Abstract: The present invention relates to hydraulically bonded cement compositions and methods. More particularly, the present invention is directed to novel compositions and methods of hydrating hydraulic cement without mechanical mixing of the cement and water. The present invention includes materials prepared by manipulating under pressure powdered hydraulic cement compositions using known or novel powder packing, casting, or expanding techniques, such that air within the powdered hydraulic cement is substantially removed while the cement is formed into a self-supporting near net final position. Thereafter, the formed hydraulic cement is hydrated without mechanical mixing of the cement and water.

Abstract: Laminate insulation barriers including a highly insulative layer and a structural layer which has a cementitious structural matrix. The laminate insulation barriers are lightweight and more environmentally compatible than those currently used; they may augment, and even take the place of, traditional insulation materials which typically contain nondegradable, environmentally damaging materials.

Abstract: Cementitious containers which have a cementitious structural matrix for use in the packaging, storing, partitioning, and/or shipping of goods. The containers are manufactured from cementitious materials in order to be strong, durable, tough, lightweight, cushioning, insulative, inexpensive, and more environmentally compatible than those currently used in packaging, storing, and/or shipping goods. The cementitious structural matrix of the containers includes a hydraulic cement paste (formed from the reaction of water with, e.g., a portland cement) in combination with a rheology-modifying plasticizer, such as methylhydroxyethylcellulose. Preferred embodiments may also include various aggregate materials, fibrous materials, and air voids, which add the necessary strength while making the product lightweight, and which can provide insulative properties (if desired) at a cost which is economically justified in comparison to conventional paper and polystyrene products.

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. 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: 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 and methods for substantially uniformly dispersing fibers throughout a starch-based composition. The fibers are dispersed throughout the composition by means of a high yield stress, high viscosity fluid fraction formed by interacting together water and a thickening agent such as gelatinized starch. The well-dispersed fibers provide for a large variety of processing conditions in the manufacture of articles from such starch-based compositions (e.g., greater variations in the use of water, the amount of water that must be removed to yield a form stable article, and wall thickness). Articles formed thereby have greatly improved mechanical properties as a result of the reinforcing effect of the uniformly dispersed fibers. 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 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 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 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 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, cardboard, polystyrene, plastic, or metal. Such sheets can be rolled, pressed, scored, perforated, folded, and glued.

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. 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: Compositions and methods for manufacturing containers from 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. Hydraulically settable sheets are formed from the mixture by extrusion, then calendering the sheets using a set of rollers and then drying the sheets in an accelerated manner to substantially harden the sheets. The resulting hydraulically settable sheets may have properties substantially similar to sheets made from presently used materials like paper, cardboard, polystyrene, or plastic. The sheets can be laminated, corrugated, coated, printed on, scored, perforated, cut, folded, rolled, spiral wound, molded, assembled and seamed to mass produce articles of manufacture from the sheets such as food and beverage containers.

Abstract: Hydraulically settable mixtures and methods for extruding such mixtures into a variety of objects which are form-stable in the green state. High green strength is achieved by increasing the yield stress of the mixture while maintaining adequate extrudability. Optimizing the particle packing density while including a deficiency of water yields a hydraulically settable mixture which will flow under pressures typically associated with the extrusion of clay or plastic. In addition, a rheology-modifying agent can be added to increase the yield stress of the mixture while not significantly increasing the viscosity. The desired strength properties and other performance criteria of the final hardened extruded product are controlled by adding aggregates, fibers, a hydraulically settable binder, water, and other admixtures.

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: 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: Sealable liquid-tight containers 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 mixtures 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 components may also be dried, coated, lined, laminated and/or receive printing.

Abstract: A design optimization process used to determine the proportions of sand, cement, coarse aggregate, water, fly ash, water reducers, air entraining agents and fillers needed to produce a concrete mixture that has desired strength and slump properties and a minimal cost. The optimization process comprises a combination of models that accurately reflect the properties of a concrete mixture based on the properties of its individual components. The process is further capable of optimizing the durability of the cementitious mixture and of accurately calculating the expected yield of the mixture.

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.

Abstract: Compositions and methods 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 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 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: 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 sheets.

Abstract: Cementitious containers which have a cementitious structural matrix for use in the packaging, storing, partitioning, and/or shipping of goods. The containers are manufactured from cementitious materials in order to be strong, durable, tough, lightweight, cushioning, insulative, inexpensive, and more environmentally compatible than those currently used in packaging, storing, and/or shipping goods. The cementitious structural matrix of the containers includes a hydraulic cement paste (formed from the reaction of water with, e.g., a portland cement) in combination with a rheology-modifying plasticizer, such as methylhydroxyethylcellulose. Preferred embodiments may also include various aggregate materials, fibrous materials, and air voids, which add the necessary strength while making the product lightweight, and which can provide insulative properties (if desired) at a cost which is economically justified in comparison to conventional paper and polystyrene products.

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 theology-modifying plasticizer, such as methylhydroxyethylcellulose, various aggregate materials and fibrous materials which provide desired properties at a cost which is economical.