Lightweight thermal insulating cement based materials

1. An insulating material formed from a mixture comprising:

a cement in an amount of about 25 to 90% of weight wet, wherein the cement comprises an Ordinary Portland cement (OPC), a calcium aluminate cement (CAC), a Sorel cement, a CSA cement, a phosphate cement, or a geo-polymer cement;

water in an amount of about 10 to 70% of weight wet;

a foaming agent comprising an aluminum powder in an amount of about 0.5 to 3.0% by weight of the cement or a surfactant in an amount of about 0.05 to 4.0% by weight of the water;

a rheology-modifying agent in an amount of about 0.1 to 4.0% of a weight of the cement and selected from the group consisting of polysaccharides, polysaccharide derivatives, proteins, protein derivatives thereof and synthetic organic materials; and

the insulating material having a maximum use temperature of about 900 degrees Celsius whenever the cement is the Ordinary Portland cement (OPC) and about 1800 degrees Celsius whenever the cement is the calcium aluminate cement (CAC), the Sorel cement, the CSA cement, the phosphate cement, or the geo-polymer cement, a density in the range of about 0.05 to 1.0 g/cm 3 , a thermal conductivity in the range of about 0.02 to 1.0 W/(m·K), a compressive strength in the range of about 10 to 3000 PSI, and a flexural strength in the range of about 10 to 3000 PSI.

2. The insulating material as recited in claim 1 , the insulating material having a minimum use temperature of about −273 degrees Celsius.

3. The insulating material as recited in claim 1 , the cement and the water have a water to cement ratio by weight in the range of about 0.2 to 2.0.

4. The insulating material as recited in claim 3 , further comprising a conventional high range water reducer in the range of about 0.25 to 4.0% of the cement weight when the water to cement ratio by weight is in the range of about 0.2 to 1.0.

5. The insulating material as recited in claim 1 , further comprising an additive material in an amount of about 0.1 to 50% of weight wet and selected from the group consisting of gypsum, silica fume, fumed silica, plaster of Paris, fly ash, slag, rock and fiber.

6. The insulating material as recited in claim 5 , the fiber is in an amount of about 0.1 to 20% of weight wet and comprise glass fibers, cellulose fibers polyvinyl alcohol fibers, polypropylene fibers, or a combination thereof.

7. The insulating material as recited in claim 1 , further comprising a strength increasing material in an amount of about 0.1 to 10% of weight wet and comprising fumed silica.

8. The insulating material as recited in claim 1 , wherein:

the polysaccharides are selected from the group consisting of cellulose-based materials, derivatives of cellulose-based materials, starch-based materials, and derivatives of starch-based materials;

the cellulose-based materials are selected from the group consisting of methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose (HPMC); and

the starch-based materials are selected from the group consisting of wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches and dialdehyde starches.

9. The insulating material as recited in claim 1 , further comprising a pH increasing agent in an amount of about 0.5 to 10% by weight of the water and selected from the group consisting of calcium oxide, calcium hydroxide and sodium hydroxide.

10. A method for manufacturing an insulating material comprising the steps of:

mixing a cement in an amount of about 25 to 90% of weight wet with water in an amount of about 10 to 70% of weight wet and a rheology modifying agent in an amount of about 0.1 to 4.0% of a weight of the cement, wherein the cement comprises an Ordinary Portland cement (OPC), a calcium aluminate cement (CAC), a Sorel cement, a CSA cement, a phosphate cement, or a geo-polymer cement and the rheology modifying agent is selected from the group consisting of polysaccharides, polysaccharide derivatives, proteins, protein derivatives thereof and synthetic organic materials;

foaming the cement-water mixture using a foaming agent comprising an aluminum powder in an amount of about 0.5 to 3.0% by weight of the cement or a surfactant in an amount of about 0.05 to 4.0% by weight of the water;

pouring the foamed cement-water mixture into a mold and allowing the foamed cement-water mixture to rise to form the insulating material;

removing the insulating material from the mold; and

the insulating material having a maximum use temperature of about 900 degrees Celsius whenever the cement is the Ordinary Portland cement (OPC) and about 1800 degrees Celsius whenever the cement is the calcium aluminate cement (CAC), the Sorel cement, the CSA cement, the phosphate cement, or the geo-polymer cement, a density in the range of about 0.05 to 1.0 g/cm 3 , a thermal conductivity in the range of about 0.02 to 1.0 W/(m·K), a compressive strength in the range of about 10 to 3000 PSI, and a flexural strength in the range of about 10 to 3000 PSI.

11. The method as recited in claim 10 , the insulating material having a minimum use temperature of about −273 degrees Celsius.

12. The method as recited in claim 10 , wherein the mixing step is performed for about 1 to 5 minutes.

13. The method as recited in claim 10 , wherein the cement comprises an Ordinary Portland cement (OPC), the foaming agent comprises the aluminum powder, and the foaming step is performed for about 5 seconds to 1 minute.

14. The method as recited in claim 10 , wherein:

the cement comprises a calcium aluminate cement (CAC), a Sorel cement, a CSA cement, phosphate cement, or a geo-polymer cement;

further comprising the step of adding a pH increasing agent in an amount of about 0.5 to 10% by weight of the water to the cement-water-rheology modifying agent mixture and mixing the cement-water-rheology modifying agent-pH increasing agent mixture for about 5 seconds to 1 minute, wherein the pH increasing agent is selected from the group consisting of calcium oxide, calcium hydroxide and sodium hydroxide;

the foaming agent comprises the aluminum powder; and

the foaming step is performed for about 5 seconds to 1 minute.

15. The method as recited in claim 10 , wherein:

the polysaccharides are selected from the group consisting of cellulose-based materials, derivatives of cellulose-based materials, starch-based materials, and derivatives of starch-based materials;

the cellulose-based materials are selected from the group consisting of methylhydroxyethylcellulose (MHEC), hydroxymethylethylcellulose (HMEC), carboxymethylcellulose (CMC), methylcellulose (MC), ethylcellulose (EC), hydroxyethylcellulose (HEC), hydroxyethylpropylcellulose (HEPC) and hydroxypropoylmethylcelluose (HPMC); and

the starch-based materials are selected from the group consisting of wheat starch, pre-gelled wheat starch, potato starch, pre-gelled potato starch, amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches and dialdehyde starches.

16. The method as recited in claim 10 , wherein:

the mixing step comprises the steps of mixing the water with the rheology-modifying agent, and mixing the cement with the water-rheology-modifying agent; and

the foaming agent comprises the surfactant.

17. The method as recited in claim 10 , further comprising the step of premixing the foaming agent with 1-90% of the water, wherein the foaming agent comprises the surfactant.

18. The method as recited in claim 10 , wherein the foaming step is performed using a venturi foaming aggregate nozzle.

19. The method as recited in claim 10 , wherein the foamed cement-water mixture is allowed to rise for about 0.5 to 2.0 hours.

20. The method as recited in claim 10 , further comprising the step of curing the insulating material by allowing the insulating material to sit for approximately 28 days in a humid environment, or allowing the insulating material to generate internal heat for 24 to 48 hours, or steam curing the insulating material for 24 to 48 hours.

21. The method as recited in claim 10 , further comprising the step of drying the insulating material.

22. The method as recited in claim 10 , further comprising the step of cutting, trimming, sanding or routing the insulating material into a specified shape, wherein the specified shape comprises a pipe, a half-pipe, a block, a panel or a sheet.

23. The method as recited in claim 10 , further comprising the step of spraying the insulating material with a water repellent.

24. The method as recited in claim 10 , the mixture having a water to cement ratio by weight in the range of about 0.2 to 2.0.

25. The method as recited in claim 10 , the mixture having a water to cement ratio by weight in the range of about 1.0.

26. The method as recited in claim 10 , further comprising the step of adding a conventional high range water reducer in the range of about 0.25 to 4.0% of the cement weight when the water to cement ratio by weight is in the range of about 0.2 to 1.0.

27. The method as recited in claim 10 , further comprising:

adding an additive material in an amount of about 0.1 to 50% of weight wet and selected from the group consisting of gypsum, silica fume, fumed silica, plaster of Paris, fly ash, slag, rock and fiber; and

wherein the fiber is in an amount of about 0.1 to 20% of weight wet and comprises glass fibers, cellulose fibers polyvinyl alcohol fibers, polypropylene fibers, or a combination thereof.

28. The method as recited in claim 10 , further comprising the step of adding a strength increasing material in an amount of about 0.1 to 10% of weight wet and comprising fumed silica.