Methods for producing low density products

A method of forming a precursor for a low density material comprising the steps of:

• providing an inorganic primary component;
• forming an aqueous mixture comprising the inorganic primary component, a blowing agent and a control agent;
• and
• drying the mixture to provide an expandable precursor for forming a low density material, wherein said blowing agent and control agent are selected to control activation of the blowing agent such that the blowing agent is activated within a predetermined optimal and different temperature range than the control agent, wherein the precursor prior to expansion has an alkali metal oxide content of less than 10 wt. % based on the total dry weight of the precursor.

A method of forming a precursor for a low density material comprising the steps of:

• providing an inorganic primary component;
• forming an aqueous mixture of the inorganic primary component and more than one blowing agent;
• and
• drying the mixture to provide an expandable precursor for forming a low density material, wherein the precursor prior to expansion has an alkali metal oxide content of less than 10 wt. % based on the total dry weight of the precursor, wherein each blowing agent is selected and distributed in the precursor to control activation of the blowing agent upon firing of the precursor such that each blowing agent is activated within a predetermined optimal and different temperature range.

A method of producing a low density material comprising

• providing a precursor by forming an aqueous mixture of inorganic primary component and more than one blowing agents, wherein the precursor has an alkali metal oxide content of less than 10 wt. % based on the total dry weight of the precursor, wherein the blowing agents are selected to be activated within predetermined and different optimal temperature ranges;
• drying the mixture;
• and
• firing the precursor to activate each blowing agents for controlled expansion of the precursor, thereby forming a low density material.