Methods for the manufacture of sheets having a highly inorganically filled organic polymer matrix

A method for manufacturing an inorganically filled sheet comprising:

• mixing water, a water-dispersible organic binder, an inorganic aggregate filler, and a fibrous material to form a moldable inorganically filled mixture having an inorganic aggregate filler concentration in a range from about 40% to about 95% by weight of total solids in the mixture, the water having a concentration such that the inorganically filled mixture is cohesive and moldable;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet substantially free of underlying support as it exits the forming rollers;
• and
• drying the green inorganically filled sheet in an accelerated manner to remove a substantial portion of the water by evaporation from the green inorganically filled sheet in order to harden the water-dispersible organic binder and form a substantially dried inorganically filled sheet having a thickness less than about 2 cm.

A method for manufacturing a spooled inorganically filled sheet comprising:

• mixing water, a water-dispersible organic binder, an inert aggregate filler, and a fibrous material to form a moldable inorganically filled mixture, the water having a concentration such that the inorganically filled mixture is cohesive and moldable;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet substantially free of underlying support as it exits the forming rollers;
• drying the green inorganically filled sheet in an accelerated manner to remove a substantial portion of the water from the green inorganically filled sheet by evaporation in order to substantially harden the water-dispersible organic binder and form a substantially hardened inorganically filled sheet;
• and
• winding the substantially hardened inorganically filled sheet onto a spool.

A method for manufacturing an inorganically filled sheet comprising:

• mixing water, a water-dispersible organic binder, and an inorganic aggregate to form a moldable inorganically filled mixture that is cohesive and moldable;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet as it exits the forming rollers, wherein the green inorganically filled sheet is formed without significant drainage of water from the inorganically filled mixture;
• and
• heating the green inorganically filled sheet in order to remove a substantial portion of the water from the green inorganically filled sheet by evaporation and substantially harden the water-dispersible organic binder and form a substantially hardened inorganically filled sheet.

A method for manufacturing an inorganically filled sheet comprising:

• mixing water, a water-dispersible organic binder, and an inorganic aggregate to form a substantially cement-free inorganically filled mixture that is cohesive and moldable;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet as it exits the forming rollers, wherein the green inorganically filled sheet is formed without significant drainage of water from the inorganically filled mixture;
• and
• heating the green inorganically filled sheet using a heated drying roller having a temperature up to about 300° C. in order to remove a substantial portion of the water from the green inorganically filled sheet by evaporation and substantially harden the water-dispersible organic binder and form a substantially hardened inorganically filled sheet.

A method for manufacturing an inorganically filled sheet comprising:

• providing an inorganically filled mixture that consists essentially of water, a water-dispersible organic binder, fibers, and an inorganic aggregate that is not hydraulically reactive;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet as it exits the forming rollers, wherein the green inorganically filled sheet is formed without significant drainage of water from the inorganically filled mixture;
• and
• heating the green inorganically filled sheet in order to remove a substantial portion of the water from the green inorganically filled sheet by evaporation and substantially harden the water-dispersible organic binder and form a substantially hardened inorganically filled sheet.

A method for manufacturing an inorganically filled sheet comprising:

• mixing water, a water-dispersible organic binder, and an inorganic aggregate to form a moldable inorganically filled mixture that is cohesive and moldable;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet as it exits the forming rollers, wherein the green inorganically filled sheet is formed without significant drainage of water from the inorganically filled mixture;
• and
• drying the green inorganically filled sheet to form a substantially hardened inorganically filled sheet, wherein the sheet includes voids dispersed therein.

A method for manufacturing an inorganically filled sheet comprising:

• mixing water, a water-dispersible organic binder, and an inorganic aggregate to form a moldable inorganically filled mixture that is cohesive and moldable, wherein the inorganic aggregate consists of particles having a size greater than about 2 microns;
• passing the inorganically filled mixture between at least one pair of forming rollers to form a green inorganically filled sheet having sufficient cohesive strength that it maintains its integrity as a sheet as it exits the forming rollers, wherein the green inorganically filled sheet is formed without significant drainage of water from the inorganically filled mixture;
• and
• drying the green inorganically filled sheet to form a substantially hardened inorganically filled sheet.