FOAM GLASSY MATERIALS AND PROCESSES FOR PRODUCTION

Disclosed herein is a process for producing foam glassy materials. The process includes providing a precursor foam glassy formulation, the precursor foam glassy formulation comprising a micronized glassy material, in which the micronized glassy material being any one or any combination of ceramic opaque frits, transparent frits, flux frit, glazes, waste from kaolin processing, porcelain waste products, slag, cement, concrete, waste tile products and a foaming agent. The precursor foam glassy formulation is then processed to form a foam glassy product by firing the precursor foam glassy formulation to a temperature in a range from about 800° C. to about 900° C., followed by a step of annealing, followed by a step of cooling to produce a foam glassy product. The chemical, mechanical, physical properties of the final foam glassy material may be adjusted or tuned by adjusting the amounts of the various constituents making up the precursor foam glassy material.

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