Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more aggregate materials, fibers, and optional admixtures in the correct proportions in order to form an article which has the desired performance criteria. The inorganically filled mixtures are molded to fashion a portion of the mixture into a form stable shape for the desired article. Once the article has obtained form stability, the article is removed from the mold and allowed to harden to gain strength. The articles may have properties substantially similar to articles presently made from traditional materials like paper, paperboard, polystyrene, plastic, or metal. They have especial utility in the mass production of containers, particularly food and beverage containers.

Abstract: Compositions and methods for manufacturing sheets having a starch-bound matrix reinforced with fibers and optionally including an inorganic mineral filler. Suitable mixtures for forming the sheets are prepared by mixing together water, unmodified and ungelatinized starch granules, a cellulosic ether, fibers, and optionally an inorganic mineral filler in the correct proportions to form a sheet having desired properties. The mixtures are formed into sheets by passing them between one or more sets of heated rollers to form green sheets. The heated rollers cause the cellulosic ether to form a skin on the outer surfaces of the sheet that prevents the starch granules from causing the sheet to adhere to the rollers upon gelation of the starch. The green sheets are passed between heated rollers to gelatinize the starch granules, and then to dry the sheet by removing a substantial portion of the water by evaporation.

Abstract: Methods and systems for readily and economically manufacturing hydraulically settable articles, particularly containers, from microstructurally engineered hydraulically settable mixtures. The mixture is pressed between a male die of a desired shape and a female die having a substantially complimentary configuration of the male die shape to immediately fashion a portion of the mixture into a form stable shape for the desired article. To assist in imparting form stability, the dies can be heated or cooled. Once the article has obtained form stability, the article is removed from the dies and dried under heated air to gain strength. The article can then receive printing or a coating, if desired, prior to packaging, shipping, and use.

Abstract: Compositions, methods, and apparatus for manufacturing sheets having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more 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 and the passing the extruded materials between a set of rollers. 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 from traditional materials like paper, paperboard, polystyrene, plastic, or metal. Such sheets can be rolled, pressed, scored, perforated, folded, and glued.

Abstract: Methods and apparatus for continuously extruding a hydraulically settable mixture and simultaneously placing continuous filaments within the extruding mixture to yield articles having a filament-reinforced, hydraulically settable matrix. The filaments can be placed within the mixtures 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, 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.

Abstract: Compositions and methods for the deposition of ettringite (3CaO-Al.sub.2 O.sub.3 .multidot.3Ca(SO.sub.4).multidot.30-32H.sub.2 O) onto the surfaces of fibers, aggregates, and other fillers. The ettringite is produced in situ within an aqueous suspension while in proximity to the fibers, aggregates, or other fillers to form a mineralized composite material comprising ettringite coated fibers, aggregates or other fillers. Ettringite treated fibers, aggregates, or other fillers are formed by adding chemical reactants such as calcium oxide and aluminum sulfate, which react together in the presence of water to form ettringite, which then precipitates onto the surface of the fibers or other substrates being treated.

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.

Abstract: Methods and systems for forming hinged starch-bound matrices. Starch-based compositions are molded between heated molds in order to form a cellular matrix and also to remove the water from the starch-based compositions in order to form a binding matrix of solidified starch. The molding apparatus is configured to form one or more creases within the hinge area in order to define one or more lines upon which the hinge will bend. The molding apparatus is also configured such that the region of the mold corresponding to the inner surface of the hinge area will transfer heat more slowly to the inner hinge surface, resulting in reduced thickness of the skin of the inner hinge. This increases the collapsibility, or ability of the inner surface of the hinge to fold or buckle, during the bending action. This in turn reduces the bending radius of hinge such that the hinging action exerts less strain on the outer surface of the hinge.

Abstract: Methods and systems for readily and economically manufacturing hydraulically settable articles, particularly containers, from microstructurally engineered hydraulically settable mixtures wherein the mixture is extruded into a sheet that is feed through a plurality of sets of rollers so as to form the sheet into the desired thickness. The sheet is then pressed between a male die of a desired shape and a female die having a substantially complimentary configuration of the male die shape to immediately fashion a portion of the sheet into a form stable shape for the desired article. To assist in imparting form stability, the dies can be heated or cooled. Once the article has obtained form stability, the article is removed from the dies and dried under heated air to gain strength. The article can then be cut from the sheet and receive printing or a coating, if desired, prior to packaging, shipping, and use.

Abstract: Containers use in the storing, dispensing, packaging, and/or portioning of food and beverage products. The disposable and nondisposable food and beverage containers are manufactured from aggregates held together by organic binders in order to be lightweight, insulative, inexpensive, and more environmentally compatible than those currently used for storing, dispensing, packaging, or portioning such products. The food and beverage containers of the present invention are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrices of the food and beverage containers include a hydrated organic binder paste (formed by mixing the binder with water) in combination with appropriate aggregate materials, such as fibers to add flexibility and strength, glass spheres to make the product more lightweight and insulative, or clay to make the product extremely inexpensive yet strong.

Abstract: Sealable liquid-tight containers and methods for economically manufacturing 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 inorganically filled mixtures comprising a water-dispersible organic polymer binder, aggregate fillers, fibers, and water. Alternatively, such containers are formed from high starch-containing compositions which optionally include inorganic fillers up to about 90%. Such compositions can be directly molded, formed into wet sheets and then molded, formed into dry sheets and then reformed, or extruded into the container components. The containers or components thereof may optionally be coated, lined, laminated, and/or receive printing.

Abstract: Compositions and methods for manufacturing sheets having a starch-bound matrix reinforced with fibers and optionally including an inorganic mineral filler. Suitable mixtures for forming the sheets are prepared by mixing together water, unmodified and ungelatinized starch granules, a cellulosic ether, fibers, and optionally an inorganic mineral filler in the correct proportions to form a sheet having desired properties. The mixtures are formed into sheets by passing them between one or more sets of heated rollers to form green sheets. The heated rollers cause the cellulosic ether to form a skin on the outer surfaces of the sheet that prevents the starch granules from causing the sheet to adhere to the rollers upon gelation of the starch. The green sheets are passed between heated rollers to gelatinize the starch granules, and then to dry the sheet by removing a substantial portion of the water by evaporation.

Abstract: Compositions and methods for manufacturing sheets having a hydraulically settable matrix are disclosed. 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.

Abstract: Compositions and methods for the post-production treatment of a starch-bound article to increase the flexibility of the treated article by softening or plasticizing the article through the application of a polyalcohol, preferably glycerin. The glycerin is preferably mixed with water before application to aid in penetrating the cellular matrix of the article. The glycerin acts as a plasticizer and a humectant, and it stabilizes the starch-bound matrix against warping that otherwise results when water-borne substances are applied to the surface of a starch-bound article. The glycerin treatment can be applied to a hinge to increase the resilience and durability of the hinge, generally by causing the inner hinge surface to be more collapsible, which greatly decreases the radius of bending of the outer surface of the hinge and which thereby reduces the amount of strain or elongation exerted on the outer surface of the hinge.

Abstract: Compositions, methods, and systems for manufacturing articles, particularly containers and packaging materials, having a starch-bound cellular matrix reinforced with substantially uniformly dispersed fibers. 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 that are uniformly dispersed by means of a high yield stress fluid fraction within the starch-based composition. In a two-step mixing process, a preblended mixture is formed by gelating a portion of the starch-based binder or other thickening agent in water to form a liquid phase having high yield stress into which the fibers are substantially uniformly dispersed. The fibers preferably have an average length of at least about 2 mm and an aspect ratio of at least about 25:1.

Abstract: Compositions, methods, and apparatus for manufacturing sheets having a highly inorganically filled matrix. Suitable inorganically filled mixtures are prepared by mixing together an organic polymer binder, water, one or more 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 and then passing the extruded materials between a set of rollers. 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 from traditional materials like paper, paperboard, polystyrene, plastic, or metal. Such sheets can be cut, rolled, pressed, scored, perforated, folded, and glued to fashion articles from the sheet.

Abstract: A method for manufacturing a hinged sheet having an inorganically filled structural matrix includes mixing together a water-dispersible organic polymer binder, an inorganic aggregate material, a fibrous material, and water in order to form a moldable inorganically filled mixture in which the components therein are substantially homogeneously dispersed. The inorganically filled mixture is formed into a substantially hardened sheet having an inorganically filled matrix in a manner such that the water is removed by evaporation. The sheet is then scored to form a hinge in the inorganically filled matrix. Alternatively, a score can be pressed into a surface of the sheet prior to drying in order to form a scored sheet which is then dried.

Abstract: Containers use in the storing, dispensing, packaging, and/or portioning of food and beverage products are disclosed. The disposable and nondisposable food and beverage containers are manufactured from aggregates held together by organic binders in order to be lightweight, insulative, inexpensive, and more environmentally compatible than those currently used for storing, dispensing, packaging, or portioning such products. The food and beverage containers of the present invention are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment.

Abstract: Methods and systems for forming hinged starch-bound matrices. Starch-based compositions are molded between heated molds in order to form a cellular matrix and also to remove the water from the starch-based compositions in order to form a binding matrix of solidified starch. The molding apparatus is configured to form one or more creases within the hinge area in order to define one or more lines upon which the hinge will bend. The molding apparatus is also configured such that the region of the mold corresponding to the inner surface of the hinge area will transfer heat more slowly to the inner hinge surface, resulting in reduced thickness of the skin of the inner hinge. This increases the collapsibility, or ability of the inner surface of the hinge to fold or buckle, during the bending action. This in mm reduces the bending radius of hinge such that the hinging action exerts less strain on the outer surface of the hinge.

Abstract: Containers incorporating a hydraulically settable structural matrix including a hydraulically settable binder such as cement for use in the storing, dispensing, and/or packaging of food and beverage products are disclosed. The disposable and nondisposable food and beverage articles of manufacture have high tensile, compressive, and flexural strengths, and are lightweight, insulative (if desired), inexpensive, and more environmentally compatible than those currently used. These disposable containers and cups are particularly useful for dispensing hot and cold food and beverages in the fast food restaurant environment. The structural matrix of the food and beverage containers includes a hydraulic cement paste (formed from the reaction of water with, e.g., a portland-type cement) preferably in combination with a rheology-modifying plasticizer, such as methylhydroxyethylcellulose, various aggregate materials, and fibrous materials, which provide desired properties at a cost which is economical.