and / or more resistant to moisture.

[0064]

[0082] 6 , in some embodiments, at least one prefabricated component 104A of a syntactic foam part 142 includes one or more spacers 116 that help maintain a desired distance 122 between the at least one prefabricated component 104A and an adjacent prefabricated component 104B. The spacers 116 extend outward from a side surface 118 of the at least one prefabricated component 104A a distance 122 that corresponds to the desired gap between the two prefabricated components 104A and 104B. The spacers 116 engage an adjacent prefabricated component 104B (e.g., by contacting a side surface 130 of the adjacent prefabricated component 104B) to maintain the distance 122 between the components 104A and 104B. In some embodiments, another spacer 116 engages a prefabricated component 104E adjacent to an adjacent prefabricated component 104B in a similar manner. In some embodiments, a spacer 116 engages the inner periphery 106 of the first mold 102A to maintain a desired gap between the at least one prefabricated component 104A and the inner periphery 106. In some embodiments, the distance 122 is between 0.01 centimeters (cm) and 4 cm, inclusive. For example, the distance 122 is between 0.01 cm and 1.5 cm, inclusive. In other embodiments, the distance 122 is greater than 4 cm.

[0065]

[0083] In some embodiments, spacer 116 is a tab. Spacer 116 can have a shape substantially similar to, for example, a substantially two-dimensional rectangle, a rectangular-based prism, a substantially two-dimensional semicircle, a hemisphere, and / or any combination thereof. In some embodiments, spacer 116 is made of the same material as at least one prefabricated component 104A. In other embodiments, spacer 116 is made of a different material than prefabricated component 104A. In some embodiments, spacer 116 is made of foam, while in other embodiments, spacer 116 is made of a non-foamed material.

[0066]

[0084] The spacer 116 can be configured to provide thermal conductivity between at least one prefabricated component 104A and an adjacent prefabricated component 104B. In these embodiments, the spacer 116 is made of a thermally conductive material, such as a metal. In some embodiments, the spacer 116 is configured to provide electrical conductivity between at least one prefabricated component 104A and an adjacent prefabricated component 104B. The spacer 116, in one or more embodiments, includes one or more openings and / or channels configured to allow wires to be routed through the spacer 116. For example, wires may be routed from at least one prefabricated component 104A through the channels of the spacer 116 to an adjacent prefabricated component 104B.

[0067]

[0085] Syntactic foam part 642, in some embodiments, includes electronic component 144. For example, prefabricated component 104B includes electronic component 144. In some embodiments, prefabricated component 104B is formed around electronic component 144. In other embodiments, openings are created in prefabricated component 104B to allow prefabricated component 104B to receive and house electronic component 144. Channels in spacer 116 allow for routing of wires from electronic component 144 through spacer 116 to another prefabricated component 104A. Electronic component 144 may include, for example, a battery, a power source, a sensor, a communication device, a navigation device, a sonar device, an illumination element, a depth gauge, and / or any combination thereof. In some embodiments, one or more of prefabricated components 104 includes and / or houses components other than electronic component 144, such as payload or other cargo and / or reinforcement members.

[0068]

[0086] In some embodiments, the syntactic foam part 142 includes several elongated members connecting the prefabricated components 104. Each elongated member may be at least partially embedded within a prefabricated component 104 and may connect to an elongated member of another prefabricated component 104 directly or via a connector. The elongated members may be, for example, substantially hollow tubes configured to receive a thermally conductive material. The elongated members may also provide electrical conductivity between the prefabricated components 104. In various embodiments, the elongated members are substantially hollow and configured to receive wires routed therethrough. In other embodiments, the elongated members are solid rods made of a thermally and / or electrically conductive material.

[0069]

[0087] With reference to FIGS. 3 and 4 , in some embodiments, one or more of prefabricated components 104 have a shape substantially different from the shape of syntactic foam pieces 342 and / or 442. In some embodiments, as shown in FIG. 3 , prefabricated components 104 have a shape substantially similar to a triangular prism and / or pyramid, while syntactic foam piece 342 has a shape substantially similar to a rectangular-based prism and / or cube. With reference to FIG. 4 , prefabricated components 104 have a shape substantially similar to a sphere and / or cylinder, and syntactic foam piece 442 has a shape substantially similar to a rectangular-based prism and / or cube. With reference to FIG. 2 , in other embodiments, the shape of prefabricated components 104 is substantially similar to the shape of syntactic foam piece 242. In some embodiments, both syntactic foam piece 242 and prefabricated components 104 have shapes substantially similar to a rectangular-based prism. In some embodiments, the outer surface 112 of the intermediate foam component 141 and / or the syntactic foam component 242 includes curved and / or substantially straight surfaces.

[0070]

[0088] 3, in some embodiments, the prefabricated components 104 are stackable in three-dimensional space. As shown in FIG. 3, the prefabricated components 104 have a shape substantially similar to a triangular prism. The triangular prisms can be stacked and arranged to form compact rows and / or columns of the prefabricated components 104.

[0071]

[0089] 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 specifically stated otherwise, as defined herein, a plurality of a particular feature does not necessarily refer to every particular feature of a particular set or class.

[0072]

[0090] 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.

[0073]

[0091] 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 connection between two elements that are not in direct contact with each other but have one or more additional elements between the connected elements. Furthermore, in this specification, fixing one element to another element may include direct fixing and indirect fixing. In addition, in this specification, "adjacent" does not necessarily mean contact. For example, one element may be adjacent to another element without touching it.

[0074]

[0092] As used herein, the phrase "at least one of" used in conjunction with enumerated items means that various combinations of one or more of the enumerated items may be used, and that only one of each enumerated item 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 may be used, but not all of the enumerated items may be required. For example, "at least one of item A, item B, and item C" may mean, e.g., "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, for example, without limitation, "two item A, one item B, and ten item C," "four item B, and seven item C," or other suitable combinations.

[0075]

[0093] 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.

[0076]

[0094] 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.

[0077]

[0095] 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.

[0078]

[0096] 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. A method (700) of making a syntactic foam component (142), comprising: loading a first prefabricated component (104A) into the mold (102) such that a gap (132) is defined between the first prefabricated component (104A) and at least one of a second prefabricated component (104B) within the mold (102) and an inner periphery (106) of the mold (102), the first prefabricated component (104A) including low-density spheres (120) embedded in a solidified first resin (138); introducing a second resin (140) into said gap (132); and The method (700) includes solidifying the second resin (140) after it is introduced into the gap (132).

2. Before loading the first prefabricated component (104A) into the mold (102), depositing and solidifying a material (108) along the inner periphery (106) of the mold (102); and forming an opening (110) through the material (108); 2. The method (700) of claim 1, wherein introducing the second resin (140) into the gap (132) further comprises inserting the second resin (140) through the opening (110).

3. The second resin (140) and the first prefabricated component (104A) after solidification form an intermediate part (141), the mold (102) comprises a first mold (102A), and the method (700) further comprises: Removing the intermediate part (141) from the first mold (102A); Inserting said intermediate part (141) into a second mold (102B); depositing a material (108) into said second mold (102B); and The method (700) of claim 1, comprising solidifying the material (108).

4. further comprising introducing the second low-density spheres (128) into the gap (132) together with the second resin (140) such that the second low-density spheres (128) are embedded in the second resin (140); 10. The method of claim 1, wherein solidifying the second resin comprises solidifying the second resin with the second low-density spheres embedded within the second resin.

5. the first prefabricated component (104A) includes a spacer (116) extending from a side (118) of the first prefabricated component (104A) a distance corresponding to a desired gap between the first prefabricated component (104A) and at least one of the second prefabricated component (104B) and the inner periphery (106) of the mold (102); 2. The method (700) of claim 1, wherein the spacer (116) engages the corresponding one of the second prefabricated components (104B) and the inner periphery (106) of the mold (102) to maintain the first prefabricated component (104A) at the desired gap from the corresponding one of the second prefabricated components (104B) and the inner periphery (106) of the mold (102).

6. 6. The method (700) of claim 5, wherein the desired gap is between 0.1 centimeters (cm) and 1.5 cm, inclusive.

7. 10. The method (700) of claim 1, wherein the second resin (140) fills the gap (132) when introduced into the mold (102).

8. the first prefabricated component (104A) and the second prefabricated component (104B) comprise prefabricated components of a plurality of prefabricated components; loading the first prefabricated component (104A) into the mold (102) includes loading the plurality of prefabricated components (104) into an internal cavity (124) of the mold (102); 2. The method (700) of claim 1, wherein the plurality of prefabricated components (104), when loaded into the internal cavity (124) of the mold (102), occupy at least 25% of a total volume of the internal cavity (124).

9. forming a third prefabricated component (104C), said third prefabricated component (104C) comprising: a density higher than the densities of said first prefabricated component (104A) and said second prefabricated component (104B); a strength greater than the strength of said first prefabricated component (104A) and said second prefabricated component (104B); or a durability greater than the durability of the first prefabricated component (104A) and the second prefabricated component (104B); 2. The method (700) of claim 1, further comprising loading the third prefabricated component (104C) into the mold (102), wherein the gap (132) is further defined between the third prefabricated component (104C) and at least one of the first prefabricated component (104A) and the second prefabricated component (104B).

10. the third prefabricated component (104C) comprises a third prefabricated component (104C) of a plurality of further prefabricated components (104C); 10. The method (700) of claim 9, wherein the plurality of further prefabricated components (104C) are loaded into the mold (102) such that the plurality of further prefabricated components (104C) are closer to the inner periphery (106) of the mold (102) than the first prefabricated component (104A) and the second prefabricated component (104B) are to the inner periphery (106) of the mold (102).

11. A syntactic foam component (142), prefabricated components (104), each having low-density spheres (120) at least partially embedded in a first resin (138), the prefabricated components (104) arranged such that a gap (132) is defined between at least two adjacent ones of the prefabricated components (104); and A syntactic foam component (142) including a second resin (140) disposed within the gap (132).

12. The syntactic foam component (142) of claim 11, wherein the second resin (140) bonds the prefabricated components (104) together.

13. 12. The syntactic foam component (142) of claim 11, further comprising second low-density spheres (128) embedded in the second resin (140) within the gap (132) such that the second resin (140) and the second low-density spheres (128) fill the gap (132).

14. 12. The syntactic foam component (142) of claim 11, further comprising a spacer (116) extending from a side (118) of a first prefabricated component (104A) of the prefabricated components (104) and contacting a side (130) of a second prefabricated component (104B) of the prefabricated components (104).

15. 15. The syntactic foam component of claim 14, wherein the spacer provides at least one of thermal conductivity or electrical conductivity between the first prefabricated component and the second prefabricated component.

16. The foam part (142) further comprises several additional pre-fabricated components (104C), Each one of the several further pre-fabricated components (104C, 104D) a density higher than the density of said prefabricated component (104); a strength greater than that of the prefabricated component (104); or a durability greater than the durability of the prefabricated component (104); The syntactic foam part (142) of claim 11, wherein a distance (134) between each one of the several further prefabricated components (104C) and the outer surface (112) of the syntactic foam part (142) is smaller than a distance (136) between any one of the prefabricated components (104) and the outer surface (112) of the syntactic foam part (142).

17. 12. The syntactic foam part (142) of claim 11, wherein each one of the prefabricated components (104) has the same or substantially similar shape as one of a triangular prism, a pyramid, a rectangular-based prism, a rod, a cylinder, a sphere, a dodecahedron, a hexagonal prism, or a cube.

18. The syntactic foam component (142) of claim 11, wherein at least one of the prefabricated components (104) includes an electronic component (144).

19. The syntactic foam component (142) of claim 11, wherein the low density spheres (120) are substantially hollow.

20. The syntactic foam component (142) of claim 11, wherein at least one of the prefabricated components (104) has a shape that is different from the overall shape of the syntactic foam component (142).

Images