Abstract: A method of forming foamed articles suitable for refractory, thermal insulation and construction application in a form such as bricks, blocks, slabs and discs includes the preparation of homogeneous mixture of at least one oxygen-containing, water-insoluble raw material having a particle size <200 microns and at least one gas forming reagent having a particle size <130 microns. The mixture is humidified and shaped and then heated to a formation temperature sufficient to melt the raw material to develop an oxygen-containing molten liquid phase. This phase reacts at the formation temperature with the gas-forming reagent to induce a foamed structure which is then cooled to a solid state. The raw materials preferably make up 99-99.95 wt % of the mixture, and the gas forming reagent makes up the balance.

Abstract: A process for making articles from perlite material includes grinding raw perlite to a particle size <200 &mgr;m. The ground perlite is mixed with ground silicon carbide powder and moisture added in an amount to achieve a homogeneous mixture having the property of being thixotropic. The mixture is introduced to a mold and agitated to assume the shape of the mold. The agitation is then halted and the material permitted to stiffen to a solidified green molded structure. The molded structure is then removed from the mold and heated at a temperature and time to react the silicon carbide reacts forming carbon dioxide, which induces a foamed structure to the material, and amorphous silicon oxide which fuses with the perlite. The structure is then cooled to yield a resultant fused, foamed perlite article, which may take the form of a building brick, block or panel structure.

Abstract: A method of forming foamed articles suitable for refractory, thermal insulation and construction application in a form such as bricks, blocks, slabs and discs includes the preparation of homogeneous mixture of at least one oxygen-containing, water-insoluble raw material having a particle size <200 microns and at least one gas forming reagent having a particle size <130 microns. The mixture is humidified and shaped and then heated to a formation temperature sufficient to melt the raw material to develop an oxygen-containing molten liquid phase. This phase reacts at the formation temperature with the gas-forming reagent to induce a foamed structure which is then cooled to a solid state. The raw materials preferably make up 99-99.95 wt % of the mixture, and the gas forming reagent makes up the balance.