Abstract:
Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a particle packed, highly inorganically filled, cellular matrix are disclosed. Suitable inorganically filled mixtures are prepared by mixing together a starch-based binder, a solvent, inorganic aggregates, and optimal admixtures, e.g., fibers, mold-releasing agents, rheology-modifying agents, plasticizers, coating materials, and dispersants, in the correct proportions to form an article which has the desired performance criteria. The inorganically filled mixtures have a predetermined viscosity and are heated between molds at an elevated temperature and pressure to produce form-stable articles having a desired shape and a selectively controlled cellular, structure matrix. The molded articles may be placed in a high humidity chamber to obtain the necessary flexibility for their intended use. The articles may be manufactured to have properties substantially similar to articles presently made from conventional materials like paper, paperboard, polystyrene, plastic, or other organic materials. They have especial utility in the mass-production of containers, particularly food and beverage containers.
Abstract:
Methods and apparatus (50) for continuously extruding a hydraulically settable mixture (52) and simultaneously placing continuous filaments (64) within the extruding mixture (52) to yield articles having a filament-reinforced, hydraulically settable matrix. The filaments (64) can be placed within the mixtures (52) in a parallel configuration, a helical configuration, or combinations thereof in order to yield an article having the desired properties of, e.g., tensile strength, flexural strength, hoop strength, burst strength, toughness, and elongation ability. The desired properties of the hydraulically settable mixture (52), as well as of the cured hydraulically settable matrix of the hardened article, may also be adjusted by including varying amounts and types of aggregates, discontinuous fibers, binders, rheology-modifying agents, dispersants, or other admixtures within the hydraulically settable mixture (52). Optimizing the particle packing density while including a deficiency of water yields a hydraulically settable mixture (52) which will flow when an extrusion pressure is applied but be form stable upon being extruded.
Abstract:
Compositions, methods and systems for manufacturing arcticles, including containers and packaging materials, from hydraulically settable and inorganically filled materials are disclosed. Suitable compositions are prepared by mixing together a hydraulically settable binder or organic binder, water, and appropriate additives, such as aggregates, fibers, and rheology-modifying agents, which impart predetermined properties so that an article formed therefrom has the desired performance criteria. The desired article can be molded from the mixture using a variety of moding processes including: die pressing, injection modling, blow molding, jiggering, wet sheet molding, and dry sheet molding. The sheet forming processes require the mixture to first be fashioned into a sheet, such as by the use of an extruder (12) or rollers, after which the sheet is formed, it is hardened. Printed indicya and a coating can then the applied.
Abstract:
The invention relates to an apparatus for constructing comprising at least feeding means for providing construction material in layers. The apparatus comprises at least first feeding means for hardening material, second feeding means for insulating material wherein said feeding means are configured to operate substantially concurrently so that a construction layer comprises materials from each feeding means. The apparatus may also provide reinforcement substantially concurrently with the other materials.
Abstract:
Compositions, methods and system for manufacturing articles, including containers and packaging materials, from inorganically filled materials are disclosed. Suitable compositions are prepared by mixing together an organic binder, water, and appropriate additives (such as aggregates, fibers, and rheology-modifying agents) which impart predetermined properties so that an article formed therefrom has the desired performance criteria. The desired article can be molded from a sheet. The sheet forming processes require the mixture to first be fashioned into a sheet, such as by the use of an extruder or rollers, after which the sheet is formed into the desired article. Once the article is formed, it is hardened. Printed indica and a coating can then be applied.
Abstract:
Compositions and methods for manufacturing sheets having a hydraulically settable matrix. Suitable compositions are prepared by mixing together a hydraulic binder, water, and appropriate additives (such as aggregates, fibers, and rheology-modifying agents) which impart predetermined properties so that a sheet formed therefrom has the desired performance criteria. The compositions are formed into sheets by first extruding them into a sheet and then calendering the sheet using a set of rollers. The calendered sheets are dried in an accelerated manner to form a substantially hardened sheet. The drying is performed by heated rollers and/or a drying chamber. The hydraulically settable sheets so formed may have properties substantially similar to sheets made from presently used materials like paper, cardboard, polystyrene, or plastic. 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.
Abstract:
Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a particle packed, highly inorganically filled, cellular matrix are disclosed. Suitable inorganically filled mixtures are prepared by mixing together a starch-based binder, a solvent, inorganic aggregates, and optimal admixtures, e.g., fibers, mold-releasing agents, rheology-modifying agents, plasticizers, coating materials, and dispersants, in the correct proportions to form an article which has the desired performance criteria. The inorganically filled mixtures have a predetermined viscosity and are heated between molds at an elevated temperature and pressure to produce form-stable articles having a desired shape and a selectively controlled cellular, structure matrix. The molded articles may be placed in a high humidity chamber to obtain the necessary flexibility for their intended use. The articles may be manufactured to have properties substantially similar to articles presently made from conventional materials like paper, paperboard, polystyrene, plastic, or other organic materials. They have especial utility in the mass-production of containers, particularly food and beverage containers.
Abstract:
Sealable liquid-tight containers (10) and methods for economically manufacturing such containers for storing and dispensing substances and any other purposes for which conventional sealable liquid-tight containers are utilized. The containers are readily and economically formed from mixtures of hydraulically settable binders such as hydraulic cement, gypsum and clay with water. Appropriate additives can also be added to the mixture which impart desired characteristics and properties to both the mixture and the hardened containers. The mixture can be utilized to form containers by various methods. One method involves forming the containers without substantial mixing of the mixture, compacting the mixture and hydrating the mixture. Other methods involve molding the mixture, extruding the mixture and forming sheets from the mixture to be converted into containers. The containers may also be dried, coated, lined, laminated and/or receive printing.