Abstract:
Articles, particularly containers and packaging materials, having a starch-bound cellular matrix (8) reinforced with substantially uniformly dispersed fibers (21) and methods for manufacturing the articles. High strength articles that have adequate flexibility and toughness immediately or very shortly after being demolded without the need for subsequent conditioning are molded from compositions having a starch-based binder and fibers (21) that are uniformly dispersed by means of a high yield stress fluid fraction within the starch-based composition. Such articles can replace articles presently made from conventional materials like paper, paperboard, polystyrene, plastic, or other organic-based materials and have special utility in the mass-production of containers, particularly food and beverage containers.
Abstract:
A molded cementitious architectural product for use in building construction has a cementitious body made of a molded cementitious material, the surface of which is polished (i e, burnished) to better resemble natural stone. The polished surface is formed by exposing a portion of the molded cementitious material while in a green condition, more particularly after initial set but before final hardening of the hydraulic cement binder, and burnishing the surface before final hardening. Burnishing the surface of the green cementitious material before final hardening aligns the cement particles at the surface and seals the surface. The inclusion of an organic polymer binder within the cementitious material, such as an acrylic or latex polymer, assists in creating a polished surface resembling natural polished stone. The extent of cement hydration may be determined by monitoring the temperature of the cementitious material within the mold.
Abstract:
Compositions, methods, and apparatus for manufacturing sheets having a highly inorganically filled matrix prepared by mixing together an organic polymer binder, water, one or more inorganic 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 (40) and then passing the extruded materials between a set of rollers (50). 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 form traditional materials like paper, paperboard, polystyrene, plastic or metal. Such sheets can be rolled, pressed, scored, perforated, folded, and glued. They have particular utility in the mass production of articles, such as food and beverage containers, and packaging materials.
Abstract:
A hinge for use in inorganically filled composite materials is provided. The hinge has an inorganically filled structural matrix comprising a water-dispersable organic polymer binder, an aggregate material, and a fibrous material. The hinge allows inorganically filled materials to be bent along a line without breakage of the material. The hinge is preferably formed by scoring a formed sheet of inorganically filled material (50). The hinge is particularly useful in containers that require bending of various container parts, such as in food containers and boxes made from inorganically filled materials.
Abstract:
Design optimization methods can be used to design concrete mixtures having optimized properties, including desired strength and slump at minimal cost. The design optimization methods use a computer-implemented process that is able to design and virtually "test" millions of hypothetical concrete compositions using mathematical algorithms that interrelate a number of variables that affect strength, slump, cost and other desired features. The design optimization procedure utilizes a constant K (or K factor) within Feret's strength equation that varies (e.g., logarithmically) with concrete strength for any given set of raw material inputs and processing equipment. That means that the binding efficiency or effectiveness of hydraulic cement increases with increasing concentration so long as the concrete remains optimized. The knowledge of how the K factor varies with binding efficiency and strength is a powerful tool that can be applied in multiple circumstances. A concrete manufacturing process may include accurately measuring the raw materials to minimize variation between predicted and actual strength, as well as carefully controlling water content throughout the manufacturing and delivery process.
Abstract:
A method for manufacturing a design optimized cement mixture comprising the steps of: calculating the maximum packing density for the cement, fine aggregate and coarse aggregate (66); setting the optimal cost mixture (69); calculating the volume of water for a desired slump (72); determining cement mixture strength (74); comparing calculated strength versus desired strength (76); calculating mixture cost (80); comparing it to optimal mixture cost (82); and comparing the volume of fine aggregate with the maximum volume of fine aggregate allowed.
Abstract:
A method of manufacturing a cementitious composite includes: (1) forming mixing an extrudable cementitious composition by first forming a fibrous mixture comprising fibers, water and a rheology modifying agent and then adding hydraulic cement; (2) extruding the extrudable cementitious composition into a green extrudate, wherein the green extrudate is characterized by being form-stable and retaining substantially a predefined cross-sectional shape; (3) removing a portion of the water by evaporation to reduce density and increase porosity; and (4) causing or allowing the hydraulic cement to hydrate to form the cementitious composite. Such a process yields a cementitious composite that is suitable for use as a wood substitute. The wood-like building products can be sawed, nailed and screwed like ordinary wood.
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 and methods of manufacturing articles, particularly containers and packaging materials, having a particle packed, highly inorganically filled, cellular matrix (8) 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 (8). 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 special 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.