Patent ID: 7744783

Claim:
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 SiO 2 to Na 2 O ranging from about 1.6 to about 3.22, and wherein said potassium silicate has a weight ratio of SiO 2 to K 2 O 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.