Cellular lightweight, alumina ceramic

Claim 1

IN A METHOD FOR PRODUCING A LIGHWEIGHT CELLULAR MATERIAL, THE STEPS OF: (1) MIXING TOGETHER IN PERCENT BY WEIGHT ABOUT 22.8-23.4 PHOSPHORIC ACID (85%), ABOUT 61.8-63.4 ALUMINA AND ABOUT 12-15 WATER? (2) AGING THE MIXTURE TO ALLOW HEAT OF REACTION TO DISSIPATE AND VISCOSITY TO STABILIZE: (3) DISPERSING IN THE MIXTURE ABOUT 0.05-0.1 PERCENT BY WEIGHT OF A FINELY DIVIDED METAL POWDER WHICH REACTS WITH THE REACTION MIXTURE TO PRODUCE A GAS WHEREBY A CELLULAR MATERIAL IS PRODUCED FROM THE MIXTURE, (4) ADDING ABOUT 1-2 PERCENT BY WEIGHT OF A WATER ABSORBING FOAM STABILIZER TO ABSORB ANY EXCESS WATER AND TO INCREASE THE VISCOSITY OF THE CELLULAR MIXTURE, (5) AIR DRYING THE CELLULAR MATERIAL AT ROOM TEMPERATURE UNTIL THE SAID MATERIAL RETAINS ITS SHAPE WITHOUT COLLAPSE OF ITS STRUCTURE, (6) HEATING FROM ROOM TEMPERATURE TO ABOUT 150*F. AT A RATE WHICH INCREASES VISCOSITY THUS TO PREVENT COLLAPSE OF THE CELLULAR STRUCTURE, (7) SLOWLY RAISING THE TEMPERATURE OF THE MATERIAL FROM ABOUT 150*F. TO ABOUT 300*F., (8) HEATING THE MATERIAL AT ABOUT 300*F., (9) AND THEN HEATING AT ABOUT 600*F. TO PROVIDE A CELLULAR MATERIAL HAVING A DENSITY OF 0.036-0.066 LB. PER CUBIC INCH AND COMPRESSIVE STRENGTH OF ABOUT 750 LBS. PER SQUARE INCH.