Elastomeric Coated Macro-Spheres for High Pressure Flotation
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Solution Overview
Problem
Flotation units made of glass or ceramic macro-spheres embedded in syntactic foam fail under pressures lower than their withstand capacity when not embedded, and existing solutions to mitigate this issue are either expensive or reduce packing efficiency.
Innovation Solution
Encasing high elastic modulus brittle fracture material macro-spheres with a low shear strength material, such as an elastomeric shell, to prevent implosion failures and enhance pressure resistance, and embedding these macro-spheres in a syntactic foam matrix to distribute compressive stresses uniformly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass or ceramic macro-spheres are embedded in syntactic foam to provide buoyancy, then buoyancy is improved, but the macro-spheres fail under pressures lower than their withstand capacity
Solution Approach 1:
The patent combines glass or ceramic macro-spheres with a rubber-like polymer coating to create a composite flotation device. The rigid ceramic provides buoyancy while the elastic polymer coating absorbs and distributes compressive stresses, preventing implosion failures under high pressure. This composite structure allows the device to withstand pressures significantly higher than the uncoated ceramic spheres alone.
2Reliability
If individual water filled chambers are used to float macro-spheres, then failure resistance is improved, but fabrication cost increases and packing efficiency decreases
Solution Approach 1:
The patent changes the material parameter of the macro-sphere surface by coating it with a rubber-like polymer. This parameter change allows the spheres to be directly embedded in syntactic foam without requiring individual water-filled chambers, thereby maintaining failure resistance while significantly simplifying fabrication and improving packing efficiency.
3Quantity of substance
If macro-spheres are embedded directly in syntactic foam, then packing efficiency is improved, but stress distribution becomes uneven causing implosion failures
Solution Approach 1:
The patent applies a rubber-like polymer coating to the macro-spheres before embedding them in syntactic foam. This coating acts as a cushioning layer that absorbs and distributes compressive stresses uniformly across the sphere surface, preventing stress concentration and implosion failures while maintaining high packing density in the syntactic foam structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively mitigates implosion failures and sympathetic failures in flotation devices, allowing them to withstand high pressures while maintaining efficient packing and buoyancy, as demonstrated by proof testing to 30,000 PSI and 36,000 feet depth capability.
Implementation Method 1
a shell of a low shear strength material surrounding the macro-sphere
Implementation Method 2
distribute compressive stresses uniformly
Implementation Method 3
flotation devices for use in underwater or other high pressure applications
Implementation Method 4
embedding these macro-spheres in a syntactic foam matrix to distribute compressive stresses uniformly
Data Source
AI summary
A high pressure resistant flotation sphere includes a brittle fracture material macro-sphere of high elastic modulus and a shell of a low shear strength elastomeric material surrounding the macro-sphere. A high pressure resistant flotation material may be made of a plurality of macro-spheres embedded in syntactic foam or other matrix material, with each macro-sphere being encased in a shell of a low shear strength material that isolates each macro-sphere hydrostatically from the surrounding matrix.