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US 5,665,442 AGranted
Laminated sheets having a highly inorganically filled organic polymer matrix
AssigneeE. Khashoggi Industries
InventorsPer Just Andersen, Simon K. Hodson
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AssigneeE. Khashoggi Industries
InventorsPer Just 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 laminated sheet comprising a first sheet having an inorganically filled matrix and a second sheet laminated to a side of the first sheet, the inorganically filled matrix comprising a substantially homogeneous mixture of organic binder and an inorganic aggregate, and a fibrous material dispersed throughout the inorganically filled matrix, the organic binder being selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, the inorganic aggregate having a concentration in a range from about 40% to about 98% by volume of total solids in the inorganically filled matrix of the first sheet, wherein the inorganically filled matrix has a thickness less than about 1 cm and degrades after prolonged exposure to water.
A laminated sheet comprising a first sheet having an inorganically filled matrix and a second sheet laminated to the first sheet, wherein the inorganically filled matrix comprises a substantially homogeneous mixture of organic binder and inorganic aggregate, has a thickness less than about 1 cm, degrades after prolonged exposure to water, and is formed by removing a substantial portion of water from an inorganically filled mixture including:
A laminated sheet comprising a first sheet having an inorganically filled matrix and a second sheet laminated to the first sheet, the inorganically filled matrix comprising a substantially homogeneous mixture of organic binder and inorganic aggregate, and organic fibers dispersed throughout the inorganically filled matrix, the organic binder being selected from the group consisting of starch-based materials, cellulose-based materials, polysaccharide gums, proteins, and mixtures or derivatives thereof, wherein the inorganic aggregate has a concentration in a range from about 40% to about 95% by weight of total solids in the inorganically filled matrix, wherein the organic binder and organic fibers have a combined concentration in a range from about 5% to about 60% by weight of total solids in the inorganically filled matrix, and wherein the inorganically filled matrix has a thickness less than about 1 cm.
A laminated sheet comprising a first sheet having an inorganically filled matrix and a second sheet laminated to a side of the first sheet, the inorganically filled matrix comprising a substantially homogeneous mixture of organic binder and inorganic aggregate material, and optionally a fibrous material dispersed throughout the inorganically filled matrix, the organic binder being selected from the group consisting of starch-based materials, cellulose-based materials, polysaccharide gums, proteins, and mixtures or derivatives thereof, the inorganic aggregate having a concentration in a range from about 40% to about 95% by weight of total solids in the inorganically filled matrix of the first sheet, wherein the inorganically filled matrix has a thickness less than about 1 cm, degrades after prolonged exposure to water, and is significantly flexible such that it can be significantly deformed without complete rupture of the inorganically filled matrix.
A laminated sheet comprising a first sheet having an inorganically filled matrix and a second sheet laminated to the first sheet, the inorganically filled matrix comprising a substantially homogeneous mixture of organic binder and inorganic aggregate material, and optionally a fibrous material dispersed throughout the inorganically filled matrix, the organic binder being selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, the inorganic aggregate having a concentration in a range from about 40% to about 95% by weight of total solids in the inorganically filled matrix of the first sheet, wherein the inorganically filled matrix has a thickness less than about 1 cm, degrades after prolonged exposure to water, and is significantly flexible such that it can be significantly deformed without complete rupture of the inorganically filled matrix.
Dependencies are inferred from the claim text.