Syntactic foams cellular structure

Syntactic foamed materials are classified as foamed plastics because they are formally similar in structure to cellular gas-expanded plastics in that they are heterophase, gas-solid systems. In general, however, they differ from ordinary foamed plastics in that they are not binary but tertiary systems because the filler and binder are made usually from different materials 3 5). 

FIGURE 2.58 Schematic representations of section through different types of cellular polymer, (a) Low-density open-cell foam, (b) High-density closed-cell foam, (c) Single-component structural foam with cellular core and integral solid skin, (d) Multicomponent structural foam, (e) Fiber-reinforced closed-cell foam, (f) Syntactic foam. 

Some special types of foams are (1) structural foams (2) syntactic foams and multifoams and (3) reinforced foams. Structural foams (Figure 2.58c and d), which possess full-density skins and cellular cores, are similar to structural sandwich constructions or to human bones, which have solid surfaces but cellular cores. Structural foams may be manufactured by high pressure processes or by low-pressure processes (Figure 2.61). The first one may provide denser, smoother skins with greater fidelity to fine detail in the mold than maybe true of low-pressure processes. Fine wood detail, for example, is used for simulated wood furniture and simulated wood beams. Surfaces made by low-pressure processes may, however, show swirl or other textures, not necessarily detracting from their usefulness. Almost any thermoplastic or thermosetting polymer can be formulated into a structural foam. 

The glass transition temperature lies considerably above the temperature of use with rigid foams and considerably below the temperature of use with flexible foams. The cellular structure may be open, closed, or mixed. All cells are open to each other with open cellular structures. In contrast, each cell is sealed off or encapsulated from the other cells by a plastic wall in closed-cell structures. Structural foams are foams with a dense outer skin and an interior of lower density they are also called integral foams or self-skinning foams. In contrast to normal foams syntactic foams do not directly enclose the gas but contain small hollow bodies of glass, ceramics, or plastics which are under vacuum or are filled with a gas. 

There are several types of foamed plastics including syntactic foam, closed-cell foam, and open-cell foam. Syntactic foam is a special type of plastic foam in which the cellular structure is formed by the use of smaU, hollow spheres made of resin, glass, or other hollow particles. The spheres are dispersed throughout a matrix of resin, usually thermosetting, which when cured resanbles a conventional foam plastic. Once mixed, syntactic foam may be cast or formed in place by a pouring or trowling action. 

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