# US 2014/0033953 A1 · Method of forming syntactic foams > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0033953 A1 - Document ID: US20140033953A1 - Status: Published application - Kind: A1 - Application number: 14/037,713 - Filed: 2013-09-26 - Published: 2014-02-06 - Earliest claimed: 2008-01-08 - Assignees: Newcastle Innovation Limited - Applicants: Newcastle Innovation Limited - Inventors: Ho Sung Kim - Web page: https://patentgrep.com/patent/US20140033953A1 ## CPC - C08J 9/32: from compositions containing microballoons, e.g. syntactic foams - B29C 70/66: the filler comprising hollow constituents, e.g. syntactic foam - C04B 38/08: by adding porous substances - C04B 40/0028: {Aspects relating to the mixing step of the mortar preparation} - C04B 2111/00129: {Extrudable mixtures} - C08J 2201/03: Extrusion of the foamable blend - Y02W 30/91: Use of waste materials as fillers for mortars or concrete - Y10T 428/249973: Mineral element - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE - Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of forming a syntactic foam, including the steps of providing a predetermined amount of constituent materials, said constituent materials including hollow microspheres or buoyant particles, a solvent and a first binder; mixing the constituent materials; allowing the constituent materials to separate into at least a phase substantially including said hollow microspheres or buoyant particles and a binder phase; transferring the hollow microsphere/buoyant particle phase into a mould; and forming a syntactic foam in said mould. Also an apparatus for forming the syntactic foam and syntactic foam. ## Claims ### Claim 1 A method of forming a syntactic foam, said method comprising the steps of: providing a predetermined amount of constituent materials, said constituent materials including buoyant particles, a solvent and a first binder; mixing the constituent materials; allowing the constituent materials to separate into at least a buoyant particle phase including said buoyant particles and said first binder and a binder phase including said solvent and said first binder; transferring the buoyant particle phase into a mould; and forming a syntactic foam in said mould. ### Claim 2 (depends on 1) The method of claim 1, wherein said transferring step includes extruding or forcing said buoyant particle phase into said mould. ### Claim 3 (depends on 1) The method of claim 1, wherein said separating step is performed in a vessel, and said buoyant particle phase is forced or extruded into said mould by feeding a liquid into said vessel after said separating step. ### Claim 4 (depends on 1) The method of claim 1, wherein said buoyant particles have a size of 1 mm to 6 mm in diameter. ### Claim 5 (depends on 1) The method of claim 1, wherein the buoyant particles are expanded particles. ### Claim 6 (depends on 5) The method of claim 5, wherein said expanded particles comprise at least one of expanded perlite particles, expanded vermiculite particles and expanded clay aggregates. ### Claim 7 (depends on 1) The method of claim 1, wherein the buoyant particles have a porous or sponge-like microstructure, or a cellular-like structure. ### Claim 8 (depends on 1) The method of claim 1, wherein said separating step and said mixing step are performed in a vessel. ### Claim 9 (depends on 1) The method of claim 1, wherein the mixing step is performed in a mixer, and the constituent materials are transferred to a separator for performing the separating step. ### Claim 10 (depends on 1) The method of claim 1, including the step of draining any excess solvent or first binder from said mould. ### Claim 11 (depends on 1) The method of claim 1, wherein the syntactic foam-forming step includes post-wetting of a pre-form formed in said mould. ### Claim 12 (depends on 11) The method of claim 11, wherein said post-wetting includes adding a second binder to said pre-form. ### Claim 13 (depends on 12) The method of claim 12, wherein the second binder is added by drawing a solution of the second binder through the pre-form. ### Claim 14 (depends on 13) The method of claim 13, wherein said solution is an acetone solution. ### Claim 15 (depends on 12) The method of claim 12, wherein said second binder is an organic binder. ### Claim 16 (depends on 1) The method of claim 1, wherein the syntactic foam-forming step includes a solidification step, said solidification step including heating. ### Claim 17 (depends on 1) The method of claim 1, wherein after said transferring step the remaining constituent materials are returned to said mixing step. ### Claim 18 (depends on 1) The method of claim 1, wherein the solvent is water or an organic solvent. ### Claim 19 (depends on 1) The method of claim 1, wherein the first binder is an organic binder. ### Claim 20 (depends on 19) The method of claim 19, wherein said first binder is a starch-based binder. ### Claim 21 (depends on 20) The method of claim 20, wherein said method includes the step of gelatinising said starch-based binder. ### Claim 22 (depends on 21) The method of claim 21, wherein said gelatinising step is performed prior to said mixing step. ### Claim 23 (depends on 21) The method of claim 21, wherein said gelatinising step is performed after said foam-forming step. ### Claim 24 (depends on 20) The method of claim 20, wherein the starch-based binder is wheat flour or potato starch. ### Claim 25 (depends on 1) The method of claim 1, wherein the first binder is an inorganic binder. ### Claim 26 (depends on 25) The method of claim 25, wherein the solvent is water and the first inorganic binder is cement. ### Claim 27 (depends on 15) The method of claim 15, wherein said organic binder is selected from amino resins, PVA, epoxy resins, phenolic resins, tar acid resins, urea resins, melamine resins, vinyl resins, styrene resins, acrylic resins, polyethylene resins, polycarbonate resins, acetal resins, fluorohydrocarbon resins, polyester resins, polyurethane resins, wheat flour and potato starch. ### Claim 28 (depends on 19) The method of claim 19, wherein said organic binder is selected from amino resins, PVA, epoxy resins, phenolic resins, tar acid resins, urea resins, melamine resins, vinyl resins, styrene resins, acrylic resins, polyethylene resins, polycarbonate resins, acetal resins, fluorohydrocarbon resins, polyester resins, polyurethane resins, wheat flour and potato starch. ### Claim 29 An apparatus for forming a syntactic foam, said apparatus including: a mixer for mixing a predetermined amount of constituent materials, said constituent materials including buoyant particles, a solvent and a first binder; a separator in communication with said mixer for separating said constituent materials into at least a buoyant particle phase including said buoyant particles and said first binder and a binder phase including said solvent and said first binder; a mould for forming said syntactic foam; and means for transferring the buoyant particle phase into said mould. ### Claim 30 (depends on 1) A syntactic foam obtained by the method of claim 1. ### Claim 31 (depends on 29) A syntactic foam obtained from the apparatus of claim 29.