insulation

Abstract

A method of making an insulating product includes the steps of: (a) forming a mixture including a solvent and a gel network former, and optionally including a foaming agent; (b) dispersing an insulating filler in the mixture; and (c) drying the mixture to form the insulating product.

Description

[Technical Field]

[0001] The present invention relates to thermal insulation products and methods for making thermal insulation products. [Background technology]

[0002] Commercially available insulation materials used in the production of insulation products, such as insulation boards or panels, include inorganic fibrous materials and organic foamed materials. While organic foamed materials are widely used, their main disadvantage is their high flammability. When exposed to a flame, such materials tend to propagate the flame and emit toxic gases. In contrast, inorganic fibrous materials can be sensitive to moisture and have higher densities and thermal conductivities compared to organic foamed materials. Therefore, it would be desirable to produce alternative lightweight insulation products. Summary of the Invention

[0003] According to a first aspect, the present invention relates to a method of making an insulating product, the method comprising the steps of: (a) forming a mixture comprising a solvent and a gel network former, and optionally a foaming agent; (b) dispersing an insulating filler in the mixture; and (c) drying the mixture to form the insulating product.

[0004] According to a second aspect, the present invention provides an insulating product comprising an insulating filler dispersed in a cellular matrix, for example, the insulating filler being a particulate material, for example, a porous particulate material such as an expanded silicate material, the expanded silicate material having a density of (a) about 15 kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 30 kg / m 3 ~about 60kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 , preferably about 30 kg / m 3 ~about 60kg / m 3a loose bulk density measured in accordance with PI 200-77 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2", and / or a resistance to compaction measured in accordance with PI 306-80 of from about 0.0300 W / mK to about 0.0700 W / mK, e.g., from about 0.0 (b) a thermal conductivity measured in accordance with EN 12667 of from 320 W / mK to about 0.0420 W / mK, from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0360 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK, or from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK; (b) a thermal conductivity of from about 3% to about 30% by weight, e.g., from about 3.5% to about 22% by weight, or from about 8% to about 30% by weight or about 13% by mass to about 22% by mass of X2O (X is an alkali metal such as Na or Li); about 0% by mass to about 20% by mass, for example, about 5% by mass to about 15% by mass, or about 0% by mass to about 15% by mass, or about 5% by mass to about 9% by mass of Al2O3; and about 50% by mass to about 90% by mass, for example, about 60% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 60% by mass to about 75% by mass of SiO2; about 0% by mass to about 10% by mass, for example, about 0.5% by mass to about 5% by mass of H2O; The silicate material may comprise less than about 5% by weight, e.g., less than about 3.5% by weight, B2O3; (c) forming a silicate mixture comprising at least one silicate material; an alkali compound; and water; hardening the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expandable silicate material; and heating the particulate expandable silicate material to form the expanded silicate material; and / or (d) expanded natural perlite. According to a third aspect, the present invention provides an insulating product produced by a method according to the first aspect. DETAILED DESCRIPTION OF THE INVENTION

[0005] It has surprisingly been found that lightweight insulating products can be produced by forming a mixture including a solvent and a gel network former (and optionally a foaming agent), dispersing an insulating filler in the mixture, and drying the mixture to form the insulating product. In particular, insulating products can be so produced that include an insulating filler dispersed in a cellular matrix. <Mixture> The first step in forming an insulating product is to form a mixture that includes a solvent and a gel network former, and may also include a foaming agent. Thus, the mixture typically includes at least a solvent and a gel network former, and may further include a foaming agent. The solvent is typically a liquid solvent. The solvent may be polar. For example, the solvent may comprise (e.g., be) one or more of the following: water, a carboxylic acid (e.g., methanoic acid (i.e., formic acid) or ethanoic acid (i.e., acetic acid)), an alcohol (e.g., methanol, ethanol, propanol, or butanol), a ketone (e.g., butanone (i.e., methyl ethyl ketone) or propanone (i.e., acetone)). Alternatively, the solvent may be non-polar.

[0006] The gel network former may be any substance or mixture of substances capable of forming a gel network structure. In this regard, a gel is understood to be a non-fluid network structure expanded (typically throughout its volume) by a fluid. Gel network structures may include, for example, covalently bonded (i.e., cross-linked) polymer networks; polymer networks formed by physical aggregation of polymer chains (e.g., caused by hydrogen bonding, crystallization, helix formation, or complex formation, which result in localized ordered regions that serve as network junctions); polymer networks formed by glassy junctions (e.g., polymer networks based on block copolymers); lamellar structures (e.g., mesophases, soap gels, phospholipids, or clays); and particulate disordered structures (e.g., floccules, or spherical or fibrous protein gels). The fluid may be a liquid or a gas (e.g., a solvent). In some embodiments, the gel network former comprises (e.g., is) a binder. The binder may be a naturally occurring substance, i.e., a natural binder. The binder may also be a (e.g., naturally occurring) polymer. The binder may comprise (e.g., be) a protein (e.g., collagen, e.g., hydrolyzed collagen (i.e., gelatin), or gluten) and / or a polysaccharide (e.g., a carbohydrate, e.g., starch, cellulose, or glycogen, a vegetable gum, chitosan, or pectin).

[0007] In some embodiments, the gel network former comprises (e.g., is) a clay mineral (i.e., clay). Clay minerals are understood to be hydrated phyllosilicates, typically hydrated aluminum phyllosilicates, including, but not limited to, the following mineral groups: kaolin (i.e., kaolinite), smectite, illite, and chlorite. The clay mineral may be a smectite clay mineral, such as montmorillonite, nontronite, beidellite, saponite, or hectorite. In some embodiments, the gel network former includes a reinforcing agent or a combination of reinforcing agents, for example, at least two reinforcing agents. A reinforcing agent is understood to be a substance that reinforces (i.e., strengthens and supports) a gel network structure formed primarily by another gel network former (i.e., primary gel network former substance). The reinforcing agent may be a polymer. The polymer may be a synthetic polymer or a naturally occurring polymer (i.e., a natural polymer). Examples of suitable synthetic polymers are poly(vinyl alcohol) (PVA), sodium polyacrylate, and polyethyleneimine (PEI). The polymer may be a protein such as casein. The polymer may be a polysaccharide such as pectin or cellulose, or an alginate (e.g., ammonium alginate or calcium alginate). The polymer may be an elastomer. The polymer may be a rubber, for example, natural rubber. The reinforcing agent may include at least two (i.e., different) polymers. For example, the reinforcing agent may include poly(vinyl alcohol) (PVA) and sodium polyacrylate. The reinforcing agent may comprise at least two (i.e., different) polymers selected from poly(vinyl alcohol) (PVA), sodium polyacrylate, polyethyleneimine (PEI), casein, pectin, cellulose or alginates (e.g., ammonium alginate or calcium alginate), rubber (e.g., natural rubber). The reinforcing agent may comprise (e.g., be) natural or synthetic fibers or whiskers (e.g., cellulose whiskers).

[0008] In some embodiments, the gel network former includes a binder and does not include a clay mineral or a reinforcing agent, e.g., the gel network former is a binder. The binder may be a naturally occurring substance, i.e., a natural binder. The binder may also be a (e.g., naturally occurring) polymer. The binder may include (e.g., be) a protein (e.g., collagen, e.g., hydrolyzed collagen (i.e., gelatin), or gluten) and / or a polysaccharide (e.g., a carbohydrate, e.g., starch, cellulose, or glycogen, a plant gum, chitosan, or pectin).

[0009] In some embodiments, the gel network former comprises a clay mineral and a reinforcing agent (or a combination of reinforcing agents). The clay mineral may be a smectite clay mineral, such as montmorillonite, nontronite, beidellite, saponite, or hectorite. The reinforcing agent may be a polymer. The polymer may be a synthetic polymer or a naturally occurring polymer (i.e., a natural polymer). Examples of suitable synthetic polymers are poly(vinyl alcohol) (PVA), sodium polyacrylate, and polyethyleneimine (PEI). The polymer may be a protein, such as casein. The polymer may be a polysaccharide, such as pectin or cellulose, or an alginate (e.g., ammonium alginate or calcium alginate). The polymer may be an elastomer. The polymer may be a rubber, such as natural rubber. The reinforcing agent may comprise at least two (i.e., different) polymers. For example, the reinforcing agent may comprise poly(vinyl alcohol) (PVA) and sodium polyacrylate. The reinforcing agent may comprise at least two (i.e., different) polymers selected from poly(vinyl alcohol) (PVA), sodium polyacrylate, polyethyleneimine (PEI), casein, pectin, cellulose or alginates (e.g., ammonium alginate or calcium alginate), rubber (e.g., natural rubber). The reinforcing agent may comprise (e.g., be) natural or synthetic fibers or whiskers (e.g., cellulose whiskers).

[0010] A foaming agent is understood to be a substance that facilitates the formation of foam in a mixture, for example, stirring or blowing the mixture. The foaming agent may further function to stabilize the foam. The foaming agent may be a surfactant. The surfactant may be a surfactant that reduces the surface tension of the solvent. The surfactant may be anionic, cationic, zwitterionic, or nonionic. The surface may be an alkyl sulfate such as ammonium dodecyl sulfate (i.e., ammonium lauryl sulfate (ALS)) or sodium dodecyl sulfate (SDS) (i.e., sodium lauryl sulfate (SLS)), or an alkyl ether sulfate such as sodium lauryl ether sulfate (SLES) (i.e., sodium laureth sulfate) or sodium myreth sulfate. In some embodiments, the gel network former includes (e.g., is) a binder and the mixture includes a foaming agent. For example, in some embodiments, the mixture includes a solvent, a binder, and a foaming agent.

[0011] In some embodiments, the gel networker includes a clay mineral and may also include a reinforcing agent, and the mixture does not include a foaming agent. For example, in some embodiments, the mixture is a foaming agent-free mixture that includes (e.g., consists of) a solvent, a clay mineral, and a reinforcing agent. However, in other embodiments, the mixture may include a foaming agent in addition to the clay mineral and the reinforcing agent. The mixture formed by combining the solvent and gel network former, and optionally a foaming agent, may be a gel. Thus, the method may include combining the solvent and gel network former, and optionally a foaming agent, to form a gel.

[0012] In embodiments in which the mixture formed by combining the solvent and gel network former, and optionally the foaming agent, is a gel, the fluid that expands the gel network structure is typically (i.e., at least primarily) a liquid solvent, at least prior to drying. After drying, the liquid solvent in the gel may be replaced with another fluid, such as air. The gel may also be a cellular (e.g., foamed) gel.

[0013] The mixture (after dispersion of the insulating filler) may comprise about 0.5% by weight or more, such as about 1% by weight or more, or about 2% by weight or more, or about 3% by weight or more, or about 3.5% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 15% by weight or more, or about 20% by weight or more, or about 25% by weight or more of the gel network former, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise about 70% by weight or less, e.g., about 65% by weight or less, or about 60% by weight or less, or about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 7% by weight or less, or about 5% by weight or less of the gel network former, based on the total weight of the mixture (after dispersion of the insulating filler). For example, the mixture (after dispersion of the insulating filler) may comprise about 0.5% by weight or more and about 10% by weight or less of the gel network former, based on the total weight of the mixture.The mixture (after dispersion of the insulating filler) may have a dispersibility of about 0.5% by weight to about 70% by weight, for example, about 0.5% by weight to about 50% by weight, or about 0.5% by weight to about 30% by weight, or about 0.5% by weight to about 10% by weight, or about 0.5% by weight to about 7% by weight, or about 0.5% by weight to about 5% by weight, or about 1% by weight to about 60% by weight, or about 1% by weight to about 50% by weight, or about 1% by weight to about 40% by weight, or about 1% by weight to about 30% by weight, or about 1% by weight to about 20% by weight, or about 1% by weight to about 15% by weight, or about 1% by weight to about 10% by weight, or about 2% by weight to about 70% by weight, or about 2% by weight to about 60% by weight, or about 2% by weight to about 50% by weight, or about 2% by weight to about 40% by weight, or about 2% by weight to about 50% by weight The gel network former may comprise about 30% by mass, or about 2% to about 20% by mass, or about 2% to about 15% by mass, or about 2% to about 10% by mass, or about 2% to about 7% by mass, or about 2% to about 5% by mass, or about 3% to about 10% by mass, or about 3% to about 7% by mass, or about 3% to about 5% by mass, or about 3.5% to about 10% by mass, or about 3.5% to about 7% by mass, or about 3.5% to about 5% by mass, or about 5% to about 70% by mass, or about 5% to about 60% by mass, or about 5% to about 50% by mass, or about 5% to about 40% by mass, or about 5% to about 30% by mass, or about 5% to about 20% by mass, or about 5% to about 15% by mass, or about 5% to about 10% by mass.

[0014] For example, the mixture (after dispersion of the insulating filler) may include about 0.5% by weight or more, e.g., about 1% by weight or more, or about 2% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 15% by weight or more, or about 20% by weight or more, or about 25% by weight or more of binder based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may include about 70% by weight or less, e.g., about 65% by weight or less, or about 60% by weight or less, or about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less of binder based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may have an average molecular weight of about 0.5% to about 70% by weight, for example, about 1% to about 60% by weight, or about 1% to about 50% by weight, or about 1% to about 40% by weight, or about 1% to about 30% by weight, or about 1% to about 20% by weight, or about 1% to about 15% by weight, or about 1% to about 10% by weight, or about 2% to about 70% by weight, or about 2% to about 60% by weight, or about 2% to about 50% by weight, based on the total weight of the mixture (after dispersion of the insulating filler). Alternatively, it may contain about 2% by mass to about 40% by mass, or about 2% by mass to about 30% by mass, or about 2% by mass to about 20% by mass, or about 2% by mass to about 15% by mass, or about 2% by mass to about 10% by mass, or about 5% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 5% by mass to about 50% by mass, or about 5% by mass to about 40% by mass, or about 5% by mass to about 30% by mass, or about 5% by mass to about 20% by mass, or about 5% by mass to about 15% by mass, or about 5% by mass to about 10% by mass of binder.

[0015] Alternatively, the mixture (after dispersion of the insulating filler) may comprise about 0.5% by weight or more, e.g., about 1% by weight or more, or about 2% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 15% by weight or more, or about 20% by weight or more, or about 25% by weight or more of the clay mineral and / or reinforcing agent, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise about 70% by weight or less, e.g., about 65% by weight or less, or about 60% by weight or less, or about 55% by weight or less, or about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less of the clay mineral and / or reinforcing agent, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may have a thermally active ingredient concentration of about 0.5% to about 70% by weight, for example, about 1% to about 60% by weight, or about 1% to about 50% by weight, or about 1% to about 40% by weight, or about 1% to about 30% by weight, or about 1% to about 20% by weight, or about 1% to about 15% by weight, or about 1% to about 10% by weight, or about 2% to about 70% by weight, or about 2% to about 60% by weight, or about 2% to about 50% by weight, or about 2% to about 60% by weight, based on the total weight of the mixture (after dispersion of the insulating filler). % to about 40% by mass, or about 2% to about 30% by mass, or about 2% to about 20% by mass, or about 2% to about 15% by mass, or about 2% to about 10% by mass, or about 5% to about 70% by mass, or about 5% to about 60% by mass, or about 5% to about 50% by mass, or about 5% to about 40% by mass, or about 5% to about 30% by mass, or about 5% to about 20% by mass, or about 5% to about 15% by mass, or about 5% to about 10% by mass of clay mineral and / or reinforcing agent.

[0016] The mixture may comprise a ratio of clay mineral and reinforcing agent of about 1:5 to about 5:1, such as about 1:4 to about 4:1, or about 1:3 to about 3:1, or about 1:2 to about 2:1, or about 1:1.5 to about 1.5:1, such as about 1:1. The mixture (after dispersion of the insulating filler) may comprise about 0.5% by weight or more, such as about 1% by weight or more, or about 2% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more, or about 60% by weight or more, or about 70% by weight or more, or about 80% by weight or more, or about 90% by weight or more of insulating filler, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise about 99% by weight or less, e.g., about 98% by weight or less, or about 95% by weight or less, or about 90% by weight or less, or about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less, or about 50% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 10% by weight or less, or about 5% by weight or less of insulating filler, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may have an average molecular weight of about 0.5% to about 99% by weight, for example, about 1% to about 98% by weight, or about 2% to about 98% by weight, or about 5% to about 98% by weight, or about 10% to about 98% by weight, or about 20% to about 98% by weight, or about 30% to about 98% by weight, or about 40% to about 98% by weight, or about 50% to about 98% by weight, or about 60% to about 98% by weight, based on the total weight of the mixture (after dispersion of the insulating filler). It may contain about 98% by mass, or about 70% to about 98% by mass, or about 5% to about 20% by mass, or about 5% to about 30% by mass, or about 5% to about 40% by mass, or about 5% to about 50% by mass, or about 10% to about 20% by mass, or about 10% to about 30% by mass, or about 10% to about 40% by mass, or about 10% to about 50% by mass, or about 1% to about 10% by mass, or about 1% to about 5% by mass of a heat insulating filler.

[0017] The mixture (after dispersion of the insulating filler) may comprise about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 0.5% by weight or more, or about 1% by weight or more, of foaming agent, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise about 5% by weight or less, e.g., about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, of foaming agent, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise from about 0.01% to about 5% by weight, e.g., from about 0.1% to about 3% by weight, or from about 0.1% to about 2% by weight, or from about 0.5% to about 3% by weight, or from about 0.5% to about 2% by weight, or from about 1% to about 2% by weight, or from about 0.1% to about 1% by weight, of foaming agent, based on the total weight of the mixture (after dispersion of the insulating filler).

[0018] The mixture may include one or more additives. The one or more additives may be selected from thickeners, emulsifiers, viscosity modifiers, softeners, plasticizers, flame retardants (e.g., aluminum hydroxide), antibacterial agents, antifungal agents (e.g., propionic acid), hydrophobic agents (e.g., silicone oil), and / or thermal conductivity regulating agents (e.g., graphite), or any combination thereof. For example, the mixture may further include one or more additives selected from antifungal agents (e.g., propionic acid), antibacterial agents, flame retardants (e.g., aluminum hydroxide), hydrophobic agents (e.g., silicone oil), stearic acid, thermal conductivity regulating agents (e.g., graphite), or any combination thereof. For example, the one or more additives may include aluminum hydroxide, ammonium polyphosphate, silica gel, potassium carbonate, borax, boric acid, melamine, silicone oil, calcium stearate, oleic acid, stearic acid, silane, and / or graphite. The mixture (after dispersion of the insulating filler) may comprise about 0.001% by weight or more, e.g., about 0.01% by weight or more, or about 0.1% by weight or more, or about 0.3% by weight or more, or about 0.5% by weight or more, or about 1% by weight or more, or about 5% by weight or more, or about 10% by weight or more of the additive, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise about 40% by weight or less, e.g., about 30% by weight or less, or about 20% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 4% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less of the additive, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may contain from about 0.001% to about 40% by weight of the additive, based on the total weight of the mixture (after dispersion of the insulating filler), for example, from about 0.01% to about 30% by weight, or from about 0.1% to about 30% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 10% by weight, or from about 0.1% to about 5% by weight, or from about 0.1% to about 4% by weight, or from about 0.3% to about 4% by weight, or from about 0.1% to about 1% by weight, or from about 0.01% to about 1% by weight, or from about 0.01% to about 0.5% by weight.

[0019] The remainder of the mixture (after dispersion of the insulating filler) other than the gel network former (e.g., binder, clay mineral, and / or reinforcing agent), foaming agent, insulating filler, and additives may consist of solvent. For example, the mixture (after dispersion of the insulating filler) may include about 1% by weight or more, e.g., about 5% by weight or more, or about 10% by weight or more, or about 15% by weight or more, or about 20% by weight or more, or about 25% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more, or about 45% by weight or more, or about 50% by weight or more, or about 55% by weight or more, or about 60% by weight or more, or about 65% by weight or more, or about 70% by weight or more of solvent, based on the total weight of the mixture (after dispersion of the insulating filler). The mixture (after dispersion of the insulating filler) may comprise about 90% by weight or less, for example about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less, or about 50% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less of solvent, based on the total weight of the mixture (after dispersion of the insulating filler).The mixture (after dispersion of the insulating filler) may have a thermally active ingredient of about 1% to about 90% by weight, for example, about 1% to about 80% by weight, or about 1% to about 70% by weight, or about 1% to about 60% by weight, or about 1% to about 50% by weight, or about 1% to about 40% by weight, or about 1% to about 30% by weight, or about 1% to about 20% by weight, or about 5% to about 90% by weight, or about 5% to about 80% by weight, or about 5% to about 70% by weight, based on the total weight of the mixture (after dispersion of the insulating filler). %, or about 5% to about 60% by mass, or about 5% to about 50% by mass, or about 5% to about 40% by mass, or about 5% to about 30% by mass, or about 5% to about 20% by mass, or about 10% to about 90% by mass, or about 10% to about 80% by mass, or about 10% to about 70% by mass, or about 10% to about 60% by mass, or about 10% to about 50% by mass, or about 10% to about 40% by mass, or about 10% to about 30% by mass, or about 10% to about 20% by mass, or about 20% to about 90% by mass, or about 20% to about 80% by mass, or about 20% to about 70% by mass, or about 20% to about 60% by mass, or about 20% to about 50% by mass, or about 20% to about 40% by mass, or about 20% to about 30% by mass, or about 30% to about 90% by mass, or about 30% to about 80% by mass, or about 30% to about 70% by mass, or about 30% to about 60% by mass, or about 30% to about 50% by mass, or It may contain about 30% to about 40% by weight of solvent, or about 40% to about 90% by weight, or about 40% to about 80% by weight, or about 40% to about 70% by weight, or about 40% to about 60% by weight, or about 40% to about 50% by weight, or about 50% to about 80% by weight, or about 50% to about 70% by weight, or about 50% to about 60% by weight, or about 60% to about 80% by weight, or about 60% to about 70% by weight, or about 70% to about 80% by weight. Unless otherwise specified, the weight percent of solvent in the mixture (after dispersion of the insulating filler) is understood to be the weight percent of solvent in the mixture immediately after dispersion of the insulating filler and before drying the mixture.

[0020] In some embodiments, the mixture (after dispersion of the insulating filler) comprises (e.g., consists of) about 1% to about 10%, e.g., about 4% to about 7%, e.g., about 6%, by weight, of a binder (e.g., a natural binder such as gelatin); about 0.1% to about 5%, e.g., about 0.5% to about 1.5%, by weight, of a foaming agent (e.g., a surfactant, e.g., SDS); about 2% to about 98% by weight of an insulating filler (e.g., an expanded silicate material); and about 0% to about 30% by weight of additives, with the remainder being solvent (e.g., a liquid solvent such as water).

[0021] In some embodiments, the mixture (after dispersion of the insulating filler) comprises (e.g., consists of) about 1% to about 10%, e.g., about 1.5% to about 5%, or about 1.8% to about 5%, or about 2% to about 6%, by weight, of a clay mineral (e.g., a smectite clay mineral such as montmorillonite); about 1% to about 10%, e.g., about 1% to about 5%, or about 2% to about 6%, by weight, of a reinforcing agent (e.g., a polymeric reinforcing agent such as polyvinyl alcohol and / or sodium polyacrylate); about 1% to about 98%, e.g., about 1% to about 10%, or about 10% to about 98%, by weight, of an insulating filler (e.g., an expanded silicate material); and about 0% to about 30%, e.g., about 0% to about 10%, by weight, of additives, with the remainder being a solvent (e.g., a liquid solvent such as water).

[0022] <Thermal insulating filler> A thermal insulating filler is understood to be a filler material having thermal insulating properties. The thermal insulating filler typically has a thermal conductivity, measured in accordance with EN 12667, that is equal to or greater than the thermal conductivity of the matrix in which the thermal insulating filler is dispersed. The thermal insulating filler may have a thermal conductivity, measured in accordance with EN 12667, of about 0.0200 W / mK or greater, e.g., about 0.0300 W / mK or greater, or about 0.0400 W / mK or greater, or about 0.0500 W / mK or greater. The thermal insulating filler may have a thermal conductivity, measured in accordance with EN 12667, of about 0.0800 W / mK or less, e.g., about 0.0700 W / mK or less, or about 0.0600 W / mK or less. The thermal insulating filler has a thermal conductivity of about 0.0200 W / mK to about 0.0800 W / mK, for example, about 0.0200 W / mK to about 0.0700 W / mK, or about 0.0200 W / mK to about 0.0600 W / mK, or about 0.0300 W / mK to about 0.0800 W / mK, or about 0.0300 W / mK to about 0.0700 W / mK, or about 0.0300 W / mK to about 0.0600 W / mK, or about 0.0400 W / mK 0.0500 W / mK to about 0.0800 W / mK, or about 0.0400 W / mK to about 0.0700 W / mK, or about 0.0400 W / mK to about 0.0600 W / mK, or about 0.0500 W / mK to about 0.0800 W / mK, or about 0.0500 W / mK to about 0.0700 W / mK, or about 0.0500 W / mK to about 0.0600 W / mK.

[0023] The insulating filler may be a granular material. The insulating filler may be a porous material. The insulating filler may be a porous granular material. The insulating filler may be an intumescent material. That is, the insulating filler may be formed by expanding an intumescent material, for example, by heating the intumescent material. The expansion of the intumescent material may be achieved by the release of bound water upon heating the material. Thus, the intumescent material may be a hydrated material. The insulating filler may be a silicate material, for example, the insulating filler may be an expanded silicate material.

[0024] Throughout this specification and the appended claims, the term "silicate material" refers to a material containing substantial proportions of silicon and oxygen. Silicate materials include silicate salts, which include orthosilicate, metasilicate, and pyrosilicate anions of the general formula:

number

[0003] Silicate materials also include silicate glasses, which are amorphous (i.e., non-crystalline) solid materials formed primarily from a covalently bonded silicon dioxide network, i.e., materials commonly referred to simply as "glass."

[0004] Silicate materials also include silicate minerals, which are rock-forming minerals having primarily silicate anions or formed primarily from silicon dioxide.

[0025] Silicate materials include aluminosilicate materials. The term "aluminosilicate material" refers to silicate materials that contain aluminum in addition to silicon and oxygen. Thus, aluminosilicate materials include aluminosilicate salts, aluminosilicate glasses, and aluminosilicate minerals.

[0026] Expanded silicate material is approximately 15 kg / m 3 More than, for example, about 20 kg / m 3 or more, or approximately 30 kg / m 3 or more, or about 40 kg / m 3 or more, or about 50 kg / m 3 or more, or approximately 55 kg / m 3 or more, or approximately 60 kg / m 3 or more, or approximately 65 kg / m 3 or more, or approximately 70 kg / m 3 The expanded silicate material may have a loose bulk density measured in accordance with PI 200-77 of about 450 kg / m or more. 3 Below, for example, about 400 kg / m 3 or less, or about 350 kg / m 3 or less, or about 300 kg / m 3or less, or about 250 kg / m 3 or less, or about 200 kg / m 3 or less, or about 150 kg / m 3 or less, or about 100 kg / m 3 or less, or about 80 kg / m 3 or less, or about 70 kg / m 3 or less, or about 60 kg / m 3 or less, or about 50 kg / m 3 or less, or about 40 kg / m 3 It may have a loose bulk density measured in accordance with PI 200-77 below. Expanded silicate material is approximately 15 kg / m 3 ~about 450kg / m 3 , for example, about 15 kg / m 3 ~about 400kg / m 3 , or about 15 kg / m 3 ~About 350kg / m 3 , or about 15 kg / m 3 ~about 300kg / m 3 , or about 15 kg / m 3 ~about 250kg / m 3 , or about 15 kg / m 3 ~about 200kg / m 3 , or about 15 kg / m 3 ~Approx. 150kg / m 3 , or about 15 kg / m 3 ~about 100kg / m 3 , or about 15 kg / m 3 ~about 80kg / m 3 , or about 15 kg / m 3 ~about 70kg / m 3 , or about 15 kg / m 3 ~about 60kg / m 3 , or about 15 kg / m 3 ~about 50kg / m 3 , or about 15 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0027] Expanded silicate material is approximately 20 kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m3 ~about 400kg / m 3 , or about 20 kg / m 3 ~About 350kg / m 3 , or about 20 kg / m 3 ~about 300kg / m 3 , or about 20 kg / m 3 ~about 250kg / m 3 , or about 20 kg / m 3 ~about 200kg / m 3 , or about 20 kg / m 3 ~Approx. 150kg / m 3 , or about 20 kg / m 3 ~about 100kg / m 3 , or about 20 kg / m 3 ~about 80kg / m 3 , or about 20 kg / m 3 ~about 70kg / m 3 , or about 20 kg / m 3 ~about 60kg / m 3 , or about 20 kg / m 3 ~about 50kg / m 3 , or about 20 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded silicate material is approximately 30 kg / m 3 ~about 450kg / m 3 , for example, about 30 kg / m 3 ~about 400kg / m 3 , or about 30 kg / m 3 ~About 350kg / m 3 , or about 30 kg / m 3 ~about 300kg / m 3 , or about 30 kg / m 3 ~about 250kg / m 3 , or about 30 kg / m 3 ~about 200kg / m 3 , or about 30 kg / m 3 ~Approx. 150kg / m 3 , or about 30 kg / m 3 ~about 100kg / m 3 , or about 30 kg / m 3 ~about 80kg / m 3 , or about 30 kg / m3 ~about 70kg / m 3 , or about 30 kg / m 3 ~about 60kg / m 3 , or about 30 kg / m 3 ~about 50kg / m 3 , or about 30 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0028] Expanded silicate material is approximately 40 kg / m 3 ~about 450kg / m 3 , for example, about 40 kg / m 3 ~about 400kg / m 3 , or about 40 kg / m 3 ~About 350kg / m 3 , or about 40 kg / m 3 ~about 300kg / m 3 , or about 40 kg / m 3 ~about 250kg / m 3 , or about 40 kg / m 3 ~about 200kg / m 3 , or about 40 kg / m 3 ~Approx. 150kg / m 3 , or about 40 kg / m 3 ~about 100kg / m 3 , or about 40 kg / m 3 ~about 80kg / m 3 , or about 40 kg / m 3 ~about 70kg / m 3 , or about 40 kg / m 3 ~about 60kg / m 3 , or about 40 kg / m 3 ~about 50kg / m 3 , or about 40 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded silicate material is approximately 50 kg / m 3 ~about 450kg / m 3 , for example, about 50 kg / m 3 ~about 400kg / m 3 , or about 50 kg / m 3 ~About 350kg / m3 , or about 50 kg / m 3 ~about 300kg / m 3 , or about 50 kg / m 3 ~about 250kg / m 3 , or about 50 kg / m 3 ~about 200kg / m 3 , or about 50 kg / m 3 ~Approx. 150kg / m 3 , or about 50 kg / m 3 ~about 100kg / m 3 , or about 50 kg / m 3 ~about 80kg / m 3 , or about 50 kg / m 3 ~about 70kg / m 3 , or about 50 kg / m 3 ~about 60kg / m 3 , or about 50 kg / m 3 ~about 50kg / m 3 , or about 50 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0029] Expanded silicate material is approximately 55 kg / m 3 ~about 450kg / m 3 , for example, about 55 kg / m 3 ~about 400kg / m 3 , or about 55 kg / m 3 ~About 350kg / m 3 , or about 55 kg / m 3 ~about 300kg / m 3 , or about 55 kg / m 3 ~about 250kg / m 3 , or about 55 kg / m 3 ~about 200kg / m 3 , or about 55 kg / m 3 ~Approx. 150kg / m 3 , or about 55 kg / m 3 ~about 100kg / m 3 , or about 55 kg / m 3 ~about 80kg / m 3 , or about 55 kg / m 3 ~about 70kg / m 3 , or about 55 kg / m3 ~about 60kg / m 3 , or about 55 kg / m 3 ~about 50kg / m 3 , or about 55 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded silicate material is approximately 60 kg / m 3 ~about 450kg / m 3 , for example, about 60 kg / m 3 ~about 400kg / m 3 , or about 60 kg / m 3 ~About 350kg / m 3 , or about 60 kg / m 3 ~about 300kg / m 3 , or about 60 kg / m 3 ~about 250kg / m 3 , or about 60 kg / m 3 ~about 200kg / m 3 , or about 60 kg / m 3 ~Approx. 150kg / m 3 , or about 60 kg / m 3 ~about 100kg / m 3 , or about 60 kg / m 3 ~about 80kg / m 3 , or about 60 kg / m 3 ~about 70kg / m 3 , or about 60 kg / m 3 ~about 60kg / m 3 , or about 60 kg / m 3 ~about 50kg / m 3 , or about 60 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0030] Expanded silicate material is approximately 65 kg / m 3 ~about 450kg / m 3 , for example, about 65 kg / m 3 ~about 400kg / m 3 , or approximately 65 kg / m 3 ~about 350kg / m 3 , or approximately 65 kg / m 3 ~about 300kg / m3 , or approximately 65 kg / m 3 ~about 250kg / m 3 , or approximately 65 kg / m 3 ~about 200kg / m 3 , or approximately 65 kg / m 3 ~Approx. 150kg / m 3 , or approximately 65 kg / m 3 ~about 100kg / m 3 , or approximately 65 kg / m 3 ~about 80kg / m 3 , or approximately 65 kg / m 3 ~about 70kg / m 3 , or approximately 65 kg / m 3 ~about 60kg / m 3 , or approximately 65 kg / m 3 ~about 50kg / m 3 , or approximately 65 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421. Expanded silicate material is approximately 70 kg / m 3 ~about 450kg / m 3 , for example, about 70 kg / m 3 ~about 400kg / m 3 , or about 70 kg / m 3 ~about 350kg / m 3 , or about 70 kg / m 3 ~about 300kg / m 3 , or about 70 kg / m 3 ~about 250kg / m 3 , or about 70 kg / m 3 ~about 200kg / m 3 , or about 70 kg / m 3 ~Approx. 150kg / m 3 , or about 70 kg / m 3 ~about 100kg / m 3 , or about 70 kg / m 3 ~about 80kg / m 3 , or about 70 kg / m 3 ~about 70kg / m 3 , or about 70 kg / m 3 ~about 60kg / m 3 , or about 70 kg / m 3 ~about 50kg / m 3, or about 70 kg / m 3 ~about 40kg / m 3 The composition may have a loose bulk density measured in accordance with PI 200-77 of the United States Patent No. 5,620,421.

[0031] For example, expanded silicate materials may have a viscosity of about 30 to about 60 kg / m as measured according to PI 200-77. 3 The powder may have a loose bulk density of 0.05 to 0.05. The loose bulk density of a material can be measured by taking a sample of the material (750-1000 mL) with a sampler, pouring the sample into a weighed cylinder, and carefully allowing it to settle without disturbing the sample. The mass and volume of the sample are then recorded, and the loose bulk density is calculated as follows: Loose bulk density [kg / m 3 ]=1000×mass[g] / volume[mL] In addition to, or as an alternative to, any of the loose bulk densities described above, the expanded silicate material may have a resistance to compaction as measured in accordance with PI 306-80 of about 3 PSI at 2" or greater, e.g., about 5 PSI at 2" or greater, or about 10 PSI at 2" or greater, or about 20 PSI at 2", or about 30 PSI at 2", or about 40 PSI at 2". The expanded silicate material may have a resistance to compaction as measured according to PI 306-80 of about 350 PSI at 2" or less, for example, about 300 PSI at 2" or less, or about 250 PSI at 2", or about 200 PSI at 2", or about 100 PSI at 2", or about 90 PSI at 2", or about 80 PSI at 2", or about 75 PSI at 2", or about 50 PSI at 2", or about 40 PSI at 2", or about 30 PSI at 2", or about 20 PSI at 2", or about 15 PSI at 2", or about 10 PSI at 2".

[0032] The expanded silicate material may have a resistance to compaction measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2", for example, from about 3 PSI to about 300 PSI at 2", or from about 3 PSI to about 250 PSI at 2", or from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 90 PSI at 2", or from about 3 PSI to about 80 PSI at 2", or from about 3 PSI to about 75 PSI at 2", or from about 3 PSI to about 50 PSI at 2", or from about 3 PSI to about 40 PSI at 2", or from about 3 PSI to about 30 PSI at 2", or from about 3 PSI to about 20 PSI at 2", or from about 3 PSI to about 15 PSI at 2", or from about 3 PSI to about 10 PSI at 2". The expanded silicate material may have a resistance to compaction measured according to PI 306-80 of from about 5 PSI to about 350 PSI at 2", for example, from about 5 PSI to about 300 PSI at 2", or from about 5 PSI to about 250 PSI at 2", or from about 5 PSI to about 200 PSI at 2", or from about 5 PSI to about 100 PSI at 2", or from about 5 PSI to about 90 PSI at 2", or from about 5 PSI to about 80 PSI at 2", or from about 5 PSI to about 75 PSI at 2", or from about 5 PSI to about 50 PSI at 2", or from about 5 PSI to about 40 PSI at 2", or from about 5 PSI to about 30 PSI at 2", or from about 5 PSI to about 20 PSI at 2", or from about 5 PSI to about 15 PSI at 2", or from about 5 PSI to about 10 PSI at 2".

[0033] The expanded silicate material may have a pressure range of about 10 PSI to about 350 PSI at 2", for example, about 10 PSI to about 300 PSI at 2", or about 10 PSI to about 250 PSI at 2", or about 10 PSI to about 200 PSI at 2", or about 10 PSI to about 100 PSI at 2", or about 10 PSI to about 90 PSI at 2", or about 10 PSI to about 80 PSI at 2", or about 10 PSI to about 100 PSI at 2". The material may have a resistance to consolidation measured according to PI 306-80 of from about 10 PSI to about 75 PSI at 2", or from about 10 PSI to about 50 PSI at 2", or from about 10 PSI to about 40 PSI at 2", or from about 10 PSI to about 30 PSI at 2", or from about 10 PSI to about 20 PSI at 2", or from about 10 PSI to about 15 PSI at 2", or from about 10 PSI to about 10 PSI at 2". The expanded silicate material may have a pressure range of about 20 PSI to about 350 PSI at 2", for example, about 20 PSI to about 300 PSI at 2", or about 20 PSI to about 250 PSI at 2", or about 20 PSI to about 200 PSI at 2", or about 20 PSI to about 100 PSI at 2", or about 20 PSI to about 90 PSI at 2", or about 20 PSI to about 80 PSI at 2", or about 20 PSI to about 100 PSI at 2". The urethane foam may have a resistance to consolidation measured according to PI 306-80 of from about 20 PSI to about 75 PSI at 2", or from about 20 PSI to about 50 PSI at 2", or from about 20 PSI to about 40 PSI at 2", or from about 20 PSI to about 30 PSI at 2", or from about 20 PSI to about 20 PSI at 2", or from about 20 PSI to about 15 PSI at 2", or from about 20 PSI to about 10 PSI at 2".

[0034] The expanded silicate material may have a pressure range of about 30 PSI to about 350 PSI at 2", for example, about 30 PSI to about 300 PSI at 2", or about 30 PSI to about 250 PSI at 2", or about 30 PSI to about 200 PSI at 2", or about 30 PSI to about 100 PSI at 2", or about 30 PSI to about 90 PSI at 2", or about 30 PSI to about 80 PSI at 2", or about 30 PSI to about 100 PSI at 2". The material may have a resistance to consolidation measured according to PI 306-80 of from about 30 PSI to about 75 PSI at 2", or from about 30 PSI to about 50 PSI at 2", or from about 30 PSI to about 40 PSI at 2", or from about 30 PSI to about 30 PSI at 2", or from about 30 PSI to about 20 PSI at 2", or from about 30 PSI to about 15 PSI at 2", or from about 30 PSI to about 10 PSI at 2".

[0035] The expanded silicate material may have a pressure range of about 40 PSI to about 3500 PSI at 2", for example, about 40 PSI to about 300 PSI at 2", or about 40 PSI to about 250 PSI at 2", or about 40 PSI to about 200 PSI at 2", or about 40 PSI to about 100 PSI at 2", or about 40 PSI to about 90 PSI at 2", or about 40 PSI to about 80 PSI at 2", or about 40 PSI to about 100 PSI at 2". In some embodiments, the urethane foam may have a resistance to consolidation measured according to PI 306-80 of from about 40 PSI to about 75 PSI at 2", or from about 40 PSI to about 50 PSI at 2", or from about 40 PSI to about 40 PSI at 2", or from about 40 PSI to about 30 PSI at 2", or from about 40 PSI to about 20 PSI at 2", or from about 40 PSI to about 15 PSI at 2", or from about 40 PSI to about 10 PSI at 2". Additionally or alternatively, the expanded silicate material may have a resistance to compaction as measured according to PI 306-80 of about 0.5 PSI at 1" or greater, e.g., about 1 PSI at 1" or greater, or about 2 PSI at 1", or about 2.5 PSI at 1". The expanded silicate material may have a resistance to compaction as measured according to PI 306-80 of about 50 PSI at 1", e.g., about 40 PSI at 1", or about 30 PSI at 1". The expanded silicate material may have a resistance to compaction as measured according to PI 306-80 of between about 0.5 PSI at 1" and about 50 PSI at 1", e.g., between about 1 PSI at 1" and about 40 PSI at 1", or between about 2 PSI at 1" and about 40 PSI at 1", or between about 2.5 PSI at 1" and about 30 PSI at 1".

[0036] The consolidation resistance of a material can be measured by taking a representative sample of the material, approximately 500 mL in volume, with a sampler. The sample is placed in the container of a computer-controlled hydraulic press. The container is shaken 25 times to allow the sample to settle. An additional 250 mL of material is then added to the container. The sample is again allowed to settle by shaking 25 more times. The sample is then leveled on top of the container. The sample is pressed under the automatic hydraulic press at a speed of 20 mm / min and a maximum load of 6800 N (or 2800 N for very light samples). The computer continuously records the load and sample displacement and plots the data as a graph. Once the maximum load is reached, the instrument calculates the total displacement and zero deformation point. The load / displacement data is exported and the respective load values ​​(B) for 1 inch (i.e., 1") and 2 inch (i.e., 2") displacements (adding the zero deformation point, i.e., 1 inch deformation distance (mm) = 25.4 + zero deformation point (mm)) are used to calculate the consolidation resistance according to the following: Consolidation resistance [PSI]=(B[N] / A[m 2 ]) * 0.000145037738007 where A is the cross-sectional area of ​​the vessel.

[0037] In addition to, or as an alternative to, the loose bulk density and / or compaction resistance mentioned above, the expanded silicate material may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of about 0.0300 W / mK or more, for example about 0.0310 W / mK or more, or about 0.0320 W / mK or more, or about 0.0330 W / mK or more, or about 0.0340 W / mK or more, or about 0.0350 W / mK or more, or about 0.0360 W / mK or more. The expanded silicate material has a thermal conductivity of about 0.0700 W / mK or less, for example about 0.0600 W / mK or less, or about 0.0500 W / mK or less, or about 0.0490 W / mK or less, or about 0.0480 W / mK or less, or about 0.0470 W / mK or less, or about 0.0460 W / mK or less, or about 0.0450 W / mK or less, or about 0.0440 W / mK or less, or about 0.0430 W / mK or less, or a thermal conductivity measured in accordance with EN 12667 of about 0.0420 W / mK or less, or about 0.0410 W / mK or less, or about 0.0400 W / mK or less, or about 0.0390 W / mK or less, or about 0.0380 W / mK or less, or about 0.0370 W / mK or less, or about 0.0360 W / mK or less, or about 0.0350 W / mK or less, or about 0.0340 W / mK or less.

[0038] The expanded silicate material may have a thermal conductivity of from about 0.0300 W / mK to about 0.0700 W / mK, for example, from about 0.0300 W / mK to about 0.0600 W / mK, or from about 0.0300 W / mK to about 0.0500 W / mK, from about 0.0300 W / mK to about 0.0490 W / mK, or from about 0.0300 W / mK to about 0.0480 W / mK. W / mK, or about 0.0300 W / mK to about 0.0470 W / mK, or about 0.0300 W / mK to about 0.0460 W / mK, or about 0.0300 W / mK to about 0.0450 W / mK, or about 0.0300 W / mK to about 0.0440 W / mK, or about 0.0300 W / mK to about 0.0430 W / mK, or is about 0.0300 W / mK to about 0.0420 W / mK, or about 0.0300 W / mK to about 0.0410 W / mK, or about 0.0300 W / mK to about 0.0400 W / mK, or about 0.0300 W / mK to about 0.0390 W / mK, or 0.0300 W / mK to about 0.0380 W / mK, or about 0.03 The thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 may be from about 0.00 W / mK to about 0.0370 W / mK, or from about 0.0300 W / mK to about 0.0360 W / mK, or from about 0.0300 W / mK to about 0.0350 W / mK, or from about 0.0300 W / mK to about 0.0340 W / mK.

[0039] The expanded silicate material may have a thermal conductivity of from about 0.0310 W / mK to about 0.0500 W / mK, for example, from about 0.0310 W / mK to about 0.0490 W / mK, or from about 0.0310 W / mK to about 0.0480 W / mK, or from about 0.0310 W / mK to about 0.0470 W / mK, or from about 0.0310 W / mK to about 0.0460 W / mK, or from about 0.0310 W / mK to about 0.0450 W / mK, or from about 0.0310 W / mK to about 0.0440 W / mK, or from about 0.0310 W / mK to about 0.0430 W / mK, or from about 0.0310 W / mK to about 0.0420 W / mK, or may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of from about 0.0310 W / mK to about 0.0410 W / mK, or from about 0.0310 W / mK to about 0.0400 W / mK, or from about 0.0310 W / mK to about 0.0390 W / mK, or from about 0.0310 W / mK to about 0.0380 W / mK, or from about 0.0310 W / mK to about 0.0370 W / mK, or from about 0.0310 W / mK to about 0.0360 W / mK, or from about 0.0310 W / mK to about 0.0350 W / mK, or from about 0.0310 W / mK to about 0.0340 W / mK.

[0040] The expanded silicate material may have a thermal conductivity of from about 0.0320 W / mK to about 0.0500 W / mK, for example, from about 0.0320 W / mK to about 0.0490 W / mK, or from about 0.0320 W / mK to about 0.0480 W / mK, or from about 0.0320 W / mK to about 0.0470 W / mK, or from about 0.0320 W / mK to about 0.0460 W / mK, or from about 0.0320 W / mK to about 0.0450 W / mK, or from about 0.0320 W / mK to about 0.0440 W / mK, or from about 0.0320 W / mK to about 0.0430 W / mK, or from about 0.0320 W / mK to about 0.0420 W / mK, or may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of from about 0.0320 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0400 W / mK, or from about 0.0320 W / mK to about 0.0390 W / mK, or from about 0.0320 W / mK to about 0.0380 W / mK, or from about 0.0320 W / mK to about 0.0370 W / mK, or from about 0.0320 W / mK to about 0.0360 W / mK, or from about 0.0320 W / mK to about 0.0350 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK.

[0041] The expanded silicate material has a thermal conductivity of about 0.0330 W / mK to about 0.0500 W / mK, for example, about 0.0330 W / mK to about 0.0490 W / mK, or about 0.0330 W / mK to about 0.0480 W / mK, or about 0.0330 W / mK to about 0.0470 W / mK, or about 0.0330 W / mK to about 0.0460 W / mK, or about 0.0330 W / mK to about 0.0450 W / mK, or about 0.0330 W / mK to about 0.0440 W / mK, or about 0.0330 W / mK to about 0.0430 W / mK, or about 0.0330 W / mK to about 0.0420 W / mK, or may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of from about 0.0330 W / mK to about 0.0410 W / mK, or from about 0.0330 W / mK to about 0.0400 W / mK, or from about 0.0330 W / mK to about 0.0390 W / mK, or from about 0.0330 W / mK to about 0.0380 W / mK, or from about 0.0330 W / mK to about 0.0370 W / mK, or from about 0.0330 W / mK to about 0.0360 W / mK, or from about 0.0330 W / mK to about 0.0350 W / mK, or from about 0.0330 W / mK to about 0.0340 W / mK.

[0042] The expanded silicate material has a thermal conductivity of about 0.0340 W / mK to about 0.0500 W / mK, for example, about 0.0340 W / mK to about 0.0490 W / mK, or about 0.0340 W / mK to about 0.0480 W / mK, or about 0.0340 W / mK to about 0.0470 W / mK, or about 0.0340 W / mK to about 0.0460 W / mK, or about 0.0340 W / mK to about 0.0450 W / mK, or about 0.0340 W / mK to about 0.0440 W / mK, or about 0.0340 W / mK to about 0.043 ... It may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of about 0.0420 W / mK, or about 0.0340 W / mK to about 0.0410 W / mK, or about 0.0340 W / mK to about 0.0400 W / mK, or about 0.0340 W / mK to about 0.0390 W / mK, or 0.0340 W / mK to about 0.0380 W / mK, or about 0.0340 W / mK to about 0.0370 W / mK, or about 0.0340 W / mK to about 0.0360 W / mK, or about 0.0340 W / mK to about 0.0350 W / mK.

[0043] The expanded silicate material may have a thermal conductivity of about 0.0350 W / mK to about 0.0500 W / mK, for example, about 0.0350 W / mK to about 0.0490 W / mK, or about 0.0350 W / mK to about 0.0480 W / mK, or about 0.0350 W / mK to about 0.0470 W / mK, or about 0.0350 W / mK to about 0.0460 W / mK, or about 0.0350 W / mK to about 0.0450 W / mK, or about 0.0350 W / mK to about 0.0440 W / mK, or about 0.0350 W / mK to about 0.0430 W / mK, or may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of from about 0.0350 W / mK to about 0.0420 W / mK, or from about 0.0350 W / mK to about 0.0410 W / mK, or from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0350 W / mK to about 0.0390 W / mK, or from 0.0350 W / mK to about 0.0380 W / mK, or from about 0.0350 W / mK to about 0.0370 W / mK, or from about 0.0350 W / mK to about 0.0360 W / mK.

[0044] The expanded silicate material has a thermal conductivity of about 0.0360 W / mK to about 0.0500 W / mK, for example, about 0.0360 W / mK to about 0.0490 W / mK, or about 0.0360 W / mK to about 0.0480 W / mK, or about 0.0360 W / mK to about 0.0470 W / mK, or about 0.0360 W / mK to about 0.0460 W / mK, or about 0.0360 W / mK to about 0.0450 W / mK, or about 0.0360 W / mK to about 0.0440 W / mK, or about 0.0360 W / mK to about 0.0470 W / mK, It may have a thermal conductivity (i.e., λ, lambda value) measured in accordance with EN 12667 of about 0.0430 W / mK, or about 0.0360 W / mK to about 0.0420 W / mK, or about 0.0360 W / mK to about 0.0410 W / mK, or about 0.0360 W / mK to about 0.0400 W / mK, or about 0.0360 W / mK to about 0.0390 W / mK, or 0.0360 W / mK to about 0.0380 W / mK, or about 0.0360 W / mK to about 0.0370 W / mK. The expanded silicate material may have a thermal conductivity (ie, λ, lambda value) measured according to EN 12667 of from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK.

[0045] For example, expanded silicate materials have a density of about 15 kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 a loose bulk density measured in accordance with PI 200-77 of from about 3 PSI to about 100 PSI at 2 inches, e.g., from about 3 PSI to about 10 PSI at 2 inches, or from about 30 PSI to about 80 PSI at 2 inches, or from about 40 PSI to about 75 PSI at 2 inches, or from about 5 PSI to about 20 PSI at 2 inches; and / or a resistance to compaction measured in accordance with PI 306-80 of from about 0.0300 W / mK to about 0.0700 W / mK , for example, from about 0.0320 W / mK to about 0.0420 W / mK, from about 0.0350 W / mK to about 0.0400 W / mK, or from about 0.0360 W / mK to about 0.0410 W / mK, or from about 0.0320 W / mK to about 0.0340 W / mK, or from about 0.042 W / mK to about 0.055 W / mK, or from about 0.055 W / mK to about 0.070 W / mK.

[0046] The thermal conductivity of a material can be measured using a Netzsch HFM 436 / 3 Lambda Heat Flow Meter. The material sample is held under standard laboratory conditions before measurements are taken. The loosely packed sample is placed in a custom frame constructed from a 30 x 30 x 2.5 cm piece of XPS, with inner dimensions of 15 x 15 cm and a thin plastic membrane at the bottom to hold the loosely packed sample in place. The average temperature, as well as the temperature difference between the cold and hot plates, are both set to 10°C. The expanded silicate material may have a water absorption (grams of water absorbed per gram of expanded silicate material) of about 0.1 g / g or more, e.g., about 0.2 g / g or more, or about 0.5 g / g or more, or about 1 g / g or more. The expanded silicate material may have a water absorption (grams of water absorbed per gram of expanded silicate material) of about 15 g / g or less, e.g., about 10 g / g or less. The expanded silicate material may have a water absorption (grams of water absorbed per gram of expanded silicate material) of about 0.1 g / g to about 15 g / g, e.g., about 0.2 g / g to about 15 g / g, or about 0.5 g / g to about 10 g / g, or about 1 g / g to about 10 g / g. The water absorption of a granular material can be measured by first accurately weighing 500 ml of the granular material and recording the mass of the sample. The 500 ml sample is transferred to a 500 ml cylinder with a very fine sieve at the bottom, sufficient to retain the granular material within the cylinder while allowing water to pass through. The cylinder is tapped 10 times to allow the material to settle. 250 g of water is weighed and poured into the cylinder containing the granular material. A timer is started, and the mass of water passing through the material and exiting the cylinder is measured after 3, 5, 7, 10, and 30 minutes. The water absorption of a granular material is therefore the mass of water that did not pass through the cylinder (i.e., the mass of water absorbed) per mass of granular material in the cylinder (expressed in g / g).

[0047] The expanded silicate material may have a water repellency of about 40% or more, for example, about 50% or more, or about 60% or more, or about 65% or more. The expanded silicate material may have a water repellency of about 95% or less, for example, about 90% or less. The expanded silicate material may have a water repellency of about 40% to about 95%, for example, about 50% to about 95%, or about 60% to about 95%, or about 65% to about 90%. The water repellency of a material can be determined by taking a representative sample of the material (500 mL) with a sampler and weighing the sample. Using a funnel, transfer the sample to a graduated cylinder with a perforated base. To allow the sample to settle, drop the cylinder from a height of approximately 7.5 cm 10 times. Slowly pour 250 g of deionized water into the cylinder containing the sample, avoiding water loss or cavitation in the sample. At 3, 5, 7, 10, and 30 minutes, collect the water that passes through the sample in a weighed glass beaker below the cylinder, and weigh the water in the glass beaker. After 30 minutes, tilt the cylinder 45° to pour off any remaining water. The water absorption rate over 30 minutes is then calculated according to the following formula:

number

[0048] The expanded silicate material may comprise about 95% or more floater, for example, about 97% or more, or about 99% or more floater. The expanded silicate material may comprise up to 100% floater. The expanded silicate material may comprise about 95% to about 100%, for example, about 97% to about 100%, or about 99% to about 100% floater. The number of suspended particles in a sample of material is determined using an Imhoff cone. Specifically, 600 mL of deionized water is poured into an Imhoff cone fixed vertically on a rack. An additional 50 mL of deionized water containing 20 drops of bromothymol blue or methylene blue indicator is added to the cone. The indicator is used to facilitate reading the cone by the color it imparts to the water. A 300 mL representative sample of the material to be investigated is taken with a sampler. The exact volume (A mL) and mass (B g) of the sample are recorded and the sample is added to the cone. An additional 300 mL of deionized water is added to the sample in the cone, so that a total of 950 mL of water is in the Imhoff cone. The sample and water are stirred 20 times with a stirring rod. The upper wall and rod of the cone are rinsed with 50 mL of deionized water (so that a total of 1000 mL of water is in the cone) to wash any particles adhering to them into the cone. The cone and its contents are allowed to stand for 45 minutes. After this time, the volume of the cone (C mL) corresponding to the level (C mL) of dark particles (i.e., "sink") at the bottom of the cone is recorded. The volume of the cone (D mL) corresponding to the level of total sediment at the bottom of the cone is also recorded. The percentages of "settler," "shattered," and "floating" are then determined according to the following formula:

[0049]

number

[0050] The expanded silicate material may have a pH, as measured according to PI 202-77, of about 8 or greater, e.g., about 9 or greater, or about 9.5 or greater. The expanded silicate material may have a pH, as measured according to PI 202-77, of about 12 or less, e.g., about 11 or less. The expanded silicate material may have a pH, as measured according to PI 202-77, of about 8 to about 12, e.g., about 9 to about 11, or about 9.5 to about 11. The pH of the expanded silicate material may be determined by mixing 0.5 g of the granular material with 50 mL of deionized water and stirring at room temperature for 30 minutes. The pH value is measured (e.g., using a pH probe) and recorded during the last 2 minutes of stirring. Natural perlite may have a pH up to about 8.5. The expanded silicate material is approximately 0.4 g / cm 3 More than, for example, about 0.5 g / cm 3 or more, or about 0.6 g / cm 3 The expanded silicate material may have a skeletal density of about 2 g / cm or more. 3 For example, about 1.8 g / cm 3 or less, or about 1.6 g / cm 3 The expanded silicate material may have a skeletal density of about 0.4 g / cm 3 ~About 2g / cm 3 , for example, about 0.5 g / cm 3 ~Approx. 1.8g / cm 3 , or about 0.6 g / cm 3 ~Approx. 1.6g / cm 3 The skeletal density of a porous material (i.e., the absolute density of a porous material determined using the volume of the porous material excluding both the volume of any pores and the volume of any voids between particles) can be measured using a stereopycnometer, for example, available from Quantachrome.

[0051] The expanded silicate material may comprise about 0.01% or more, e.g., about 0.1% or more, or about 0.2% or more, or about 0.3% or more, or about 0.4% or more, or about 1% or more, or about 1.5% or more, or about 2% or more, or about 3% or more, by weight, of X2O (where X is an alkali metal such as Na or Li). The expanded silicate material may comprise about 25% or less, e.g., about 20% or less, or about 15% or less, or about 10% or less, or about 5% or less, or about 3% or less, or about 2% or less, or about 1% or less, or about 0.6% or less, by weight of X2O (where X is an alkali metal such as Na or Li). The expanded silicate material is present in an amount of from about 0.01% to about 25% by weight, for example, from about 0.01% to about 20% by weight, or from about 0.01% to about 15% by weight, or from about 0.01% to about 10% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.1% to about 10% by weight, or from about 1% to about 20% by weight, or from about 1% to about 15% by weight, or from about 1% to about 10% by weight, or about 3% by weight. % to about 20% by mass, or about 3% to about 15% by mass, or about 3% to about 10% by mass, or about 0.1% to about 5% by mass, or about 0.2% to about 5% by mass, or about 0.2% to about 1% by mass, or about 0.4% to about 1% by mass, or about 0.4% to about 0.6% by mass, or about 1% to about 3% by mass, or about 1% to about 2% by mass of XO (wherein X is an alkali metal such as Na or Li).

[0052] For example, the expanded silicate material may contain about 0.01% by weight or more NaO, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more, or about 2% by weight or more, or about 3% by weight or more. The expanded silicate material may contain about 25% by weight or less NaO, e.g., about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.6% by weight or less. The expanded silicate material is present in an amount of from about 0.01% to about 25% by weight, for example, from about 0.01% to about 20% by weight, or from about 0.01% to about 15% by weight, or from about 0.01% to about 10% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.1% to about 10% by weight, or from about 1% to about 20% by weight, or from about 1% to about 15% by weight, or from about 1% to about It may contain 10% by mass, or about 3% to about 20% by mass, or about 3% to about 15% by mass, or about 3% to about 10% by mass, or about 0.1% to about 5% by mass, or about 0.2% to about 5% by mass, or about 0.2% to about 1% by mass, or about 0.4% to about 1% by mass, or about 0.4% to about 0.6% by mass, or about 1% to about 3% by mass, or about 1% to about 2% by mass of Na2O.

[0053] The expanded silicate material may contain about 0.01% by weight or more LiO, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more, or about 2% by weight or more, or about 3% by weight or more. The expanded silicate material may contain about 25% by weight or less LiO, e.g., about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.6% by weight or less. The expanded silicate material is present in an amount of from about 0.01% to about 25% by weight, for example, from about 0.01% to about 20% by weight, or from about 0.01% to about 15% by weight, or from about 0.01% to about 10% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.1% to about 10% by weight, or from about 1% to about 20% by weight, or from about 1% to about 15% by weight, or from about 1% to about It may contain 10% by mass, or about 3% to about 20% by mass, or about 3% to about 15% by mass, or about 3% to about 10% by mass, or about 0.1% to about 5% by mass, or about 0.2% to about 5% by mass, or about 0.2% to about 1% by mass, or about 0.4% to about 1% by mass, or about 0.4% to about 0.6% by mass, or about 1% to about 3% by mass, or about 1% to about 2% by mass of LiO.

[0054] The expanded silicate material may comprise about 0.1% by weight or more, e.g., about 0.2% by weight or more, or about 0.4% by weight or more, or about 1% by weight or more, or about 2% by weight or more, or about 3% by weight or more, or about 4% by weight or more Al2O3. The expanded silicate material may comprise about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 15% by weight or less, or about 10% by weight or less, or about 8% by weight or less, or about 6% by weight or less, or about 5% by weight or less, or about 4% by weight or less, or about 1% by weight or less, or about 0.8% by weight or less Al2O3. The expanded silicate material may contain from about 0.1% to about 30% by weight Al2O3, for example, from about 0.1% to about 25% by weight, or from about 0.1% to about 20% by weight, or from about 0.1% to about 15% by weight, or from about 0.2% to about 10% by weight, or from about 0.4% to about 1% by weight, or from about 0.4% to about 0.8% by weight, or from about 1% to about 5% by weight, or from about 2% to about 5% by weight, or from about 2% to about 4% by weight, or from about 4% to about 5% by weight.

[0055] The expanded silicate material may contain about 30% by weight or more of SiO2, for example, about 35% by weight or more, or about 40% by weight or more, or about 45% by weight or more. The expanded silicate material may contain about 80% by weight or less of SiO2, for example, about 70% by weight or less, or about 60% by weight or less, or about 55% by weight or less, or about 50% by weight or less. The expanded silicate material may contain about 30% to about 80% by weight of SiO2, for example, about 30% to about 70% by weight, or about 30% to about 60% by weight, or about 35% to about 55% by weight, or about 40% to about 50% by weight. The expanded silicate material may contain about 0.001% by weight or more of Fe2O3, e.g., about 0.01% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more. The expanded silicate material may contain about 1% by weight or less, or about 0.5% by weight or less, or about 0.4% by weight or less, or about 0.1% by weight or less of Fe2O3. The expanded silicate material may contain about 0.001% to about 1% by weight of Fe2O3, e.g., about 0.01% to about 0.5% by weight, or about 0.05% to about 0.5% by weight, or about 0.05% to about 0.1% by weight, or about 0.3% to about 0.5% by weight, or about 0.3% to about 0.4% by weight.

[0056] The expanded silicate material may contain about 0.01% by weight or more, for example about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.15% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more, or about 0.5% by weight or more CaO. The expanded silicate material may contain about 2% by weight or less, for example about 1% by weight or less, or about 0.8% by weight or less, or about 0.6% by weight or less, or about 0.5% by weight or less CaO. The expanded silicate material may contain about 0.01% to about 2% by weight of CaO, for example, about 0.05% to about 1% by weight, or about 0.1% to about 0.8% by weight, or about 0.15% to about 0.2% by weight, or about 0.3% to about 0.6% by weight, or about 0.3% to about 0.5% by weight, or about 0.5% to about 0.6% by weight. The expanded silicate material may contain about 0.001% by weight or more of MgO, for example, about 0.005% by weight or more, or about 0.01% by weight or more, or about 0.05% by weight or more. The expanded silicate material may contain about 1% by weight or less, or about 0.5% by weight or less, or about 0.1% by weight or less of MgO. The expanded silicate material may contain about 0.001% to about 1% by weight of MgO, for example, about 0.005% to about 0.5% by weight, or about 0.01% to about 0.1% by weight, or about 0.05% to about 0.1% by weight of MgO.

[0057] The expanded silicate material may contain about 0.05% by weight or more, e.g., about 0.1% by weight or more, or about 0.15% by weight or more, or about 0.2% by weight or more, or less than about 0.5% by weight, or about 1% by weight or more, or about 1.2% by weight or more of KO. The expanded silicate material may contain about 5% by weight or less, e.g., about 3% by weight or less, or about 2% by weight or less, or about 1.6% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less of KO. The expanded silicate material may contain about 0.05% to about 5% by weight KO, for example, about 0.1% to about 3% by weight, or about 0.15% to about 2% by weight, or about 0.15% to about 1% by weight, or about 0.15% to about 0.5% by weight, or about 0.5% to about 3% by weight, or about 0.5% to about 2% by weight, or about 1% to about 2% by weight, or about 1.2% to about 1.6% by weight. The expanded silicate material may contain about 0.1% by weight or more of B2O3, e.g., about 0.5% by weight or more, or about 1% by weight or more, or about 1.5% by weight or more. The expanded silicate material may contain about 5% by weight or less of B2O3, e.g., about 3.5% by weight or less, or about 3% by weight or less, or about 2.5% by weight or less. The expanded silicate material may contain about 0.1% to about 5% by weight of B2O3, e.g., about 0.5% to about 3.5% by weight, or about 1% to about 2.5% by weight.

[0058] The expanded silicate material may contain about 10% by weight or more, e.g., about 15% by weight or more, or about 20% by weight or more, or about 25% by weight or more, of water and / or volatile substances (i.e., substances that contribute to the "loss on ignition" (LOI)). The expanded silicate material may contain about 50% by weight or less, e.g., about 40% by weight or less, or about 30% by weight or less, of water and / or volatile substances (i.e., substances that contribute to the "loss on ignition" (LOI)). The expanded silicate material may contain about 10% to about 50% by weight, e.g., about 15% to about 40% by weight, or about 20% to about 30% by weight, or about 25% to about 40% by weight, or about 25% to about 30% by weight of water and / or volatile substances (i.e., substances that contribute to the "loss on ignition" (LOI)). The expanded silicate material may contain about 0.1% to about 25% by weight, for example, about 0.2% to about 5% by weight, XO (wherein X is an alkali metal such as Na or Li); about 0.1% to about 30% by weight, for example, about 0.2% to about 20% by weight, AlO; about 30% to about 80% by weight, for example, about 40% to about 60% by weight, SiO; about 10% to about 40% by weight, for example, about 15% to about 30% by weight, HO, and may contain about 5% by weight or less, for example, about 3.5% by weight or less, BO.

[0059] The expanded silicate material may comprise from about 0.1% to about 25%, e.g., from about 0.2% to about 5%, by weight of XO (wherein X is an alkali metal such as Na or Li); from about 0.1% to about 30%, e.g., from about 0.2% to about 10%, by weight of AlO; from about 30% to about 80%, e.g., from about 40% to about 60%, by weight of SiO; from about 0.01% to about 2%, e.g., from about 0.05% to about 1%, by weight of F. e2O3; about 0.01% by mass to about 1% by mass, for example, about 0.05% by mass to about 0.8% by mass of CaO; about 1% by mass or less, for example, about 0.5% by mass or less of MgO; about 0.05% by mass to about 3% by mass, for example, about 0.1% by mass to about 2% by mass of K2O; about 10% by mass to about 40% by mass, for example, about 15% by mass to about 30% by mass of H2O, and may also contain about 5% by mass or less, for example, about 3.5% by mass or less of B2O3. The expanded silicate material may be amorphous (i.e., non-crystalline). The expanded silicate material may include (e.g., be formed from) an inorganic polymer network, i.e., an inorganic polymer network that incorporates water, e.g., in the form of hydroxyl groups. Thus, the expanded silicate material may be described as a synthetic perlitic material, e.g., synthetic perlite.

[0060] The expanded silicate material can be produced by forming a silicate mixture including a silicate material; an alkali compound; and water; hardening the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expanded silicate material; and heating the particulate expanded silicate material to form the expanded silicate material. The silicate material in the silicate mixture may be a silicate salt. The silicate material in the silicate mixture may be an aluminosilicate salt. For example, the silicate material in the silicate mixture may be sodium silicate, i.e., water glass, or sodium aluminosilicate.

[0061] The silicate material in the silicate mixture may be a silicate glass. The silicate glass may primarily comprise (e.g., consist of) silicon and oxygen. However, the silicate glass may also contain one or more elements in addition to silicon and oxygen. For example, the silicate glass may contain aluminum, sodium, iron, chromium, lead, zinc, calcium, manganese, magnesium, barium, potassium, boron, fluorine, germanium, sulfur, selenium, and / or tellurium in addition to silicon and oxygen. The silicate glass may be selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. The silicate glass may include (e.g., may be) virgin glass. Additionally or alternatively, the silicate glass may include (e.g., may be) recycled glass, such as recycled glass cullet.

[0062] Unless otherwise specified, particle size characteristics referred to herein for particulate materials such as powdered glass or minerals, when particle sizes are stated to be less than 300 μm, are as measured in the well-known manner by wet Malvern laser scattering (standard ISO 13320-1). In this technique, the size of particles in powders, suspensions, and emulsions can be measured using the diffraction of a laser beam based on the application of Mie theory. Such machines, such as the Malvern Mastersizer S (supplied by Malvern instruments), provide measurements and plots of the cumulative volume percentage of particles having a size less than a given "equivalent sphere diameter" (esd), referred to in the art as the "esd." The mean particle size d 50 is the value of particle ESD thus determined, and its d 50 There are 50% by volume of particles with equivalent spherical diameters less than the value.

[0063] When particle sizes are stated to be 300 μm or larger, the particle size is measured by applying sieve size analysis. Specifically, a representative sample of the material is taken with a sampler (300-400 mL) and weighed. The sample is placed on top of a sieve with openings of 300 μm or larger (sieves with smaller openings can be used for finer samples). The sample is introduced into the sieve with the largest opening (located at the top) and a lid is attached on top. The column containing the sieve is shaken back and forth 30 times (as if scrolling) while maintaining contact with the ground. The column is then allowed to free fall four times from a height of 10 cm. The column is rotated 90° and the procedure is repeated. The fraction smaller than 300 μm is then analyzed using a laser particle analyzer. The silicate glass may be provided in the form of crushed silicate glass (i.e., silicate glass cullet). The crushed silicate glass may have a maximum particle size of about 200 μm, for example, about 150 μm, or about 100 μm, or about 80 μm, or about 70 μm, or about 65 μm. The crushed silicate glass may have a particle size of about 100 μm or less, for example, about 80 μm or less, or about 60 μm or less, or about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 30 μm or less, or about 29 μm or less, or about 28 μm or less. 50 The crushed silicate glass may have a d of about 5 μm or more, for example, about 10 μm or more, or about 15 μm or more, or about 20 μm or more, or about 25 μm or more, or about 26 μm or more, or about 27 μm or more, or about 28 μm or more. 50 The crushed silicate glass may have a diameter of about 5 μm to about 100 μm, for example, about 10 μm to about 80 μm, or about 15 μm to about 50 μm, or about 20 μm to about 35 μm, or about 25 μm to about 30 μm, or about 26 μm to about 28 μm, or about 27 μm to about 28 μm, or about 27 μm to about 29 μm, or about 28 μm to about 29 μm. 50 may have

[0064] The silicate glass may be crushed soda-lime glass having a maximum particle size of about 200 μm, e.g., about 150 μm, or about 100 μm, or about 80 μm, or about 70 μm, or about 65 μm. The silicate glass may have a diameter of about 5 μm to about 100 μm, e.g., about 10 μm to about 80 μm, or about 15 μm to about 50 μm, or about 20 μm to about 35 μm, or about 25 μm to about 30 μm, or about 27 μm to about 29 μm, or about 28 μm to about 29 μm. 50 The glass may be crushed soda lime glass having a The silicate glass may be a crushed borosilicate glass having a maximum particle size of about 200 μm, e.g., about 150 μm, or about 100 μm, or about 80 μm, or about 70 μm. The silicate glass may have a diameter of about 5 μm to about 100 μm, e.g., about 10 μm to about 80 μm, or about 15 μm to about 50 μm, or about 20 μm to about 35 μm, or about 25 μm to about 30 μm, or about 26 μm to about 28 μm, or about 27 μm to about 28 μm, or about 27 μm to about 29 μm. 50 The glass may be a crushed borosilicate glass having the formula:

[0065] Throughout this specification and the appended claims, unless otherwise specified, it is understood that the elemental composition of a glass, mineral, or silicate mixture is expressed in terms of the oxide equivalents of the elements present, as is standard in the art. For example, the composition of a glass, mineral, or silicate mixture containing silicon, aluminum, iron, calcium, magnesium, potassium, sodium, and / or boron is expressed in terms of the equivalent content of SiO2, Al2O3, Fe2O3, CaO, MgO, KO, Na2O, and / or BO3, respectively. The elemental composition of a glass, mineral, or silicate mixture can be determined using energy dispersive X-ray fluorescence (EDXRF), for example, using a Xepos instrument available from SPECTRO AI GmbH. Similarly, the mineralogical content of a material can be determined using X-ray diffraction, for example, using a SIEMENS D5000 Diffractometer with Cu Kα1 (with Ni filter) radiation, in the 2θ range of 2° to 72° and in steps of 0.02° / sec.

[0066] The silicate glass may contain about 50% by mass or more of SiO2, for example, about 60% by mass or more, or about 70% by mass or more, or about 75% by mass or more, or about 78% by mass or more. The silicate glass may contain about 100% by mass or less of SiO2, for example, about 90% by mass or less, or about 85% by mass or less, or about 80% by mass or less, or about 75% by mass or less, or about 72% by mass or less. The silicate glass may contain about 50% to about 100% by mass of SiO2, for example, about 60% to about 90% by mass, or about 70% to about 80% by mass, or about 70% to about 75% by mass, or about 70% to about 72% by mass, or about 75% to about 80% by mass, or about 78% to about 80% by mass. The silicate glass may be soda-lime glass containing about 50% to about 95% by mass of SiO2, for example, about 60% to about 90% by mass, or about 70% to about 80% by mass, or about 70% to about 75% by mass, or about 70% to about 72% by mass. The silicate glass may be borosilicate glass containing about 50% to about 95% by mass of SiO2, for example, about 60% to about 90% by mass, or about 70% to about 80% by mass, or about 75% to about 80% by mass, or about 78% to about 80% by mass.

[0067] The silicate glass may contain about 0.1% by weight or more, e.g., about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.5% by weight or more, or about 1.0% by weight or more, or about 2.0% by weight or more, or about 3.0% by weight or more Al2O3. The silicate glass may contain about 10% by weight or less, e.g., about 8.0% by weight or less, or about 6.0% by weight or less, or about 5.0% by weight or less, or about 4.0% by weight or less, or about 3.5% by weight or less, or about 3.0% by weight or less, or about 2.0% by weight or less, or about 1.0% by weight or less, or about 0.5% by weight or less Al2O3. The silicate glass may contain about 0.1% to about 10% by mass of Al2O3, for example, about 0.2% to about 8.0% by mass, or about 0.3% to about 6.0% by mass, or about 0.3% to about 0.5% by mass, or about 0.3% to about 0.4% by mass, or about 2% to about 6% by mass, or about 3% to about 4% by mass. The silicate glass may also be soda-lime glass containing about 0.1% to about 10% by mass of Al2O3, for example, about 0.2% to about 8.0% by mass, or about 0.3% to about 6.0% by mass, or about 0.3% to about 0.5% by mass, or about 0.3% to about 0.4% by mass. The silicate glass may be a borosilicate glass containing about 0.1% to about 10% by mass of Al2O3, for example, about 0.2% to about 8.0% by mass, or about 0.3% to about 6.0% by mass, or about 2% to about 6% by mass, or about 3% to about 4% by mass.

[0068] The silicate glass may contain about 0.001% by weight or more, e.g., about 0.005% by weight or more, or about 0.01% by weight or more, or about 0.02% by weight or more, or about 0.03% by weight or more, or about 0.03% by weight or more, or about 0.04% by weight or more, or about 0.05% by weight or more, or about 0.06% by weight or more, or about 0.07% by weight or more, or about 0.08% by weight or more, of Fe2O3. The silicate glass may contain about 1.0% by weight or less, e.g., about 0.5% by weight or less, or about 0.1% by weight or less, or about 0.09% by weight or less, or about 0.08% by weight or less, or about 0.07% by weight or less, or about 0.06% by weight or less of Fe2O3. The silicate glass may contain about 0.001% by mass to about 1.0% by mass of FeO, for example, about 0.005% by mass to about 0.5% by mass, or about 0.01% by mass to about 0.1% by mass, or about 0.04% by mass to about 0.08% by mass, or about 0.05% by mass to about 0.07% by mass, or about 0.05% by mass to about 0.1% by mass, or about 0.06% by mass to about 0.1% by mass, or about 0.07% by mass to about 0.09% by mass. The silicate glass may be soda-lime glass containing about 0.001% to about 1.0% by mass of FeO, for example, about 0.005% to about 0.5% by mass, or about 0.01% to about 0.1% by mass, or about 0.04% to about 0.08% by mass, or about 0.05% to about 0.07% by mass. The silicate glass may be borosilicate glass containing about 0.001% to about 1.0% by mass of FeO, for example, about 0.005% to about 0.5% by mass, or about 0.01% to about 0.1% by mass, or about 0.05% to about 0.1% by mass, or about 0.06% to about 0.1% by mass, or about 0.07% to about 0.09% by mass.

[0069] The silicate glass may contain about 0.01% by weight or more of CaO, e.g., about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.15% by weight or more, or about 1% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 11% by weight or more. The silicate glass may contain about 20% by weight or less of CaO, e.g., about 15% by weight or less, or about 13% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less, or about 0.2% by weight or less. The silicate glass may contain about 0.01% to about 20% by mass of CaO, for example, about 0.05% to about 15% by mass, or about 0.1% to about 13% by mass, or about 10% to about 20% by mass, or about 10% to about 15% by mass, or about 11% to about 13% by mass, or about 0.05% to about 1% by mass, or about 0.1% to about 1% by mass, or about 0.1% to about 0.2% by mass. The silicate glass may also be soda-lime glass containing about 0.01% to about 20% by mass of CaO, for example, about 0.05% to about 15% by mass, or about 0.1% to about 13% by mass, or about 10% to about 20% by mass, or about 10% to about 15% by mass, or about 11% to about 13% by mass. The silicate glass may be borosilicate glass containing about 0.01% by mass to about 20% by mass of CaO, for example, about 0.05% by mass to about 15% by mass, or about 0.1% by mass to about 13% by mass, or about 0.05% by mass to about 1% by mass, or about 0.1% by mass to about 1% by mass, or about 0.1% by mass to about 0.2% by mass.

[0070] The silicate glass may contain about 10% by mass or less, for example, about 5% by mass or less, or about 3% by mass or less, of MgO. The silicate glass may contain about 1% by mass or more, for example, about 2% by mass or more, or about 2.5% by mass or more, of MgO. The silicate glass may contain about 1% to about 10% by mass, for example, about 2% to about 5% by mass, or about 2.5% to about 3% by mass of MgO. The silicate glass may be soda-lime glass containing about 1% to about 10% by mass, for example, about 2% to about 5% by mass, or about 2.5% to about 3% by mass of MgO. The silicate glass may be substantially free of MgO, i.e., the silicate glass may be substantially free of MgO. For example, the silicate glass may contain 0.1% by weight or less, e.g., 0.01% by weight or less, or 0.001% by weight or less, of MgO. The silicate glass may be substantially free of MgO, e.g., a borosilicate glass containing 0.1% by weight or less, e.g., 0.01% by weight or less, or 0.001% by weight or less, of MgO.

[0071] The silicate glass may contain about 0.001% by weight or more, e.g., about 0.01% by weight or more, or about 0.04% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.3% by weight or more, or about 0.4% by weight or more of KO. The silicate glass may contain about 5% by weight or less, e.g., about 1% by weight or less, or about 0.5% by weight or less, or about 0.45% by weight or less, or about 0.2% by weight or less, or about 0.1% by weight or less, or about 0.06% by weight or less of KO. The silicate glass may contain about 0.001% to about 5% by mass of KO, for example, about 0.01% to about 1% by mass, or about 0.04% to about 0.5% by mass, or about 0.04% to about 0.1% by mass, or about 0.04% to about 0.06% by mass, or about 0.1% to about 1% by mass, or about 0.2% to about 0.5% by mass, or about 0.4% to about 0.5% by mass. The silicate glass may be soda-lime glass containing about 0.001% to about 5% by mass of KO, for example, about 0.01% to about 1% by mass, or about 0.04% to about 0.5% by mass, or about 0.04% to about 0.1% by mass, or about 0.04% to about 0.06% by mass. The silicate glass may be borosilicate glass containing about 0.01% by mass to about 1% by mass, or about 0.04% by mass to about 0.5% by mass, or about 0.1% by mass to about 1% by mass, or about 0.2% by mass to about 0.5% by mass, or about 0.4% by mass to about 0.5% by mass of KO.

[0072] The silicate glass may contain about 1% by weight or more of NaO, for example, about 2% by weight or more, or about 3% by weight or more, or about 5% by weight or more, or about 10% by weight or more, or about 11% by weight or more, or about 12% by weight or more. The silicate glass may contain about 20% by weight or less of NaO, for example, about 15% by weight or less, or about 13% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 4% by weight or less. The silicate glass may contain about 1% to about 20% by weight of NaO, for example, about 2% to about 15% by weight, or about 3% to about 13% by weight, or about 10% to about 15% by weight, or about 11% to about 13% by weight, or about 12% to about 13% by weight, or about 1% to about 5% by weight, or about 2% to about 4% by weight. The silicate glass may be soda-lime glass containing about 1% to about 20% by mass of NaO, for example, about 2% to about 15% by mass, or about 3% to about 13% by mass, or about 10% to about 15% by mass, or about 11% to about 13% by mass, or about 12% to about 13% by mass. The silicate glass may be borosilicate glass containing about 1% to about 20% by mass of NaO, for example, about 2% to about 15% by mass, or about 3% to about 13% by mass, or about 1% to about 5% by mass, or about 2% to about 4% by mass.

[0073] The silicate glass may contain about 1% by mass or more of B2O3, for example, about 5% by mass or more, or about 10% by mass or more, or about 13% by mass or more. The silicate glass may contain about 25% by mass or less of B2O3, for example, about 20% by mass or less, or about 15% by mass or less, or about 14% by mass or less. The silicate glass may contain about 1% to about 25% by mass of B2O3, for example, about 5% to about 20% by mass, or about 10% to about 15% by mass, or about 13% to about 14% by mass. The silicate glass may be borosilicate glass containing about 1% to about 25% by mass of B2O3, for example, about 5% to about 20% by mass, or about 10% to about 15% by mass, or about 13% to about 14% by mass. The silicate glass may consist primarily of SiO2, Al2O3, Fe2O3, CaO, MgO, K2O, Na2O, and / or B2O3. The silicate glass may contain at least 80% by weight, e.g., at least 90% by weight, or at least 95% by weight, or at least 98% by weight, or at least 99% by weight, of SiO2, Al2O3, Fe2O3, CaO, MgO, K2O, Na2O, and / or B2O3. The silicate glass may be soda-lime glass consisting primarily of SiO2, Al2O3, Fe2O3, CaO, MgO, K2O, and Na2O. The silicate glass may be borosilicate glass consisting primarily of SiO2, Al2O3, Fe2O3, CaO, K2O, Na2O, and B2O3.

[0074] The silicate glass may contain one or more elements or compounds in addition to SiO, AlO, FeO, CaO, MgO, KO, NaO, and / or BO. The silicate glass may contain about 0.001% by weight or more, e.g., about 0.01% by weight or more, or about 0.05% by weight or more, or about 0.1% by weight or more, of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate glass may contain about 1% by weight or less, e.g., about 0.5% by weight or less, or about 0.2% by weight or less, or about 0.1% by weight or less, of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate glass may contain from about 0.001% to about 1% by weight, e.g., from about 0.01% to about 0.5% by weight, or from about 0.05% to about 0.2% by weight, or from about 0.1% to about 0.2% by weight, of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The loss on ignition (LOI) of a material may be determined by heating a dry (ie moisture-free) finely ground sample of the material to 1050° C. for 1 hour and measuring the mass loss after heating.

[0075] The silicate glass may be soda-lime glass comprising about 60% to about 80% by weight of SiO2; about 0.1% to about 1% by weight of Al2O3; about 0.01% to about 0.1% by weight of Fe2O3; about 5% to about 20% by weight of CaO; about 1% to about 5% by weight of MgO; about 0.01% to about 0.1% by weight of KO2; and about 5% to about 20% by weight of Na2O; and may contain about 0.01% to about 0.5% by weight of water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate glass may be a borosilicate glass comprising about 70% to about 90% by weight SiO2; about 1% to about 10% by weight Al2O3; about 0.01% to about 0.15% by weight Fe2O3; about 0.05% to about 0.25% by weight CaO; about 0.1% to about 1% by weight KO; about 1% to about 5% by weight Na2O; and about 5% to about 20% by weight BO3; and optionally about 0.01% to about 0.5% by weight water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)). The silicate material in the silicate mixture may be a silicate mineral. For purposes of this specification, the term "mineral" is not limited to crystalline materials, but also includes naturally occurring glasses (e.g., volcanic glasses such as obsidian or perlite), amorphous phases of minerals (e.g., metakaolin), sedimentary rocks (e.g., siliceous rocks), and fossilized biological materials (e.g., diatomaceous earth).

[0076] The silicate minerals in the silicate mixture may be naturally occurring silicate minerals. The silicate minerals in the silicate mixture may be naturally occurring silicate minerals that have been subjected to physical and / or chemical treatment, such as calcination or heat treatment. Alternatively, the silicate minerals in the silicate mixture may be synthetic silicate minerals. The silicate mineral may be an aluminosilicate mineral. The silicate material may be a volcanic glass. Volcanic glass may contain about 50% by weight or more of SiO2, for example, about 60% by weight or more, or about 65% by weight or more, or about 70% by weight or more, or about 75% by weight or more. Volcanic glass may contain about 95% by weight or less of SiO2, for example, about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or less, or about 75% by weight or less, or about 70% by weight or less. Volcanic glass may contain about 50% to about 95% by weight of SiO2, for example, about 60% to about 90% by weight, or about 60% to about 80% by weight, or about 60% to about 70% by weight, or about 70% to about 80% by weight.

[0077] The volcanic glass may contain about 5% by weight or more Al2O3, for example, about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more. The volcanic glass may contain about 25% by weight or less Al2O3, for example, about 20% by weight or less, or about 15% by weight or less, or about 12% by weight or less. The volcanic glass may contain about 5% to about 25% by weight Al2O3, for example, about 8% to about 20% by weight, for example, about 8% to about 12% by weight, or about 12% to about 15% by weight. The volcanic glass may contain about 0.5% by weight or more Fe2O3, for example, about 1% by weight or more, or about 2% by weight or more. The volcanic glass may contain about 5% by weight or less Fe2O3, for example, about 3% by weight or less, or about 2% by weight or less. The volcanic glass may contain about 0.5% to about 5% by weight Fe2O3, for example, about 1% to about 3% by weight, or about 2% to about 3% by weight, or about 1% to about 2% by weight. The volcanic glass may contain about 0.5% by weight or more of CaO, for example, about 0.8% by weight or more. The volcanic glass may contain about 5% by weight or less of CaO, for example, about 3% by weight or less, or about 2% by weight or less. The volcanic glass may contain about 0.5% to about 5% by weight of CaO, for example, about 0.8% to about 3% by weight, or about 0.8% to about 2% by weight.

[0078] Volcanic glass may contain about 0.05% by weight or more of MgO, for example, about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.5% by weight or more, or about 1% by weight or more, or about 1.2% by weight or more. Volcanic glass may contain about 10% by weight or less of MgO, for example, about 5% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less, or about 0.3% by weight or less. Volcanic glass may contain about 0.05% to about 10% by weight of MgO, for example, about 0.1% to about 5% by weight, or about 0.2% to about 2% by weight, or about 0.2% to about 1% by weight, or about 0.2% to about 0.5% by weight, or about 0.2% to about 0.3% by weight, or about 1% to about 5% by weight, or about 1% to about 2% by weight. The volcanic glass may contain about 1% by weight or more of KO, for example, about 2% by weight or more, or about 3% by weight or more, or about 4% by weight or more. The volcanic glass may contain about 10% by weight or less of KO, for example, about 8% by weight or less, or about 6% by weight or less, or about 5% by weight or less. The volcanic glass may contain about 1% to about 10% by weight of KO, for example, about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 4% to about 5% by weight.

[0079] The volcanic glass may contain about 1% by weight or more of Na2O, for example, about 2% by weight or more, or about 3% by weight or more. The volcanic glass may contain about 10% by weight or less of Na2O, for example, about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less. The volcanic glass may contain about 1% to about 10% by weight of Na2O, for example, about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 3% to about 4% by weight. The volcanic glass may be substantially free of B2O3, for example, the volcanic glass may contain less than 1% by weight B2O3, such as less than 0.1% by weight, or less than 0.01% by weight. Volcanic glass may contain about 1% by weight or more, e.g., about 2% by weight or more, or about 2.5% by weight or more, or about 3% by weight or more, or about 4% by weight or more, or about 5% by weight or more, of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). Volcanic glass may contain about 10% by weight or less, e.g., about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less, or about 3% by weight or less, of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). Volcanic glass may contain about 1% to about 10% by weight, e.g., about 2% to about 8% by weight, or about 2% to about 6% by weight, or about 2% to about 3% by weight, or about 5% to about 6% by weight.

[0080] Volcanic glass may contain about 70% to about 80% by weight SiO2; about 5% to about 15% by weight Al2O3; about 0.5% to about 1.5% by weight Fe2O3; about 0.5% to about 2% by weight CaO; about 0.05% to about 1% by weight MgO; about 1% to about 10% by weight KO; about 1% to about 8% by weight Na2O; about 1% to about 5% by weight chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than about 1% by weight B2O3. Volcanic glass may contain about 65% to about 75% by weight SiO2; about 8% to about 17% by weight Al2O3; about 1% to about 5% by weight Fe2O3; about 0.5% to about 2% by weight CaO; about 0.5% to about 5% by weight MgO; about 1% to about 10% by weight KO; about 1% to about 8% by weight Na2O; about 3% to about 8% by weight chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than 1% by weight B2O3.

[0081] The volcanic glass has a diameter of about 1 μm or more, for example, about 3 μm or more, or about 5 μm or more, or about 6 μm or more, or about 10 μm or more, or about 20 μm or more, or about 25 μm or more, or about 30 μm or more. 50The volcanic glass may have a diameter of about 250 μm or less, e.g., about 200 μm or less, or about 150 μm or less, or about 100 μm or less, or about 80 μm or less, or about 60 μm or less, or about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 30 μm or less, or about 15 μm or less, or about 10 μm or less, or about 8 μm or less, or about 7 μm or less. 50 The volcanic glass may have a diameter of about 1 μm to about 250 μm, for example, about 1 μm to about 200 μm, or about 1 μm to about 150 μm, or about 1 μm to about 100 μm, or about 1 μm to about 80 μm, or about 1 μm to about 60 μm, or about 1 μm to about 50 μm, or about 3 μm to about 40 μm, or about 5 μm to about 35 μm, or about 5 μm to about 10 μm, or about 5 μm to about 8 μm, or about 6 μm to about 7 μm, or about 20 μm to about 40 μm, or about 25 μm to about 35 μm. 50 may have The silicate material (e.g., silicate glass or silicate mineral) may be a perlitic material. The perlitic material may be perlite. The perlitic material may be naturally occurring perlite, such as naturally occurring perlite ore. Naturally occurring perlite is an amorphous volcanic glass typically formed primarily of silicon dioxide in combination with aluminum oxide, sodium oxide, potassium oxide, iron oxide, magnesium oxide, and / or calcium oxide. Perlite may be naturally formed by the hydration of obsidian. The perlitic material may contain minor crystalline phases, such as biotite, quartz, cristobalite, feldspar, or hydroxysodalite.

[0082] The perlitic material may be unexpanded perlite, such as unexpanded natural perlite ore. The unexpanded perlite, such as unexpanded natural perlite ore, may have a water content of greater than about 2% by mass. The unexpanded perlite, such as unexpanded natural perlite ore, may also be unexpanded perlite obtained from the tailings of natural perlite ore, such as unexpanded natural perlite ore. That is, the unexpanded perlite may be a perlitic material (i.e., a by-product) remaining after the more valuable fractions are removed from the unexpanded natural perlite ore. The tailings of natural perlite ore may be obtained from different stages of perlite ore processing. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 50% by weight or more of SiO2, for example, about 60% by weight or more, or about 65% by weight or more, or about 70% by weight or more, or about 75% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 95% by weight or less of SiO2, for example, about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or less, or about 75% by weight or less, or about 70% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 50% to about 95% by weight of SiO2, for example, about 60% to about 90% by weight, or about 60% to about 80% by weight, or about 60% to about 70% by weight, or about 70% to about 80% by weight.

[0083] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% by weight or more Al2O3, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 25% by weight or less Al2O3, e.g., about 20% by weight or less, or about 15% by weight or less, or about 12% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% to about 25% by weight Al2O3, e.g., about 8% to about 20% by weight, e.g., about 8% to about 12% by weight, or about 12% to about 15% by weight. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% by weight or more Fe2O3, such as about 1% by weight or more, or about 2% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% by weight or less Fe2O3, such as about 3% by weight or less, or about 2% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% to about 5% by weight Fe2O3, such as about 1% to about 3% by weight, or about 2% to about 3% by weight, or about 1% to about 2% by weight.

[0084] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% by weight or more, for example, about 0.8% by weight or more, of CaO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 5% by weight or less, for example, about 3% by weight or less, or about 2% by weight or less, of CaO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.5% to about 5% by weight, for example, about 0.8% to about 3% by weight, or about 0.8% to about 2% by weight of CaO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.05% by weight or more, e.g., about 0.1% by weight or more, or about 0.2% by weight or more, or about 0.5% by weight or more, or about 1% by weight or more, or about 1.2% by weight or more MgO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less, e.g., about 5% by weight or less, or about 2% by weight or less, or about 1% by weight or less, or about 0.5% by weight or less, or about 0.3% by weight or less MgO. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 0.05% to about 10% by weight of MgO, for example, about 0.1% to about 5% by weight, or about 0.2% to about 2% by weight, or about 0.2% to about 1% by weight, or about 0.2% to about 0.5% by weight, or about 0.2% to about 0.3% by weight, or about 1% to about 5% by weight, or about 1% to about 2% by weight.

[0085] The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% by weight or more of KO, e.g., about 2% by weight or more, or about 3% by weight or more, or about 4% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less of KO, e.g., about 8% by weight or less, or about 6% by weight or less, or about 5% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% to about 10% by weight of KO, e.g., about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 4% to about 5% by weight. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% by weight or more of NaO, for example, about 2% by weight or more, or about 3% by weight or more. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less of NaO, for example, about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% to about 10% by weight of NaO, for example, about 2% to about 8% by weight, or about 3% to about 6% by weight, or about 3% to about 4% by weight.

[0086] The perlitic material (e.g., unexpanded natural perlite ore) may be substantially free of B2O3. For example, the perlitic material (e.g., unexpanded natural perlite ore) may contain less than 1% by weight B2O3, such as less than 0.1% by weight, or less than 0.01% by weight B2O3. The perlitic material (e.g., unexpanded natural perlite ore) may contain about 1% by weight or more, e.g., about 2% by weight or more, or about 2.5% by weight or more, or about 3% by weight or more, or about 4% by weight or more, or about 5% by weight or more of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). The perlitic material (e.g., unexpanded natural perlite ore) may contain about 10% by weight or less, e.g., about 8% by weight or less, or about 6% by weight or less, or about 4% by weight or less, or about 3% by weight or less of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)). The perlitic material (e.g., unexpanded natural perlite ore) may contain from about 1% to about 10%, e.g., from about 2% to about 8%, or from about 2% to about 6%, or from about 2% to about 3%, or from about 5% to about 6%, by weight, of chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)).

[0087] Perlitic materials (e.g., unexpanded natural perlite ore) may contain, by weight, about 70% to about 80% SiO2; about 5% to about 15% Al2O3; about 0.5% to about 1.5% Fe2O3; about 0.5% to about 2% CaO; about 0.05% to about 1% MgO; about 1% to about 10% KO; about 1% to about 8% NaO; about 1% to about 5% chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than about 1% BO3. Perlitic materials (e.g., unexpanded natural perlite ore) may contain, by weight, about 65% to about 75% SiO; about 8% to about 17% AlO; about 1% to about 5% FeO; about 0.5% to about 2% CaO; about 0.5% to about 5% MgO; about 1% to about 10% KO; about 1% to about 8% NaO; about 3% to about 8% chemically bound water and / or volatile matter (i.e., materials that contribute to "loss on ignition" (LOI)), and may contain less than 1% BO.

[0088] The perlitic material (e.g., unexpanded natural perlite ore) has a diameter of about 1 μm or more, e.g., about 3 μm or more, or about 5 μm or more, or about 6 μm or more, or about 10 μm or more, or about 20 μm or more, or about 25 μm or more, or about 30 μm or more. 50 The perlitic material (e.g., unexpanded natural perlite ore) may have a diameter of about 250 μm or less, e.g., about 200 μm or less, or about 150 μm or less, or about 100 μm or less, or about 80 μm or less, or about 60 μm or less, or about 50 μm or less, or about 40 μm or less, or about 35 μm or less, or about 30 μm or less, or about 15 μm or less, or about 10 μm or less, or about 8 μm or less, or about 7 μm or less. 50 The perlitic material (for example, unexpanded natural perlitic ore) may have a diameter of about 1 μm to about 250 μm, for example, about 1 μm to about 200 μm, or about 1 μm to about 150 μm, or about 1 μm to about 100 μm, or about 1 μm to about 80 μm, or about 1 μm to about 60 μm, or about 1 μm to about 50 μm, about 3 μm to about 40 μm, or about 5 μm to about 35 μm, or about 5 μm to about 10 μm, or about 5 μm to about 8 μm, or about 6 μm to about 7 μm, or about 20 μm to about 40 μm, or about 25 μm to about 35 μm. 50 may have

[0089] The silicate material (e.g., silicate mineral) may be a phyllosilicate mineral. The phyllosilicate mineral may be a clay mineral, i.e., a hydrated aluminum phyllosilicate mineral. The silicate material (e.g., silicate mineral) may be selected from halloysite, kaolinite, illite, montmorillonite, nontronite, beidellite, vermiculite, talc, sepiolite, palygorskite, and pyrophyllite. The silicate material (e.g., silicate mineral) may be kaolin, such as calcined kaolin (i.e., metakaolin). The silicate material (e.g., silicate mineral) may be bentonite or any other smectite-containing clay mineral. The silicate material (e.g., silicate mineral) may be bentonite tailings, such as Na-bentonite tailings or Ca-bentonite tailings. The silicate material (eg, silicate mineral) may be diatomaceous earth or a diatomaceous earth-containing mineral, such as a mineral containing both diatomaceous earth and clay minerals (in any relative proportions). The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may comprise about 30% by weight or more, e.g., about 40% by weight or more, or about 50% by weight or more, or about 60% by weight or more of SiO2. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may comprise up to about 100% by weight, e.g., about 99% by weight or less, or about 95% by weight or less, or about 90% by weight or less, or about 85% by weight or less, or about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of SiO2. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 30% to about 100% by weight SiO2, for example, about 40% to about 99% by weight, or about 50% to about 95% by weight, or about 60% to about 90% by weight, or about 60% to about 85% by weight SiO2.

[0090] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.1% by weight or more NaO, e.g., about 0.5% by weight or more, or about 1% by weight or more, or about 2% by weight or more. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 40% by weight or less NaO, e.g., about 30% by weight or less, or about 20% by weight or less, or about 15% by weight or less. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.1% to about 40% by weight NaO, e.g., about 0.5% to about 30% by weight, or about 1% to about 30% by weight, or about 2% to about 15% by weight NaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of K2O. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of K2O. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of K2O, e.g., about 15% by weight or less, or about 10% by weight or less, or about 6% by weight or less of K2O. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of K2O, e.g., about 0% to about 15% by weight, or about 0.01% to about 10% by weight, or about 0.01% to about 6% by weight.

[0091] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.05% by weight or more of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of CaO, for example, about 15% by weight or less of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of CaO, for example, about 0.05% to about 15% by weight of CaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% Al2O3 by mass. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.1% Al2O3 by mass or more. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% Al2O3 by mass or less, for example, about 15% Al2O3 by mass or less. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% Al2O3 by mass, for example, about 0.1% to about 15% Al2O3 by mass.

[0092] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of B2O3. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of B2O3, e.g., about 0.05% by weight or more, or about 0.1% by weight or more of B2O3. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of B2O3, e.g., about 15% by weight or less, or about 10% by weight or less of B2O3. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of B2O3, for example, about 0% to about 15% by weight, or about 0.01% to about 10% by weight, or about 0.1% to about 10% by weight. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of PbO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of PbO, e.g., about 0.05% by weight or more, or about 0.1% by weight or more of PbO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 20% by weight or less of PbO, e.g., about 15% by weight or less, or about 10% by weight or less of PbO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 20% by weight of PbO, e.g., about 0% to about 15% by weight, or about 0.01% to about 10% by weight, or about 0.1% to about 10% by weight of PbO.

[0093] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more, e.g., about 0.05% by weight or more, or about 0.1% by weight or more of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 10% by weight or less, e.g., about 5% by weight or less, or about 2% by weight or less of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 10% by weight of MgO, e.g., about 0% to about 5% by weight, or about 0.01% to about 2% by weight, or about 0.1% to about 2% by weight of MgO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain substantially 0% by weight of BaO. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0.01% by weight or more of BaO, for example, about 0.05% by weight or more, or about 0.1% by weight or more. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 10% by weight or less of BaO, for example, about 5% by weight or less, or about 2% by weight or less. The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may contain about 0% to about 10% by weight of BaO, for example, about 0% to about 5% by weight, or about 0.01% to about 2% by weight, or about 0.1% to about 2% by weight.

[0094] The silicate material (e.g., silicate salt, silicate glass, or silicate mineral) may include about 50% to about 95% by weight, e.g., about 60% to about 85% by weight, SiO2; about 1% to about 30% by weight, e.g., about 2% to about 15% by weight, Na2O; about 0% to about 15% by weight, e.g., about 0.01% to about 6% by weight, KO; about 0% to about 20% by weight, e.g., about 0.05% to about 15% by weight, CaO; about 0% to about 20% by weight, e.g., about 0.1% to about 15% by weight, Al2O3; about 20% or less by weight, e.g., less than about 15% by weight, BO3; about 20% or less by weight, e.g., less than about 15% by weight, PbO; about 10% or less by weight, e.g., less than about 5% by weight, MgO; and about 10% or less by weight, e.g., less than about 5% by weight, BaO. The silicate material may be crystalline. Alternatively, the silicate material may be amorphous. The silicate material may comprise about 25% by weight or more, e.g., about 50% by weight or more, or about 75% by weight or more, or about 90% by weight or more of amorphous material. For example, the silicate material may comprise about 25% by weight to about 100% by weight, e.g., about 50% by weight to about 100% by weight, or about 75% by weight to about 100% by weight, or about 90% by weight to about 100% by weight of amorphous material.

[0095] An alkali compound is a compound of an alkali metal or an alkaline earth metal. Thus, the alkali compound may be an alkali metal compound or an alkaline earth metal compound. The alkali compound may be an alkali salt. An alkali salt is a basic salt of an alkali metal or an alkaline earth metal. Therefore, the alkali salt may be an alkali metal salt or an alkaline earth metal salt. The alkali salt may be a hydroxide, carbonate, or silicate salt of an alkali metal or an alkaline earth metal, i.e., the alkali salt may be an alkali hydroxide, alkali carbonate, or alkali silicate. The alkali salt may be an alkali metal hydroxide, alkali metal carbonate, or alkali metal silicate. The alkali salt may be selected from sodium hydroxide (NaOH), lithium hydroxide (LiOH), potassium hydroxide (KOH), sodium carbonate (NaCO), lithium carbonate (LiCO), potassium carbonate (NaCO), sodium silicate (NaSiO, NaSiO, or NaSiO), lithium silicate (LiSiO, LiSiO, or LiSiO), potassium silicate (KSiO, KSiO, or KSiO).

[0096] In certain embodiments, the alkali salt is a sodium salt, for example, sodium hydroxide. In certain embodiments, the alkali salt is a lithium salt, such as lithium hydroxide. In certain embodiments, the alkali salt is a mixture of sodium and lithium salts, such as a mixture of sodium hydroxide and lithium hydroxide. The ratio of the mass percent of the sodium salt to the mass percent of the lithium salt in the mixture may be about 1 or more, such as about 1.5 or more. The ratio of the mass percent of the sodium salt to the mass percent of the lithium salt in the mixture may be about 20 or less, such as about 15 or less, or about 10 or less. The ratio of the mass percent of the sodium salt to the mass percent of the lithium salt in the mixture may be about 1 to about 20, such as about 1.5 to about 15, or about 1.5 to about 10. For example, the ratio of the mass percent of the sodium hydroxide to the mass percent of the lithium hydroxide in the mixture is about 1 or more, such as about 1.5 or more. The ratio of the mass percent of the sodium hydroxide to the mass percent of the lithium hydroxide in the mixture may be about 20 or less, such as about 15 or less, or about 10 or less. The ratio of the weight percent sodium hydroxide to the weight percent lithium hydroxide in the mixture may be from about 1 to about 20, such as from about 1.5 to about 15, or from about 1.5 to about 10. The alkali salts may therefore be described as mixed alkali salts, such as sodium / lithium salts or sodium / potassium salts, such as sodium / lithium silicate or sodium / potassium silicate.

[0097] The silicate mixture may include reactive silica in addition to the silicate material, which, if present, has a different chemical composition and / or physical structure (e.g., crystalline, microcrystalline, nanocrystalline, or amorphous phase, microstructure, particle morphology, or shape) than the silicate material. The reactive silica may be a high surface area (i.e., particulate) form of silica. For example, the reactive silica may be about 50 m 2 / g or more, or approximately 100m 2 / g or more, or approximately 200m 2 / g or more, or approximately 300m 2 / g or more (e.g., it may include silica particles having such a specific surface area (e.g., BET specific surface area). 2 / g or less, for example, about 800m 2 / g or less, or about 600m 2The reactive silica may have a specific surface area (e.g., BET specific surface area) of about 50 m / g or less (e.g., may include particles of silica having such a specific surface area). 2 / g~about 1000m 2 / g, for example, about 100m 2 / g~about 1000m 2 / g, or approximately 200m 2 / g~about 1000m 2 / g, or approximately 300m 2 / g~about 1000m 2 / g, or approximately 50m 2 / g~about 800m 2 / g, or approximately 200m 2 / g~about 800m 2 / g, or approximately 100m 2 / g~about 800m 2 / g, or approximately 300m 2 / g~about 800m 2 / g, or approximately 50m 2 / g~about 600m 2 / g, or approximately 600m 2 / g~about 600m 2 / g, or approximately 100m 2 / g~about 600m 2 / g, or approximately 300m 2 / g~about 600m 2 / g (for example, it may include silica particles having such a specific surface area).

[0098] The reactive silica may be in the form of a medium surface area (i.e., particulate) form of silica. For example, the reactive silica may be in the form of a medium surface area (i.e., particulate) form of silica. 2 / g or more, or approximately 8m 2 / g or more, or about 10m 2 / g or more, or approximately 12m 2 / g or more, or about 15m 2 / g or more (e.g., BET specific surface area) (e.g., may include silica particles having such a specific surface area). 2 / g or less, for example, about 75m 2 / g or less, or about 50m 2 / g or less, or about 30m2 The reactive silica may have a specific surface area (e.g., BET specific surface area) of about 5 m / g or less (e.g., may include silica particles having such a specific surface area). 2 / g~about 100m 2 / g, for example, about 8m 2 / g~about 100m 2 / g, or approximately 10m 2 / g~about 100m 2 / g, or approximately 12 m 2 / g~about 100m 2 / g, or approximately 15m 2 / g~about 100m 2 / g, or approximately 5m 2 / g ~ approx. 75m 2 / g, or approximately 8m 2 / g ~ approx. 75m 2 / g, or approximately 10m 2 / g ~ approx. 75m 2 / g, or approximately 12 m 2 / g ~ approx. 75m 2 / g, or approximately 15m 2 / g ~ approx. 75m 2 / g, or approximately 5m 2 / g~about 50m 2 / g, or approximately 8m 2 / g~about 50m 2 / g, or approximately 10m 2 / g~about 50m 2 / g, or approximately 12 m 2 / g~about 50m 2 / g, or approximately 15m 2 / g~about 50m 2 / g, or approximately 5m 2 / g ~ approx. 30m 2 / g, or approximately 8m 2 / g ~ approx. 30m 2 / g, or approximately 10m 2 / g ~ approx. 30m 2 / g, or approximately 12 m 2 / g ~ approx. 30m 2 / g, or approximately 15m 2 / g ~ approx. 30m 2 / g (for example, it may include silica particles having such a specific surface area).

[0099] The reactive silica may be a low surface area (i.e., particulate) form of silica. For example, the reactive silica may be in the form of a silica having a surface area of ​​about 1 m 2 / g or more, or about 2m 2 / g or more (e.g., BET specific surface area) (e.g., may include silica particles having such a specific surface area). 2 / g or less, for example, about 5m 2 / g or less, or about 3m 2 The reactive silica may have a specific surface area (e.g., BET specific surface area) of about 1 m / g or less (e.g., may include silica particles having such a specific surface area). 2 / g~about 10m 2 / g, for example, about 1 m 2 / g~about 5m 2 / g, or approximately 1 m 2 / g ~ approx. 3m 2 / g, or approximately 2m 2 / g~about 10m 2 / g, or approximately 2m 2 / g~about 5m 2 / g, or approximately 2m 2 / g ~ approx. 3m 2 / g (for example, it may include silica particles having such a specific surface area).

[0100] The reactive silica may be predominantly (e.g., completely) amorphous. The reactive silica may be at least about 50% (e.g., by volume), such as at least about 60%, or at least about 70%, or at least about 80%, or at least about 90%, or at least about 95% amorphous. The reactive silica may include silica fume (e.g., may be silica fume). Silica fume, also known as microsilica, is an amorphous polymorph of silicon dioxide. Silica fume may be provided in the form of a powder, e.g., a powder of spherical particles. Silica fume particles have a diameter of about 10 nm or more, e.g., about 50 nm or more, or about 100 nm or more, or about 200 nm or more, or about 500 nm or more. 50The silica fume particles may have a diameter of about 5 μm or less, or about 1 μm or less, or about 900 nm or less, or about 800 nm or less, or about 600 nm or less, or about 500 nm or less, or about 400 nm or less, or about 300 nm or less, or about 200 nm or less. 50 The silica fume particles may have a diameter of about 10 nm to about 5 μm, for example, about 50 nm to about 1 μm, or about 100 nm to about 500 nm, or about 100 nm to about 200 nm. 50 may have

[0101] Additionally or alternatively, the reactive silica may include fumed silica (e.g., may be fumed silica). Fumed silica, also known as pyrogenic silica, comprises branched aggregates of amorphous silicon dioxide primary particles. The silicon dioxide primary particles have a diameter of about 1 nm or more, or about 5 nm or more, or about 10 nm or more. 50 The silicon dioxide primary particles may have a d of about 1 μm or less, or about 500 nm or less, or about 100 nm or less, or about 50 nm or less. 50 The silicon dioxide primary particles may have a diameter of about 1 nm to about 1 μm, for example, about 5 nm to about 500 nm, or about 10 nm to about 100 nm, or about 10 nm to about 50 nm. 50 may have Additionally or alternatively, the reactive silica may comprise (eg be) silica gel, natural volcanic glass, perlitic material or burnt organic matter such as rice husk ash.

[0102] The silicate mixture may contain glass network formers other than silicon. The glass network formers other than silicon in the silicate mixture may be provided by the silicate material. Glass network formers are elements whose oxides can spontaneously form covalent glass network structures (e.g., conforming to the Zachariasen rule of glass network formation). Glass network formers include silicon, boron, germanium, and phosphorus. Thus, the glass network-forming element other than silicon present in the mixture may be boron. For example, the silicate material may be a silicate glass, which is a boron-containing glass, such as a borosilicate glass. Additionally or alternatively, the mixture may include one or more other boron sources, such as boric acid or one or more borates (e.g., Borax, i.e., sodium borate). Alternatively, the glass network former other than silicon present in the mixture may be germanium, for example, the silicate material may be a silicate glass, which is a germanium-containing glass such as a silica-germania glass.

[0103] Alternatively, the glass network-forming element other than silicon present in the mixture may be phosphorus. For example, the silicate material may be a silicate glass, which is a phosphorus-containing glass. Additionally or alternatively, the mixture may include one or more other phosphorus sources, such as phosphoric acid or one or more phosphates. The silicate mixture may include one or more glass network intermediate elements. The one or more glass network intermediate elements in the silicate mixture may be provided by a silicate material. Glass network intermediate elements are elements whose oxides do not spontaneously form glass network structures, but which can function like glass network formers when combined with other glass network formers. Glass network intermediates include titanium, aluminum, zirconium, beryllium, magnesium, and zinc. The silicate material may be a silicate glass containing one or more glass network intermediate elements, such as titanium, aluminum, zirconium, beryllium, magnesium, or zinc. For example, the silicate glass may be an aluminum-containing glass, such as an aluminosilicate glass.

[0104] The silicate mixture may include one or more glass network modifying elements. The one or more glass network modifying elements present in the silicate mixture may be provided by a silicate material and / or an alkali compound. A glass network modifier is an element whose oxide, alone or in combination with a glass network former, does not form a glass network structure. When present in a glass, the glass network modifier disrupts or modifies the glass network structure. Glass network modifiers are typically present in glass in ionic form, with the charge of the glass network modifier ion being counterbalanced by nearby non-bridging oxygen atoms covalently bonded to nearby glass network formers. Glass network modifiers include calcium, lead, lithium, sodium, and potassium. The silicate material may be a silicate glass containing one or more glass network modifiers, such as calcium, lead, lithium, sodium, or potassium.

[0105] The silicate mixture may contain about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of silicate material. The silicate mixture may contain about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of silicate material. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about It may contain 5% by mass to about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass of the silicate material.

[0106] The silicate mixture may contain about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of amorphous silicate material. The silicate mixture may contain about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of amorphous silicate material. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 5 The amorphous silicate material may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0107] The silicate mixture may comprise about 5% by weight or more, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of the aluminosilicate material. The silicate mixture may comprise about 90% by weight or less, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of the aluminosilicate material. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 50% by mass to about 80% by mass. The aluminosilicate material may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0108] The silicate mixture may contain about 5% by weight or more of silicate salt, for example, about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The silicate mixture may contain about 90% by weight or less of silicate salt, for example, about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, It may contain about 5% by mass to about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass of silicate salt.

[0109] The silicate mixture may contain about 5% by weight or more of the aluminosilicate salt, for example, about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The silicate mixture may contain about 90% by weight or less of the aluminosilicate salt, for example, about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 5 % to about 70% by mass, or about 10% to about 70% by mass, or about 20% to about 70% by mass, or about 30% to about 70% by mass, or about 40% to about 70% by mass, or about 50% to about 70% by mass, or about 5% to about 60% by mass, or about 10% to about 60% by mass, or about 20% to about 60% by mass, or about 30% to about 60% by mass, or about 40% to about 60% by mass, or about 50% to about 60% by mass of an aluminosilicate salt.

[0110] The silicate mixture may contain about 5% by weight or more of silicate glass, for example about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The silicate mixture may contain about 90% by weight or less of silicate glass, for example about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about It may contain 5% by mass to about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass of silicate glass.

[0111] The silicate mixture may comprise about 5% by weight or more, e.g., about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of aluminosilicate glass. The silicate mixture may comprise about 90% by weight or less, e.g., about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of aluminosilicate glass. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 50% by mass to about 80% by mass. The aluminosilicate glass may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass of aluminosilicate glass.

[0112] The silicate mixture may contain about 5% by weight or more, e.g., about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of borosilicate glass. The silicate mixture may contain about 90% by weight or less, e.g., about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of borosilicate glass. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 5 The borosilicate glass may comprise about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0113] For example, the silicate mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 13% by weight or more, or about 14% by weight or more of borosilicate glass. The silicate mixture may contain about 50% by weight or less, e.g., about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 17% by weight or less, or about 16% by weight or less, or about 15% by weight or less, or about 14% by weight or less of borosilicate glass. The silicate mixture may contain about 5% to about 50% by mass of borosilicate glass, for example, about 5% to about 30% by mass, or about 5% to about 25% by mass, or about 10% to about 20% by mass, or about 12% to about 16% by mass, or about 12% to about 14% by mass, or about 13% to about 14% by mass, or about 14% to about 16% by mass, or about 14% to about 15% by mass.

[0114] The silicate mixture may contain about 5% by weight or more of silicate minerals, for example, about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The silicate mixture may contain about 90% by weight or less of silicate minerals, for example, about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about It may contain 5% by mass to about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass of silicate mineral.

[0115] The silicate mixture may contain about 5% by weight or more, for example about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more of aluminosilicate minerals. The silicate mixture may contain about 90% by weight or less, for example about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less of aluminosilicate minerals. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about 50% by mass to about 80% by mass. The aluminosilicate mineral may be present in an amount of about 50% to about 60% by mass, about 10% to about 70% by mass, about 20% to about 70% by mass, about 30% to about 70% by mass, about 40% to about 70% by mass, about 50% to about 70% by mass, about 5% to about 60% by mass, about 10% to about 60% by mass, about 20% to about 60% by mass, about 30% to about 60% by mass, about 40% to about 60% by mass, or about 50% to about 60% by mass.

[0116] The silicate mixture may contain about 5% by weight or more of volcanic glass, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The silicate mixture may contain about 90% by weight or less of volcanic glass, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, It may contain about 5% by mass to about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass of volcanic glass.

[0117] For example, the silicate mixture may contain about 20% by weight or more of volcanic glass, e.g., about 25% by weight or more, or about 28% by weight or more, or about 30% by weight or more, or about 34% by weight or more. The silicate mixture may contain about 50% by weight or less of volcanic glass, e.g., about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The silicate mixture may contain about 20% by weight to about 50% by weight of volcanic glass, e.g., about 25% by weight to about 45% by weight, or about 25% by weight to about 35% by weight, or about 25% by weight to about 30% by weight, or about 28% by weight to about 30% by weight, or about 30% by weight to about 40% by weight, or about 34% by weight to about 35% by weight.

[0118] The silicate mixture may contain about 5% by weight or more of perlitic material, such as about 10% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 40% by weight or more, or about 50% by weight or more. The silicate mixture may contain about 90% by weight or less of perlitic material, such as about 80% by weight or less, or about 70% by weight or less, or about 60% by weight or less. The silicate mixture is about 5% by mass to about 90% by mass, for example, about 10% by mass to about 90% by mass, or about 20% by mass to about 90% by mass, or about 30% by mass to about 90% by mass, or about 40% by mass to about 90% by mass, or about 50% by mass to about 90% by mass, or about 5% by mass to about 80% by mass, or about 10% by mass to about 80% by mass, or about 20% by mass to about 80% by mass, or about 30% by mass to about 80% by mass, or about 40% by mass to about 80% by mass, or about 50% by mass to about 80% by mass, or about It may contain 5% by mass to about 70% by mass, or about 10% by mass to about 70% by mass, or about 20% by mass to about 70% by mass, or about 30% by mass to about 70% by mass, or about 40% by mass to about 70% by mass, or about 50% by mass to about 70% by mass, or about 5% by mass to about 60% by mass, or about 10% by mass to about 60% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 60% by mass, or about 40% by mass to about 60% by mass, or about 50% by mass to about 60% by mass of pearlitic material. For example, the silicate mixture may contain about 20% by weight or more of perlitic material, e.g., about 25% by weight or more, or about 28% by weight or more, or about 30% by weight or more, or about 34% by weight or more. The silicate mixture may contain about 50% by weight or less of perlitic material, e.g., about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The silicate mixture may contain about 20% by weight to about 50% by weight of perlitic material, e.g., about 25% by weight to about 45% by weight, or about 25% by weight to about 35% by weight, or about 25% by weight to about 30% by weight, or about 28% by weight to about 30% by weight, or about 30% by weight to about 40% by weight, or about 34% by weight to about 35% by weight.

[0119] The silicate mixture may contain about 20% by weight or more of unexpanded natural perlite raw ore, for example, about 25% by weight or more, or about 28% by weight or more, or about 30% by weight or more, or about 34% by weight or more. The silicate mixture may contain about 50% by weight or less, for example, about 45% by weight or less, or about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less of unexpanded natural perlite raw ore. The silicate mixture may contain about 20% by weight to about 50% by weight, for example, about 25% by weight to about 45% by weight, or about 25% by weight to about 35% by weight, or about 25% by weight to about 30% by weight, or about 28% by weight to about 30% by weight, or about 30% by weight to about 40% by weight, or about 34% by weight to about 35% by weight of unexpanded natural perlite raw ore. The silicate mixture may contain about 5% by weight or more of the alkali compound, for example, about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more. The silicate mixture may contain about 30% by weight or less of the alkali compound, for example, about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less. The silicate mixture may contain about 5% by mass to about 30% by mass of the alkali compound, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass.

[0120] The silicate mixture may contain about 5% by weight or more of alkali hydroxide, for example about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more. The silicate mixture may contain about 30% by weight or less of alkali hydroxide, for example about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less. The silicate mixture may contain about 5% by mass to about 30% by mass of alkali hydroxide, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass.

[0121] The silicate mixture may contain about 5% by weight or more of alkali carbonate, for example, about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more. The silicate mixture may contain about 30% by weight or less of alkali carbonate, for example, about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less. The silicate mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of alkali carbonate.

[0122] The silicate mixture may contain about 5% by weight or more, for example about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of alkali silicate. The silicate mixture may contain about 30% by weight or less, for example about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of alkali silicate. The silicate mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of alkali silicate.

[0123] For example, the silicate mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of sodium hydroxide, lithium hydroxide, and / or potassium hydroxide. The silicate mixture may contain about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of sodium hydroxide, lithium hydroxide, and / or potassium hydroxide. The silicate mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of sodium hydroxide, lithium hydroxide, and / or potassium hydroxide.

[0124] The silicate mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of sodium carbonate, lithium carbonate, and / or potassium carbonate. The silicate mixture may contain about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of sodium carbonate, lithium carbonate, and / or potassium carbonate. The silicate mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of sodium carbonate, lithium carbonate, and / or potassium carbonate.

[0125] The silicate mixture may contain about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 17% by weight or more of sodium, lithium, and / or potassium silicate. The silicate mixture may contain about 30% by weight or less, e.g., about 25% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 17% by weight or less, or about 15% by weight or less, or about 14% by weight or less of sodium, lithium, and / or potassium silicate. The silicate mixture may contain about 5% by mass to about 30% by mass, for example, about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 10% by mass to about 15% by mass, or about 12% by mass to about 15% by mass, or about 12% by mass to about 14% by mass, or about 10% by mass to about 14% by mass, or about 14% by mass to about 18% by mass, or about 15% by mass to about 17% by mass, or about 16% by mass to about 20% by mass of sodium silicate, lithium silicate, and / or potassium silicate.

[0126] The silicate mixture may contain about 15% by weight or more of water, for example, about 20% by weight or more, or about 22% by weight or more, or less than about 25% by weight. The silicate mixture may contain about 45% by weight or less of water, for example, about 40% by weight or less, or about 35% by weight or less, or about 30% by weight or less. The silicate mixture may contain about 15% to about 45% by weight of water, for example, about 20% to about 40% by weight, or about 20% to about 30% by weight, or about 25% to about 30% by weight.

[0127] The silicate mixture may include two different silicate materials. For example, the silicate mixture may include silicate glass (e.g., aluminosilicate glass) and silicate minerals (e.g., aluminosilicate minerals). The silicate mixture may include about 5% by weight or more, e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 20% by weight or more of silicate glass (e.g., aluminosilicate glass). The silicate mixture may include about 50% by weight or less, e.g., about 40% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 16% by weight or less of silicate glass (e.g., aluminosilicate glass). The silicate mixture may contain about 5% to about 50% by weight of silicate glass (e.g., aluminosilicate glass), e.g., about 8% to about 40% by weight, or about 10% to about 30% by weight, or about 10% to about 20% by weight, or about 12% to about 16% by weight. Additionally, the silicate mixture may contain about 10% or more by weight of silicate mineral (e.g., aluminosilicate mineral), e.g., about 15% or more by weight, or about 20% or more by weight, or about 25% or more by weight. The silicate mixture may contain about 60% or less by weight of silicate mineral (e.g., aluminosilicate mineral), e.g., about 50% or less by weight, or about 45% or less by weight, or about 40% or less by weight, or about 35% or less by weight. The silicate mixture may contain about 10% by mass to about 60% by mass, for example, about 15% by mass to about 50% by mass, or about 20% by mass to about 45% by mass, or about 25% by mass to about 45% by mass, or about 25% by mass to about 30% by mass of silicate mineral (e.g., aluminosilicate mineral).

[0128] Alternatively, the silicate mixture may include a first silicate glass (e.g., a first aluminosilicate glass) and a second silicate glass (e.g., a second aluminosilicate glass). The silicate mixture may include about 5% by weight or more of the first silicate glass (e.g., the first aluminosilicate glass), e.g., about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 20% by weight or more. The silicate mixture may include about 50% by weight or less of the first silicate glass (e.g., the first aluminosilicate glass), e.g., about 40% by weight or less, or about 30% by weight or less, or about 25% by weight or less, or about 20% by weight or less, or about 16% by weight or less. The silicate mixture may include about 5% to about 50% by weight of the first silicate glass (e.g., the first aluminosilicate glass), for example, about 8% to about 40% by weight, or about 10% to about 30% by weight, or about 10% to about 20% by weight, or about 12% to about 16% by weight. Additionally, the silicate mixture may include about 5% by weight or more of the second silicate glass (e.g., the second aluminosilicate glass), for example, about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 15% by weight or more, or about 20% by weight or more. The silicate mixture may contain about 50% by mass or less of the second silicate glass (e.g., the second aluminosilicate glass), for example, about 40% by mass or less, or about 30% by mass or less, or about 25% by mass or less, or about 20% by mass or less, or about 16% by mass or less. The silicate mixture may contain about 5% to about 50% by mass of the second silicate glass (e.g., the second aluminosilicate glass), for example, about 8% to about 40% by mass, or about 10% to about 30% by mass, or about 10% to about 20% by mass, or about 12% to about 16% by mass.

[0129] One of the two different silicate materials may be selected from a perlitic material, such as unexpanded natural perlite ore having a water content of greater than about 2% by weight; a phyllosilicate mineral, such as bentonite, kaolin, or calcined kaolin; or diatomaceous earth. Additionally or alternatively, one of the two different silicate materials may be selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. For example, the silicate mixture may be volcanic glasses, such as perlitic materials, for example unexpanded natural perlite ore having a water content of more than about 2% by weight; a first silicate material selected from a phyllosilicate mineral, such as bentonite, kaolin, or calcined kaolin; and diatomaceous earth; or a combination thereof; and Fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, silica-germania glass The second silicate material may be selected from:

[0130] The silicate mixture may include a first silicate material that is a perlitic material and a second silicate material selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. The silicate mixture may include perlitic material, such as unexpanded natural perlite ore having a water content greater than about 2% by weight, and a silicate glass other than perlitic material. For example, the silicate mixture may include perlitic material, such as unexpanded natural perlite ore having a water content greater than about 2% by weight, and a borosilicate glass. Both the first silicate material and the second silicate material may be silicate glasses. For example, the silicate mixture may include two different silicate glasses selected from fused silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germania glass. The silicate mixture may include borosilicate glass and soda-lime glass.

[0131] The silicate mixture may include three or more different silicate materials. For example, the silicate mixture may include a first silicate glass, a second silicate glass different from the first silicate glass, and a silicate mineral different from the first and second silicate glasses. For example, the silicate mixture may include first and second silicate glasses selected from spent silica glass, soda-lime glass, borosilicate glass, lead oxide glass, aluminosilicate glass, and silica-germanium glass; and a silicate mineral selected from volcanic glass, such as perlitic material, e.g., unexpanded natural perlite ore having a water content of greater than about 2% by weight; a phyllosilicate mineral, such as bentonite, kaolin, or calcined kaolin; diatomaceous earth; or a combination thereof, such as Moller (i.e., a clayey diatomite containing both clay minerals and diatomaceous earth). The silicate mixture may include borosilicate glass, soda-lime glass, and perlitic material (eg, unexpanded natural perlite ore having a water content greater than about 2% by weight). Whenever a silicate mixture is described as including both a silicate material (e.g., a silicate glass or a silicate mineral) and a perlitic material, it is understood that the silicate material (e.g., a silicate glass or a silicate mineral) is not a perlitic material. Similarly, whenever a silicate mixture is described as including both a silicate glass and a silicate mineral, the silicate glass and the silicate mineral are not the same material, i.e., the silicate glass and the silicate mineral differ in chemical composition and / or physical structure, e.g., crystalline or amorphous phase and / or microstructure.

[0132] The silicate mixture may contain about 1% by weight or more, for example about 5% by weight or more, or about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 14% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more reactive silica. The silicate mixture may contain about 60% by weight or less reactive silica, for example about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 15% by weight or less. The silicate mixture may contain about 1% by mass to about 60% by mass of reactive silica, for example, about 5% by mass to about 50% by mass, or about 5% by mass to about 45% by mass, or about 5% by mass to about 25% by mass, or about 5% by mass to about 20% by mass, or about 8% by mass to about 20% by mass, or about 8% by mass to about 18% by mass, or about 8% by mass to about 12% by mass, or about 10% by mass to about 18% by mass, or about 12% by mass to about 18% by mass, or about 14% by mass to about 15% by mass, or about 20% by mass to about 60% by mass, or about 30% by mass to about 50% by mass, or about 35% by mass to about 45% by mass.

[0133] For example, the silicate mixture may contain about 1% by weight or more, such as about 5% by weight or more, or about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 14% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more of silica fume. The silicate mixture may contain about 60% by weight or less, such as about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 15% by weight or less of silica fume. The silicate mixture may contain about 1% to about 60% by weight of silica fume, for example, about 5% to about 50% by weight, or about 5% to about 45% by weight, or about 5% to about 25% by weight, or about 5% to about 20% by weight, or about 8% to about 20% by weight, or about 8% to about 18% by weight, or about 8% to about 12% by weight, or about 10% to about 18% by weight, or about 12% to about 18% by weight, or about 14% to about 15% by weight, or about 20% to about 60% by weight, or about 30% to about 50% by weight, or about 35% to about 45% by weight.

[0134] Alternatively, the silicate mixture may contain about 1% by weight or more, for example about 5% by weight or more, or about 8% by weight or more, or about 10% by weight or more, or about 12% by weight or more, or about 14% by weight or more, or about 20% by weight or more, or about 30% by weight or more, or about 35% by weight or more, or about 40% by weight or more fumed silica. The silicate mixture may contain about 60% by weight or less, for example about 50% by weight or less, or about 45% by weight or less, or about 40% by weight or less, or about 30% by weight or less, or about 20% by weight or less, or about 18% by weight or less, or about 15% by weight or less fumed silica. The silicate mixture may contain about 1% to about 60% by weight of fumed silica, for example, about 5% to about 50% by weight, or about 5% to about 45% by weight, or about 5% to about 25% by weight, or about 5% to about 20% by weight, or about 8% to about 20% by weight, or about 8% to about 18% by weight, or about 8% to about 12% by weight, or about 10% to about 18% by weight, or about 12% to about 18% by weight, or about 14% to about 15% by weight, or about 20% to about 60% by weight, or about 30% to about 50% by weight, or about 35% to about 45% by weight. The silicate mixture may contain about 5% to about 80% by weight, for example, about 10% to about 70% by weight, or about 10% to about 20% by weight, or about 20% to about 70% by weight, or about 30% to about 70% by weight, or about 40% to about 70% by weight, or about 50% to about 70% by weight of silicate material; about 5% to about 30% by weight, for example, about 5% to about 20% by weight of alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 30% by weight of water.

[0135] For example, the silicate mixture may comprise about 40% to about 80% by weight, e.g., about 50% to about 70% by weight, of a silicate material; about 5% to about 30% by weight, e.g., about 5% to about 20% by weight, of an alkali compound; and about 20% to about 50% by weight, e.g., about 20% to about 40% by weight, of water. The silicate mixture may comprise about 40% to about 80% by weight, e.g., about 50% to about 70% by weight, of a silicate glass (e.g., borosilicate glass); about 5% to about 30% by weight, e.g., about 5% to about 20% by weight, of an alkali compound; and about 20% to about 50% by weight, e.g., about 20% to about 40% by weight, of water. The silicate mixture may contain about 5% to about 80% by weight, for example, about 10% to about 70% by weight, or about 10% to about 50% by weight, or about 10% to about 30% by weight of silicate material; about 10% to about 60% by weight, for example, about 15% to about 50% by weight of reactive silica other than the silicate material; about 5% to about 30% by weight, for example, about 5% to about 25% by weight of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight of water.

[0136] For example, the silicate mixture may be composed of about 5% to about 80% by weight, e.g., about 10% to about 70% by weight, or about 10% to about 50% by weight, or about 10% to about 30% by weight of silicate glass (e.g., borosilicate glass and / or soda-lime glass); about 10% to about 60% by weight, e.g., about 15% to about 50% by weight of reactive silica; about 5% to about 30% by weight, e.g., about 5% to about 25% by weight of an alkali compound; and about 20% to about 40% by weight, e.g., about 20% to about 35% by weight of water. The silicate mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of a first silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of a second silicate material; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water. The silicate mixture may include about 5% to about 50% by mass, for example, about 5% to about 40% by mass, of a first silicate glass (e.g., borosilicate glass); about 5% to about 50% by mass, for example, about 5% to about 40% by mass, of a second silicate glass (e.g., soda-lime glass); about 5% to about 30% by mass, for example, about 5% to about 25% by mass, of an alkali compound; and about 20% to about 40% by mass, for example, about 20% to about 35% by mass, of water.

[0137] The silicate mixture may contain about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of silicate glass (e.g., borosilicate and / or soda-lime glass); about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of a silicate mineral other than silicate glass; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water. The silicate mixture may include about 5% to about 50%, e.g., about 5% to about 40%, by weight, of perlitic material (e.g., unexpanded natural perlite ore having a water content greater than about 2% by weight); about 5% to about 50%, e.g., about 5% to about 40%, by weight, of silicate glass other than perlitic material (e.g., borosilicate and / or soda-lime glass); about 5% to about 30%, e.g., about 5% to about 25%, by weight, of an alkali compound; and about 20% to about 40%, e.g., about 20% to about 35%, by weight, of water. The silicate mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of the first silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of the second silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of reactive silica other than the first and second silicate materials; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water.

[0138] The silicate mixture may include about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of the first silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of the second silicate material; about 5% to about 50% by weight, for example, about 5% to about 40% by weight, of reactive silica other than the first and second silicate materials; about 5% to about 30% by weight, for example, about 5% to about 25% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 35% by weight, of water. The silicate mixture may include about 5% to about 50% by mass, for example about 5% to about 40% by mass, of a first silicate glass; about 5% to about 50% by mass, for example about 5% to about 40% by mass, of a second silicate glass; about 5% to about 50% by mass, for example about 5% to about 40% by mass, of a reactive silica; about 5% to about 30% by mass, for example about 5% to about 25% by mass, of an alkali compound; and about 20% to about 40% by mass, for example about 20% to about 35% by mass, of water.

[0139] The silicate mixture may include about 5% to about 50%, for example, about 5% to about 40%, by weight, of perlitic material (e.g., unexpanded natural perlite ore having a water content greater than about 2% by weight); about 5% to about 50%, for example, about 5% to about 40%, by weight, of silicate glass other than perlitic material (e.g., borosilicate glass and / or soda-lime glass); about 5% to about 50%, for example, about 5% to about 40%, by weight, of reactive silica other than the first and second silicate materials; about 5% to about 30%, for example, about 5% to about 25%, by weight, of an alkali compound; and about 20% to about 40%, for example, about 20% to about 35%, by weight, of water. The silicate mixture may contain about 5% to about 25% by mass, for example, about 10% to about 20% by mass of silicate glass; about 1% to about 50% by mass, for example, about 5% to about 45% by mass of reactive silica; about 5% to about 30% by mass, for example, about 10% to about 20% by mass of an alkali compound; about 20% to about 40% by mass, for example, about 20% to about 30% by mass of water, and about 20% to about 55% by mass, for example, about 25% to about 50% by mass of a perlite-based material. For example, the silicate mixture may contain about 5% to about 25% by weight, for example, about 10% to about 20% by weight, of borosilicate glass; about 5% to about 20% by weight, for example, about 10% to about 45% by weight, of silica fume; about 5% to about 20% by weight, for example, about 10% to about 20% by weight, of sodium hydroxide and / or lithium hydroxide; about 20% to about 40% by weight, for example, about 20% to about 30% by weight, of water; and about 20% to about 55% by weight, for example, about 25% to about 50% by weight, of unexpanded natural perlite ore.

[0140] The silicate mixture may include about 5% to about 25% by weight, for example, about 10% to about 20% by weight, of silicate glass; about 20% to about 50% by weight, for example, about 25% to about 45% by weight, of perlite material; about 5% to about 20% by weight, for example, about 10% to about 15% by weight, of reactive silica; about 5% to about 20% by weight, for example, about 10% to about 17% by weight, of an alkali compound; and about 20% to about 40% by weight, for example, about 20% to about 30% by weight, of water. For example, the silicate mixture may include about 5% to about 25% by weight, e.g., about 10% to about 20% by weight, of borosilicate glass; about 20% to about 50% by weight, e.g., about 25% to about 45% by weight, of unexpanded natural pearlite ore; about 5% to about 20% by weight, e.g., about 10% to about 15% by weight, of silica fume; about 5% to about 20% by weight, e.g., about 10% to about 17% by weight, of sodium hydroxide and / or lithium hydroxide; and about 20% to about 40% by weight, e.g., about 20% to about 30% by weight, of water. The silicate mixture may comprise (e.g., consist essentially of, or consist of) about 10% to about 15% by weight of silicate glass; about 35% to about 45% by weight of reactive silica; about 15% to about 20% by weight of an alkali compound; and about 25% to about 35% by weight of water. For example, the silicate mixture may comprise (e.g., consist essentially of, or consist of) about 10% to about 15% by weight of borosilicate glass; about 35% to about 45% by weight of silica fume; about 15% to about 20% by weight of sodium hydroxide and / or lithium hydroxide; and about 25% to about 35% by weight of water.

[0141] The silicate mixture may comprise (e.g., consist essentially of, or consist of) about 30% to about 40% by weight of perlitic material, about 10% to about 20% by weight of silicate glass, about 5% to about 15% by weight of reactive silica, about 10% to about 15% by weight of an alkali compound, and about 20% to about 30% by weight of water. For example, the silicate mixture may comprise (e.g., consist essentially of, or consist of) about 30% to about 40% by weight of unexpanded natural perlite ore, about 10% to about 20% by weight of borosilicate glass, about 5% to about 15% by weight of silica fume, about 10% to about 15% by weight of sodium hydroxide and / or lithium hydroxide, and about 20% to about 30% by weight of water. The silicate mixture may comprise (e.g., consist essentially of, or consist of) about 25% to about 35% by weight of perlitic material, about 10% to about 20% by weight of silicate glass, about 10% to about 20% by weight of reactive silica, about 10% to about 20% by weight of an alkali compound, and about 20% to about 30% by weight of water. For example, the silicate mixture may comprise (e.g., consist essentially of, or consist of) about 25% to about 35% by weight of unexpanded natural perlite ore, about 10% to about 20% by weight of borosilicate glass, about 10% to about 20% by weight of silica fume, about 10% to about 20% by weight of sodium hydroxide and / or lithium hydroxide, and about 20% to about 30% by weight of water.

[0142] The silicate mixture may comprise (e.g., consist essentially of, or consist of) about 20% to about 50% by weight of silicate mineral, about 10% to about 20% by weight of silicate glass, about 5% to about 45% by weight of reactive silica, about 5% to about 30% by weight of an alkali compound, and about 15% to about 40% by weight of water. For example, the silicate mixture may comprise (e.g., consist essentially of, or consist of) about 20% to about 50% by weight of perlitic material, about 10% to about 20% by weight of borosilicate and / or soda-lime glass, about 5% to about 45% by weight of silica fume, about 5% to about 30% by weight of sodium hydroxide and / or lithium hydroxide, and about 15% to about 40% by weight of water. The silicate mixture may include (e.g., consist essentially of, or consist of) about 20% to about 50% by weight perlitic material; about 10% to about 20% by weight borosilicate and / or soda-lime glass; about 5% to about 45% by weight silica fume; about 5% to about 20% by weight sodium hydroxide; about 0% to about 10% by weight lithium hydroxide; and about 15% to about 40% by weight water.

[0143] The silicate mixture may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 1% by weight or more, of glass network formers other than silicon. The silicate mixture may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less, of glass network formers other than silicon. The silicate mixture may contain about 0.01% to about 10% by weight, e.g., about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight of glass network formers other than silicon. For example, the silicate mixture may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 1% by weight or more, of boron. The silicate mixture may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less, of boron. The silicate mixture may contain about 0.01% to about 10% by weight, e.g., about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight of boron.

[0144] The silicate mixture may include an amount of boron such that the set silicate mixture (i.e., solid precursor or expandable material) and / or the expandable material includes less than about 5.0 wt. % B2O3, such as less than about 3.5 wt. % B2O3. The silicate mixture may contain about 0.01% by weight or more of glass network intermediate elements, for example, about 0.1% by weight or more, or about 1% by weight or more. The silicate mixture may contain about 20% by weight or less, for example, about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less of glass network intermediate elements. The silicate mixture may contain about 0.01% to about 10% by weight of glass network intermediate elements, for example, about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight. The silicate mixture may contain about 0.01% by weight or more, e.g., about 0.1% by weight or more, or about 1% by weight or more, of glass network modifying elements. The silicate mixture may contain about 20% by weight or less, e.g., about 15% by weight or less, or about 10% by weight or less, or about 5% by weight or less, or about 3% by weight or less, or about 1% by weight or less, of glass network modifying elements. The silicate mixture may contain about 0.01% to about 10% by weight, e.g., about 0.01% to about 5% by weight, or about 0.01% to about 3% by weight, or about 0.01% to about 1% by weight of glass network modifying elements.

[0145] The ratio of the total weight percent of reactive silica in the silicate mixture to the total weight percent of silicate glass in the silicate mixture, i.e.

number

[0146] The ratio of the total mass % of silica fume in the silicate mixture to the total mass % of borosilicate glass in the silicate mixture, i.e.

number

[0147] The ratio of the sum of the total mass % of reactive silica and silicate minerals in the silicate mixture to the total mass % of silicate glass in the silicate mixture, i.e.

number

[0148] The ratio of the sum of the total mass percent of silica fume and perlitic materials in the silicate mixture to the total mass percent of borosilicate glass in the silicate mixture, i.e.

number

[0149] The ratio of the total weight percent reactive silica in the silicate mixture to the total weight percent silicate minerals in the silicate mixture may be about 0.1 or greater, or about 0.2 or greater, or about 0.3 or greater. The ratio of the total mass % of silicon in the silicate mixture to the total mass % of sodium in the silicate mixture (i.e., the Si / Na ratio) may be about 1 or more, or about 1.2 or more, or about 1.4 or more, or about 1.5 or more. The Si / Na ratio may be about 4 or less, or about 3.5 or less, or about 3 or less, or about 2.9 or less. The Si / Na ratio may be about 1 to about 4, for example, about 1.2 to about 3.5, or about 1.4 to about 3, or about 1.5 to about 2.9. The method may include dissolving an alkaline compound in water to form an alkaline aqueous solution. Dissolving the alkaline compound in water may be an exothermic process. The method may include adding a silicate material to the alkaline aqueous solution and stirring. Adding the silicate material to the alkaline aqueous solution may include adding any other input materials, including any silicate glass, silicate material, and / or reactive silica, to the alkaline aqueous solution. The method may include stirring the silicate mixture, typically for 1 to 10 minutes, to form a paste. Heat generated during dissolution of the alkaline compound may assist in dissolving the other input materials.

[0150] The method may include shaping the silicate mixture before curing. The silicate mixture may be cured in an oven. The silicate mixture may be cured at a temperature of about 250°C or less, for example, about 20°C to about 200°C, or about 20°C to about 150°C, or about 20°C to about 120°C, or about 50°C to about 120°C, or about 50°C to about 110°C, or about 70°C to about 100°C. The silicate mixture may be cured for about 1 hour or more, for example, about 2 hours or more, or about 4 hours or more, or about 6 hours or more, or about 8 hours or more, or about 10 hours or more, or about 12 hours or more, or about 24 hours or more. The silicate mixture may be cured for about 72 hours or less, for example, about 48 hours or less, or about 24 hours or less. The silicate mixture may be cured for about 1 hour to about 72 hours, for example, about 2 hours to about 48 hours, or about 4 hours to about 24 hours, or about 4 hours to about 12 hours, or about 12 hours to about 72 hours, or about 24 hours to about 72 hours.

[0151] During curing, the silicate mixture may polymerize to form an inorganic polymer network. The polymerization of the silicate mixture may be similar to a geopolymerization process. In geopolymerization, aluminosilicate materials polymerize after alkaline activation to form a rigid three-dimensional framework of SiO and AlO tetrahedra linked by shared oxygen. The morphology of the framework formed (i.e., poly(sialate), poly(sialate-siloxo), or poly(sialate-disiloxo)) depends on the ratio of SiO to AlO in the initial silicate mixture. However, the inorganic polymer network formed during curing of the silicate mixture in the present invention is typically less rigid and more linear than geopolymers and incorporates a large amount of water.

[0152] The solid precursor may be crushed after hardening to form a granular material (i.e., a granular expandable material). The method may include sieving the solid precursor (i.e., the granular material) after crushing. The method may include crushing (and optionally sieving) the solid precursor to obtain a particle size (e.g., d 50 The method may include crushing (and optionally sieving) the solid precursor to obtain a granular material (i.e., granular expandable material) having an average particle size (e.g., d) of about 10 mm or less, e.g., about 8 mm or less, or about 6 mm or less, or about 4 mm or less, 2 mm or less, or about 1.5 mm or less, or about 1 mm or less. 50 The method may include crushing (and optionally sieving) the solid precursor to obtain a granular material (i.e., granular expandable material) having an average particle size (e.g., d) of about 10 μm to about 10 mm, or about 10 μm to about 8 mm, or about 10 μm to about 6 mm, or about 10 μm to about 4 mm, or about 10 μm to about 2 mm, or about 100 μm to about 2 mm, or about 500 μm to about 1 mm, or about 250 μm to about 750 μm, or about 500 μm to about 1.5 mm, or about 750 μm to about 1.5 mm. 50 The method may include obtaining a granular material (i.e., a granular expandable material) having a granular composition.

[0153] The method may include two or more crushing and / or sieving steps. For example, the method may include crushing a solid precursor in a first crushing step to form a particulate material having a first particle size; determining the first particle size; and then crushing the particulate material in a second crushing step to form a particulate material having a second particle size, the second particle size being smaller than the first particle size.

[0154] The method may include heating the granular material (i.e., the granular intumescent material) to form an expanded granular material. The method may include heating the granular material (i.e., the granular intumescent material) to a temperature of about 1100°C or less, e.g., about 1000°C or less, or about 900°C or less, or about 700°C or less, or about 600°C or less. The method may include heating the granular material (i.e., the granular intumescent material) to a temperature of about 200°C or more, e.g., about 300°C or more, or about 400°C or more. The method may include heating the granular material (i.e., the granular intumescent material) to a temperature of about 200°C to about 1100°C, e.g., about 200°C to about 1000°C, or about 200°C to about 900°C, or about 300°C to about 700°C, or about 300°C to about 700°C, or about 400°C to about 600°C. The method may include heating the granular material (i.e., the granular expandable material) in a furnace, for example, in a furnace selected from an infrared (IR) furnace, an electrically heated furnace, a natural gas or LPG expansion furnace. The furnace may be a horizontal furnace, a vertical furnace, or a tilt furnace. The method may include heating the granular material (i.e., the granular expandable material) in a fluidized bed reactor.

[0155] The method comprises crushing (and optionally sieving) the solid precursor to produce a particle size (e.g., d 50 and heating the granular material (i.e., the granular intumescent material) in an infrared (IR) furnace to form an intumescent granular material. An exemplary IR furnace includes an Elstein HTS (125 x 125 mm) ceramic infrared panel radiator operating at 64 kW / m with a maximum operating temperature of 860°C. The IR furnace may include a steel vibrating plate for vibrating the granular material during heating. An exemplary mechanical vibrating element is available from Italvibras G. Silingardi SpA, such as Model M3 / 45-S02, Series: AA, CFKN 0.44 / 0.64, RPM 3000 / 3800. The method involves crushing (and optionally sieving) a solid precursor to a particle size of about 500 μm or less (e.g., d 50and heating the granular material (i.e., the granular expandable material) in an electric furnace (e.g., a vertical electric furnace) to form the expanded granular material.

[0156] For the avoidance of doubt, expanded silicate materials are: (a) Approximately 15kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; and / or a resistance to consolidation measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2"; and / or a thermal conductivity measured in accordance with EN 12667 of about 0.0300 W / mK to about 0.0700 W / mK, for example, about 0.0320 W / mK to about 0.0420 W / mK, about 0.0350 W / mK to about 0.0400 W / mK, or about 0.0360 W / mK to about 0.0410 W / mK, or about 0.0320 W / mK to about 0.0340 W / mK, or about 0.042 W / mK to about 0.055 W / mK, or about 0.055 W / mK to about 0.070 W / mK; may have; (b) about 8% to about 30% by weight, for example, about 13% to about 22% by weight, of XO, where X is an alkali metal such as Na or Li; about 0% to about 15% by weight, e.g., about 5% to about 9% by weight, Al2O3; and It may contain about 50% by mass to about 80% by mass, for example, about 60% by mass to about 75% by mass of SiO2, and may contain about 0% to about 10% by weight, for example, about 0.5% to about 5% by weight, of HO; The expanded silicate material may contain less than about 5% by weight, e.g., less than about 3.5% by weight, B2O3; and / or (c) forming a silicate mixture comprising a silicate material; an alkali compound; and water; curing the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expandable silicate material; and It may be made by heating a particulate expanded silicate material to form the expanded silicate material.

[0157] The expanded silicate material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0158] The expanded silicate material is (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0159] The expanded silicate material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have The expanded silicate material is (a) Approx. 20kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0160] The expanded silicate material is about 44% to about 54% by weight SiO2; about 0.1% to about 1% by weight Na2O; about 0.1% to about 1% by weight Al2O3; less than about 0.2% by weight Fe2O3; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.1 to about 1% by weight water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a silicate mixture including: The expanded silicate material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0161] The expanded silicate material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a silicate mixture including: The expanded silicate material is (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0162] The expanded silicate material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a silicate mixture including: The expanded silicate material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0163] The expanded silicate material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water It may be formed from a silicate mixture including: The expanded silicate material is (a) Approx. 20kg / m 3 ~about 40kg / m 3loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0164] The expanded silicate material may be formed from a silicate mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; The expanded silicate material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0165] The expanded silicate material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0166] The expanded silicate material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; The expanded silicate material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0167] The expanded silicate material may be formed from a silicate mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approx. 20kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0168] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 1 mm (as determined by particle size distribution by sieving), the expandable granular material comprising: about 44% to about 54% by weight SiO2; about 0.1% to about 1% by weight Na2O; about 0.1% to about 1% by weight Al2O3; less than about 0.2% by weight Fe2O3; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.1 to about 1% by weight water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 18kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0400 W / mK may have

[0169] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 2 mm or less (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 50kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) Resistance to compaction measured in accordance with PI 306-80 from about 30 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0170] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.1 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0350 W / mK to approximately 0.0450 W / mK may have

[0171] The expanded silicate material may be formed by heating an expandable granular material having a particle size of less than about 1 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); Alkaline salts; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 20kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0172] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material is about 44% to about 54% by weight SiO2; about 0.1% to about 1% by weight Na2O; about 0.1% to about 1% by weight Al2O3; less than about 0.2% by weight Fe2O3; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.1 to about 1% by weight water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 18kg / m 3 ~about 25kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0320 W / mK to approximately 0.0360 W / mK may have

[0173] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving); The expandable granular material is about 44% to about 54% by weight SiO2; about 0.1% to about 1% by weight Na2O; about 0.1% to about 1% by weight Al2O3; less than about 0.2% by weight Fe2O3; about 0.05% to about 0.5% by weight CaO; less than about 0.1% by weight MgO; about 0.05% to about 0.5% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.1 to about 1% by weight water and / or volatile materials (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 25kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0174] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.3 mm to about 2 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 55kg / m 3 ~about 65kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 35 PSI to about 40 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0400 W / mK may have

[0175] The expanded silicate material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 90kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 70 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0420 W / mK may have

[0176] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 75kg / m 3 ~about 85kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 50 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0410 W / mK may have

[0177] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 78kg / m 3 ~about 86kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 60 PSI to about 74 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0420 W / mK may have

[0178] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.1 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 3% to about 6% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 60 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0430 W / mK may have

[0179] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 20kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 10 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0360 W / mK may have

[0180] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); alkaline compounds; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approx. 25kg / m 3 ~Approx. 35kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0181] The expanded silicate material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving); The expandable granular material is about 42% to about 52% by weight SiO2; about 1.2% to about 2.4% by weight Na2O; about 2.5% to about 4.5% by weight Al2O3; about 0.1% to about 1% by weight Fe2O3; about 0.1% to about 1% by weight CaO; less than about 0.2% by weight MgO; about 1% to about 2% by weight K2O; about 1% to about 3% by weight B2O3; and one or more silicate materials and / or reactive silicas containing about 0.5 to about 1.5% by weight water and / or volatiles (i.e., materials that contribute to "loss on ignition" (LOI)); Alkaline salts; and water The silicate mixture may be formed from a silicate mixture comprising: The expanded silicate material is (a) Approximately 30kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 8 PSI to about 16 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0350 W / mK may have

[0182] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; The expanded silicate material is (a) Approx. 18kg / m 3 ~about 25kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0320 W / mK to approximately 0.0360 W / mK may have

[0183] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 10% to about 15% by weight borosilicate glass; about 35% to about 45% by weight silica fume; about 15% to about 20% by weight sodium hydroxide; and about 25% to about 32% by weight water; The expanded silicate material is (a) Approx. 25kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 4 PSI to about 8 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0184] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.3 mm to about 2 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approximately 55kg / m 3 ~about 65kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 35 PSI to about 40 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0400 W / mK may have

[0185] The expanded silicate material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 15% by weight silica fume; about 10% to about 15% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approximately 90kg / m 3 ~about 100kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 70 PSI to about 80 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0420 W / mK may have

[0186] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; The expanded silicate material is (a) Approximately 75kg / m 3 ~about 85kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 40 PSI to about 50 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0370 W / mK to approximately 0.0410 W / mK may have

[0187] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; The expanded silicate material is (a) Approx. 78kg / m 3 ~about 86kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 60 PSI to about 74 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0420 W / mK may have

[0188] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.1 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 12% to about 18% by weight borosilicate glass; about 5% to about 10% by weight silica fume; about 8% to about 16% by weight sodium hydroxide; and about 20% to about 32% by weight water; The expanded silicate material is (a) Approximately 70kg / m 3 ~About 105kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 60 PSI to about 75 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0360 W / mK to approximately 0.0430 W / mK may have

[0189] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.5 mm to about 1 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approx. 20kg / m 3 ~about 30kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 10 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0360 W / mK may have

[0190] The expanded silicate material may be formed by heating an expandable granular material having a particle size of about 0.125 mm to about 0.5 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approx. 25kg / m 3 ~Approx. 35kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 5 PSI to about 15 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0310 W / mK to approximately 0.0350 W / mK may have

[0191] The expanded silicate material may be formed by heating an expandable granular material having a particle size of less than about 0.3 mm (as determined by particle size distribution by sieving); The expandable granular material may be formed from a silicate mixture including about 10% to about 20% by weight borosilicate glass; about 10% to about 20% by weight silica fume; about 10% to about 20% by weight sodium hydroxide; and about 20% to about 30% by weight water; The expanded silicate material is (a) Approximately 30kg / m 3 ~about 40kg / m 3 loose bulk density measured in accordance with PI 200-77; (b) a resistance to compaction measured in accordance with PI 306-80 of about 8 PSI to about 16 PSI at 2 inches; and / or (c) Thermal conductivity measured in accordance with EN 12667 of approximately 0.0300 W / mK to approximately 0.0350 W / mK may have Additionally or alternatively, the insulating filler may comprise expanded natural products such as expanded natural minerals (e.g. expanded natural perlite) or expanded synthetic polymers (e.g. expanded polystyrene) or glass such as glass beads (e.g. expanded glass beads) or agricultural waste (e.g. poppy husk particles, straw, barley straw, corn pith, rice husks, corn cobs, rice straw, coconut pith, hemp fibre, or wood-based materials such as spruce, pine, wood chips, black locust bark, eucalyptus, spruce or fir fibre, waste pine plywood, or cork dust).

[0192] <Method> As discussed hereinabove, the method may include combining a solvent and a gel networker former, and optionally a foaming agent and / or one or more additives, to form a gel. The method may further include aerating the gel. Aerating the gel is understood to include foaming the gel, i.e., forming gas (e.g., air) bubbles in the gel. Aeration of the gel may be achieved by mechanically agitating the gel, for example, by swirling the gel. The method may include shaping the mixture prior to the drying step. Shaping the mixture may include any suitable shaping process known in the art, including molding (e.g., in a mold), rolling, cutting, extruding, and / or smoothing, prior to the drying step. The method may include forming the mixture into the form of a panel or board. It is understood that the shaping step typically occurs after dispersing an insulating filler in the mixture.

[0193] The step of drying the mixture to form the insulating product may include forming a cellular matrix. A cellular matrix is ​​a porous matrix, and it is understood that the matrix includes a plurality of cavities or bubbles that may be filled with a gas (e.g., air). The cellular matrix may be a foam. The cellular matrix may be a xerogel, i.e., a solid formed from a liquid-containing gel by drying in which shrinkage is not prevented. The cellular matrix may be an aerogel, i.e., a solid formed from a liquid-containing gel by drying under supercritical conditions in which shrinkage of the gel network structure is prevented (e.g., substantially prevented). The aerogel may be a clay aerogel, i.e., an aerogel sometimes referred to as an aeroclay, in which the gel network structure includes clay minerals (e.g., clay minerals reinforced with a reinforcing agent). The aerogel (e.g., clay aerogel) may be a foamed aerogel (e.g., foamed clay aerogel). A foamed aerogel (e.g., a foamed clay aerogel) may be formed by agitating (e.g., frothing or whipping) the mixture to form the aerogel (e.g., a clay aerogel) before drying, thereby incorporating air bubbles into the mixture and thus the resulting aerogel (e.g., a clay aerogel).

[0194] The step of drying the mixture may include freeze-drying the mixture. Freeze-drying is understood to be a low-temperature drying process in which the mixture is frozen, for example, at a temperature below about −30° C. or up to about −196° C. (i.e., such that the solvent in the mixture freezes), the pressure is reduced (e.g., by placing the mixture in a vacuum), and the solvent is then removed from the mixture by sublimation, for example, by heating the frozen mixture at low pressure. Freeze-drying may better preserve gel network structures, particularly cellular gel network structures such as those of clay aerogels. Alternatively, the step of drying the mixture may involve drying the mixture under ambient conditions (i.e., at ambient temperature (i.e., room temperature) and pressure, for example, at a temperature of about 20° C. and a pressure of about 1 atmosphere (i.e., about 101.325 kPa)). Further alternatively, the step of drying the mixture may involve drying the mixture at an elevated temperature, for example, up to about 25° C., or from about 25° C. to about 50° C. Drying under ambient conditions or at an elevated temperature may be faster than freeze-drying.

[0195] <Insulation products> Insulation products typically contain insulating fillers dispersed in a cellular matrix. The cellular matrix may be a foam. The foam may be a flexible foam. For example, the foam may have a modulus of elasticity (e.g., Young's modulus or flexural modulus) of less than about 5 GPa, e.g., less than about 4 GPa, or less than about 3 GPa, or less than about 2 GPa, or less than about 1 GPa. For example, the foam may include (e.g., be primarily formed of) a binder, such as a polymeric (e.g., elastomeric) binder. The foam may include (e.g., be primarily formed of) a foamed natural binder, such as foamed cellulose or foamed gelatin. In embodiments where the cellular matrix is ​​a foam (e.g., a flexible foam, e.g., a foam that includes (i.e., is primarily formed of) a foamed binder), the insulation product may have a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of about 0.010 W / mK or more, such as about 0.0125 W / mK or more, or about 0.015 W / mK or more. In embodiments where the cellular matrix is ​​a foam (e.g., a flexible foam, e.g., a foam that includes (i.e., is primarily formed of) a foamed binder), the insulation product may have a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of about 0.045 W / mK or less, such as about 0.040 W / mK or less, or about 0.037 W / mK or less. In embodiments in which the cellular matrix is ​​a foam (e.g., a flexible foam, e.g., a foam that includes (i.e., is formed primarily of) a foamed binder), the insulation product may have a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of from about 0.010 W / mK to about 0.045 W / mK, e.g., from about 0.010 W / mK to about 0.040 W / mK, or from about 0.015 W / mK to about 0.037 W / mK.

[0196] In embodiments where the cellular matrix is ​​a foam (e.g., a flexible foam, e.g., a foam that includes (i.e., is formed primarily of) a foamed binder), the insulation product has a density of about 0.035 g / cm 3 Less than about 0.02 g / cm 3 In embodiments where the cellular matrix is ​​a foam (e.g., a flexible foam, e.g., a foam that includes (i.e., is formed primarily of) a foamed binder), the insulation product may have a density of less than about 0.01 g / cm 3 In embodiments where the cellular matrix is ​​a foam (e.g., a flexible foam, e.g., a foam that includes (i.e., is formed primarily of) a foamed binder), the insulation product may have a density of about 0.01 g / cm 3 ~Approx. 0.035g / cm 3 , for example, about 0.01 g / cm 3 ~about 0.02g / cm 3 The density may be The cellular matrix may be an aerogel, e.g., a foamed aerogel, e.g., a clay aerogel, such as a foamed clay aerogel. The aerogel (e.g., foamed aerogel, clay aerogel, or foamed clay aerogel) may be rigid. For example, the aerogel (e.g., foamed aerogel, clay aerogel, or foamed clay aerogel) may have an elastic modulus (e.g., Young's modulus or flexural modulus) of greater than about 5 GPa, e.g., greater than about 10 GPa, or greater than about 15 GPa, or greater than about 20 GPa, or greater than about 25 GPa. For example, the aerogel (e.g., foamed aerogel, clay aerogel, or foamed clay aerogel) may include (e.g., consist essentially of) a clay mineral, such as a smectite clay mineral, bentonite, hectorite, or montmorillonite, and may also include a reinforcing agent, e.g., a polymer.

[0197] In embodiments where the cellular matrix is ​​an aerogel (e.g., a foamed aerogel, a clay aerogel, or a foamed clay aerogel, e.g., a rigid aerogel such as a rigid foamed aerogel, a rigid clay aerogel, or a rigid foamed clay aerogel), the insulation product may have a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of about 0.020 W / mK or more, e.g., about 0.025 W / mK or more, or about 0.030 W / mK or more. In embodiments where the cellular matrix is ​​an aerogel (e.g., a foamed aerogel, a clay aerogel, or a foamed clay aerogel, e.g., a rigid aerogel such as a rigid foamed aerogel, a rigid clay aerogel, or a rigid foamed clay aerogel), the insulation product may have a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of about 0.050 W / mK or less, e.g., about 0.045 W / mK or less, or about 0.040 W / mK or less. In embodiments where the cellular matrix is ​​an aerogel (e.g., a foamed aerogel, a clay aerogel, or a foamed clay aerogel, e.g., a rigid aerogel such as a rigid foamed aerogel, a rigid clay aerogel, or a rigid foamed clay aerogel), the insulation product may have a thermal conductivity (λ, lambda value) measured according to EN 12667 of from about 0.020 W / mK to about 0.050 W / mK, e.g., from about 0.025 W / mK to about 0.045 W / mK, or from about 0.030 W / mK to about 0.040 W / mK.

[0198] In embodiments where the cellular matrix is ​​an aerogel (e.g., a foamed aerogel, a clay aerogel, or a foamed clay aerogel, e.g., a rigid aerogel such as a rigid foamed aerogel, a rigid clay aerogel, or a rigid foamed clay aerogel), the thermal insulation product has a thermal conductivity of about 0.02 g / cm 3 More than, for example, about 0.03 g / cm 3 In embodiments where the cellular matrix is ​​an aerogel (e.g., a foamed aerogel, a clay aerogel, or a foamed clay aerogel, e.g., a rigid aerogel such as a rigid foamed aerogel, a rigid clay aerogel, or a rigid foamed clay aerogel), the insulation product may have a density of about 0.1 g / cm 3 Below, for example, about 0.09 g / cm 3 or less, or about 0.08 g / cm 3 In embodiments where the cellular matrix is ​​an aerogel (e.g., a foamed aerogel, a clay aerogel, or a foamed clay aerogel, e.g., a rigid aerogel such as a rigid foamed aerogel, a rigid clay aerogel, or a rigid foamed clay aerogel), the insulation product may have a density of about 0.02 g / cm 3 ~about 0.1g / cm 3 , for example, about 0.03 g / cm 3 ~Approx. 0.09g / cm 3 , or about 0.03 to about 0.07 g / cm 3 The density may be

[0199] The thermal insulation product (whether the cellular matrix is ​​a flexible foam or a rigid aerogel) may have a total intrusion volume as measured by mercury porosimetry of about 8 mL / g or more, e.g., about 9 mL / g or more, or about 10 mL / g or more. The thermal insulation product (whether the cellular matrix is ​​a flexible foam or a rigid aerogel) may have a total intrusion volume as measured by mercury porosimetry of about 20 mL / g or less, e.g., about 17 mL / g or less, or about 13 mL / g or less. The thermal insulation product (whether the cellular matrix is ​​a flexible foam or a rigid aerogel) may have a total intrusion volume as measured by mercury porosimetry of about 8 mL / g to about 20 mL / g, e.g., about 9 mL / g to about 17 mL / g, or about 10 mL / g to about 13 mL / g.

[0200] The insulation product (whether the cellular matrix is ​​a flexible foam or a rigid aerogel) may have a total open porosity as measured by mercury porosimetry of greater than about 70%, e.g., greater than about 80%, or greater than about 85%, or greater than about 89%. The insulation product (whether the cellular matrix is ​​a flexible foam or a rigid aerogel) may have a total open porosity as measured by mercury porosimetry of greater than about 99%, e.g., greater than about 96%, or greater than about 95%, or greater than about 94%. The insulation product (whether the cellular matrix is ​​a flexible foam or a rigid aerogel) may have a total open porosity as measured by mercury porosimetry of between 70% and about 99%, e.g., between about 80% and about 96%, or between about 89% and about 94%.

[0201] For the avoidance of doubt, this application relates to the subject matter described in the following numbered paragraphs: 1. A method for producing an insulating product, comprising: (a) forming a mixture comprising a solvent and a gel network former, and optionally a foaming agent; (b) dispersing an insulating filler in the mixture; (c) drying the mixture to form an insulating product; A method comprising: 2. The method of paragraph 1, further comprising the step of shaping the mixture before the drying step. 3. The method of paragraph 1 or 2, wherein the gel network former comprises a binder, for example a natural binder such as cellulose or gelatin. 4. The gel network former is (i) clay minerals, such as smectite clay minerals, bentonite, montmorillonite, or hectorite; and (ii) a reinforcing agent (e.g., one or more reinforcing agents), such as a polymer 4. The method of any of paragraphs 1 to 3, comprising: 5. The method of any of paragraphs 1 to 4, wherein the foaming agent is a surfactant, such as sodium dodecyl sulfate (SDS). 6. The method of any of paragraphs 1 to 5, wherein the mixture of step (a) further comprises at least one additive, for example, at least one additive selected from an antifungal agent such as propionic acid, an antibacterial agent, a flame retardant such as aluminum hydroxide, a hydrophobic agent such as silicone oil, stearic acid, and a thermal conductivity control agent such as graphite. 7. The method of any of paragraphs 1 to 6, wherein the insulating filler is a particulate material, for example a porous particulate material such as an expanded silicate material.

[0202] 8. Expanded silicate material (a) Approximately 15kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3 ~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 , or about 30 to about 60 kg / m 3 , preferably about 30 to about 60 kg / m 3 loose bulk density measured in accordance with PI 200-77; and / or a resistance to consolidation measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2"; and / or a thermal conductivity measured in accordance with EN 12667 of about 0.0300 W / mK to about 0.0700 W / mK, for example, about 0.0320 W / mK to about 0.0420 W / mK, about 0.0350 W / mK to about 0.0400 W / mK, or about 0.0360 W / mK to about 0.0410 W / mK, or about 0.0320 W / mK to about 0.0340 W / mK, or about 0.042 W / mK to about 0.055 W / mK, or about 0.055 W / mK to about 0.070 W / mK having; (b) about 3% to about 30% by weight, e.g., about 8% to about 30% by weight, or about 13% to about 22% by weight, or about 3.5% to about 22% by weight, of XO (X is an alkali metal such as Na or Li); about 0% to about 20% by weight, e.g., about 0% to about 15% by weight, or about 5% to about 9% by weight, or about 5% to about 15% by weight Al2O3; and about 50% to about 90% by weight, e.g., about 50% to about 80% by weight, or about 60% to about 75% by weight, or about 60% to about 80% by weight of SiO2; may contain about 0% to about 10% by weight, for example, about 0.5% to about 5% by weight, of HO; The expanded silicate material may include less than about 5% by weight, such as less than about 3.5% by weight, of B2O3; (c) forming a silicate mixture comprising (e.g., at least one) silicate material; an alkali compound; and water; curing the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expandable silicate material; produced by heating a particulate expandable silicate material to form an expanded silicate material; and / or (d) the method of paragraph 7, wherein the expanded natural perlite.

[0203] 9. The method of any of paragraphs 1-8, wherein the mixture formed by combining the solvent and gel network former, and optionally the foaming agent and / or at least one additive, is a gel. 10. The method of paragraph 9, further comprising aerating the gel, for example by mechanically agitating the gel, to form a cellular gel. 11. The method of any of paragraphs 1-10, wherein the step of drying the mixture to form an insulating product includes forming a cellular matrix, such as a foam or aerogel, having an insulating filler dispersed therein, e.g., a clay aerogel, such as a foamed aerogel or a foamed clay aerogel. 12. The step of drying the mixture comprises: (i) freeze-drying the mixture; (ii) drying the mixture under ambient conditions; or (iii) the method of any of paragraphs 1 to 11, comprising drying the mixture at elevated temperature.

[0204] 13. The method of any of paragraphs 1 to 12, wherein the solvent is water or an alcohol, such as ethanol. 14. An insulating product comprising an insulating filler dispersed in a cellular matrix. 15. The insulating product of paragraph 14, wherein the insulating filler is a granular material, for example a porous granular material such as an expanded silicate material. 16. The expanded silicate material is (a) Approximately 15kg / m 3 ~about 450kg / m 3 , for example, about 20 kg / m 3 ~about 100kg / m 3 , or about 30 to about 60 kg / m 3 , or approximately 20 kg / m 3 ~about 30kg / m 3 , or approximately 20 kg / m 3~about 40kg / m 3 , or approximately 55 kg / m 3 ~about 100kg / m 3 , or approximately 70 kg / m 3 ~about 100kg / m 3 , preferably about 30 to about 60 kg / m 3 loose bulk density measured in accordance with PI 200-77; and / or a resistance to consolidation measured according to PI 306-80 of from about 3 PSI to about 350 PSI at 2", e.g., from about 3 PSI to about 200 PSI at 2", or from about 3 PSI to about 100 PSI at 2", or from about 3 PSI to about 10 PSI at 2", or from about 30 PSI to about 80 PSI at 2", or from about 40 PSI to about 75 PSI at 2", or from about 5 PSI to about 20 PSI at 2"; and / or a thermal conductivity measured in accordance with EN 12667 of about 0.0300 W / mK to about 0.0700 W / mK, for example, about 0.0320 W / mK to about 0.0420 W / mK, about 0.0350 W / mK to about 0.0400 W / mK, or about 0.0360 W / mK to about 0.0410 W / mK, or about 0.0320 W / mK to about 0.0340 W / mK, or about 0.042 W / mK to about 0.055 W / mK, or about 0.055 W / mK to about 0.070 W / mK having; (b) about 3% to about 30% by weight, e.g., about 8% to about 30% by weight, or about 13% to about 22% by weight, or about 3.5% to about 22% by weight, of XO (X is an alkali metal such as Na or Li); about 0% to about 20% by weight, e.g., about 0% to about 15% by weight, or about 5% to about 9% by weight, or about 5% to about 15% by weight Al2O3; and about 50% to about 90% by weight, e.g., about 50% to about 80% by weight, or about 60% to about 75% by weight, or about 60% to about 80% by weight of SiO2; may contain about 0% to about 10% by weight, for example, about 0.5% to about 5% by weight, of HO; The expanded silicate material may include less than about 5% by weight, such as less than about 3.5% by weight, of B2O3; (c) forming a silicate mixture comprising a silicate material; an alkali compound; and water; curing the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expandable silicate material; produced by heating a particulate expandable silicate material to form an expanded silicate material; and / or (d) The insulation product of paragraph 15, which is expanded natural perlite.

[0205] 17. The insulating product of any of paragraphs 14 to 16, wherein the cellular matrix is ​​a foam, for example a flexible foam. 18. The insulating product of paragraph 17, wherein the foam comprises an expanded natural binder, such as expanded cellulose or expanded gelatin. 19. The thermal insulation product of paragraph 17 or paragraph 18, having a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of between about 0.010 W / mK and about 0.040 W / mK, for example between about 0.015 W / mK and about 0.037 W / mK.

[0206] 20. Approx. 0.035g / cm 3 Less than about 0.02 g / cm 3 Less than, or about 0.01 g / cm 3 ~about 0.02g / cm 3 20. The insulating product of any of paragraphs 17 to 19, having a density of 21. The thermal insulation product of any of paragraphs 14 to 16, wherein the cellular matrix is ​​an aerogel, for example a clay aerogel, such as a foamed aerogel or a foamed clay aerogel. 22. The thermal insulation product according to paragraph 21, wherein the aerogel, such as clay aerogel, expanded aerogel or expanded clay aerogel, is rigid. 23. The insulation product of paragraph 21 or paragraph 22, wherein the aerogel is a clay aerogel, such as a foamed clay aerogel formed from a clay mineral, such as a smectite clay mineral, bentonite, hectorite, or montmorillonite, and (e.g., at least one) reinforcing agent, such as a polymer.

[0207] 24. The thermal insulation product according to any of paragraphs 20 to 22, having a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of between about 0.020 W / mK and about 0.050 W / mK, for example between about 0.030 W / mK and about 0.040 W / mK. 25. Approx. 0.02g / cm 3 ~about 0.1g / cm 3 , for example, about 0.03 g / cm 3 ~Approx. 0.09g / cm 3 , or about 0.03 to about 0.07 g / cm 3 25. The insulating product of any of paragraphs 21 to 24, having a density of 26. An insulating product produced by the method described in any of paragraphs 1 to 13. 27. The insulating product of any of paragraphs 14 to 26, which is an insulating board. 28. The insulation product of any of paragraphs 14 to 27, having a total intrusion volume as measured in a mercury porosimeter of from about 9 mL / g to about 17 mL / g, e.g., from about 10 mL / g to about 13 mL / g; and / or a total open porosity as measured in a mercury porosimeter of greater than about 80%, e.g., from about 80% to about 96%, or from about 89% to about 94%. [Example]

[0208] Example 1 A mixture was prepared by dissolving 6% w / w gelatin with 0.66% w / w sodium dodecyl sulfate (SDS) in deionized water at approximately 60°C. The mixture was whipped to form a cellular gel. An insulating filler in the form of expanded synthetic perlite was added to the mixture, which was then mixed until homogeneous. Two samples of the mixture were cast in a mold and dried to form insulating panels. The first sample was dried by a freeze-drying process, which involved freezing the mixture to below approximately -30°C. The second sample was dried at room temperature. The density and thermal conductivity of the samples were measured. The first sample had a density of 0.015 g / cm 3 The second sample was found to have a density of 0.02 gm / cm 3Both panels were found to have a density of 0.035 W / mK. Both samples were found to have a thermal conductivity of 0.035 W / mK. Both panels were found to be flexible and could be bent around a pipe without breaking. Both panels could also be easily cut by hand using scissors.

[0209] Example 2 Insulation panels were prepared in the same manner as in Example 1, except that the concentration of SDS was increased from 0.66% w / w to 1% w / w. The thermal conductivity and mechanical behavior of the panels were found to be the same as those in Example 1. The density of the panels was found to be 10% lower than that of Example 1. Example 3 A mixture was prepared by mixing 3% w / w sodium montmorillonite (MMT) clay mineral with 3% w / w polyvinyl alcohol (PVA) and deionized water. A sample of the mixture was cast in a mold and dried by a freeze-drying process, which involves freezing the mixture to below about -30°C, to form a clay-aerogel-based insulation panel. The density of the freeze-dried sample was 0.05 g / cm 3 The thermal conductivity was found to be 0.035 W / mK. The panel was found to be rigid.

[0210] Example 4 Insulation panels were prepared in the same manner as in Example 3, except that the concentrations of MMT and PVA were both increased to 5% w / w. The density of the panels was found to increase by 35%. Example 5 12% w / w insulating filler in the form of expanded synthetic perlite (0.0833 g / cm 3 Insulation panels were prepared by the same method as in Example 3, except that a cellulose acylate stearate (having a density of 0.078 g / cm and a thermal conductivity of less than 0.04 W / mK) was incorporated into the mixture before drying. 3 and thermal conductivity of 0.036 W / mK.

[0211] Example 6 8% w / w insulating filler in the form of expanded polystyrene saturated with water (0.0833 g / cm 3 Insulation panels were prepared by the same method as in Example 3, except that a cellulose ester (having a density of 0.06 g / cm and a thermal conductivity of less than 0.04 W / mK) was incorporated into the mixture before drying. 3 It was found to have a density of Example 7 Mixtures were prepared by dissolving sodium montmorillonite (MMT) clay mineral with reinforcing agents (polyvinyl alcohol (PVA) and / or sodium polyacrylate) and deionized water. The mixtures were foamed by stirring, molded, frozen at -40°C, and freeze-dried. The results are shown in Table 1. [Table 1]

[0212] Example 8 A mixture was prepared by dissolving sodium montmorillonite (MMT) clay mineral with reinforcing agents (polyvinyl alcohol (PVA) and sodium polyacrylate), dispersing agent (sodium hexametaphosphate (Na-Hexam)), and deionized water. The mixture was foamed by stirring, molded, frozen at -40°C, and freeze-dried. The results are shown in Table 2. [Table 2]

[0213] Example 9 Insulating filler in the form of expanded synthetic perlite (USP) (43 kg / m 3 The mixtures were prepared as described in Example 7, except that 100% PEG-40 ... [Table 3]

[0214] Example 10 The thermal insulating filler (43 kg / m) with different contents of expanded synthetic perlite (USP) morphology was 3 The mixtures were prepared as described in Example 7, except that a 100% PEG-400 sieve (having a density of 100%) was incorporated into the foam mixture before freezing. The results are shown in Table 4. [Table 4]

[0215] Example 11 Mixtures were prepared as described in Example 7, except that 76% v / v insulating filler in the form of expanded synthetic perlite (USP) of various densities was incorporated into the foamed mixture before freezing. The results are shown in Table 5. [Table 5]

[0216] Example 12 76% v / v hydrophobic insulating filler in the form of expanded synthetic perlite (USP) (49.3 kg / m 3 Mixtures were prepared as described in Example 7, except that cellulose acetate (having a density of 1000 ppm) was incorporated into the foamed mixture before freezing. The results are shown in Table 6. Water vapor sorption was defined according to ASTM C1104 / C1104M. [Table 6]

[0217] Example 13 76% v / v insulating filler in the form of expanded synthetic perlite (USP) (43 kg / m 3 Mixtures were prepared as described in Example 7, except that a hydrophobic agent (having a density of 1000 MPa) was incorporated into the foam mixture before freezing. The results are shown in Table 7. Water vapor sorption was defined according to ASTM C1104 / C1104M. [Table 7]

[0218] Example 14 76% v / v insulating filler in the form of expanded synthetic perlite (USP) (43 kg / m 3 Mixtures were prepared as described in Example 7, except that graphite of different particle size distributions (A and B) was incorporated into the foamed mixture before freezing. The results are shown in Table 8. [Table 8]

Claims

1. 1. A method of making an insulation product, comprising: (a) forming a mixture comprising a solvent and a gel network former; (b) dispersing a thermal insulating filler in the mixture; (c) drying the mixture to form an insulating product; Including, the gel network former comprises a natural binder; and / or The gel network former, (i) clay minerals, and (ii) one or more reinforcing agents containing polymers; Including, the insulating filler is an expanded silicate material; The expanded silicate material is (a) a loose bulk density, measured in accordance with PI 200-77, of 15 kg / m 3 to 450 kg / m 3 ; Resistance to compaction measured in accordance with PI 306-80 from 3 PSI to 350 PSI at 2 inches; and / or a thermal conductivity measured in accordance with EN 12667 of 0.0300 W / mK to 0.0700 W / mK; having (b) 3% to 30% by weight of X 2 O, where X is an alkali metal; 0% to 20% by weight of Al 2 O 3 ; 50% to 90% by weight of SiO 2 ; and Contains 0% to 10% by weight of H 2 O; the expanded silicate material comprises less than 5 wt. % B2O3; (c) forming a silicate mixture comprising at least one silicate material; an alkali compound; and water; curing the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expandable silicate material; produced by heating a particulate expandable silicate material to form an expanded silicate material; and / or (d) expanded natural perlite; The method.

2. The method of claim 1 , wherein the mixture further comprises a foaming agent.

3. 3. The method of claim 1 or 2, further comprising the step of shaping the mixture before drying.

4. the natural binder comprises cellulose or gelatin; and / or 4. The method according to claim 1, wherein the clay mineral is a smectite clay mineral, bentonite, montmorillonite or hectorite.

5. The method of claim 2 wherein the foaming agent is a surfactant.

6. 6. The method of any one of claims 1 to 5, wherein the mixture of step (a) further comprises at least one additive selected from an antifungal agent, an antibacterial agent, a flame retardant, a hydrophobic agent, and a thermal conductivity control agent.

7. The method of any one of claims 1 to 6, wherein the mixture formed is a gel or a foam gel.

8. The method of any one of claims 1 to 7, wherein drying the mixture to form an insulating product comprises forming a cellular matrix having an insulating filler dispersed therein.

9. drying the mixture (i) freeze-drying the mixture; (ii) drying the mixture under ambient conditions; or The method of any one of claims 1 to 8, comprising (iii) drying the mixture at an elevated temperature.

10. The method according to any one of claims 1 to 9, wherein the solvent is water or an alcohol.

11. 1. A thermal insulation product having a thermal insulating filler dispersed in a cellular matrix, comprising: the cellular matrix is ​​a foam containing an expanded natural binder; or the cellular matrix is ​​a clay cellular gel formed from a clay mineral and at least one reinforcing agent containing a polymer; The insulating filler is an expanded silicate material, and the expanded silicate material is (a) a loose bulk density, measured in accordance with PI 200-77, of 15 kg / m 3 to 450 kg / m 3 ; Resistance to compaction measured in accordance with PI 306-80 from 3 PSI to 350 PSI at 2 inches; and / or a thermal conductivity measured in accordance with EN 12667 of 0.0300 W / mK to 0.0700 W / mK; having (b) 3% to 30% by weight of X 2 O, where X is an alkali metal; 0% to 20% by weight of Al 2 O 3 ; 50% to 90% by weight of SiO 2 ; and Contains 0% to 10% by weight of H 2 O; the expanded silicate material comprises less than 5 wt. % B2O3; (c) forming a silicate mixture comprising: a silicate material; an alkali compound; and water; curing the silicate mixture to form a solid precursor; crushing and / or milling the solid precursor to form a particulate expandable silicate material; produced by heating a particulate expandable silicate material to form an expanded silicate material; and / or (d) expanded natural perlite; The thermal insulation product.

12. the foam is a flexible foam, and / or the foamed natural binder comprises foamed cellulose or foamed gelatin; The insulation product has a thermal conductivity (λ, lambda value) measured in accordance with EN 12667 of 0.010 W / mK to 0.040 W / mK; and / or 0.035 g / cm 3 12. The insulation product of claim 11 having a density of less than 1000 .mu.m.

13. The clay aerogel is a foamed clay aerogel, the clay aerogel or expanded clay aerogel is rigid; the clay mineral is a smectite clay mineral, bentonite, hectorite or montmorillonite; and / or 12. The thermal insulation product of claim 11, wherein the thermal insulation product has a thermal conductivity (λ, lambda value) measured according to EN 12667 of between 0.020 W / mK and 0.050 W / mK.

14. The insulation product is an insulation board, a total intrusion volume measured in a mercury porosimeter of 9 mL / g to 17 mL / g; and / or a total open porosity as measured by mercury porosimetry of greater than 80%; The insulating product of any one of claims 11 to 13, having

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