David L Melmeth

US Patent:

7455798, Nov 25, 2008

Filed:

Feb 25, 2004

Appl. No.:

10/787894

Inventors:

Amlan Datta - Rancho Cucamonga CA, US
Hamid Hojaji - Claremont CA, US
Shannon Marie Labernik - Rancho Cucamonga CA, US
David Leslie Melmeth - Upland CA, US
Thinh Pham - Kensington, AU
Huagang Zhang - Yucaipa CA, US

Assignee:

James Hardie International Finance B.V. - Amsterdam

International Classification:

C04B 35/64
C03B 19/08

US Classification:

264 43, 264 54, 264628

Abstract:

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.

US Patent:

7651563, Jan 26, 2010

Filed:

Aug 25, 2003

Appl. No.:

10/648009

Inventors:

Amlan Datta - Rancho Cucamonga CA, US
Hamid Hojaji - Claremont CA, US
David L. Melmeth - Upland CA, US
James A. McFarlane - Rancho Cucamonga CA, US
Thinh Pham - Kensington, AU
Noel E. Thompson - Carlingford, AU
Huagang Zhang - Yucaipa CA, US

Assignee:

James Hardie Technology Limited - Dublin

International Classification:

C04B 14/22
C04B 14/24

US Classification:

106672, 106676, 106679, 106705, 106716, 106DIG 1

Abstract:

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.

US Patent:

7658794, Feb 9, 2010

Filed:

Apr 15, 2003

Appl. No.:

10/414505

Inventors:

James A. Gleeson - Alta Loma CA, US
Kalynne H. Paradis - Rancho Cucamonga CA, US
Brian P. Sloane - Old Toongabbie, AU
David L. Melmeth - Upland CA, US
Dean M. Seligman - Mission Viejo CA, US

Assignee:

James Hardie Technology Limited - Dublin

International Classification:

C04B 14/24

US Classification:

106672, 106644, 106676, 106705, 106713, 106714, 106730, 106737, 264333

Abstract:

This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.

US Patent:

7666505, Feb 23, 2010

Filed:

Aug 25, 2003

Appl. No.:

10/648184

Inventors:

Amlan Datta - Rancho Cucamonga CA, US
Hamid Hojaji - Claremont CA, US
David L. Melmeth - Upland CA, US
James A. McFarlane - Rancho Cucamonga CA, US
Thinh Pham - Kensington, AU
Noel E. Thompson - Carlingford, AU
Huagang Zhang - Yucaipa CA, US

Assignee:

James Hardie Technology Limited - Dublin

International Classification:

B32B 5/16
C03C 10/04
C03C 10/06
C03C 10/10

US Classification:

428402, 4231181, 428406, 501 5, 501 6, 501 8

Abstract:

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.

US Patent:

7727329, Jun 1, 2010

Filed:

Feb 28, 2008

Appl. No.:

12/039372

Inventors:

James A. Gleeson - Alta Loma CA, US
Kalynne H. Paradis - Rancho Cucamonga CA, US
Brian P. Sloane - Old Toongabble, AU
David L. Melmeth - Upland CA, US
Dean M. Seligman - Mission Viejo CA, US

Assignee:

James Hardie Technology Limited - Dublin

International Classification:

C04B 14/04

US Classification:

106705, 106644, 106726, 106737

Abstract:

This invention relates to a formulation with the addition of low density additives of volcanic ash, hollow ceramic microspheres or a combination of microspheres and volcanic ash or other low density additives into cementitious cellulose fiber reinforced building materials. This formulation is advantageously lightweight or low density compared as compared to current fiber cement products without the increased moisture expansion and freeze-thaw degradation usually associated with the addition of lightweight inorganic materials to fiber cement mixes. The low density additives also give the material improved thermal dimensional stability.

US Patent:

7744689, Jun 29, 2010

Filed:

Feb 24, 2006

Appl. No.:

11/361694

Inventors:

Hamid Hojaji - Claremont CA, US
David Leslie Melmeth - Upland CA, US

Assignee:

James Hardie Technology Limited - Dublin

International Classification:

C04B 35/16

US Classification:

106605, 106600, 501 33, 501 53, 501 68

Abstract:

An alkali resistant glass composition having improved durability to withstand highly alkali environments at elevated temperatures, such as curing of cementitious products in an autoclave, is conveniently formed from economical and abundant materials. The glass composition includes increased levels of calcium and iron, and relatively low levels of alkali metals, as compared to many other alkali resistant glass products, and comprises essentially of, by weight, >35% SiO, 1-25% CaO, 1-15% FeO, 1-10% RO, and an amount of AlOsuch that the ratio of SiO:AlOis greater than or equal to 1. Alkali resistance can be improved by forming a passivity layer on the surface of glass articles by treating the articles hydrothermally in a basic environment. Optionally zirconia and/or titania may be added to the composition to further improve alkali resistance.

US Patent:

7878026, Feb 1, 2011

Filed:

Aug 25, 2003

Appl. No.:

10/648585

Inventors:

Amlan Datta - Rancho Cucamonga CA, US
Hamid Hojaji - Claremont CA, US
David L. Melmeth - Upland CA, US
James A. McFarlane - Rancho Cucamonga CA, US
Thinh Pham - Kensington, AU
Noel E. Thompson - Carlingford, AU
Huagang Zhang - Yucaipa CA, US

Assignee:

James Hardie Technology Limited - Dublin

International Classification:

C03B 9/00

US Classification:

65 214

Abstract:

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.

US Patent:

7897534, Mar 1, 2011

Filed:

Apr 16, 2009

Appl. No.:

12/425217

Inventors:

Giang Biscan - Fontana CA, US
Hamid Hojaji - Las Vegas NV, US
David Leslie Melmeth - Upland CA, US
Thinh Pham - Rancho Cucamonga CA, US
Mark G. Stevens - Rancho Cucamonga CA, US
Huagang Zhang - Yacaipa CA, US

International Classification:

C04B 35/565
C03C 6/00
C03C 6/04

US Classification:

501 88, 501 27, 501 29, 501 32, 423345

Abstract:

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.