# US 7,744,783 B2 · Method of making non-flammable thermal insulatiion foam and products made by the method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,744,783 B2 - Document ID: US7744783B2 - Status: Granted - Kind: B2 - Application number: 11/417,629 - Filed: 2006-05-04 - Published: 2007-11-08 - Granted: 2010-06-29 - Earliest claimed: 2006-05-04 - Inventors: Felix Dimanshteyn - Web page: https://patentgrep.com/patent/US7744783B2 ## CPC - C09K 21/02: Inorganic materials - C04B 28/26: Silicates of the alkali metals - C04B 2111/00215: {Mortar or concrete mixtures defined by their oxide composition} - C04B 2111/28: Fire resistance, i.e. materials resistant to accidental fires or high temperatures - C09K: MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE ## Abstract The present invention is directed to a method of preparing non-flammable thermal insulation foam, comprising the steps of (a) providing a mixture comprising (1) at least one water soluble alkali metal silicate, (2) optionally, at least one filler, and (3) at least one inorganic material which releases non-flammable gases when exposed to heat; (b) applying the mixture to a support or mold; and (c) heating the mixture to form the non-flammable thermal insulation foam. ## Claims ### Claim 1 A method of preparing non-flammable thermal insulation foam, comprising the steps of: (a) providing a liquid mixture comprising (1) at least one water soluble alkali metal silicate selected from the group consisting of sodium silicate, potassium silicate, and combinations thereof, and wherein said sodium silicate has a weight ratio of SiO2 to Na2O ranging from about 1.6 to about 3.22, and wherein said potassium silicate has a weight ratio of SiO2to K2O ranging from 2.1 to 2.5, (2) at least one inorganic material which releases non-flammable gases when exposed to heat; and (3) at least one filler selected from the group consisting of silica; mica; talc; microspheres; microcells; glass; ceramic; chopped fibers; cement; perlite; zinc oxide and zeolite; (b) applying said mixture in a liquid state on a support layer or in between support layers; (c) placing said support layer or support layers into or onto a heating device which provides a temperature of between 450 and 1750° F. to the support layer or support layers and where heat is applied to said liquid mixture to form a foam. ### Claim 2 (depends on 1) The method of claim 1, wherein said inorganic material is selected from the group consisting of sodium tetraborate and hydrated borate salts. ### Claim 3 (depends on 1) The method of claim 1, wherein said support layer or support layers are selected from the group consisting of pipes, paper, cardboard, fiberboard, ceramics, cement, wood, woven or non-woven fiberglass, mat fiberglass, glass, sheetrock, metal sheets, foils, and metal screens. ### Claim 4 (depends on 1) The method of claim 1, wherein said heating device is selected from the group consisting of an electric or electromagnetic furnace or oven, microwaves, hot plate, or heating device powered by gas, oil, or solid fuel. ### Claim 5 A method of preparing non-flammable thermal insulation foam, comprising the steps of: (a) providing a liquid mixture comprising (1) at least one water soluble alkali metal silicate selected from the group consisting of sodium silicate, potassium silicate, and combinations thereof, and wherein said sodium silicate has a weight ratio of SiO2 to Na2O ranging from about 1.6 to about 3.22, and wherein said potassium silicate has a weight ratio of SiO2 to K2O ranging from 2.1 to 2.5, (2) silica selected from the group consisting of fumed silica, precipitated silica, and combinations thereof; and (3) at least one filler selected from the group consisting of silica; mica; talc; microspheres; microcells; glass; ceramic; chopped fibers; cement; perlite; zinc oxide and zeolite; (b) applying said mixture in a liquid state on a support layer or in between support layers; (c) placing said support layer or support layers into or onto a heating device which provides a temperature of between 450 and 1750° F. to the support layer or support layers and where heat is applied to said liquid mixture to form a foam. ### Claim 6 (depends on 5) The method of claim 5, wherein said support layer or support layers are selected from the group consisting of pipes, paper, cardboard, fiberboard, ceramics, cement, wood, woven or non-woven fiberglass, mat fiberglass, glass, sheetrock, metal sheets, foils, and metal screens. ### Claim 7 (depends on 5) The method of claim 5, wherein said heating device is selected from the group consisting of an electric or electromagnetic furnace or oven, microwaves, hot plate, or heating device powered by gas, oil, or solid fuel. ### Claim 8 A method of preparing non-flammable thermal insulation foam, comprising the steps of: (a) providing a liquid mixture comprising (1) at least one water soluble alkali metal silicate selected from the group consisting of sodium silicate, potassium silicate, and combinations thereof, and wherein said sodium silicate has a weight ratio of SiO2 to Na2O ranging from about 1.6 to about 3.22, and wherein said potassium silicate has a weight ratio of SiO2 to K2O ranging from 2.1 to 2.5, (2) at least one filler selected from the group consisting of silica; mica; talc; microspheres; microcells; glass; ceramic; chopped fibers; cement; perlite; zinc oxide and zeolite; (b) applying said mixture in a liquid state on a support layer or in between support layers; (c) placing said support layer or support layers into or onto a heating device which provides a temperature of between 450 and 1750° F. to the support layer or support layers and where heat is applied to said liquid mixture to form a foam. ### Claim 9 (depends on 8) The method of claim 8, wherein said support layer or support layers are selected from the group consisting of pipes, paper, cardboard, fiberboard, ceramics, cement, wood, woven or non-woven fiberglass, mat fiberglass, glass, sheetrock, metal sheets, foils, and metal screens. ### Claim 10 (depends on 8) The method of claim 8, wherein said heating device is selected from the group consisting of an electric or electromagnetic furnace or oven, microwaves, hot plate, or heating device powered by gas, oil, or solid fuel. ### Claim 11 A method of preparing non-flammable thermal insulation foam, comprising the steps of: (a) providing a liquid mixture comprising (1) at least one water soluble alkali metal silicate selected from the group consisting of sodium silicate, potassium silicate, and combinations thereof, and wherein said sodium silicate has a weight ratio of SiO2 to Na2O ranging from about 1.6 to about 3.22, and wherein said potassium silicate has a weight ratio of SiO2 to K2O ranging from 2.1 to 2.5, (2) at least one inorganic material which releases non-flammable gases when exposed to heat; and (3) at least one filler selected from the group consisting of silica; mica; talc; microspheres; microcells; glass; ceramic; chopped fibers; cement; perlite; zinc oxide and zeolite; (b) applying said mixture in a liquid state in a mold or in between rollers; (c) placing said mold or rollers into or onto a heating device which provides temperatures of between 450 and 1750° F. inside the mold or space between rollers and where heat is applied to said liquid mixture to form a foam. ### Claim 12 (depends on 11) The method of claim 11, wherein said heating device is selected from the group consisting of an electric or electromagnetic furnace or oven, microwaves, hot plate, or heating device powered by gas, oil, or solid fuel. ### Claim 13 A method of preparing non-flammable thermal insulation foam, comprising the steps of: (a) providing a liquid mixture comprising (1) at least one water soluble alkali metal silicate selected from the group consisting of sodium silicate, potassium silicate, and combinations thereof, and wherein said sodium silicate has a weight ratio of SiO2 to Na2O ranging from about 1.6 to about 3.22, and wherein said potassium silicate has a weight ratio of SiO2 to K2O ranging from 2.1 to 2.5, (2) at least one filler selected from the group consisting of silica; mica; talc; microspheres; microcells; glass; ceramic; chopped fibers; cement; perlite; zinc oxide and zeolite; (b) applying said mixture in a liquid state in a mold or in between rollers; (c) placing said mold or rollers into or onto a heating device which provides temperatures of between 450and 1750° F. inside the mold or space between rollers and where heat is applied to said liquid mixture to form a foam. ### Claim 14 (depends on 13) The method of claim 13, wherein said heating device is selected from the group consisting of an electric or electromagnetic furnace or oven, microwaves, hot plate, or heating device powered by gas, oil, or solid fuel.