| US 7,455,798 B2 | ||
| Methods for producing low density products | ||
| Amlan Datta, Rancho Cucamonga, Calif. (US); Hamid Hojaji, Claremont, Calif. (US); Shannon Marie Labernik, Rancho Cucamonga, Calif. (US); David Leslie Melmeth, Upland, Calif. (US); Thinh Pham, Kensington (Australia); and Huagang Zhang, Yucaipa, Calif. (US) | ||
| Assigned to James Hardie International Finance B.V., Amsterdam (Netherlands) | ||
| Filed on Feb. 25, 2004, as Appl. No. 10/787,894. | ||
| Application 10/787894 is a continuation in part of application No. 10/648184, filed on Aug. 25, 2003. | ||
| Claims priority of provisional application 60/405790, filed on Aug. 23, 2002. | ||
| Claims priority of provisional application 60/471400, filed on May 16, 2003. | ||
| Prior Publication US 2004/0262801 A1, Dec. 30, 2004 | ||
| Int. Cl. C04B 35/64 (2006.01); C03B 19/08 (2006.01) | ||
| U.S. Cl. 264—43 [264/54; 264/628] | 77 Claims |
| 1. A method of producing a low density material comprising
providing a precursor by forming an aqueous mixture of inorganic primary component and more than one blowing agent, wherein
each blowing agent is selected to and operates at a different temperature range, wherein the precursor has an alkali metal
oxide content of less than 10 wt. % based on the total dry weight of the precursor;
drying the mixture and
firing the precursor to activate each blowing agent to expand the precursor and form a low density material wherein activation
of each blowing agent is controlled and this activation controls expansion of the precursor such that each blowing agent is
activated within its own predetermined optimal temperature range.
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