Method for manufacturing articles having inorganically filled, starch-bound cellular matrix

A method for manufacturing an article of manufacture having a starch-bound cellular structural matrix, the method comprising the steps of:

• (a) preparing a moldable mixture including unmodified starch having a concentration in a range from about 10% to about 80% by weight of total solids in the moldable mixture, water, and an inorganic aggregate having a concentration greater than about 20% by weight of total solids in the moldable mixture, at least a portion of the unmodified starch including substantially ungelatinized starch granules;
• and
• (b) molding the moldable mixture between heated molds in order to gelatinize the unmodified starch, remove a substantial portion of the water from the moldable mixture by evaporation, and form the starch-bound cellular structural matrix of the article of manufacture, wherein the starch-bound cellular structural matrix is form stable in less than 15 minutes after being molded into a desired shape of the article of manufacture.

A method for manufacturing an article of manufacture having a starch-bound cellular structural matrix, the method comprising the steps of:

• (a) preparing a moldable mixture including substantially ungelatinized starch granules present in an amount in a range from about 10% to about 80% by weight of total solids in the moldable mixture, water, and an inorganic aggregate present in an amount greater than about 20% by weight of total solids in the moldable mixture;
• and
• (b) molding the moldable mixture between heated molds in order to gelatinize the starch granules, remove a substantial portion of the water from the moldable mixture by evaporation, and form the starch-bound cellular structural matrix of the article of manufacture wherein the starch-bound cellular structural matrix is form stable in less than 15 minutes after being molded into a desired shape of the article of manufacture.