The present disclosure relates to composite materials comprising a resin and at least one sheet that comprise optionally cellulose filaments (CF), fillers and optionally reinforcing fibers as well as methods for the preparation thereof. The methods comprise impregnating the sheets comprising the cellulose filaments, fillers and optionally the reinforcing fibers or a stack thereof with resin. The composite materials can optionally comprise at least one other sheet, the at least one other sheet being different from the at least one sheet and comprising fibers chosen from wood pulp, fiberglass, natural fibers and mixtures thereof. The sheet can also be in the form of a panel of a preform.

Inorganic polymer/organic polymer composites and methods for their preparation are described herein. The inorganic polymer/organic polymer composites comprise a first layer comprising an inorganic polymer and a second layer adhered to the first layer comprising an organic polymer. The inorganic polymer is formed by reacting, in the presence of water, a reactive powder, an activator, and optionally a retardant. The reactive powder comprises 85% by weight or greater fly ash and less than 10% by weight portland cement. Also described herein are building materials including the composites.

Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.

A composition comprising thermoset polymer, shape memory polymer to facilitate macro scale damage closure, and a means for molecular scale healing is disclosed; the composition has the ability to resolve structural defects by a bio-mimetic close-then heal process. In use, the shape memory polymer serves to bring surfaces of a structural defect into approximation, whereafter use of the means for molecular scale healing allowed for movement of the healing means into the defect and thus obtain molecular scale healing. The means for molecular scale healing can be a thermoplastic such as fibers, particles or spheres which are used by heating to a level at or above the thermoplastic's melting point, then cooling of the composition below the melting temperature of the thermoplastic. Compositions of the invention have the ability to not only close macroscopic defects, but also to do so repeatedly even if another wound/damage occurs in a previously healed/repaired area.

The present invention relates to a process of fabricating a multi-layer composite structure by 3D printing, said composite structure comprises at least one cured mortar layer formed by curing of a mortar composition, and at least one polyurethane layer formed by polymerization of a first polyurethane forming composition, wherein said mortar composition and said first polyurethane forming composition are dispensed individually and simultaneously via adjacent printing nozzles. The mortar composition is optionally modified by a second polyurethane forming composition.

Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets and low density fillers distributed throughout. The combination of entrained air pockets and low density fillers provide a low density fiber cement matrix with physical and mechanical properties similar to comparable low density fiber cement matrix without entrained air pockets.

Disclosed herein are low density fiber cement articles, such as fiber cement building panels and sheets, comprised of multiple overlaying fiber cement substrate layers having small and uniform entrained air pockets distributed throughout. Also disclosed herein are air entrainment systems and methods for manufacturing aerated low density fiber cement panels or sheets with consistent air void content and uniform air void distribution. Also disclosed herein are air entrainment technologies adapted to work in conjunction with the Hatschek process to produce aerated fiber cement articles having controlled air void content and distribution.

A method of manufacturing a highly insulating three-dimensional (3D) structure is provided. The method includes depositing a first layer of hollow microspheres onto a base. The hollow microspheres have a metallic coating formed thereon. A laser beam is scanned over the hollow microspheres so as to sinter the metallic coating of the hollow microspheres at predetermined locations. At least one layer of the hollow microspheres is deposited onto the first layer. Scanning by the laser beam is repeated for each successive layer until a predetermined 3D structure is constructed. The 3D structure includes a composite thermal barrier coating (TBC), which may be applied to a surface of components within an internal combustion engine, and the like. The composite TBC is bonded to the components of the engine to provide low thermal conductivity and low heat capacity insulation that is sealed against combustion gasses.

Gypsum panels, sheathing systems, and methods of making and using the same are provided. A gypsum panel includes a gypsum core associated with a first fiberglass mat having a continuous barrier coating, the coating penetrating a portion of the first fiberglass mat opposite the gypsum core, wherein gypsum penetrates a remaining fibrous portion of the first fiberglass mat such that voids in the first fiberglass mat are substantially eliminated. A building sheathing system includes at least two gypsum panels and a seaming component to provide a seam at an interface between the gypsum panels.

A calcium sulphate-based product including gypsum and a shrinkage resistance additive. The shrinkage resistance additive is a metal nitrate, hydroxide, acetate or sulphate and is preferably provided in an amount greater than 4 wt % (based on the amount of additive and gypsum). The additive may be a nitrate of an alkali metal (e.g. potassium), an alkaline earth metal (e.g. magnesium or calcium), a transition metal (e.g. iron or zinc) or aluminium.