James Hardie Technology Limited

James Hardie International Finance B.v.

Thinh Pham

Huagang Zhang

Hamid Hojaji

David Leslie Melmeth

James A McFarlane

Amlan Datta

Noel E Thompson

Shannon Marie Labernik

Giang Biscan

Weiling Peng

Yongjun Chen

Thomas Patrick Mueller

Xiangyuan Liu

Jongmin Keum

Lijun Mao

Mark G Stevens

Nandakumar Natarajan

Farshad J Motamedi

Yan Li

David L Melmeth

James A Mcfarlane

A fiber cement material formulation comprising a cementitious binder, a siliceous material, fiber, alumina trihydrate and a bifunctional low density additive wherein the bifunctional low density additive comprises any one or more of diatomaceous earth, recycled autoclave fiber cement dust or cellulose dust. The fiber cement material formulation optionally further comprises a secondary low density additive which may be perlite. In some embodiments, a fiber cement article manufactured from the fiber cement material formulation comprises a density of approximately 1.1 g/cmor below.

Fiber cement material formulations and compositions thereof

Disclosed herein are synthetic microparticles substantially free of monovalent and divalent metal elements and a method of forming such synthetic microparticles. The synthetic microparticle may be suitable for use as a density modifying filler. The synthetic microsphere can be made from an agglomerate precursor that includes an aluminosilicate material, such as fly ash, a blowing agent such as sugar, carbon black, and silicon carbide, and a binding agent. The synthetic microsphere is produced when the precursor is fired at a pre-determined temperature profile so as to form either solid or hollow synthetic microspheres depending on the processing conditions and/or components used. The synthetic microparticle is capable of being formed into a large range of predetermined shapes.

Synthetic microparticles

A low density material and a method for preparing a low-density material and precursor for forming a low-density material are provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. The firing conditions are also controlled to provide a low density sphere containing a heterogeneous sphere wall structure comprising a combination of amorphous glass and a crystalline phase or gas phase or both.

Engineered low-density heterogeneous microparticles and methods and formulations for producing the microparticles

Shaped geopolymeric particles, fibers, and articles incorporating at least one geopolymer are provided; the geopolymeric particles, fibers, and articles having a structure that is solid, foamed, hollow or with one or more voids. Geopolymers are formed by alkali activation of an aluminosilicate and/or aluminophosphate material. The end-products are shaped as spheres, flakes, fibers, aggregates thereof or articles. Such products are formed at low temperatures; wherein forming includes processing using techniques such as spray drying, melt spinning, or blowing. The shaped geopolymeric particles and fibers have high chemical durability, high mechanical strength, application-targeted flowability and packing properties, and are specially suited for incorporating into composite materials, articles, and for use in cementitious, polymeric, paint, printing, adhesion and coating applications. Shaped geopolymeric particles, fibers and articles having voids, hollow or foam-like structures are formed by adding one or more blowing agents.

Geopolymeric particles, fibers, shaped articles and methods of manufacture

Precursor materials and methods of making are disclosed. The precursor materials include at least one of a silica source, and a carbon source, with or without liquid and a binder The methods described include pyrolyzing the precursor material to form a carbonaceous mixture and heat treating the mixture for a pre-determined time and at an elevated temperature during which carbon and/or nitrogen react with silica in the mixture to form carbides and/or nitrides. The carbides and nitrides formed from said methods may be used as blowing agents in a glass, ceramic, or metal forming processes or for promoting dispersion of the carbides and nitrides throughout a glass, ceramic, or metal composite.

Manufacture and use of engineered carbide and nitride composites

A synthetic microsphere having a low alkali metal oxide content and methods of forming the microsphere and its components are provided. The synthetic microsphere is substantially chemically inert and thus a suitable replacement for natural cenospheres, particularly in caustic environments such as cementitious mixtures. The synthetic microsphere can be made from an agglomerate precursor that includes an aluminosilicate material, such as fly ash, a blowing agent such as sugar, carbon black, and silicon carbide, and a binding agent. The synthetic microsphere is produced when the precursor is fired at a pre-determined temperature profile so as to form either solid or hollow synthetic microspheres depending on the processing conditions and/or components used.

Synthetic microspheres and methods of making same

Synthetic microspheres comprising aluminosilicate and methods of making same

A building product incorporating synthetic microspheres having a low alkali metal oxide content is provided. The synthetic microspheres are substantially chemically inert and thus a suitable replacement for cenospheres derived from coal combustion, particularly in caustic environments such as cementitious mixtures. The building product can have a cementitious matrix such as a fiber cement product. The synthetic microspheres can be incorporated as a low density additive and/or a filler for the building product and/or the like.

A method of preparing a low-density material and precursor for forming a low-density material is provided. An aqueous mixture of inorganic primary component and a blowing agent is formed, the mixture is dried and optionally ground to form an expandable precursor. Such a precursor is then fired with activation of the blowing agent being controlled such that it is activated within a predetermined optimal temperature range. Control of the blowing agent can be accomplished via a variety of means including appropriate distribution throughout the precursor, addition of a control agent into the precursor, or modification of the firing conditions such as oxygen deficient or fuel rich environment, plasma heating etc.

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Kensington, Australia

Thinh Pham