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US 5,508,072 AGranted
Sheets having a highly inorganically filled organic polymer matrix
AssigneeE. Khashoggi Industries
InventorsPer J. Andersen, Simon K. Hodson
Life of this patent
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AssigneeE. Khashoggi Industries
InventorsPer J. Andersen, Simon K. Hodson
Estimating the term…
Compositions and methods for manufacturing sheets having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more inorganic aggregate materials, fibers, and optional admixtures in the correct proportions in order to form a sheet which has the desired performance criteria. The inorganically filled mixtures are formed into sheets by first extruding the mixtures and the passing the extruded materials between a set of rollers. The rolled sheets are dried in an accelerated manner to form a substantially hardened sheet, such as by heated rollers and/or a drying chamber. The inorganically filled sheets may have properties substantially similar to sheets presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. Such sheets can be rolled, pressed, scored, perforated, folded, and glued. They have especial utility in the mass production of containers, particularly food and beverage containers.
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, a fibrous material, and an inorganic aggregate material, the aggregate material being present in a concentration in a range from about 40% to about 98% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, wherein the matrix degrades after prolonged exposure to water.
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet being formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, an inorganic aggregate, and a fibrous material, the aggregate material having a concentration of at least about 40% by volume of the total solids in the inorganically filled mixture, the water-dispersible organic polymer binder and fibrous material together having a concentration in a range from about 5% to about 60% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, wherein the matrix degrades after prolonged exposure to water.
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet being formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, an aggregate material, and an organic fibrous material, the aggregate material having a concentration in a range from about 40% to about 95% by volume of total solids in the inorganically filled mixture, the organic polymer binder and organic fibrous material together having a concentration in range from about 5% to about 60% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm.
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including:
Dependencies are inferred from the claim text.