Abstract:
The present invention relates to continuous concrete casting by extrusion and, in particular discloses the process, method and apparatus by which substantially continuous lengths of cast reinforced or prestressed concrete products or other composite products from different materials can be extruded. Pressure used in the extrusion process can lead to beneficial effects arising from faster setting and concrete hardening under high pressure, mix dewatering in porous mould surfaces and the introduction of reinforcement. Judicious combinations of surface lubrication with driving pressures can lead to longitudinal prestressing of reinforcement. Multi-layered composite products can also be extruded. Products may be flat or have single or double curvature in axi-symmetric three dimensional shapes, as well as other more complex three dimensional shapes such as the helix. The output from the process may be either continuous or discrete elements.
Abstract:
The present invention relates to compositions, methods and apparatus for preparing composite materials. A method of fabricating a fibrous monolith composite includes extruding a first material laden composition into a filament, passing the filament through a coextrusion assembly, coating the filament with a second material laden composition as the filament passes through the coextrusion assembly and arranging the coated filament into a desired architecture to form a fibrous monolith composite. A coextrusion assembly (19) includes an extrusion head (21), a tapered nozzle (22), a spinnerette (26), a spinnerette housing (25), a guide rod support (24) and a guide rod (23).
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:
A production method for a paper feed roller, capable of mass-producing a high-precision paper feed roller, having no connection unit at its roller unit, at low costs and with a higher precision by means of an extrusion method using a hydraulic composition. The production method for a paper feed roller consisting of a rotating shaft and a cylindrical roller unit integrally formed on the outer periphery of the shaft, characterized in that the roller unit is formed by extruding, curing and hardening a hydraulic composition.
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.
Abstract:
The invention relates to an apparatus and a method for constructing a construction element or a building comprising at least feeding means for providing construction material in layers. The apparatus comprises at least first feeding means (340) for hardening material, second feeding means (350) for insulating material wherein said feeding means are configured to operate substantially concurrently so that a construction layer comprises materials from each feeding means (340, 350). The apparatus may also provide reinforcement substantially concurrently with the other materials.
Abstract:
A method of manufacturing a cementitious composite including: (1) 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) heating the green extrudate at a temperature from greater than 65°C to less than 99°C is disclosed. Such a process yields a cementitious composite that is suitable for use as a wood substitute. Particularly, by using higher curing temperatures for preparing the cementitious building products, the building products have a lower bulk density and a higher flexural strength as compared to conventional products. The wood-like building products can be sawed, nailed and screwed like ordinary wood.