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AssigneeE. Khashoggi Industries
InventorsPer Just Andersen, Simon K. Hodson
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Compositions, methods, and apparatus 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 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 then 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 controlled, pressed, scored, perforated, folded, and glued to fashion articles for the sheets. They have especial utility in the mass production of containers, particularly food and beverage containers.
An article of manufacture fashioned from a sheet comprising an inorganically filled matrix including a substantially homogeneous mixture of a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, water-soluble polymers, and mixtures or derivatives thereof, a fibrous material, and an inorganic aggregate, 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, wherein the inorganically filled matrix of the sheet has a thickness in a range from about 0.01 mm to about 1 cm and degrades after prolonged exposure to water, wherein the fibrous material is substantially homogeneously dispersed throughout the inorganically filled matrix.
An article of manufacture fashioned from an inorganically filled sheet comprising a substantially homogeneous matrix of organic binder and aggregate, with fibers substantially homogeneously dispersed throughout the matrix of organic binder and aggregate, the organic binder being selected from the group consisting of polysaccharides, proteins, water-soluble polymers, and mixtures or derivatives thereof, the aggregate comprising an inorganic aggregate having a concentration in a range of about 40% to about 98% by volume of total solids in the matrix of organic binder and aggregate, the inorganically filled sheet having a thickness in a range from about 0.01 mm to about 1 cm and degrades after prolonged exposure to water.
An article of manufacture fashioned from an inorganically filled sheet comprising a substantially homogeneous matrix of organic binder and aggregate, wherein the matrix has a thickness in a range from about 0.01 mm to 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 matrix, and is fashioned into a desired shape of the article by bending, folding or rolling, the matrix of organic binder and aggregate being formed from an inorganically filled mixture including:
Dependencies are inferred from the claim text.