Methods of molding articles having an inorganically filled organic polymer matrix

A method for manufacturing an article having an inorganically filled matrix, the method comprising the steps of:

• mixing together an organic polymer binder, an inert inorganic aggregate, water, and an organic fibrous material to form a green inorganically filled moldable mixture, the organic polymer binder and organic fibrous material having a combined concentration in a range from about 2% to about 70% by volume of total solids within the moldable mixture, the inert inorganic aggregate having a concentration in a range, from about 20% to 95% by weight of total solids within the moldable mixture, wherein the organic polymer binder develops strength properties as a result of removing water by evaporation from the moldable mixture
• die pressing the green moldable mixture into a desired shape of the article without any significant removal of the water while in a liquid state from the moldable mixture;
• and
• removing a significant portion of the water by evaporation from the die pressed green moldable mixture in an accelerated manner in order for the organic polymer binder to develop strength properties and thereby form the inorganically filled matrix, the inorganically filled matrix of the article having a thickness in a range from about 0.05 mm to about 2 cm.

A method for manufacturing an article having an inorganically filled matrix, the method comprising the steps of:

• mixing together an organic polymer binder, an inert inorganic aggregate, water, and an organic fibrous material to form a green inorganically filled moldable mixture, the organic polymer binder and organic fibrous material having a combined concentration in a range from about 2% to about 70% by volume of total solids within the moldable mixture, the inert inorganic aggregate having a concentration in a range from about 30% to about 98% by volume of total solids within the moldable mixture, wherein the organic polymer binder develops strength properties as a result of removing water by evaporation from the moldable mixture, wherein the fibrous material is substantially homogeneously dispersed throughout the green inorganically filled moldable mixture;
• forming the green moldable mixture into a green sheet by passing the mixture between at least one pair of reduction rollers without any significant removal of the water while in a liquid state from the moldable mixture;
• molding the green sheet into a desired shape of the article in a manner which causes the molded article to be form stable in about ten minutes or less after first being molded into the desired shape;
• and
• removing a significant portion of the water by evaporation from the green moldable mixture of the molded green sheet in an accelerated manner in order for the organic polymer binder to develop strength properties and thereby form the inorganically filled matrix of the article.

A method for manufacturing an article having an inorganically filled matrix, the method comprising the steps of:

• mixing together an organic polymer binder, an inert inorganic aggregate, water, and an organic fibrous material to form a green inorganically filled moldable mixture, the inert inorganic aggregate being included in an amount in a range from about 20% to 95% by weight of total solids in the moldable mixture, the organic fibrous material being included in an amount in a range from about 5% to about 20% by volume of total solids in the moldable mixture and being substantially homogeneously dispersed throughout the green moldable mixture;
• molding the green moldable mixture into a desired shape of the article without any significant removal of the water while in a liquid state from the moldable mixture;
• and
• hardening the molded article by removing a significant portion of the water by evaporation from the molded green moldable mixture in an accelerated manner in order to substantially dry the organic polymer binder and thereby form the inorganically filled matrix and in a manner which causes the article to be form stable in about ten minutes or less after first being molded into the desired shape, the inorganically filled matrix having a thickness in a range from about 0.05 mm to about 2 cm.

A method for manufacturing a final article having an inorganically filled matrix, the method comprising the steps of:

• mixing together an organic polymer binder, an inorganic aggregate, water, and an organic fibrous material to form a green inorganically filled moldable mixture, the inorganic aggregate being included in an amount in a range from about 30% to about 98% by volume of total solids in the moldable mixture, the water being included in an amount in a range from about 5% to about 50% by volume of the moldable mixture, the fibrous material being included in an amount in a range from about 2% to about 40% by volume of total solids in the moldable mixture, wherein the fibrous material is substantially homogeneously dispersed throughout the green inorganically filled moldable mixture;
• molding the green moldable mixture into a desired shape of the article without any significant removal of the water while in a liquid state from the moldable mixture, the molded article having a base and at least one sidewall;
• and
• hardening the molded article in order to form the inorganically filled matrix, the article being form stable in about ten minutes or less after first being molded into the desired shape, the inorganically filled matrix becoming substantially hardened upon evaporation of a substantial portion of the water in order to substantially dry the organic polymer binder and thereby from the final article.

A method for manufacturing an article having an inorganically filled matrix, the method comprising the steps of:

• mixing together an organic polymer binder, an inert inorganic aggregate, water, and an organic fibrous material without foaming to form an unfoamed inorganically filled moldable mixture in which the fibrous material is substantially homogeneously mixed throughout the moldable mixture, the inert inorganic aggregate being included in an amount in a range from about 20% to 95% by weight of total solids of the moldable mixture, the moldable mixture having a yield stress in a range from about 2 kPa to about 5 MPa;
• molding the moldable mixture into a desired shape of the article without any significant removal of the water while in a liquid state from the moldable mixture, the article having a base and at least one sidewall;
• and
• hardening the molded article in order to form the inorganically filled matrix, the article being form stable in about ten minutes or less after first being molded into the desired shape, the inorganically filled matrix becoming substantially hardened upon evaporation of a substantial portion of the water in order to substantially dry the organic polymer binder.