Patents by Inventor James A. McFarlane

James A. McFarlane has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 8609244
    Abstract: 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.
    Type: Grant
    Filed: December 8, 2006
    Date of Patent: December 17, 2013
    Assignee: James Hardie Technology Limited
    Inventors: Huagang Zhang, Hamid Hojaji, Shannon Marie Labernik, David L. Melmeth, Thinh Pham, James A. McFarlane
  • Patent number: 7878026
    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.
    Type: Grant
    Filed: August 25, 2003
    Date of Patent: February 1, 2011
    Assignee: James Hardie Technology Limited
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang
  • Publication number: 20100192808
    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 natural cenospheres, 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.
    Type: Application
    Filed: December 30, 2009
    Publication date: August 5, 2010
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang
  • Patent number: 7666505
    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.
    Type: Grant
    Filed: August 25, 2003
    Date of Patent: February 23, 2010
    Assignee: James Hardie Technology Limited
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang
  • Patent number: 7651563
    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.
    Type: Grant
    Filed: August 25, 2003
    Date of Patent: January 26, 2010
    Assignee: James Hardie Technology Limited
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang
  • Publication number: 20040080063
    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.
    Type: Application
    Filed: August 25, 2003
    Publication date: April 29, 2004
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang
  • Publication number: 20040081827
    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.
    Type: Application
    Filed: August 25, 2003
    Publication date: April 29, 2004
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang
  • Publication number: 20040079260
    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 natural cenospheres, 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.
    Type: Application
    Filed: August 25, 2003
    Publication date: April 29, 2004
    Inventors: Amlan Datta, Hamid Hojaji, David L. Melmeth, James A. McFarlane, Thinh Pham, Noel E. Thompson, Huagang Zhang