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US5508072A
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Sheets having a highly inorganically filled organic polymer matrix
Assignee: E Khashoggi Industries LLC
•
Filing: 1993-11-19
•
Granted: 1996-04-16
•
Expires: 2013-11-19
Abstract
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. They have especial utility in the mass production of containers, particularly food and beverage containers.
Inventors
- 👤 Per J. Andersen
- 👤 Simon K. Hodson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 10:48
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/60; C04B41/61; B; B01; B01F; B01F23/00; B01F23/50; B01F23/51; B01F23/511; B01F23/56; B28; B28B; B28B1/00; B28B1/52; B28B11/00; B28B11/003; B28B11/008; B28B13/00; B28B13/02; B28B13/021; B28B13/04; B28B13/06; B28B23/00; B28B23/0081; B28B23/0087; B28B3/00; B28B3/02; B28B3/12; B28B3/126; B28B3/20; B28B3/26; B28B3/2645; B28B7/00; B28B7/40; B28B7/42; B28C; B28C7/00; B28C7/02; B29; B29C; B29C43/00; B29C43/003; B29C43/02; B29C43/22; B29C43/222; B29C43/24; B29C43/32; B29C43/34; B29C43/36; B29C43/44; B29C43/46; B29C44/00; B29C44/34; B29C44/3402; B29C45/00; B29C45/0013; B29C48/00; B29C48/03; B29C48/07; B29C48/12; B29C48/13; B29C49/00; B29C49/0005; B29C49/02; B29C49/04; B29C49/0411; B29C49/0412; B29C49/06; B29C49/061; B29C49/062; B29C49/063; B29C51/00; B29C51/002; B29C51/04; B29C51/10; B29C53/00; B29C53/02; B29C53/04; B29C53/06; B29C53/063; B29C55/00; B29C55/02; B29C55/18; B29C67/00; B29C67/24; B29C67/242; B29C67/243; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/50; B29C71/00; B29C71/0009; B31; B31D; B31D1/00; B31D1/0043; B31D1/005; B32; B32B; B32B13/00; B32B13/02; B32B27/00; B32B27/04; B32B27/18; B32B27/20; B32B37/00; B32B37/14; B32B37/144; B32B5/00; B32B5/02; B32B9/00; B65; B65D; B65D11/00; B65D11/02; B65D43/00; B65D43/14; B65D43/16; B65D43/162; B65D5/00; B65D65/00; B65D65/38; B65D65/46; B65D65/466; C04B14/00; C04B14/02; C04B14/04; C04B14/06; C04B14/064; C04B16/00; C04B16/02; C04B20/00; C04B20/0016; C04B20/002; C04B20/0048; C04B22/00; C04B22/02; C04B22/04; C04B24/00; C04B24/12; C04B24/14; C04B24/24; C04B24/38; C04B26/00; C04B26/02; C04B26/026; C04B26/28; C04B26/285; C04B28/00; C04B28/02; C04B38/00; C04B38/0006; C04B38/02; C04B40/00; C04B40/0028; C04B40/006; C04B41/009; C04B41/45; C08; C08J; C08J5/00; C08J5/18; C08L; C08L1/00; C08L1/08; C08L1/26; C08L1/28; C08L1/286; C08L3/00; C08L3/02; C08L5/00; C08L5/02; C08L5/12; C08L5/14; C08L89/00; C08L89/04; C08L89/06; C08L97/00; C08L97/02; E; E05; E05D; E05D1/00; E05D1/02; B05; B05C; B05C1/00; B05C1/04; B05C1/08; B05C1/0826; B05C1/0834; B05C3/00; B05C3/18; B05C5/00; B05C5/02; B05C5/0245; B29C43/021; B29C2043/022; B29C2043/023; B29C2043/3433; B29C2043/3676; B29C2043/3689; B29C2043/461; B29C2043/463; B29C2043/464; B29C2043/466; B29C2049/023; B29C49/42; B29C49/46; B29C2049/4602; B29C2049/4605; B29C2049/4608; B29C2791/00; B29C2791/004; B29C2791/006; B29C2795/00; B29C2795/007; B29C2949/00; B29C2949/07; B29C2949/0715; B29C43/04; B29C43/06; B29C43/08; B29C48/001; B29C48/0011; B29C48/0012; B29C48/0019; B29C48/0022; B29C48/08; B29C49/06905; B29C49/0691; B29C49/64; B29C49/6604; B29C49/6605; B29C51/08; B29C51/082; B29C53/56; B29C53/58; B29K; B29K2001/00; B29K2003/00; B29K2005/00; B29K2089/00; B29K2105/00; B29K2105/04; B29K2105/06; B29K2105/12; B29K2105/16; B29L; B29L2024/00; B29L2031/00; B29L2031/60; B29L2031/608; B29L2031/712; B29L2031/7132; B31B; B31B2105/00; B31B2105/002; B31B2105/0022; B31B50/00; B31B50/26; B31B50/28; B31B50/30; B31B50/32; B32B37/12; B65D2301/00; B65D2301/20; B65D2565/00; B65D2565/38; B65D2565/381; B65D2565/385; C04B2111/00; C04B2111/00034; C04B2111/00129; C04B2111/00241; C04B2111/0037; C04B2111/00379; C04B2111/00413; C04B2111/00474; C04B2111/00612; C04B2111/00948; C04B2111/00965; C04B2111/80; C08J2323/00; C08J2323/02; E05Y; E05Y2999/00; Y; Y10; Y10S; Y10S229/00; Y10S229/93; Y10S428/00; Y10S428/906; Y10T; Y10T428/00; Y10T428/13; Y10T428/131; Y10T428/1314; Y10T428/1348; Y10T428/1352; Y10T428/1372; Y10T428/1376; Y10T428/15; Y10T428/24; Y10T428/24355; Y10T428/24372; Y10T428/2438; Y10T428/24446; Y10T428/24471; Y10T428/24479; Y10T428/24612; Y10T428/24628; Y10T428/24669; Y10T428/24694; Y10T428/249921; Y10T428/249924; Y10T428/249928; Y10T428/249953; Y10T428/249967; Y10T428/249968; Y10T428/249969; Y10T428/249971; Y10T428/249974; Y10T428/249986; Y10T428/26; Y10T428/269; Y10T428/31504; Y10T428/31971
Claims Analysis
Total Claims: 136
Claim 1
Independent Claim
132 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, a fibrous material, and an inorganic aggregate material, the aggregate material being present in a concentration in a range from about 40% to about 98% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, wherein the matrix degrades after prolonged exposure to water.
Claim 2
Dependent Claim
132 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, a fibrous material, and an inorganic aggregate material, the aggregate material being present in a concentration in a range from about 40% to about 98% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, wherein the matrix degrades after prolonged exposure to water.
Claim 3
Dependent Claim
32 words
A sheet as defined in claim 1, the aggregate material having a concentration in a range from about 50% to about 95% by volume of total solids in the inorganically filled mixture.
Claim 4
Dependent Claim
32 words
A sheet as defined in claim 1, the aggregate material having a concentration in a range from about 60% to about 80% by volume of total solids in the inorganically filled mixture.
Claim 5
Dependent Claim
18 words
A sheet as defined in claim 1, wherein the aggregate material comprises at least two different aggregate materials.
Claim 6
Dependent Claim
31 words
A sheet as defined in claim 1, wherein the aggregate material comprises individual particles that are size optimized in order to achieve a predetermined particle packing density of the aggregate material.
Claim 7
Dependent Claim
21 words
A sheet as defined in claim 5, wherein the particle packing density of the aggregate material is at least about 0.65.
Claim 8
Dependent Claim
21 words
A sheet as defined in claim 5, wherein the particle packing density of the aggregate material is at least about 0.75.
Claim 9
Dependent Claim
21 words
A sheet as defined in claim 5, wherein the particle packing density of the aggregate material is at least about 0.85.
Claim 10
Dependent Claim
27 words
A sheet as defined in claim 1, wherein the aggregate material comprises a lightweight aggregate which reduces the density and increases the insulation ability of the sheet.
Claim 11
Dependent Claim
34 words
A sheet as defined in claim 9, wherein the lightweight aggregate is selected from the group consisting of perlite, vermiculite, hollow glass spheres, porous ceramic spheres, lightweight expanded geologic materials, pumice, and mixtures thereof.
Claim 12
Dependent Claim
32 words
A sheet as defined in claim 1, wherein the aggregate material is selected from the group consisting of clay, gypsum, calcium carbonate, mica, silica, alumina, sand, gravel, sandstone, limestone, and mixtures thereof.
Claim 13
Dependent Claim
31 words
A sheet as defined in claim 1, wherein the aggregate material comprises an organic aggregate selected from the group consisting of seeds, starches, gelatins, agar materials, and mixtures or derivatives thereof.
Claim 14
Dependent Claim
15 words
A sheet as defined in claim 1, wherein the aggregate material includes an inorganic gel.
Claim 15
Dependent Claim
29 words
A sheet as defined in claim 13, wherein the inorganic gel is selected from the group consisting of silica gel, aluminum silicate gel, calcium silicate gel, and mixtures thereof.
Claim 16
Dependent Claim
28 words
A sheet as defined in claim 13, wherein the gel has a concentration within the sheet such that a predetermined amount of moisture is maintained within the sheet.
Claim 17
Dependent Claim
20 words
A sheet as defined in claim 1, wherein the aggregate material includes an inorganic material that is precipitated in situ.
Claim 18
Dependent Claim
15 words
A sheet as defined in claim 1, wherein the aggregate material comprises a polymerized silicate.
Claim 19
Dependent Claim
19 words
A sheet as defined in claim 1, wherein the thickness of the sheet is less than about 1 mm.
Claim 20
Dependent Claim
19 words
A sheet as defined in claim 1, wherein the thickness of the sheet is less than about 0.5 min.
Claim 21
Dependent Claim
39 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder and fibrous material have a total concentration in a range from about 5% to about 60% by volume of total solids in the inorganically filled mixture.
Claim 22
Dependent Claim
34 words
A sheet as defined in claim 20, wherein the water-dispersible organic polymer binder and fibrous material have a total concentration less than about 40% by volume of total solids in the inorganically filled mixture.
Claim 23
Dependent Claim
34 words
A sheet as defined in claim 20, wherein the water-dispersible organic polymer binder and fibrous material have a total concentration less than about 30% by volume of total solids in the inorganically filled mixture.
Claim 24
Dependent Claim
35 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder has a concentration in a range from about 1% to about 50% by volume of total solids in the inorganically filled mixture.
Claim 25
Dependent Claim
35 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder has a concentration in a range from about 2% to about 30% by volume of total solids in the inorganically filled mixture.
Claim 26
Dependent Claim
35 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder has a concentration in a range from about 5% to about 20% by volume of total solids in the inorganically filled mixture.
Claim 27
Dependent Claim
17 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder comprises a cellulose-based polymer.
Claim 28
Dependent Claim
30 words
A sheet as defined in claim 26, wherein the cellulose-based polymer is selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethylpropylcellulose, and mixtures or derivatives thereof.
Claim 29
Dependent Claim
17 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder comprises a starch-based polymer.
Claim 30
Dependent Claim
42 words
A sheet as defined in claim 28, wherein the starch-based polymer is selected from the group consisting of amylopectin, amylose, seagel, starch acetates, starch hydroxyethyl ethers, ionic starches, long-chain alkylstarches, dextrins, amine starches, phosphate starches, dialdehyde starches, and mixtures or derivatives thereof.
Claim 31
Dependent Claim
27 words
A sheet as defined in claim 1, wherein the protein is selected from the group consisting of prolamine, collagen, gelatin, glue, casein, and mixtures or derivatives thereof.
Claim 32
Dependent Claim
42 words
A sheet as defined in claim 1, wherein the water-dispersible organic polymer binder comprises a polysaccharide selected from the group consisting of alginic acid, phycocolloids, agar, gum arabic, guar gum, locust bean gum, gum karaya, gum tragacanth, and mixtures or derivatives thereof.
Claim 33
Dependent Claim
18 words
A sheet as defined in claim 1, wherein the inorganically filled mixture further includes a synthetic organic polymer.
Claim 34
Dependent Claim
51 words
A sheet as defined in claim 32, wherein the synthetic organic polymer is selected from the group consisting of polyvinyl pyrrolidone, polyethylene glycol, polyvinyl alcohol, polyvinylmethyl ether, polyacrylic acids, polyacrylic acid salts, polyvinylacrylic acids, polyvinylacrylic acid salts, polyacrylimides, polylactic acid, ethylene oxide polymers, synthetic clay, latex, and mixtures or derivatives thereof.
Claim 35
Dependent Claim
33 words
A sheet as defined in claim 1, wherein the fibrous material has a concentration in a range from about 0.5% to about 50% by volume of total solids in the inorganically filled mixture.
Claim 36
Dependent Claim
33 words
A sheet as defined in claim 1, wherein the fibrous material has a concentration in a range from about 5% to about 40% by volume of total solids in the inorganically filled mixture.
Claim 37
Dependent Claim
33 words
A sheet as defined in claim 1, wherein the fibrous material has a concentration in a range from about 15% to about 30% by volume of total solids in the inorganically filled mixture.
Claim 38
Dependent Claim
14 words
A sheet as defined in claim 1, wherein the fibrous material comprises organic fibers.
Claim 39
Dependent Claim
34 words
A sheet as defined in claim 37, wherein the organic fibers are selected from the group consisting of hemp, cotton, bagasse, abaca, flax, southern pine, and southern hardwood fibers, and mixtures or derivatives thereof.
Claim 40
Dependent Claim
14 words
A sheet as defined in claim 1, wherein the fibrous material comprises inorganic fibers.
Claim 41
Dependent Claim
33 words
A sheet as defined in claim 39, wherein the inorganic fibers are selected from the group consisting of glass fibers, silica fibers, ceramic fibers, carbon fibers, metal fibers, and mixtures or derivatives thereof.
Claim 42
Dependent Claim
22 words
A sheet as defined in claim 1, wherein the fibrous material comprises a mixture of different fibers having varying strengths and flexibilities.
Claim 43
Dependent Claim
18 words
A sheet as defined in claim 1, wherein the fibrous material increases the tensile strength of the sheet.
Claim 44
Dependent Claim
17 words
A sheet as defined in claim 1, wherein the fibrous material increases the flexibility of the sheet.
Claim 45
Dependent Claim
23 words
A sheet as defined in claim 1, wherein the fibrous material includes individual fibers having an aspect ratio of at least about 10:1.
Claim 46
Dependent Claim
23 words
A sheet as defined in claim 1, wherein the fibrous material includes individual fibers having an aspect ratio of at least about 100:1.
Claim 47
Dependent Claim
24 words
A sheet as defined in claim 1, wherein the fibrous material includes individual fibers having an aspect ratio of at least about 1000: 1.
Claim 48
Dependent Claim
13 words
A sheet as defined in claim 1, wherein the sheet is water degradable.
Claim 49
Dependent Claim
17 words
A sheet as defined in claim 1, wherein the sheet is readily degradable into environmentally neutral components.
Claim 50
Dependent Claim
25 words
A sheet as defined in claim 1, wherein the sheet has a tensile strength in a range from about 0.05 MPa to about 70 MPa.
Claim 51
Dependent Claim
25 words
A sheet as defined in claim 1, wherein the sheet has a tensile strength in a range from about 5 MPa to about 40 MPa.
Claim 52
Dependent Claim
32 words
A sheet as defined in claim 1, wherein the sheet has a tensile strength to density ratio in a range from about 2 MPa-cm 3 /g to about 200 MPa-cm 3 /g.
Claim 53
Dependent Claim
32 words
A sheet as defined in claim 1, wherein the sheet has a tensile strength to density ratio in a range from about 3 MPa-cm 3 /g to about 50 MPa-cm 3 /g.
Claim 54
Dependent Claim
19 words
A sheet as defined in claim 1, wherein a portion of the aggregate material includes a hydraulically settable material.
Claim 55
Dependent Claim
16 words
A sheet as defined in claim 53, wherein the hydraulically settable material comprises a hydraulic cement.
Claim 56
Dependent Claim
15 words
A sheet as defined in claim 54, wherein the hydraulic cement comprises portland grey cement.
Claim 57
Dependent Claim
44 words
A sheet as defined in claim 54, wherein the hydraulic cement is selected from the group consisting of portland white cement, slag cement, calcium aluminate cement, silicate cement, phosphate cement, high-alumina cement, magnesium oxychloride cement, aggregates coated with microfine cernent particles, and mixtures thereof.
Claim 58
Dependent Claim
16 words
A sheet as defined in claim 53, wherein the hydraulically settable material comprises calcium sulfate hemihydrate.
Claim 59
Dependent Claim
15 words
A sheet as defined in claim 53, wherein the hydraulically settable material comprises calcium oxide.
Claim 60
Dependent Claim
28 words
A sheet as defined in claim 53, wherein the hydraulically settable material has a concentration within the sheet great enough to impart a binding effect within the sheet.
Claim 61
Dependent Claim
20 words
A sheet as defined in claim 1, wherein the sheet has a maximum density of about 2 g/cm 3 .
Claim 62
Dependent Claim
27 words
A sheet as defined in claim 1, wherein the sheet has a density in a range from about 0.4 g/cm 3 to about 1.5 g/cm 3 .
Claim 63
Dependent Claim
24 words
A sheet as defined in claim 1, wherein the sheet can elongate in a range from about 0.5% to about 8% without completely fracturing.
Claim 64
Dependent Claim
12 words
A sheet as defined in claim 62, wherein the sheet is dry.
Claim 65
Dependent Claim
19 words
A sheet as defined in claim 1, wherein the sheet can elongate up to about 20% without completely fracturing.
Claim 66
Dependent Claim
12 words
A sheet as defined in claim 64, wherein the sheet is moist.
Claim 67
Dependent Claim
12 words
A sheet as defined in claim 1, wherein the sheet is corrugated.
Claim 68
Dependent Claim
12 words
A sheet as defined in claim 1, wherein the sheet is creped.
Claim 69
Dependent Claim
12 words
A sheet as defined in claim 1, wherein the sheet is compacted.
Claim 70
Dependent Claim
12 words
A sheet as defined in claim 1, wherein the sheet is calendered.
Claim 71
Dependent Claim
13 words
A sheet as defined in claim 1, wherein the sheet includes an indicia.
Claim 72
Dependent Claim
13 words
A sheet as defined in claim 70, wherein the indicia comprises an imprint.
Claim 73
Dependent Claim
14 words
A sheet as defined in claim 1, wherein the sheet includes a score cut.
Claim 74
Dependent Claim
13 words
A sheet as defined in claim 1, wherein the sheet includes a score.
Claim 75
Dependent Claim
13 words
A sheet as defined in claim 1, wherein the sheet includes a perforation.
Claim 76
Dependent Claim
26 words
A sheet as defined in claim 1, wherein the water has a concentration within the inorganically filled mixture such that the sheet made therefrom is mass-producible.
Claim 77
Dependent Claim
29 words
A sheet as defined in claim 1, wherein the water has a concentration in a range from about 5% to about 50% by volume of the inorganically filled mixture.
Claim 78
Dependent Claim
15 words
A sheet as defined in claim 1, wherein the sheet includes finely dispersed air voids.
Claim 79
Dependent Claim
23 words
A sheet as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially random orientation within the sheet.
Claim 80
Dependent Claim
23 words
A sheet as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially unidirectional orientation within the sheet.
Claim 81
Dependent Claim
23 words
A sheet as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially bidirectional orientation within the sheet.
Claim 82
Dependent Claim
40 words
A sheet as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially higher level of directional orientation at or near the surface of the sheet compared to fibers within the interior of the sheet.
Claim 83
Dependent Claim
22 words
A sheet as defined in claim 1, wherein the sheet may be bent over an angle of about 90° without substantially fracturing.
Claim 84
Dependent Claim
22 words
A sheet as defined in claim 1, wherein the sheet may be bent over an angle of about 180° without substantially fracturing.
Claim 85
Dependent Claim
22 words
A sheet as defined in claim 1, wherein the sheet may be bent over an angle of about 360° without substantially fracturing.
Claim 86
Dependent Claim
21 words
A sheet as defined in claim 1, wherein the sheet will fracture when bent over an angle greater than about 5°.
Claim 87
Dependent Claim
21 words
A sheet as defined in claim 1, wherein the sheet will fracture when bent over an angle greater than about 45°.
Claim 88
Dependent Claim
18 words
A sheet as defined in claim 1, wherein the sheet has been fashioned into an article of manufacture.
Claim 89
Dependent Claim
16 words
A sheet as defined in claim 1, wherein the sheet has been fashioned into a container.
Claim 90
Dependent Claim
21 words
A sheet as defined in claim 1, wherein the sheet comprises a continuous sheet that has been rolled onto a spool.
Claim 91
Dependent Claim
22 words
A sheet as defined in claim 1, wherein the sheet has been stacked onto other sheets to form a stack of sheets.
Claim 92
Dependent Claim
158 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet being formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, an inorganic aggregate, and a fibrous material, the aggregate material having a concentration of at least about 40% by volume of the total solids in the inorganically filled mixture, the water-dispersible organic polymer binder and fibrous material together having a concentration in a range from about 5% to about 60% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, wherein the matrix degrades after prolonged exposure to water.
Claim 93
Dependent Claim
158 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet being formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, an inorganic aggregate, and a fibrous material, the aggregate material having a concentration of at least about 40% by volume of the total solids in the inorganically filled mixture, the water-dispersible organic polymer binder and fibrous material together having a concentration in a range from about 5% to about 60% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, wherein the matrix degrades after prolonged exposure to water.
Claim 94
Dependent Claim
17 words
A sheet as defined in claim 91, said sheet having a maximum thickness of about 1 mm.
Claim 95
Dependent Claim
28 words
A sheet as defined in claim 91, wherein the water is included in an amount within the inorganically filled mixture such that the sheet made therefrom is mass-producible.
Claim 96
Dependent Claim
15 words
A sheet as defined in claim 91, wherein the sheet can be substituted for paper.
Claim 97
Dependent Claim
15 words
A sheet as defined in claim 91, wherein the sheet can be substituted for paperboard.
Claim 98
Dependent Claim
34 words
A sheet as defined in claim 91, wherein the water-dispersible organic polymer binder comprises a polysaccharide selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose. hydroxyethylcellulose, hydroxyethylpropylcellulose, and mixtures or derivatives thereof.
Claim 99
Dependent Claim
31 words
A sheet as defined in claim 91, the inorganic aggregate having a concentration in a range from about 50% to about 95% by volume of solids within the inorganically filled mixture.
Claim 100
Dependent Claim
30 words
A sheet as defined in claim 91, wherein the inorganic aggregate comprises individual particles that are size optimized in order to achieve a particle packing density greater than about 0.65.
Claim 101
Dependent Claim
32 words
A sheet as defined in claim 91, wherein the aggregate material is selected from the group consisting of clay, gypsum, calcium carbonate, mica, silica, alumina, sand, gravel, sandstone, limestone, and mixtures thereof.
Claim 102
Dependent Claim
18 words
A sheet as defined in claim 91, wherein the sheet has a thickness less than about 0.5 min.
Claim 103
Dependent Claim
34 words
A sheet as defined in claim 91, wherein the water-dispersible organic polymer binder and fibrous material have a total concentration less than about 40% by volume of total solids in the inorganically filled mixture.
Claim 104
Dependent Claim
33 words
A sheet as defined in claim 91, wherein the fibrous material has a concentration in a range from about 5% to about 40% by volume of total solids in the inorganically filled mixture.
Claim 105
Dependent Claim
18 words
A sheet as defined in claim 91, wherein the sheet has been fashioned into an article of manufacture.
Claim 106
Dependent Claim
16 words
A sheet as defined in claim 91, wherein the sheet has been fashioned into a container.
Claim 107
Dependent Claim
21 words
A sheet as defined in claim 91, wherein the sheet comprises a continuous sheet that has been rolled onto a spool.
Claim 108
Dependent Claim
25 words
A sheet as defined in claim 91, wherein the sheet has a tensile strength in a range from about 5 MPa to about 40 MPa.
Claim 109
Dependent Claim
152 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet being formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, an aggregate material, and an organic fibrous material, the aggregate material having a concentration in a range from about 40% to about 95% by volume of total solids in the inorganically filled mixture, the organic polymer binder and organic fibrous material together having a concentration in range from about 5% to about 60% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm.
Claim 110
Dependent Claim
152 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet being formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including water, a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof, an aggregate material, and an organic fibrous material, the aggregate material having a concentration in a range from about 40% to about 95% by volume of total solids in the inorganically filled mixture, the organic polymer binder and organic fibrous material together having a concentration in range from about 5% to about 60% by volume of total solids in the inorganically filled mixture, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, said sheet having a thickness in a range from about 0.01 mm to about 3 mm.
Claim 111
Dependent Claim
17 words
A sheet as defined in claim 107, said sheet having a maximum thickness of about 1 mm.
Claim 112
Dependent Claim
28 words
A sheet as defined in claim 107, wherein the water is included in an amount within the inorganically filled mixture such that the sheet made therefrom is mass-producible.
Claim 113
Dependent Claim
34 words
A sheet as defined in claim 107, wherein the water-dispersible organic polymer binder comprises a polysaccharide selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethylpropylcellulose, and mixtures or derivatives thereof.
Claim 114
Dependent Claim
30 words
A sheet as defined in claim 107, wherein the inorganic aggregate comprises individual particles that are size optimized in order to achieve a particle packing density greater than about 0.65.
Claim 115
Dependent Claim
32 words
A sheet as defined in claim 107, wherein the aggregate material is selected from the group consisting of clay, gypsum, calcium carbonate, mica, silica, alumina, sand, gravel, sandstone, limestone, and mixtures thereof.
Claim 116
Dependent Claim
18 words
A sheet as defined in claim 107, wherein the sheet has a thickness less than about 0.5 mm.
Claim 117
Dependent Claim
34 words
A sheet as defined in claim 107, wherein the water-dispersible organic polymer binder and fibrous material have a total concentration less than about 40% by volume of total solids in the inorganically filled mixture.
Claim 118
Dependent Claim
33 words
A sheet as defined in claim 107, wherein the fibrous material has a concentration in a range from about 5% to about 40% by volume of total solids in the inorganically filled mixture.
Claim 119
Dependent Claim
18 words
A sheet as defined in claim 107, wherein the sheet has been fashioned into an article of manufacture.
Claim 120
Dependent Claim
16 words
A sheet as defined in claim 107, wherein the sheet has been fashioned into a container.
Claim 121
Dependent Claim
21 words
A sheet as defined in claim 107, wherein the sheet comprises a continuous sheet that has been rolled onto a spool.
Claim 122
Dependent Claim
25 words
A sheet as defined in claim 107, wherein the sheet has a tensile strength in a range from about 5 MPa to about 40 MPa.
Claim 123
Dependent Claim
171 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including: water; a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof and having a concentration in a range from about 1% to about 50% by volume of total solids in the inorganically filled mixture; an inorganic aggregate having a concentration in a range from about 40% to about 98% by volume of total solids in the inorganically filled mixture; and a fibrous material having a concentration in a range from about 0.5% to about 50% by volume of total solids in the inorganically filled mixture, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, wherein the matrix degrades after prolonged exposure to water.
Claim 124
Dependent Claim
171 words
A sheet comprising a matrix reinforced with fibers, the matrix comprising a substantially homogeneous mixture of aggregate and organic binder, the sheet formed by removing a substantial quantity of water by evaporation from an inorganically filled mixture including: water; a water-dispersible organic polymer binder selected from the group consisting of polysaccharides, proteins, and mixtures or derivatives thereof and having a concentration in a range from about 1% to about 50% by volume of total solids in the inorganically filled mixture; an inorganic aggregate having a concentration in a range from about 40% to about 98% by volume of total solids in the inorganically filled mixture; and a fibrous material having a concentration in a range from about 0.5% to about 50% by volume of total solids in the inorganically filled mixture, said sheet having a thickness in a range from about 0.01 mm to about 3 mm, the fibrous material being substantially homogeneously dispersed throughout the matrix of aggregate and organic binder, wherein the matrix degrades after prolonged exposure to water.
Claim 125
Dependent Claim
17 words
A sheet as defined in claim 120, said sheet having a maximum thickness of about 1 mm.
Claim 126
Dependent Claim
28 words
A sheet as defined in claim 120, wherein the water is included in an amount within the inorganically filled mixture such that the sheet made therefrom is mass-producible.
Claim 127
Dependent Claim
34 words
A sheet as defined in claim 120, wherein the water-dispersible organic polymer binder comprises a polysaccharide selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethylpropylcellulose, and mixtures or derivatives thereof.
Claim 128
Dependent Claim
30 words
A sheet as defined in claim 120, wherein the inorganic aggregate comprises individual particles that are size optimized in order to achieve a particle packing density greater than about 0.65.
Claim 129
Dependent Claim
32 words
A sheet as defined in claim 120, wherein the aggregate material is selected from the group consisting of clay, gypsum, calcium carbonate, mica, silica, alumina, sand, gravel, sandstone, limestone, and mixtures thereof.
Claim 130
Dependent Claim
18 words
A sheet as defined in claim 120, wherein the sheet has a thickness less than about 0.5 mm.
Claim 131
Dependent Claim
34 words
A sheet as defined in claim 120, wherein the water-dispersible organic polymer binder and fibrous material have a total concentration less than about 40% by volume of total solids in the inorganically filled mixture.
Claim 132
Dependent Claim
33 words
A sheet as defined in claim 120, wherein the fibrous material has a concentration in a range from about 5% to about 40% by volume of total solids in the inorganically filled mixture.
Claim 133
Dependent Claim
18 words
A sheet as defined in claim 120, wherein the sheet has been fashioned into an article of manufacture.
Claim 134
Dependent Claim
16 words
A sheet as defined in claim 120, wherein the sheet has been fashioned into a container.
Claim 135
Dependent Claim
21 words
A sheet as defined in claim 120, wherein the sheet comprises a continuous sheet that has been rolled onto a spool.
Claim 136
Dependent Claim
25 words
A sheet as defined in claim 120, wherein the sheet has a tensile strength in a range from about 5 MPa to about 40 MPa.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1999-04-16 | 1999-10-16 | 2000-04-16 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2003-04-16 | 2003-10-16 | 2004-04-16 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2007-04-16 | 2007-10-16 | 2008-04-16 | $7700.00 | Window Closed / Lapsed |