The present invention relates to a composite material, particularly a composite material for ceramic tiles, stone cladding, surface tops (e.g. worktops), and the like. The composite materials are typically derived from waste products. The composite materials of the present invention are formed from a glass component and a non-glass mineral component (e.g. ceramics and/or glaze). Generally the composite materials do not require any binders (especially synthetic binders) to hold the materials together. Therefore, the composite materials and products made therefrom are typically recyclable.

A method of manufacturing a plurality of expanded microspheres, comprises mixing a plurality of solid particles, at least one binding material capable of binding the plurality of solid particles, and a plurality of reactive expansion components into a batch, forming a plurality of agglomerated particles from the batch, heating the plurality of agglomerated particles in an expansion equipment to above a softening temperature of at least a portion of the plurality of agglomerated particles and activating the plurality of reactive expansion components, and forming a gas and expanding the plurality of agglomerated particles into the plurality of expanded microspheres, the step of activating the plurality of reactive expansion components occurring independently from a chemical composition of an atmosphere surrounding the plurality of agglomerated particles inside the expansion equipment.

A method of manufacturing a plurality of expanded microspheres, comprises mixing a plurality of solid particles, at least one binding material capable of binding the plurality of solid particles, and a plurality of reactive expansion components into a batch, forming a plurality of agglomerated particles from the batch, heating the plurality of agglomerated particles in an expansion equipment to above a softening temperature of at least a portion of the plurality of agglomerated particles and activating the plurality of reactive expansion components, and forming a gas and expanding the plurality of agglomerated particles into the plurality of expanded microspheres, the step of activating the plurality of reactive expansion components occurring independently from a chemical composition of an atmosphere surrounding the plurality of agglomerated particles inside the expansion equipment.

A method of manufacturing a plurality of expanded microspheres, comprises mixing a plurality of solid particles, at least one binding material capable of binding the plurality of solid particles, and a plurality of reactive expansion components into a batch, forming a plurality of agglomerated particles from the batch, heating the plurality of agglomerated particles in an expansion equipment to above a softening temperature of at least a portion of the plurality of agglomerated particles and activating the plurality of reactive expansion components, and forming a gas and expanding the plurality of agglomerated particles into the plurality of expanded microspheres, the step of activating the plurality of reactive expansion components occurring independently from a chemical composition of an atmosphere surrounding the plurality of agglomerated particles inside the expansion equipment.

A method of manufacturing a plurality of expanded microspheres, comprises mixing a plurality of solid particles, at least one binding material capable of binding the plurality of solid particles, and a plurality of reactive expansion components into a batch, forming a plurality of agglomerated particles from the batch, heating the plurality of agglomerated particles in an expansion equipment to above a softening temperature of at least a portion of the plurality of agglomerated particles and activating the plurality of reactive expansion components, and forming a gas and expanding the plurality of agglomerated particles into the plurality of expanded microspheres, the step of activating the plurality of reactive expansion components occurring independently from a chemical composition of an atmosphere surrounding the plurality of agglomerated particles inside the expansion equipment.