ULTRA LOW DENSITY SYNTACTIC FOAM BUOYANCY MODULE
A flotation device comprises three-dimensional cellular structure comprising a plurality of lengthwise adjacent and radially adjacent hollow cylindrical tubes, wherein interstices between the plurality of cylinders are filled with a composite matrix of macrospheres and syntactic foam.
1 . A flotation device, comprising:
three-dimensional cellular structure comprising a plurality of lengthwise adjacent and radially adjacent hollow cylindrical tubes, wherein interstices between the plurality of cylinders are filled with a composite matrix of macrospheres and syntactic foam.
2 . The flotation device of claim 1 , where the cylindrical tubes comprise filament wound carbon fibers.
3 . The flotation device of claim 1 , where the cylindrical tubes comprise filament wound carbon or glass fibers with an epoxy resin binder.
4 . The flotation device of claim 1 , where the cylindrical tubes are made of a wide variety of other materials.
5 . The flotation device of claim 3 , where the syntactic foam comprises microspheres and a polymeric binder.
6 . The flotation device of claim 1 , where the cylindrical tubes comprise thermoplastic.
7 . A method of manufacturing a flotation device, comprising:
coating a mold with a release agent;
lining the coated mold with a liner;
placing a plurality of lengthwise adjacent and radially adjacent tubes into the coated mold to substantially fill the mold;
introducing macrospheres into the mold to fill interstices between the tubes;
injected syntactic foam into the mold to fill in spaces between the macrospheres and the tubes; and
placing the filled mold into an oven to be cured.