Syntactic foam components and related manufacturing methods

Abstract

This relates to lightweight foams, and more particularly to syntactic lightweight foams made of low-density spheres embedded in resin. [Solution] A method for manufacturing syntactic foam parts comprises loading low-density spheres into a mold. The method also comprises introducing a first resin into the mold. The method further comprises coating the low-density spheres with the first resin to form a coating made of the first resin around each entire low-density sphere. The method further comprises allowing the first resin to solidify after it has been coated onto the low-density spheres. The method also comprises allowing a second resin to solidify after it has filled the mold.

Description

[Technical Field]

[0001]

[0001] This disclosure relates more broadly to buoyancy foam, and more particularly to syntactic buoyancy foam made of low-density spheres embedded in a resin. [Background technology]

[0002]

[0002] Lightweight foam is incorporated into parts to enhance the lightness of the parts in higher-density fluids. Some parts incorporating lightweight foam include, but are not limited to, submarines, ships, oil drilling rigs and their components, offshore platforms, and other offshore-based systems. Typical lightweight foam is compressible and, in some cases, water-resistant, durable, and reliable. It can be challenging to produce lightweight foam with these properties in an efficient, cost-effective, and reliable manufacturing process. [Overview of the Initiative]

[0003]

[0003] The subject matter of this application was developed in accordance with the current state of the art, in particular in response to the shortcomings of conventional lightweight foams and conventional methods for producing such lightweight foams. These shortcomings have not yet been fully resolved by currently available technologies. Accordingly, the subject matter of this application was developed to provide syntactic foam components and corresponding methods for producing such components. These overcome at least some of the aforementioned shortcomings of the prior art.

[0004]

[0004] The following is a non-exclusive list of some embodiments of the subject matter disclosed herein, which may or may not be claimed.

[0005]

[0005] A method for manufacturing syntactic foam parts is disclosed herein. The method comprises loading low-density spheres into a mold, thereby forming a grid arrangement within the mold, where each one low-density sphere is in contact with at least two other low-density spheres at a single point of contact, and a gap is defined between the corresponding one low-density sphere and at least two other low-density spheres. The method also comprises introducing a first resin into the mold. The method further comprises coating the low-density spheres in the grid arrangement with the first resin to form a coating made of the first resin around each of the entire low-density spheres. The method further comprises allowing the first resin to solidify after it has been coated onto the low-density spheres. The method also comprises allowing a second resin to solidify after it has filled the mold and the gaps. The preceding subject of this paragraph characterizes Example 1 of the present disclosure.

[0006]

[0006] Coating the low-density spheres involves wicking the first resin portion around the gaps defined between adjacent low-density spheres and around the single points of contact between adjacent low-density spheres. Thereafter, around the points of adjacent low-density spheres that are closest to each other, the coating is thicker than at locations further away from those points. The subject matter preceding this paragraph characterizes Example 2 of the present disclosure, which also includes the subject matter of Example 1 described above.

[0007]

[0007] The low-density spheres are coated such that the coating around each individual low-density sphere has a variable thickness. The subject matter preceding this paragraph characterizes Example 3 of the present disclosure, which also includes the subject matter according to Example 1 or 2 described above.

[0008]

[0008] The method further includes removing any excess of the first resin from the mold before the first resin is solidified. The subject matter preceding this paragraph characterizes Example 4 of the present disclosure, which also includes the subject matter according to any one of Examples 1 to 3 described above.

[0009]

[0009] Coating the low-density spheres involves pouring a first resin through a mold. Any excess of the first resin is discharged from the bottom of the mold. The subject matter preceding this paragraph characterizes Example 5 of the present disclosure, which also includes the subject matter according to Example 4 described above.

[0010]

[0010] The method further includes at least one of the following: actively pushing the first resin from the top of the mold to encourage the first resin to flow through the mold generally from top to bottom; and actively pulling the first resin from the bottom of the mold to encourage the first resin to flow through the mold from top to bottom. The subject matter preceding this paragraph characterizes Example 6 of the present disclosure, which also includes the subject matter of Example 5 described above.

[0011]

[0011] The second resin is introduced into the bottom of the mold and fills the mold generally from the bottom towards the top. The subject matter preceding this paragraph characterizes Example 7 of the present disclosure, which also includes the subject matter according to Example 5 or 6 described above.

[0012]

[0012] The first resin comprises a curable material and a solvent when introduced into the mold. Discharging the excess portion of the first resin includes discharging at least the solvent of the first resin. The subject matter preceding this paragraph characterizes Example 8 of the present disclosure, which also includes the subject matter of any one of Examples 4 to 7 described above.

[0013]

[0013] The first resin has a first curing temperature. The second resin has a second curing temperature. The first curing temperature is lower than the second curing temperature. The subject matter preceding this paragraph characterizes Example 9 of the present disclosure, which also includes the subject matter of any one of Examples 1 to 8 described above.

[0014]

[0014] The low-density spheres are made of a polymer material having a softening temperature. The first curing temperature is lower than the softening temperature. The second curing temperature is higher than the softening temperature. The preceding subject of this paragraph characterizes Example 10 of the present disclosure, which also includes the subject of Example 9 described above.

[0015]

[0015] The method further includes loading at least one second low-density sphere into the mold after the first resin has cured and before the second resin is introduced. Thereafter, one corresponding to the at least one second low-density sphere is positioned in the gap. The second resin fills the gap around the corresponding one of the at least one second low-density sphere when it is introduced into the mold. The subject matter preceding this paragraph characterizes Example 11 of the present disclosure, which also includes the subject matter according to any one of Examples 1 to 10 described above.

[0016]

[0016] The first resin comprises a preceramic material. Solidifying the first resin converts the preceramic material into a ceramic material. The subject matter preceding this paragraph characterizes Example 12 of the present disclosure, which also includes the subject matter of any one of Examples 1 to 11 described above.

[0017]

[0017] The first resin is at least one of being harder or stronger than the second resin. The subject matter preceding this paragraph characterizes Example 13 of the present disclosure, which also includes the subject matter of any one of Examples 1 to 12 described above.

[0018]

[0018] The method further includes adding an adhesion promoter to the low-density spheres after loading them and before introducing the first resin. The subject matter preceding this paragraph characterizes Example 14 of the present disclosure, which also includes the subject matter of any one of Examples 1 to 13 described above.

[0019]

[0019] The first resin is a resin matrix composite material comprising a reinforcing material embedded within a matrix material. The subject matter preceding this paragraph characterizes Example 15 of the present disclosure, which also includes the subject matter of any one of Examples 1 to 14 described above.

[0020]

[0020] At least one of the low-density spheres has a first size. At least one of the low-density spheres has a second size. The first size is different from the second size. The subject matter preceding this paragraph characterizes Example 16 of the present disclosure, which also includes the subject matter of any one of Examples 1 to 15 described above.

[0021]

[0021] A syntactic foam component is disclosed herein, comprising low-density spheres arranged in a grid configuration of at least one set of at least three low-density spheres. Thereafter, gaps are defined between each of the one low-density spheres in the at least one set of at least three low-density spheres. The syntactic foam component also includes a coating made of a first resin around each of the entire one low-density spheres. The thickness of the coating around each one low-density sphere varies, being greater around the point of adjacent low-density spheres that are closest to each other in the at least one set of at least three low-density spheres than at positions further away from that point. The syntactic foam component further includes a second resin that is in the gaps and encases the low-density spheres. The preceding subject of this paragraph characterizes Example 17 of the present disclosure.

[0022]

[0022] The first resin has a first curing temperature. The second resin has a second curing temperature. The first curing temperature is lower than the second curing temperature. The subject matter preceding this paragraph characterizes Example 18 of the present disclosure, which also includes the subject matter according to Example 17 described above.

[0023]

[0023] The low-density spheres are made of a polymer material having a softening temperature. The first curing temperature is lower than the softening temperature. The second curing temperature is higher than the softening temperature. The subject matter preceding this paragraph characterizes Example 19 of the present disclosure, which also includes the subject matter of Example 18 described above.

[0024]

[0024] The first resin is at least one of harder or stronger than the second resin. The preceding subject matter of this paragraph characterizes Example 20 of the present disclosure, and Example 20 also includes the subject matter according to any one of Examples 17 to 19 described above.

[0025]

[0025] The syntactic foam part further includes second low-density spheres in the gap. The second resin in the gap wraps the second low-density spheres. The preceding subject matter of this paragraph characterizes Example 21 of the present disclosure, and Example 21 also includes the subject matter according to any one of Examples 17 to 20 described above.

[0026]

[0026] The maximum thickness of the coating is smaller than the maximum thickness of the second resin. The preceding subject matter of this paragraph characterizes Example 22 of the present disclosure, and Example 22 also includes the subject matter according to any one of Examples 17 to 21 described above.

[0027]

[0027] The syntactic foam part forms the whole or a part of a marine-based system selected from the group consisting of submarines, ships, oil drilling devices, oil drilling parts, and offshore platforms. The preceding subject matter of this paragraph characterizes Example 23 of the present disclosure, and Example 23 also includes the subject matter according to any one of Examples 17 to 22 described above.

[0028]

[0028] At least the first of the low-density spheres has a first size. At least the second of the low-density spheres has a second size. The first size is different from the second size. The preceding subject matter of this paragraph characterizes Example 24 of the present disclosure, and Example 24 also includes the subject matter according to any one of Examples 17 to 23 described above.

[0029]

[0029] Another method for manufacturing syntactic foam parts is further disclosed herein. The method comprises loading low-density spheres into a first mold, thereby forming a grid arrangement within the first mold, in which case each one low-density sphere is in contact with each of at least two other low-density spheres at a single contact point, and a gap is defined between the corresponding one low-density sphere and at least two other low-density spheres. The method also comprises introducing a first resin into the first mold, further comprising coating the low-density spheres in the grid arrangement with the first resin to form a coating made of the first resin around each of the entire low-density spheres, the method further comprises allowing the first resin to solidify after it has coated the low-density spheres, thereby forming an intermediate part with the coating and the low-density spheres. The method also comprises removing the intermediate part from the first mold. The method further includes loading an intermediate component into a second mold. The method also includes introducing a second resin into the second mold, thereby filling the second mold and the gap. The method also includes allowing the second resin to solidify after it has filled the second mold and the gap. The preceding subject matter of this paragraph characterizes Example 25 of the present disclosure.

[0030]

[0030] At least one of the low-density spheres has a first size. At least one of the low-density spheres has a second size. The first size is different from the second size. The subject matter preceding this paragraph characterizes Example 26 of the present disclosure, which also includes the subject matter according to Example 25 described above.

[0031]

[0031] The features, structures, advantages, and / or properties of the subject matter of this disclosure described herein may be combined in any suitable manner in one or more examples and / or embodiments. The following description provides numerous specific details to facilitate a comprehensive understanding of multiple examples of the subject matter of this disclosure. Those skilled in the art will recognize that the subject matter of this disclosure can be implemented without one or more of the specific features, details, components, materials, and / or methods of a particular example or embodiment. In other cases, further features and advantages may be recognized in certain multiple examples and / or embodiments, but may not be present in all examples or embodiments. Furthermore, in some cases, well-known structures, materials, or processes are not described or illustrated in detail so as not to obscure aspects of the subject matter of this disclosure. The features and advantages of the subject matter of this disclosure will become more apparent from the following description and the appended claims, or will be understood by implementing the subject matter as described below.

[0032]

[0032] In order to make the merits of this subject matter easier to understand, a more detailed description of the subject matter outlined above is provided by referring to the specific embodiments shown in the accompanying drawings. These drawings, which are not necessarily drawn to a fixed scale, show only specific embodiments of the subject matter and should therefore not be considered limiting in scope, and it should be understood that the subject matter will be described with further specificity and detail using the drawings. [Brief explanation of the drawing]

[0033] [Figure 1]

[0033] This is a schematic cross-sectional front elevation view of a low-density sphere loaded into a mold according to one or more embodiments of the present disclosure. [Figure 2]

[0034] This is a schematic cross-sectional front elevation view of the grid arrangement of low-density spheres in the mold shown in Figure 1, according to one or more embodiments of the present disclosure. [Figure 3A]

[0035] This is a schematic cross-sectional front elevation of a first resin introduced into a mold and covering the low-density spheres in the mold shown in Figure 1, according to one or more embodiments of the present disclosure. [Figure 3B]

[0036] This is a schematic cross-sectional front elevation view of a low-density sphere coated with a first resin in a grid arrangement, according to one or more embodiments of the present disclosure. [Figure 3C]

[0037] This is a schematic cross-sectional front elevation view of a low-density sphere coated with a first resin in a grid arrangement, according to one or more embodiments of the present disclosure. [Figure 4]

[0038] This is a schematic cross-sectional front elevation view of a second resin introduced into the mold of Figure 1 and filling the mold of Figure 1, according to one or more embodiments of the present disclosure. [Figure 5]

[0039] This is a schematic cross-sectional front elevation view of a syntactic foam component formed in the mold shown in Figure 1, according to one or more embodiments of the present disclosure. [Figure 6]

[0040] This is a schematic flowchart illustrating a method for manufacturing syntactic form parts according to one or more embodiments of the present disclosure. [Figure 7]

[0041] This is a schematic cross-sectional front elevation view of a second resin introduced into and filling the mold of Figure 1, according to one or more embodiments of the present disclosure, in which smaller low-density spheres are arranged in the gaps between the low-density spheres that form a grid arrangement. [Figure 8]

[0042] This is a schematic cross-sectional front elevation view of the grid arrangement of low-density spheres in a mold and a second resin filling the mold, according to one or more embodiments of the present disclosure. [Figure 9]

[0043] This is a schematic cross-sectional front elevation view of the grid arrangement of low-density spheres in a mold and a second resin filling the mold, according to one or more embodiments of the present disclosure. [Figure 10]

[0044] This is a schematic flowchart of a method for manufacturing syntactic form parts according to one or more embodiments of the present disclosure. [Figure 11]

[0045] This is a schematic flowchart of a method for manufacturing syntactic form parts according to one or more embodiments of the present disclosure. [Modes for carrying out the invention]

[0034]

[0046] Whenever the terms “one embodiment,” “a certain embodiment,” or similar wording are used herein, it means that the specific features, structures, or properties described in relation to the embodiment are included in at least one embodiment of this disclosure. The phrases “one embodiment,” “a certain embodiment,” and similar wording appearing throughout this disclosure may, but may not, refer to the same embodiment. Similarly, the term “embodiment” means an embodiment having a specific feature, structure, or property described in relation to one or more embodiments of this disclosure, but such embodiment may be associated with one or more embodiments unless there is an obvious correlation suggesting otherwise.

[0035]

[0047] Several conventional methods for manufacturing syntactic foam parts involve stacking low-density spheres in a mold with each sphere in contact with the others at a single point of contact. The mold is then filled with a single type of resin that fills the spheres. In certain types of low-density spheres, such as glass or ceramic spheres, the single point of contact can increase stress and potentially damage the spheres, especially when the part is compressed. Alternatively, certain conventional methods for manufacturing syntactic foam parts involve stacking low-density spheres. The low-density spheres are pre-coated with a protective coating before being stacked in the mold and before the resin fills the mold. While such pre-coated low-density spheres offer some advantages over uncoated spheres, the single point of contact between the protective coatings of the spheres still potentially causes increased stress that can lead to damage and can result in increased foam density.

[0036]

[0048] Multiple embodiments of a method for producing syntactic foam parts made of low-density spheres embedded in resin, minimizing the occurrence of stress rise, are described herein. The method results in syntactic foam parts with higher strength per density and greater reliability than conventional syntactic foam parts. Specific embodiments of the method involve coating the low-density spheres in-mold with a variable-thickness coating before injecting the resin into the mold and embedding the spheres. The coating becomes thicker where the low-density spheres are in contact with each other or where they are closest to each other. Such thicker coatings at these specific locations on the low-density spheres help reduce the occurrence of stress rise and improve the overall strength-to-weight ratio of the syntactic foam parts produced by the method.

[0037]

[0049] According to several embodiments, a method 200 for producing syntactic foam parts, such as the syntactic foam part 142 in Figure 5, is shown in Figure 10. Referring generally to Figure 10 and in particular to Figures 1 and 2, the method 200 includes loading low-density spheres 120 into a mold 102 (block 210). In some embodiments, the mold 102 includes a selectively openable lid that selectively covers an opening in the mold 102. Through this opening, the low-density spheres 120 can be loaded into the mold 102. The low-density spheres 120 are loaded such that they form a grid arrangement 130 within the mold 102. In the grid arrangement 130, each of the low-density spheres 120 is in contact with at least two other low-density spheres 120 at a single contact point 134. In some embodiments, the low-density spheres 120 may be arranged to form at least a bimodal or trimodal distribution of spheres. Furthermore, in the grid arrangement 130, gaps 132 are defined between a corresponding low-density sphere 120 and at least two other low-density spheres 120. Since the drawing shows the low-density spheres 120 in two-dimensional space, each gap 132 is shown to be defined by only three low-density spheres 120. However, as can be seen, when the grid arrangement 130 is considered in three-dimensional space, it may have low-density spheres 120 entering and / or leaving the page. Thus, in three-dimensional space, each gap 132 may be further defined by one or two additional low-density spheres 120. According to some embodiments, using spheres of a single size, all or part of the grid arrangement 130 is packed up to 74%, for example, up to 69% in one embodiment and up to 50% in another embodiment. When used herein, a grid arrangement is a three-dimensional arrangement of objects (e.g., low-density spheres). The three-dimensional arrangement of objects does not need to be a perfectly repeating geometric arrangement in order to be considered a grid arrangement. Rather, a grid arrangement can be any grouping, bed, dense packing, or loose packing of objects, whether it is a perfectly repeating geometric arrangement, a substantially repeating geometric arrangement, or a non-repeat geometric arrangement of objects. A gap is defined herein as the space between one of the low-density spheres 120 and at least one of the following:That is, (1) the second low-density sphere 120, and (2) the inner circumference of the mold 102.

[0038]

[0050] In some embodiments, the low-density spheres 120 occupy at least 50% of the total volume of the internal cavity 112 of the mold 104 when introduced into the internal cavity 112. In some embodiments, the low-density spheres 120 occupy 50% or more and 99% or less of the total volume of the internal cavity 112.

[0039]

[0051] The mold 102 forms part of the molding tool 100. The molding tool 100 further includes a first resin introduction system and a second resin introduction system. The first resin introduction system is operable to introduce a first resin into the internal cavity 112 of the mold 102. In some embodiments, the first resin introduction system includes a first resin inlet 104 and a first resin outlet 106. The first resin inlet 104 is operable to introduce a first resin 138 from a first resin source of the first resin introduction system into the internal cavity 112 (see, for example, Figure 3A). The first resin outlet 106 is operable to discharge any excess portion 137 of the first resin 138 from the internal cavity 112 (see, for example, Figure 3A). Each of the first resin inlet 104 and the first resin outlet 106 may include a valve that can be selectively operated to regulate the flow of the first resin 138 into and out of the internal cavity 112. A second resin introduction system is operable to introduce the second resin into the internal cavity 112. In the illustrated embodiment, the first resin inlet 104 is located at the top of the mold 102, and the first resin outlet 106 is located at the bottom of the mold 102. In several other embodiments, the first resin inlet 104 and the first resin outlet 106 may be located at other respective locations on the mold 102.

[0040]

[0052] A second resin introduction system is operable to introduce a second resin into the internal cavity 112 of the mold 102. In some embodiments, the second resin introduction system includes a second resin inlet 108 and a second resin outlet 110. The second resin inlet 108 is operable to introduce a second resin 140 from the second resin source of the second resin introduction system into the internal cavity 112 (see, for example, Figure 4). The second resin outlet 110 is operable to release excess second resin from the internal cavity 112 (see, for example, Figure 5). One of the second resin inlet 108 and one of the second resin outlet 110 may each include a valve that is selectively operable to regulate the flow of the second resin 140 into and out of the internal cavity 112. In the illustrated embodiments, the second resin inlet 108 is located at the bottom of the mold 102, and the second resin outlet 110 is located at the top of the mold 102. In several other embodiments, a second resin inlet 108 and a second resin outlet 110 may be located at other respective locations on the mold 102. Alternatively, the tool 100 may include a plurality of resin inlets 108 and / or resin outlets 110 located at various locations around the mold 102.

[0041]

[0053] The size and shape of the internal cavity 112 of the mold 102 define the size and shape of the syntactic form component 142 (see, for example, Figure 5). The syntactic form component 142, and therefore the internal cavity 112 of the mold, may have any of a variety of shapes and sizes, non-limitingly, such as standard shapes (e.g., prisms with rectangular bases, cuboids, cubes, pyramids, cones, etc.) or complex shapes. Furthermore, in certain embodiments, the size and shape of the internal cavity 112 are configured to form a grid arrangement 130 (see, for example, Figure 2) when the low-density spheres 120 are loaded into the mold 102. Therefore, the size and shape of the internal cavity 112 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 to scale. For example, in the illustrated representation, the size of the low-density sphere 120 is unusually large relative to the size of the mold 102 in order to more clearly illustrate and explain the present invention. In reality, the size of the low-density sphere 120 is considerably smaller relative to the size of the mold 102 than shown. In some embodiments, the maximum diameter D of the low-density sphere 120 is between 5 microns and 153 millimeters (mm) including both ends, for example, in one embodiment between 20 microns and 10,000 microns including both ends, in another embodiment between 25 microns and 5,000 microns including both ends, for example, in yet another embodiment between 250 microns and 35,000 microns including both ends, and in yet another embodiment between 500 microns and 1,000 microns including both ends.

[0042]

[0054] In some embodiments, as shown in Figures 1 to 7 and Figure 9, one or at least one of the low-density spheres 120 is a hollow sphere 121A. The hollow sphere 121A has a hollow internal space 126 defined by the inner surface 124 of the side wall, which also defines the outer surface 122 of the low-density sphere 120. The hollow sphere 121A has a thin-walled structure. In other words, the thickness T1 of the side wall is smaller than the diameter D of the low-density sphere 120. In some embodiments, the ratio of thickness T1 to diameter D is between 0.001 and 0.1 including both ends, for example, between 0.01 and 0.1 including both ends in one embodiment, and between 0.02 and 0.08 including both ends in another embodiment. The hollow sphere 121A can be made of any of a variety of materials, non-limitingly, such as glass, ceramic, metal, or polymer.

[0043]

[0055] In several alternative embodiments, as shown in Figure 8, one or at least one of the low-density spheres 120 is a non-hollow foam sphere 121B. The non-hollow foam sphere 121B does not have a single hollow space like the hollow sphere 121A. Rather, the non-hollow foam sphere 121B is made from a solid piece of foam having multiple hollow spaces in the form of multiple open cells or closed cells. In some embodiments, the foam of the non-hollow foam sphere 121B is one or more of the following: polystyrene foam, expanded polystyrene (EPS) foam, expanded polypropylene (EPP) foam, polyethylene foam, polyurethane foam, and / or various other types of foam.

[0044]

[0056] When used herein, in certain examples, the low-density sphere 120 is 0.005 g / cm³ including both ends. 3 and 0.6 g / cm³ 3 For example, in one embodiment, the total volume including both ends is 0.05 g / cm³. 3 and 0.4 g / cm³ 3 In another embodiment, the total volume including both ends is 0.1 g / cm³. 3 and 0.3 g / cm³ 3 In yet another embodiment, the concentration is 0.02 g / cm³ including both ends. 3 and 0.15 g / cm³ 3During, in a further embodiment, including both ends, 0.015 g / cm 3 and 0.03 g / cm 3 Among them, it is a hollow or non-hollow sphere having a density of

[0045]

[0057] Although not shown, in some embodiments, in block 210, the low-density spheres 120 can be pre-coated with a uniform coating before being loaded into the mold 102. The uniform coating has a constant (i.e., non-varying) thickness across the entire sphere. In fact, when pre-coated, the uniform coating defines the outer surface 122 of the low-density sphere 120. Thereby, a single contact 134 is between points on the uniform coating. The uniform coating can be made of any of a variety of materials, including but not limited to pre-ceramic materials, resin matrix composite materials, nanoscale materials, glass, water glass, colloidal silica nanoparticles, polymers, ceramics, etc. In some cases, such as when the low-density sphere 120 is a non-hollow foam sphere, the uniform coating can provide strength to the underlying sphere and / or increase the thermal conductivity.

[0046]

[0058] In some embodiments as shown in FIG. 2, all of the low-density spheres 120 loaded into the mold 102 in block 210 have the same size. However, in other embodiments as shown in FIG. 9, the low-density spheres loaded into the mold 102 in block 210 have different sizes and can be loaded into the mold 102 at separate times corresponding to their sizes. In other words, at least one (e.g., some) of the low-density spheres 120 is determined to be a different size from at least one other (e.g., some other) of the low-density spheres 120. In FIG. 9, for example, a third low-density sphere 120B is loaded into the mold 102 together with a low-density sphere 120 that is larger than the third low-density sphere 120B. The sizes of the low-density spheres of different shapes are selected considering the size of the mold 102. Thereby, the low-density spheres of different shapes form a lattice arrangement as described above.

[0047]

[0059] Generally as shown in Figure 10 and especially in Figure 3A, after the low-density spheres 120 have been loaded into the mold 102 in block 210, method 200 further includes introducing the first resin 138 into the mold 102 in the direction of 139 (block 220). Referring to Figure 3A, in one embodiment, the first resin 138 is introduced into the mold 102 through the first resin inlet 104 at the top of the mold 102 and is allowed to flow from the top of the mold 102 to the bottom of the mold 102, generally in a top-to-bottom direction (i.e., generally parallel to the direction arrow 139). In some embodiments, the first resin 138 is passively supplied by gravity through the mold 102 generally in a top-to-bottom direction. However, in several other embodiments, the flow of the first resin 138 through the mold 102 is actively pushed and / or actively pulled to encourage the first resin 138 to flow from the top to the bottom of the mold 102, generally in a top-to-bottom direction. According to one embodiment, the first resin 138 may be actively pushed via positive pressure introduced at the top of the mold 102 via a positive pressure device (e.g., a blower, compressor, etc.). In a further embodiment, the first resin 138 may be actively pulled via negative pressure introduced at the bottom of the mold 102 via a negative pressure device (e.g., a vacuum device). Although not shown, in several alternative embodiments, the first resin 138 may be introduced into the mold 102 from the bottom and allowed to flow generally upward in a bottom-to-top direction to fill the mold 102 and coat the low-density sphere 120. In several other embodiments, the first resin 138 may be introduced into the mold 102 from the side of the mold 102 and may be allowed to flow upward and downward to fill the mold 102 and coat the low-density spheres 120.

[0048]

[0060] Referring generally to Figure 10 and especially to Figure 3A, Method 200 further includes coating the low-density spheres 120 in a grid arrangement 130 within the mold 102 with a first resin 138 introduced into the mold 102 in block 220 (block 230). Coating the low-density spheres 120 in block 230 forms a coating 136 made of the first resin 138 around each entire low-density sphere 120. The low-density spheres 120 are coated when the first resin 138 flows through the mold 102 and comes into contact with and adheres to the outer surface 122 of the low-density spheres 120. The method of introducing the first resin 138 may facilitate the adhesion of the first resin 138 onto the low-density spheres 120 and the coating of the first resin 138. In one embodiment, the first resin 138 is aspirated or vaporized and sprayed into the mold 102. According to several embodiments, in order to promote the adhesion of the first resin 138 to the outer surface 122 of the low-density sphere 120 (especially when the low-density sphere 120 is made of a material having relatively low adhesion, such as polystyrene), Method 200 may also include adding an adhesion promoter to the outer surface 122 before the first resin 138 is introduced into the mold 102. The adhesion promoter or wetting agent may be any of the various agents configured to promote adhesion, and non-limited to silanes.

[0049]

[0061] As the first 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 point 135 between adjacent low-density spheres 120 that are closest to each other, or immediately near or around that point) induce wicking or capillary action of the first resin 138 into these narrow spaces (see, for example, Figures 3B and 3C). As the first resin 138 accumulates in these narrow spaces, the thickness of the first resin 138 increases, creating thickened regions 152 of the first resin 138. Thus, the first resin 138 thickens or builds up around the point 135 between adjacent low-density spheres 120 that are closest to each other. The increased thickness of the first resin 138 within the thickened regions 152 around point 135 strengthens the bond between adjacent low-density spheres 120, and therefore strengthens the syntactic foam component 142. Furthermore, filling the narrow spaces increases the bonding area between adjacent low-density spheres 120, suppressing stress increases and thus increasing the overall durability of the syntactic foam component 142 and its resistance to crushing. The size of the thickened region 152 around point 135 can be defined as the circumferential distance L that the thickened region 152 extends away from point 135. In some embodiments, the distance L is between 5% and 37.5% of the radius r of the low-density sphere 120, including both ends; for example, in one embodiment, it is between 10% and 25% of the radius r of the low-density sphere 120, including both ends; in another embodiment, it is between 5% and 15% of the radius r of the low-density sphere 120, including both ends.

[0050]

[0062] Since the thickness of the first resin 138 is thicker in the thickened region 152 (see, for example, Figure 3B) than away from the thickened region 152, the coating 136 around each of the low-density spheres 120 has a variable or changing thickness. In particular, the thickness T2 of the coating 136 away from the thickened region 152 is less than the maximum thickness T3 of the thickened region 152. In some embodiments, the thickness of the coating 136 around each of the low-density spheres 120 is constant except in the thickened region 152 (e.g., the thickness T2 is constant). According to certain embodiments, the ratio of the maximum thickness T3 to the thickness T2 is between 2 and 10 including both ends, for example, between 3 and 5 including both ends in one embodiment, and between 3.5 and 4.5 including both ends in another embodiment. The thickness T2 of the coating 136 is based on any of a variety of factors, not limited to the following: Specifically, these factors include the viscosity of the first resin 138 when it is introduced into the mold 102 (which itself is based on several factors such as the temperature of the first resin 138), the state of the first resin 138 (i.e., fluid or gas), the pressure inside the mold 102, the flow rate of the first resin 138 through the mold 102, the adhesion characteristics of the low-density spheres 120, the method of introducing the first resin 138 into the mold 102, and the presence or absence of a solvent in the first resin 138. By controlling any one or more of these factors, a desired value for the thickness T2 can be achieved.

[0051]

[0063] As shown in Figure 3B, in some embodiments, the wicking force of the first resin 138 is not sufficient to separate adjacent low-density spheres 120 from each other. Therefore, in several such embodiments, adjacent low-density spheres 120 remain in contact at a single contact point 134 while a thickened region 152 of the first resin 138 is formed around the single contact point 134. In this way, the single contact point 134 is reinforced, and the stress is distributed to the thickened region 152 of the first resin 138 rather than accumulating at the single contact point 134 and generating a stress increase. A single contact point 134 is created when points 135 are also in contact with each other. Points 135 are defined as the points of adjacent low-density spheres 120 that are closest to each other. In other words, a single contact point 134 exists when the distance between points 135 is zero.

[0052]

[0064] As shown in Figure 3C, the wicking force of the first resin 138 is sufficient to separate adjacent low-density spheres 120 from each other. In several such embodiments, adjacent low-density spheres 120 are separated by the first resin 138 because the first resin 138 is introduced into the mold 102 and coats the low-density spheres 120, thereby creating gaps between adjacent points 135 of the low-density spheres 120 that are filled by the first resin 138. Furthermore, thickened regions 152 of the first resin 138 are generated between and around the points 135. In this way, the joint between adjacent low-density spheres 120 is strengthened and stress is distributed to the thickened regions 152 of the first resin 138 rather than accumulating at a single point of contact. To facilitate the separation of adjacent low-density spheres 120, the internal cavity 112 of the mold 102 may be pressurized to shrink the size of the low-density spheres 120 as the first resin 138 coats them, after the low-density spheres 120 form a grid arrangement 130 within the mold 102 and the first resin 138 fills the gaps between adjacent points 135 of the low-density spheres 120. In an alternative embodiment, the internal cavity 112 of the mold 102 may be partially filled with the first resin 138 to facilitate the separation of adjacent low-density spheres 120 and to allow the first resin 138 to fill the gaps between adjacent points 135 of the low-density spheres 120. This allows the low-density spheres 120 to separate until a desired gap size is established between adjacent low-density spheres 120.

[0053]

[0065] As specified herein, when substantially all of the low-density spheres 120 are coated with the first resin 138, the entire low-density spheres 120 are coated with the first resin 138, or when a single contact 134 is maintained between adjacent low-density spheres 120, substantially all of the low-density spheres 120, except for the single contact 134, are coated with the first resin 138.

[0054]

[0066] The first resin 138 can be any of various types of resins that facilitate coating of the low-density spheres. According to several embodiments, the first resin 138 is one or more of the following: pre-ceramic resins (e.g., silicone pre-ceramic resins), resin matrix composites (i.e., reinforcing materials embedded in the matrix material), nanoscale materials introduced via a slip-casting process, glass, water glass (e.g., sodium silicate), high-elasticity polymers (e.g., highly crosslinked rigid-chain polymers, polymers supported with nanoparticles, polymers supported with colloidal silica nanoparticles, and / or crystalline polymers). The reinforcing material of the resin matrix composite can be any of various materials such as fumed silica, nanoparticles, and crushed carbon fibers. In certain embodiments, the first resin 138 contains a solvent that helps to thin the first resin 138 and facilitate coating of the low-density spheres.

[0055]

[0067] Referring to Figure 3A, the first resin 138 is specially formulated and controlled to coat the surface, so that the walls of the mold 102 defining the internal cavity 112 are also coated with the coating 136. Any excess portion 137 of the first resin 138 that has been introduced into the mold 102 but does not coat the low-density sphere 120 or the walls of the mold 102 accumulates at the bottom of the mold 102. The excess portion 137 of the first resin 138 can then be discharged from the mold 102 (towards 141) via the first resin outlet 106 as a step of Method 200. If the first resin 138 contains a solvent, the solvent, as well as any other excess portion of the first resin 138, can be discharged from the mold 102 as part of Method 200.

[0056]

[0068] In some embodiments, after coating the low-density spheres 120 in block 230, method 200 includes cleaning the coated low-density spheres. Thereafter, the portion of the coating 136 having a thickness T2 around most of the low-density spheres is removed from the low-density spheres, leaving only the thickened region 152 of the coating. Alternatively, the coated low-density spheres may be cleaned so as to simply reduce the thickness T2 by removing only a portion of the coating 136, rather than removing all of the coating 136 around the thickened region 152. The portion of the coating 136 removed from the low-density spheres can then be discharged from the mold 102 through a first resin outlet 106.

[0057]

[0069] Generally referring to Figure 10, after coating the low-density spheres 120 in block 230, method 200 also includes solidifying the first resin 138 (block 240). Solidifying the first resin 138 includes changing the state of the first resin 138 from one state to a harder state (for example, from a flowable or semi-flowable state to a non-flowable state), for example, changing the first resin 138 from a fluid to a solid. According to one embodiment, solidifying the first resin 138 includes partially or completely curing or drying the first resin 138. Completely curing the first resin 138 may include raising the temperature of the first resin 138 to a first curing temperature of the first resin 138. In some embodiments, the first resin 138 is partially cured in block 240 by raising the temperature of the first resin 138 to a temperature between 100°C and 400°C, including both ends, and then completely cured by firing the first resin 138 to a temperature between 700°C and 1,600°C, including both ends, for example, in one particular embodiment, between 800°C and 1,200°C, including both ends. In several alternative embodiments, the first resin 138 may be solidified in block 240 by holding the first resin 138 at room temperature (e.g., 20°C to 22°C) for 2 to 24 hours, or by holding the first resin 138 at a temperature above room temperature (e.g., between 60°C and 350°C) for 30 minutes to 4 hours. In alternative embodiments, the first resin 138 is partially or completely cured by alternative methods such as radiation treatment of the first resin 138 (e.g., ultraviolet treatment, electron beam treatment, X-ray treatment, etc.). The curing of the first resin 138 may be irreversible (e.g., the first resin 138 is a thermosetting material) or reversible (e.g., the first resin 138 is a thermoplastic material). When the first resin 138 is a preceramic resin, solidifying the first resin 138 in block 240 may involve converting the preceramic resin to a ceramic resin. According to one embodiment, the first resin 138, and therefore the coating 136, may be a conductive resin (optionally, to establish electrical connectivity from coating to coating through the component), a thermally conductive resin, or a combination of both.

[0058]

[0070] Although the coating 136 is shown to have a single layer in several illustrated embodiments, in some embodiments the coating 136 may have multiple layers of resin. Thereafter, the thickness of the coating 136 is the combined thickness of the individual layers of the coating 136. Each of the layers of the multiple-layer coating 136 may be formed in the same manner as described in blocks 220-240 of Method 200, including draining excess resin as part of block 230. In other words, blocks 220-240 may be repeated until the desired number of layers of the coating 136 are formed. However, in some embodiments, the step of solidifying the resin in block 240 is performed only after all the layers of the coating 136 have been added onto the low-density sphere 120 by repeating the steps of blocks 220-230. The resins of the multiple layers of the coating 136 may be the same type of resin or different types of resin. In one embodiment where the resin of coating 136 is of a different type, the first resin applied to the low-density sphere 120 may be a resin that seals the low-density sphere 120, and the second layer and subsequent layers may be resins stronger than the resin that seals the low-density sphere 120. According to another embodiment where the resin of coating 136 is of a different type, the first resin applied to the low-density sphere 120 may be a solid or homogeneous resin, and the second layer and subsequent layers may be a composite resin or a resin having small microspheres.

[0059]

[0071] Generally as shown in Figure 10 and especially in Figure 4, after the first resin 138 has solidified in block 240, method 200 also includes introducing a second resin 140 into the mold 102 (block 250). Thereafter, the second resin 140 fills the gap 132 between the mold 102 and the low-density spheres 120. Referring to Figure 4, in one embodiment, the second resin 140 is introduced into the mold 102 (in the direction of 143) through a second resin inlet 108 at the bottom of the mold 102 and flows through the mold 102 from the bottom to the top of the mold 102, generally in the bottom-to-top direction (i.e., generally parallel to the direction arrows). In some embodiments, the second resin 140 is pumped (i.e., actively pushed) into the mold 102 through the second resin inlet 108 via a pump (not shown). In one embodiment, the second resin 140 may also be actively drawn in via negative pressure introduced at the top of the mold 102, such as through a negative pressure device (e.g., a vacuum device). After the mold 102 is filled with the second resin 140 so that the low-density spheres 120 and the coating 136 are embedded in the second resin 140, any excess portion of the second resin 140 is removed from the mold 102 in the direction of 145 via a second resin outlet 110 or the like.

[0060]

[0072] Referring again to Figure 10, after the second resin 140 is introduced into the mold 102 and the mold 102 is filled, method 200 also includes solidifying the second resin 140 (block 260). According to one embodiment, solidifying the second resin 140 includes partially or completely curing the second resin 140. Completely curing the second resin 140 may include raising the temperature of the second resin 140 to a second curing temperature of the second resin 140. To promote void-free curing of the second resin 140, the internal cavities 112 of the mold 102 may be pressurized. In some alternative embodiments, the second resin 140 is partially or completely cured via an alternative method such as ultraviolet treatment of the second resin 140. The curing of the second resin 140 may be irreversible (for example, if the second resin 140 is a thermosetting material) or reversible (for example, if the second resin 140 is a thermoplastic material).

[0061]

[0073] In some embodiments, the solidification temperature of the second resin 140 is, non-limitingly, between 21°C (i.e., room temperature) and 232°C, including both ends, for example, between 21°C and 180°C including both ends in one particular embodiment, between 21°C and 125°C including both ends in another particular embodiment, and between 21°C and 65°C including both ends in yet another particular embodiment. The second resin 140 is held at the solidification temperature for a predetermined period of time to achieve solidification of the second resin 140 (and / or the second resin 140 may experience multiple identical or different curing cycles associated with a particular temperature and ramp rate).

[0062]

[0074] The second resin 140 can be any of various types of resins that help encapsulate and immobilize the low-density spheres 120. According to several embodiments, the second resin 140 is one or more of the following: pure resin materials (e.g., epoxy resins), pre-ceramic resins (e.g., silicone pre-ceramic resins), resin matrix composites (i.e., reinforcing materials embedded in the matrix material), high modulus polymers (e.g., highly crosslinked rigid-chain polymers, nanoparticle-supported polymers, colloidal silica nanoparticle-supported resins), etc. The reinforcing material of the resin matrix composite can be any of various materials such as fumed silica, nanoparticles, or crushed carbon fibers. According to several embodiments, the second resin 140 contains density-reducing components, such as smaller low-density spheres (e.g., glass spheres), which help reduce the density of the second resin 140 without impairing the strength of the second resin 140.

[0063]

[0075] The second resin 140 is different from the first resin 138. For example, the second resin 140 is a different type of resin from the first resin 138, or the second resin 140 is configured differently from the first resin 138. For example, the first resin 138 may be stronger, denser, harder, and / or more durable than the second resin 140. Because the percentage of syntactic foam parts 142 made from the first resin 138 is significantly lower than the percentage of the second resin 140 (for example, the first resin 138 only forms a coating on the low-density sphere 120), the first resin 138 may be stronger and harder than the second resin 140. This is without significantly negatively affecting the overall density of the part. On the other hand, it helps to improve the overall strength of the part. According to some embodiments, the first curing temperature of the first resin 138 is lower than the second curing temperature of the second resin 140. Such a configuration allows the first resin 138 to be cured at a temperature that does not damage the low-density sphere 120. Once cured, the first resin 138 may be stronger, harder, denser, and / or more durable than the low-density sphere 120, protecting the integrity of the low-density sphere 120 when the second resin 140 is injected and / or cured at a higher temperature, such as a temperature that would normally soften or damage the low-density sphere 120. Thus, in certain embodiments, the first curing temperature is below the softening temperature of the low-density sphere 120, and the second curing temperature is above the softening temperature of the low-density sphere 120. The softening temperature may be the temperature at which the sphere softens to the point where it can no longer support mechanical loads.

[0064]

[0076] According to several embodiments, after the second resin 140 has solidified in block 260, the low-density sphere 120, the coating 136, and the second resin 140 form a syntactic foam part 142 (see, for example, Figure 5). As shown in Figure 5, method 200 may further include removing the syntactic foam part 142 from the mold 102. After being removed from the mold 102, the syntactic foam part 142 may form an independent part or be combined with one or more other parts or components (e.g., other syntactic foam parts or blocks) to form a larger or more complex part. In certain embodiments, the coating 136 on the inner surface of the mold 102 may be removed together with the syntactic foam part 142. This coating 136 may then be removed from the part or may form part of the part.

[0065]

[0077] According to several examples, the syntactic foam component 142 has a density of 0.2 g / cm³ including both ends. 3 and 0.5 g / cm³ 3 It has a density between 200 psi and a crushing strength of 30,000 psi including both ends (for example, in one embodiment, between 500 psi and 15,000 psi including both ends, and in another embodiment, between 1,000 psi and 10,000 psi including both ends).

[0066]

[0078] Referring to Figure 7, according to several embodiments, after the first resin 138 has solidified in block 240 and before the second resin 140 is introduced into mold 102, method 200 may include loading the second low-density sphere 120A into mold 102 within the gaps 132 defined around and / or between the low-density spheres 120. The second low-density sphere 120A may be considerably smaller than the low-density sphere 120. In one embodiment, the second low-density sphere 120A is between 3 and 50 times smaller than the low-density sphere 120, including both ends; for example, in one embodiment, between 5 and 25 times smaller than the low-density sphere 120, including both ends; and in another embodiment, between 7 and 20 times smaller than the low-density sphere 120, including both ends. After the second low-density sphere 120A is loaded into mold 102, the second resin 140 may be loaded into mold 102 in block 250. As a result, the second resin 140 fills the mold 102 around the second low-density sphere 120A, and the second low-density sphere 120A is embedded in or encased by the second resin 140. In one embodiment, the second low-density sphere 120A is the same type of sphere (e.g., the same material) as the low-density sphere 120, but smaller. However, in several alternative embodiments, the second low-density sphere 120A is a different type of sphere from the low-density sphere 120.

[0067]

[0079] Generally referring to Figure 11 and especially Figure 6, according to several embodiments, a method 300 for producing syntactic foam parts 142 (see, for example, Figure 5) includes steps similar to those of blocks 210-240 of method 200. In particular, method 300 includes loading low-density spheres 120 into a first mold 102A (block 310). Thereafter, the low-density spheres 120 form a grid arrangement 130 within the first mold 102A (see, for example, Figure 2). Method 300 further includes introducing a first resin 138 into the first mold 102A (block 320), coating the low-density spheres 120 within the grid arrangement 130 with the first resin 138 to form a coating 136 around each of the low-density spheres 120 (block 330), and allowing the first resin 138 to solidify (block 340). However, instead of introducing the second resin 140 into the first mold 102A to fill the first mold 102A, Method 300 includes removing the intermediate component 150 from the first mold 102A (block 350) and loading the intermediate component 150 into the second mold 102B (block 360). The intermediate component 150 includes low-density spheres 120 bound together by a solidified coating 136. In some embodiments, after removing the intermediate component 150 from the first mold 102A and before loading the intermediate component 150 into the second mold 102B, Method 300 may include a secondary solidification step to further solidify the coating 136. In one embodiment, the first resin 138 is partially cured in block 340 while it is in the first mold 102A, and then fully cured in block 350 after the intermediate part 150 is removed from the first mold 102A.

[0068]

[0080] Method 300 further includes loading the intermediate part 150 into the second mold 102B (block 360) and introducing the second resin 140 into the second mold 102B (block 370). Thereafter, the second resin 140 fills the second mold 102B around the intermediate part 150 and within the gap 132. Furthermore, Method 300 includes allowing the second resin 140 to solidify after it has filled the second mold 102B and the gap 132 (block 380). The syntactic foam part 142 formed through the steps associated with blocks 310-380 can then be removed from the second mold 102B. In some embodiments, the first mold 102A and the second mold 102B are different molds. However, in several other embodiments, the first mold 102A and the second mold 102B are the same mold. Furthermore, after the intermediate component 150 has been loaded into the second mold 102B, and before the second resin 140 has been introduced into the second mold 102B, the second low-density sphere may be loaded into the second mold 102B around the intermediate component 150 and / or within the gap 132 of the intermediate component 150, similar to the second low-density sphere 120A.

[0069]

[0081] In the above explanation, certain words such as "up," "down," "upper," "lower," "horizontal," "vertical," "left," "right," "over," and "under" may be used. These words are used as appropriate to bring some clarity to the explanation 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, simply reversing its top and bottom can make the "upper" surface the "lower" surface. Yet, it is still the same object. Furthermore, the words "including," "comprising," and "having," and their variations, mean "including, but not limited to" (unless explicitly stated otherwise). The listed items do not imply that any or all of them exclude and / or include each other, unless otherwise explicitly stated. Terms such as “a,” “an,” and “the” also mean “one or more,” unless otherwise explicitly stated. Furthermore, the term “plural” may be defined as “at least two.” Moreover, unless otherwise specified, as clarified herein, plural specific features do not necessarily mean every specific feature of a particular set or class of features.

[0070]

[0082] In some embodiments, the terms “about” or “substantially” are defined to mean within + / - 5% of a given value, but in several further embodiments, any disclosure of “about” may be further narrowed and requested 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 particularly intended to include a range between the two values, whether disclosed with respect to their separate embodiments or examples, and particularly intended to include a range less than or equal to the smaller of the two values, and / or less than or equal to the larger of the two values. Furthermore, when at least three values ​​of a variable are disclosed, such disclosure is particularly intended to include a range between any two of the values, regardless of whether they are disclosed in relation to separate embodiments or examples, and is particularly intended to include a range less than or equal to at least value A and / or value B, where A may be any of the disclosed values ​​other than the largest disclosed value, and B may be any of the disclosed values ​​other than the smallest disclosed value.

[0071]

[0083] Furthermore, in this specification, instances of one element being "coupled" to another may include direct and indirect couplings. A direct coupling may be defined as one element being connected to another element and having some contact with the other element. An indirect coupling may be defined as a coupling between two elements that do not directly touch each other but have one or more additional elements between the coupled elements. Furthermore, in this specification, fixing one element to another may include both direct 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 contact.

[0072]

[0084] When used herein, the expression “at least one of the listed items” means that one or more different combinations of the listed items may be used, and only one of each listed item may be required. An item can be a specific object, article, or category. In other words, “at least one of the listed items” means that any combination of items or any number of items from the listed items may be used, but not all of the listed items are required. For example, “at least one of item A, item B, and item C” could 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” could mean, but are not limited to, “two items A, one item B, and ten items C,” “four items B, and seven items C,” or other preferred combinations.

[0073]

[0085] Unless otherwise indicated, terms such as "first," "second," etc., are used merely as symbols in this book and are not intended to impose any sequential, positional, or hierarchical requirements on the items they represent. Furthermore, a reference to item "second," for example, does not require or exclude the existence of items numbered "first" or lower, and / or items numbered "third" or higher.

[0074]

[0086] When used herein, a system, device, structure, article, element, component, or hardware "configured to" perform a specified function does not mean that it is actually capable of performing that specified function without any modification, and is merely capable of performing that specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware "configured to" perform a specified function is specifically selected, produced, implemented, used, programmed, and / or designed for the purpose of performing that specified function. In this specification, the expression "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. Any system, apparatus, structure, article, element, component, or hardware described in this disclosure as “configured to” perform a particular function may additionally or alternatively be described as “adapted to” and / or “operative to” perform that function.

[0075]

[0087] The schematic flowcharts included in this book are, in general terms, explicitly presented as logical flowcharts. Therefore, the order and marked steps represent one embodiment of the method presented. Other steps and methods equivalent to the function, logic, or effect of one or more steps or parts thereof of the method shown may be recalled. Furthermore, it is understood that the forms and symbols used are provided to illustrate the logical steps of the method and do not limit its scope. Various types of arrows and lines may be used in the flowcharts, but these do not limit the scope of the corresponding method. In fact, some arrows or other connectors may be used solely to indicate the logical flow of the method. For example, arrows may indicate waiting or monitoring times of unspecified length between enumerated steps of the illustrated method. Furthermore, the order in which a particular method is performed may or may not strictly follow the order of the corresponding steps illustrated.

[0076]

[0088] The subject matter of this book may be embodied in other specific forms without deviating from its essence and substantial characteristics. The embodiments described above should be interpreted in all respects as merely illustrative and not restrictive. All modifications that fall within the meaning and scope of the claims and their equivalents should be included within the claims.

Claims

1. A method (200) for manufacturing syntactic form parts (142), Loading low-density spheres (120) into a mold (102), wherein the low-density spheres (120) form a grid arrangement (130) within the mold (102), and each of the low-density spheres (120) is in contact with each of at least two other low-density spheres (120) at a single contact point (134), and a gap (132) is defined between the corresponding low-density sphere (120) and the at least two other low-density spheres (120), Introducing the first resin (138) into the mold (102), To form a coating (136) made of the first resin (138) around each of the low-density spheres (120) in the grid arrangement (130), the low-density spheres (120) in the grid arrangement (130) are covered with the first resin (138), After the first resin (138) is coated onto the low-density sphere (120), the first resin (138) is solidified. After the first resin (138) has solidified, the second resin (140) is introduced into the mold (102) so as to fill the mold (102) and the gap (132), and A method (200) comprising solidifying the second resin (140) after it has filled the mold (102) and the gap (132).

2. The method according to claim 1 (200), wherein coating the low-density spheres (120) involves wicking the portion of the first resin (138) such that the thickness of the coating (136) is greater around a point (135) of adjacent low-density spheres (120) that is closest to each other, and around a gap defined between adjacent low-density spheres (120) and around a single contact point (134) between adjacent low-density spheres (120).

3. The method according to claim 1 (200), wherein the low-density spheres (120) are covered with the coating (136) around each of the low-density spheres (120) such that the coating has a variable thickness.

4. The method according to claim 1 (200), further comprising discharging the excess portion (137) of the first resin (138) from the mold (102) before the first resin (138) is solidified.

5. Coating the low-density sphere (120) includes pouring the first resin (138) through the mold (102), The method according to claim 4 (200), wherein the excess portion (137) of the first resin (138) is discharged from the bottom of the mold (102).

6. In order to encourage the first resin (138) to flow through the mold (102) generally from the top to the bottom, the first resin (138) is actively pushed from the top of the mold (102), In order to encourage the first resin (138) to flow from the top to the bottom through the mold (102), the first resin (138) is actively pulled from the bottom of the mold (102), The method according to claim 5 (200), further comprising at least one of the above.

7. The method according to claim 5 (200), wherein the second resin (140) is introduced into the bottom of the mold (102) and the mold (102) is filled generally from the bottom towards the top.

8. The first resin (138), when introduced into the mold (102), contains a curable material and a solvent. The method according to claim 4 (200), wherein discharging the excess portion (137) of the first resin (138) includes discharging at least the solvent of the first resin (138).

9. The first resin (138) has a first curing temperature, The second resin (140) has a second curing temperature, The method according to claim 1 (200), wherein the first curing temperature is lower than the second curing temperature.

10. The low-density sphere (120) is made of a polymer material having a softening temperature. The first curing temperature is lower than the softening temperature. The method according to claim 9 (200), wherein the second curing temperature is higher than the softening temperature.

11. The method according to claim 1 (200), comprising loading at least one second low-density sphere (120A) into the mold (102) after the first resin (138) has hardened and before the second resin (140) has been introduced, further comprising loading at least one second low-density sphere (120A) in which the corresponding one of the at least one second low-density sphere (120A) is positioned in the gap (132), and the second resin (140) fills the gap (132) around the corresponding one of the at least one second low-density sphere (120A) when introduced into the mold (102).

12. The first resin (138) includes a preceramic material. The method according to claim 1 (200), wherein solidifying the first resin (138) converts the preceramic material into a ceramic material.

13. The method according to claim 1 (200), wherein the first resin (138) is at least harder or stronger than the second resin (140).

14. The method according to claim 1 (200), further comprising adding an adhesion promoter to the low-density sphere (120) after loading the low-density sphere (120) and before introducing the first resin (138).

15. The method according to claim 1 (200), wherein the first resin (138) is a resin matrix composite material including a reinforcing material embedded in a matrix material.

16. At least one of the low-density spheres (120) has a first size, At least the second of the low-density spheres (120) has a second size, The method according to claim 1 (200), wherein the first size is different from the second size.

17. Syntactic form component (142), The low-density spheres (120) are arranged in a grid arrangement (130) of the at least one set of at least three low-density spheres (120) such that gaps (132) are defined between each low-density sphere (120) in at least one set of at least three low-density spheres (120), A coating (136) made of a first resin (138) around each of the low-density spheres (120), wherein the thickness of the coating (136) around each of the low-density spheres (120) varies, and the thickness of the coating (136) is greater around a point (135) of adjacent low-density spheres (120) that are closest to each other in the at least one set of the at least three low-density spheres (120) than at a position further away from the point (135), and A syntactic foam component (142) comprising a second resin (140) located within the gap (132) and enclosing the low-density sphere (120).

18. The first resin (138) has a first curing temperature, The second resin (140) has a second curing temperature, The syntactic foam component (142) according to claim 17, wherein the first curing temperature is lower than the second curing temperature.

19. The low-density sphere (120) is made of a polymer material having a softening temperature. The first curing temperature is lower than the softening temperature. The syntactic foam component (142) according to claim 18, wherein the second curing temperature is higher than the softening temperature.

20. The syntactic foam component (142) according to claim 17, wherein the first resin (138) is at least harder or stronger than the second resin (140).

21. The gap (132) further contains a second low-density sphere (120A), The syntactic foam component (142) according to claim 17, wherein the second resin (140) in the gap (132) encloses the second low-density sphere (120A).

22. The syntactic foam component (142) according to claim 17, wherein the maximum thickness of the coating (136) is less than the maximum thickness of the second resin (140).

23. The syntactic form component (142) according to claim 17, wherein the syntactic form component forms all or part of an offshore-based system selected from the group consisting of submarines, ships, oil drilling rigs, oil drilling components, and offshore platforms.

24. At least one of the low-density spheres (120) has a first size, At least the second of the low-density spheres (120) has a second size, The syntactic form component (142) according to claim 17, wherein the first size is different from the second size.

25. A method (300) for manufacturing syntactic form parts (142), Loading low-density spheres (120) into a first mold (102A), wherein the low-density spheres (120) form a grid arrangement (130) within the first mold (102A), and each of the low-density spheres (120) is in contact with each of at least two other low-density spheres (120) at a single contact point (134), and a gap (132) is defined between the corresponding low-density sphere (120) and the at least two other low-density spheres (120), Introducing the first resin (138) into the first mold (102A), To form a coating (136) made of the first resin (138) around each of the low-density spheres (120) in the grid arrangement (130), the low-density spheres (120) in the grid arrangement (130) are covered with the first resin (138), After the first resin (138) is coated onto the low-density sphere (120), the first resin (138) is solidified such that the coating (136) and the low-density sphere (120) form an intermediate component (150). Removing the intermediate part from the first mold (102A), Loading the aforementioned intermediate part (120) into the second mold (102B), Introducing the second resin (140) into the second mold (102B) such that the second resin (140) fills the second mold and the gap (132), and A method (300) comprising solidifying the second resin (140) after it has filled the second mold (102B) and the gap (132).

26. At least one of the low-density spheres (120) has a first size, At least the second of the low-density spheres (120) has a second size, The method according to claim 25 (300), wherein the first size is different from the second size.

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