Process for making a lightweight cellular inorganic material

C - Chemistry – Metallurgy – 04 – B

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C04B 38/06 (2006.01) C03C 1/00 (2006.01) C03C 11/00 (2006.01) C03C 14/00 (2006.01) C04B 35/18 (2006.01) C04B 35/26 (2006.01) C04B 35/49 (2006.01) C04B 35/64 (2006.01)

Patent

CA 2026559

-34- ABSTRACT OF THE DISCLOSURE A process for making a cellular inorganic material is disclosed. In this process a sol is formed by dispersing inorganic particles having a size of less than 1000 .ANG. in a dispersant liquid. A liquid, immiscible in the dispersant liquid, is added to the sol. A stabilizing effective amount of surfactant is added to the sol prior to, concurrently with or subsequent to the introduction of the immiscible liquid. The stabilized sol is converted into a gel by increasing the viscosity of the sol. The gel is next treated such that the immiscible liquid is dispersed into a plurality of droplets or vaporized into an interconnected gaseous network wherein the gel becomes cellular. The dispersant liquid and the immiscible liquid are removed from the cellular gel followed by removal of the surfactant and sintering to form the cellular inorganic material. The above process may be supplemented by the additional inclusion of an inorganic material selected from the group consisting of inorganic whiskers and inorganic fibers introduced into the dispersant liquid along with the inorganic particles.

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