Inorganic nano-composite thermal insulation material and method of manufacture

A method of fabricating a cement based thermal insulation composite material, the method comprising:

• providing a water;
• providing a foaming agent, a rheological agent, and a water repellent;
• combining the water with the foaming agent, the rheological agent, and the water repellent;
• mixing the water with the foaming agent, the rheological agent, and the water repellent to form a homogeneous solution;
• adding a pre-blend dry powder to the homogeneous solution, the pre-blended dry power comprising a cement, a filling and reinforcing agent, a cement curing retarder, a cement curing accelerator and further mixing the pre-blend dry power with the homogeneous solution to form a resulting mixture;
• Injecting a gas into the resulting mixture to cause a froth the resulting mixture causing formation of a foamed mixture characterized by a volume increase from about 25% to about 300%;
• transferring the foamed mixture into a recessed region;
• causing the foamed mixture to set and harden at temperature from room temperature to about 80 Celsius to form a shaped cement block;
• removing the shaped cement block;
• and
• fully drying the shaped cement block from room temperature to about 150 Celsius until fully dried.

A method of fabricating a thermal insulation material, the method comprising:

• providing a water;
• providing a foaming agent, a rheological agent, and a water repellent;
• combining the water with the foaming agent, the rheological agent, and the water repellent in a vessel;
• mixing the water with the foaming agent, the rheological agent, and the water repellent to form a homogeneous solution;
• adding a pre-blend dry powder to the homogeneous solution, the pre-blended dry power comprising a cement, a filling and reinforcing agent, a cement curing retarder, a cement curing accelerator and further mixing the pre-blend dry power with the homogeneous solution to form a resulting mixture;
• injecting a gas into the resulting mixture to cause a froth the resulting mixture causing formation of a foamed mixture characterized by a volume increase from about 25% to about 300%;
• transferring the foamed mixture into a recessed region configured as a shaped block;
• causing the foamed mixture to set and harden at temperature from room temperature to about 80 Celsius to form a shaped block within the recessed region;
• removing the shaped cement block from the recessed region;
• and
• fully drying the shaped block from room temperature to about 150 Celsius until fully dried.