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AssigneeJames Hardie Technology Limited
InventorsGiang Biscan, Hamid Hojaji, David L. Melmeth, Thinh Pham, Huagang Zhang
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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.
A geopolymer precursor formulation for forming a shaped geopolymeric particle by geopolymerization, said geopolymer precursor formulation comprising an amorphous alumino phosphate, an alkali activator comprising sodium hydroxide, and a rheology modifier, wherein a mole ratio of sodium from the alkali activator to alumina from the alumino phosphate is between 5 to 0.1, wherein the rheology modifier is selected to modify the viscoelastic behavior of the precursor formulation so that the rate of geopolymerization is controlled to provide sufficient time for shaping of the geopolymer particle into a predetermined configuration.
Dependencies are inferred from the claim text.