Syntactic foams, methods of producing syntactic foams, and products including syntactic foams

Abstract

A method for producing a syntactic foam for high-pressure environments includes providing a housing having a void volume. The housing may include an inlet and an outlet to the void volume of the housing. The method includes injecting a plurality of microspheres comprising glass into the housing. The plurality of microspheres include a first set of microspheres comprising an average diameter ranging from 5 microns to 150 microns. The method includes agitating the housing to settle the plurality of microspheres within the housing. The method includes injecting a resin from the inlet of the housing to the outlet of the housing to fill voids between the plurality of microspheres to form a resin-microsphere matrix. The resin may have a viscosity less than 100 centipoise. The method may include curing the resin-microsphere matrix in the housing to produce a cured composition.

Dependencies are inferred from the claim text.