Articles of manufacture fashioned from hydraulically settable sheets

• US 5,665,439 A
• Filed: 12/07/1993
• Issued: 09/09/1997
• Est. Priority Date: 08/11/1992
• Status: Expired due to Fees

• Current Assignee: E. Khashoggi Industries, LLC
• Original Assignee: E. Khashoggi Industries, LLC
• Inventors: Andersen, Per Just, Hodson, Simon K.
• Primary Examiner(s): McCamish, Marion E.
• Assistant Examiner(s): Copenheaver, Blaine R.
• Application Number:
  US08/164,012
• Time in Patent Office: 1,372 Days
• Field of Search: 428/703, 428/34.4, 428/34.5, 428/34.7, 428/36.4, 428/312.4, 106/210, 106/400, 106/713, 106/638, 106/730, 206/449, 206/524.3, 206/524.6, 206/524.7
• US Class Current: 428/34.5
• CPC Class Codes: B01F 23/511 characterised by the composition of the liquids or solids
• CPC Class Codes: B01F 23/56 by introducing solids in liquids, e.g. dispersing or dissolving
• CPC Class Codes: B05C 1/0826 the work being a web or sheets B05C1/0804, B05C1/0808, B05C1/0813, B05C1/0817, B05C1/0821, B05C1/10, B05C1/12 take precedence
• CPC Class Codes: B05C 1/0834 the coating roller co-operating with other rollers, e.g. dosing, transfer rollers
• CPC Class Codes: B05C 3/18 only one side of the work coming into contact with the liquid or other fluent material B05C3/02 takes precedence
• CPC Class Codes: B05C 5/0245 for applying liquid or other fluent material to a moving work of indefinite length, e.g. to a moving web B05C5/0241, B05C5/0254, B05C5/027, B05C5/0283 take precedence
• CPC Class Codes: B28B 1/00 Producing shaped prefabricated articles from the material using presses B28B3/00; shaping on moving conveyors B28B5/00; producing tubular articles B28B21/00 ; producing articles with embedded elements B28B23/00
• CPC Class Codes: B28B 1/52 specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cementby wrapping on to mandrels B28B1/42
• CPC Class Codes: B28B 11/00 Apparatus or processes for treating or working the shaped or preshaped articles specially adapted for tubular articles B28B21/92; decoration or surface treatment in general B05, B44; compacting concrete in situ in connection with building E04G21/06; drying F26
• CPC Class Codes: B28B 11/003 the shaping of preshaped articles, e.g. by bending B28B11/08 takes precedence
• CPC Class Codes: B28B 11/008 Blow moulding, e.g. with or without the use of a membrane
• CPC Class Codes: B28B 13/021 by fluid pressure acting directly on the material, e.g. using vacuum, air pressure
• CPC Class Codes: B28B 13/06 Removing the shaped articles from moulds by means incorporated in, or carried by, the moulds B28B7/10
• CPC Class Codes: B28B 23/0081 Embedding aggregates to obtain particular properties
• CPC Class Codes: B28B 23/0087 Lightweight aggregates for making lightweight articles
• CPC Class Codes: B28B 3/00 Producing shaped articles from the material by using presses shaping on moving conveyors B28B5/00; Presses specially adapted therefor presses in general B30B
• CPC Class Codes: B28B 3/02 wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
• CPC Class Codes: B28B 3/126 on material passing directly between the co-operating rollers
• CPC Class Codes: B28B 3/20 wherein the material is extruded extrusion moulding of plastics B29C48/00
• CPC Class Codes: B28B 3/2645 using means for inserting reinforcing members
• CPC Class Codes: B28B 7/42 : for heating or cooling, e.g. steam jackets , by means of treating agents acting directly on the moulding material
• CPC Class Codes: B28C 7/02 : Controlling the operation of the mixing
• CPC Class Codes: B29C 2043/3433 : using dispensing heads, e.g. extruders, placed over or apart from the moulds
• CPC Class Codes: B29C 2043/3689 : on a support table, e.g. flat disk-like tables having moulds on the periphery
• CPC Class Codes: B29C 2043/463 : corrugated, patterned or embossed surface
• CPC Class Codes: B29C 2043/464 : having projections or knives, e.g. for cutting-out or for forming local depressions
• CPC Class Codes: B29C 2043/466 : the rollers having specific shape, e.g. non cylindrical rollers, conical rollers
• CPC Class Codes: B29C 2049/4608 : Nitrogen
• CPC Class Codes: B29C 2791/006 : Using vacuum
• CPC Class Codes: B29C 2795/007 : after shaping
• CPC Class Codes: B29C 2949/0715 : the preform having one end closed
• CPC Class Codes: B29C 43/00 : Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor by liberation of internal stresses B29C61/006
• CPC Class Codes: B29C 43/003 : characterised by the choice of material
• CPC Class Codes: B29C 43/02 : of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 43/22 : of articles of indefinite length
• CPC Class Codes: B29C 43/222 : characterised by the shape of the surface
• CPC Class Codes: B29C 43/24 : Calendering
• CPC Class Codes: B29C 43/34 : Feeding the material to the mould or the compression means B29C43/085 takes precedence
• CPC Class Codes: B29C 43/46 : Rollers
• CPC Class Codes: B29C 44/3402 : Details of processes or apparatus for reducing environmental damage or for working-up compositions comprising inert blowing agents or biodegradable components
• CPC Class Codes: B29C 45/0013 : using fillers dispersed in the moulding material, e.g. metal particles
• CPC Class Codes: B29C 48/07 : Flat, e.g. panels
• CPC Class Codes: B29C 48/08 : flexible, e.g. films
• CPC Class Codes: B29C 48/12 : Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/13 : Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
• CPC Class Codes: B29C 49/0005 : characterised by the material
• CPC Class Codes: B29C 49/04 : Extrusion blow-moulding
• CPC Class Codes: B29C 49/06 : Injection blow-moulding
• CPC Class Codes: B29C 49/0691 : using sheet like material, e.g. sheet blow-moulding from joined sheets
• CPC Class Codes: B29C 49/6605 : Heating the article, e.g. for hot fill
• CPC Class Codes: B29C 51/002 : characterised by the choice of material
• CPC Class Codes: B29C 51/04 : Combined thermoforming and prestretching, e.g. biaxial stretching
• CPC Class Codes: B29C 51/08 : Deep drawing or matched-mould forming, i.e. using mechanical means only
• CPC Class Codes: B29C 51/082 : by shaping between complementary mould parts
• CPC Class Codes: B29C 51/10 : Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 53/063 : combined with folding
• CPC Class Codes: B29C 53/58 : helically
• CPC Class Codes: B29C 55/18 : by squeezing between surfaces, e.g. rollers
• CPC Class Codes: B29C 67/242 : Moulding mineral aggregates bonded with resin, e.g. resin concrete shaping ceramic compositions without binder or water-setting cementitious material B28B; compositions per se C04B
• CPC Class Codes: B29C 67/243 : for making articles of definite length
• CPC Class Codes: B29C 70/50 : for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• CPC Class Codes: B29K 2001/00 : Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29K 2003/00 : Use of starch or derivatives as moulding material
• CPC Class Codes: B29K 2005/00 : Use of polysaccharides or derivatives as moulding material
• CPC Class Codes: B29K 2089/00 : Use of proteins, e.g. casein, gelatine or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/16 : Fillers
• CPC Class Codes: B29L 2024/00 : Articles with hollow walls
• CPC Class Codes: B29L 2031/608 : Honeycomb structures
• CPC Class Codes: B29L 2031/712 : Containers; Packaging elements or accessories, Packages closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418
• CPC Class Codes: B32B 1/00 : Layered products having a non-planar shape
• CPC Class Codes: B32B 15/12 : of paper or cardboard
• CPC Class Codes: B32B 15/14 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2255/02 : on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/12 : on paper layer
• CPC Class Codes: B32B 2255/20 : Inorganic coating
• CPC Class Codes: B32B 2255/205 : Metallic coating
• CPC Class Codes: B32B 2255/24 : Organic non-macromolecular coating
• CPC Class Codes: B32B 2255/26 : Polymeric coating
• CPC Class Codes: B32B 2262/023 : Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2262/06 : Vegetal fibres
• CPC Class Codes: B32B 2262/10 : Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2262/14 : Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2264/0214 : Particles made of materials belonging to B32B27/00
• CPC Class Codes: B32B 2264/04 : Cellulosic particles, e.g. rayon
• CPC Class Codes: B32B 2264/06 : Vegetal particles
• CPC Class Codes: B32B 2264/12 : Mixture of at least two particles made of different materials
• CPC Class Codes: B32B 2307/41 : Opaque
• CPC Class Codes: B32B 2307/414 : Translucent
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2439/40 : Closed containers
• CPC Class Codes: B32B 2439/70 : Food packaging
• CPC Class Codes: B32B 27/04 : as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/10 : of paper or cardboard
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 29/002 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 37/00 : Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
• CPC Class Codes: B32B 37/12 : characterised by using adhesives
• CPC Class Codes: B32B 37/144 : using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding constructional features for tensioning B32B38/1825
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B65D 11/02 : of curved cross-section thermally insulated B65D81/3813
• CPC Class Codes: B65D 2301/20 : made of plastic material
• CPC Class Codes: B65D 2565/385 : especially suited for or with means facilitating recycling
• CPC Class Codes: B65D 43/162 : the container, the lid and the hinge being made of one piece B65D43/161 takes precedence
• CPC Class Codes: B65D 5/00 : Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper rigid pallets with side walls B65D19/02
• CPC Class Codes: B65D 65/38 : Packaging materials of special type or form
• CPC Class Codes: B65D 65/466 : Bio- or photodegradable packaging materials
• CPC Class Codes: C04B 14/06 : Quartz; Sand
• CPC Class Codes: C04B 14/064 : Silica aerogel
• CPC Class Codes: C04B 14/10 : Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/16 : porous, e.g. pumice
• CPC Class Codes: C04B 14/18 : Perlite
• CPC Class Codes: C04B 14/20 : Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/24 : porous, e.g. foamed glass
• CPC Class Codes: C04B 14/28 : of calcium
• CPC Class Codes: C04B 14/301 : porous or hollow
• CPC Class Codes: C04B 14/303 : Alumina
• CPC Class Codes: C04B 14/365 : Gypsum synthetic gypsum C04B18/0445, C04B18/064
• CPC Class Codes: C04B 16/02 : Cellulosic materials cellulosic waste materials, e.g. sawdust, rice husks, C04B18/24
• CPC Class Codes: C04B 18/022 : agglomerated by an organic binder
• CPC Class Codes: C04B 18/24 : Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper , cork
• CPC Class Codes: C04B 20/002 : Hollow or porous granular materials
• CPC Class Codes: C04B 20/0048 : Fibrous materials
• CPC Class Codes: C04B 2103/0079 : Rheology influencing agents
• CPC Class Codes: C04B 2103/304 : Air-entrainers
• CPC Class Codes: C04B 2111/00129 : Extrudable mixtures
• CPC Class Codes: C04B 2111/00413 : Materials having an inhomogeneous concentration of ingredients or irregular properties in different layers
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/00948 : for the fabrication of containers
• CPC Class Codes: C04B 2111/00965 : for household applications, e.g. use of materials as cooking ware
• CPC Class Codes: C04B 2111/27 : Water resistance, i.e. waterproof or water-repellent materials
• CPC Class Codes: C04B 22/04 : Metals, e.g. aluminium used as blowing agent
• CPC Class Codes: C04B 24/00 : Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
• CPC Class Codes: C04B 24/14 : Peptides; Proteins; Derivatives thereof
• CPC Class Codes: C04B 24/26 : obtained by reactions only involving carbon-to-carbon unsaturated bonds C04B24/243 takes precedence
• CPC Class Codes: C04B 24/38 : Polysaccharides or derivatives thereof C04B24/243 takes precedence
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• CPC Class Codes: C04B 26/00 : Compositions of mortars, concrete or artificial stone, containing only organic binders , e.g. polymer or resin concrete mechanical aspects of moulding polymer or resin concrete B29C67/242
• CPC Class Codes: C04B 26/02 : Macromolecular compounds
• CPC Class Codes: C04B 26/026 : Proteins or derivatives thereof
• CPC Class Codes: C04B 26/28 : Polysaccharides or derivatives thereof
• CPC Class Codes: C04B 26/285 : Cellulose or derivatives thereof C04B26/24 takes precedence
• CPC Class Codes: C04B 28/00 : Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: C04B 38/0006 : Honeycomb structures from one or more corrugated sheets by winding or stacking C04B38/0083
• CPC Class Codes: C04B 38/02 : by adding chemical blowing agents
• CPC Class Codes: C04B 40/00 : Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability active ingredients C04B22/00 - C04B24/00; hardening of a well-defined composition C04B26/00 - C04B28/00; making porous, cellular or lightening C04B38/00; mechanical aspects B28, e.g. conditioning the materials prior to shaping B28B17/02
• CPC Class Codes: C04B 40/0028 : Aspects relating to the mixing step of the mortar preparation
• CPC Class Codes: C04B 40/006 : involving the elimination of excess water from the mixture
• CPC Class Codes: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/45 : Coating or impregnating paints C09D, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements ion-implantation C04B41/0027
• CPC Class Codes: C04B 41/61 : Coating or impregnation
• CPC Class Codes: C08L 1/28 : Alkyl ethers
• CPC Class Codes: C08L 2666/02 : Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/04 : Macromolecular compounds according to groups C08L7/00 - C08L49/00, or C08L55/00 - C08L57/00; Derivatives thereof
• CPC Class Codes: C08L 3/00 : Compositions of starch, amylose or amylopectin or of their derivatives or degradation products
• CPC Class Codes: C08L 3/02 : Starch; Degradation products thereof, e.g. dextrin
• CPC Class Codes: C08L 5/02 : Dextran; Derivatives thereof
• CPC Class Codes: C08L 5/12 : Agar or agar-agar , i.e. mixture of agarose and agaropectin; Derivatives thereof
• CPC Class Codes: C08L 5/14 : Hemicellulose; Derivatives thereof
• CPC Class Codes: C08L 89/06 : derived from leather or skin , e.g. gelatin
• CPC Class Codes: C08L 97/02 : Lignocellulosic material, e.g. wood, straw or bagasse manufacture of articles made from lignocellulosic material by dry processes B27N
• CPC Class Codes: E05D 1/02 : made of one piece
• CPC Class Codes: E05Y 2900/602 : for containers
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/1314 : Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
• CPC Class Codes: Y10T 428/1321 : Polymer or resin containing [i.e., natural or synthetic]
• CPC Class Codes: Y10T 428/1372 : Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/249968 : Of hydraulic-setting material

Abstract

Articles of manufacture fashioned from sheets having a hydraulically settable matrix are disclosed, particularly food containers, beverage containers and packaging containers. 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.

Claims

1. An article of manufacture comprising at least a portion of a substantially hardened hydraulically settable sheet, the sheet being formed from a hydraulically settable mixture comprising a hydraulically settable binder, rheology-modifying agent, fibers, and water, wherein the fibers are substantially homogeneously dispersed throughout the hydraulically settable sheet such that the sheet can be bent, folded or rolled to significantly mechanically deform the sheet after the hydraulically settable sheet has been substantially dried during formation of the article of manufacture without complete rupture of the hydraulically settable sheet, said hydraulically settable sheet having a maximum thickness of about 5 mm.

2. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet has a thickness in a range from about 0.01 mm to about 5 mm.

3. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet has a thickness up to about 3 mm.

4. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet has a thickness up to about 1 mm.

5. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet has a thickness in a range from about 0.5 mm to about 1 mm.

6. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet has a thickness in a range from about 0.01 mm to about 0.5 mm.

7. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent increases the yield stress of the hydraulically settable mixture and the cohesive strength of the sheet formed therefrom.

8. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent is included within the hydraulically settable mixture in an amount in a range from about 0.1% to about 30% by volume of total solids of the hydraulically settable mixture.

9. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent is included within the hydraulically settable mixture in an amount in a range from about 0.5% to about 15% by volume of total solids of the hydraulically settable mixture.

10. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent is included within the hydraulically settable mixture in an amount in a range from about 1% to about 10% by volume of total solids of the hydraulically settable mixture.

11. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent is included within the hydraulically settable mixture in an amount in a range from about 2% to about 5% by volume of total solids of the hydraulically settable mixture.

12. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent comprises a cellulosic material or a derivative thereof.

13. An article of manufacture as defined in claim 12, wherein the cellulosic material is selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethylpropylcellulose, and mixtures or derivatives thereof.

14. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent comprises a starch or a derivative thereof.

15. An article of manufacture as defined in claim 14, wherein the starch 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.

16. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent comprises a protein or a derivative thereof.

17. An article of manufacture as defined in claim 16, wherein the protein is selected from the group consisting of prolamine, collagen, gelatin, glue, casein, and mixtures or derivatives thereof.

18. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent comprises a synthetic organic material.

19. An article of manufacture as defined in claim 18, wherein the synthetic organic material 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.

20. An article of manufacture as defined in claim 1, wherein the rheology-modifying agent comprises a material 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.

21. An article of manufacture as defined in claim 1, wherein the fibers increase the tensile strength of the article of manufacture.

22. An article of manufacture as defined in claim 1, wherein the fibers have a concentration in a range from about 0.2% to about 50% by volume of total solids in the hydraulically settable mixture.

23. An article of manufacture as defined in claim 1, wherein the fibers have a concentration in a range from about 1% to about 30% by volume of total solids in the hydraulically settable mixture.

24. An article of manufacture as defined in claim 1, wherein the fibers have a concentration in a range from about 5% to about 20% by volume of total solids in the hydraulically settable mixture.

25. An article of manufacture as defined in claim 1, wherein the fibers include organic fibers.

26. An article of manufacture as defined in claim 25, wherein the organic fibers are selected from the group of fibers consisting of hemp, cotton, bagasse, abaca, southern pine, southern hardwood, and mixtures thereof.

27. An article of manufacture as defined in claim 1, wherein the fibers include inorganic fibers.

28. An article of manufacture as defined in claim 27, wherein the inorganic fibers are selected from the group of fibers consisting of glass, silica, ceramic, carbon, metal, and mixtures thereof.

29. An article of manufacture as defined in claim 1, wherein the fibers include a mixture of different fibers that vary in strength and flexibility.

30. An article of manufacture as defined in claim 1, wherein the hydraulically settable mixture includes an aggregate material.

31. An article of manufacture as defined in claim 30, wherein the aggregate material comprises a lightweight aggregate.

32. An article of manufacture as defined in claim 31, wherein the lightweight aggregate decreases the density and increases the insulation ability of the hydraulically settable sheet.

33. An article of manufacture as defined in claim 31, wherein the lightweight aggregate is selected from the group consisting of perlite, cork, vermiculite, hollow glass spheres, porous ceramic spheres, lightweight expanded geologic materials, pumice, and mixtures thereof.

34. An article of manufacture as defined in claim 30, wherein the aggregate material comprises a higher density aggregate.

35. An article of manufacture as defined in claim 34, wherein the higher density aggregate increases the strength and mass of the hydraulically settable sheet.

36. An article of manufacture as defined in claim 34, wherein the higher density aggregate is selected from the group consisting of clay, gypsum, calcium carbonate, mica, silica, alumina, sand, gravel, sandstone, limestone, partially hydrated cement materials, and mixtures thereof.

37. An article of manufacture as defined in claim 30, wherein the aggregate material comprises an organic aggregate selected from the group consisting of seeds, starches, gelatins, agar materials, and mixtures or derivatives thereof.

38. An article of manufacture as defined in claim 30, wherein the aggregate material has a concentration up to about 90% by volume of total solids of the hydraulically settable mixture.

39. An article of manufacture as defined in claim 30, wherein the aggregate material has a concentration in a range from about 5% to about 70% by volume of total solids of the hydraulically settable mixture.

40. An article of manufacture as defined in claim 30, wherein the aggregate material has a concentration in a range from about 20% to about 50% by volume of total solids of the hydraulically settable mixture.

41. An article of manufacture as defined in claim 30, wherein the aggregate material comprises individual particles that are size optimized in order to achieve a predetermined particle packing density of the aggregate material.

42. An article of manufacture as defined in claim 1, wherein the hydraulically settable binder comprises a hydraulic cement.

43. An article of manufacture as defined in claim 42, wherein the hydraulic cement comprises portland cement.

44. An article of manufacture as defined in claim 1, wherein the hydraulically settable binder comprises gypsum hemihydrate.

45. An article of manufacture as defined in claim 1, wherein the hydraulically settable binder has a concentration in a range from about 2% to about 60% by volume of total solids of the hydraulically settable mixture.

46. An article of manufacture as defined in claim 1, wherein the hydraulically settable binder has a concentration in a range from about 4% to about 40% by volume of total solids of the hydraulically settable mixture.

47. An article of manufacture as defined in claim 1, wherein the hydraulically settable binder has a concentration in a range from about 5% to about 30% by volume of total solids of the hydraulically settable mixture.

48. An article of manufacture as defined in claim 1, wherein the water has a concentration in a range from about 5% to about 50% by volume of the hydraulically settable mixture.

49. An article of manufacture as defined in claim 1, wherein the article of manufacture includes a second sheet laminated to the hydraulically settable sheet.

50. An article of manufacture as defined in claim 49, wherein the second sheet is a hydraulically settable sheet.

51. An article of manufacture as defined in claim 49, wherein the second sheet is a nonhydraulically settable sheet.

52. An article of manufacture as defined in claim 49, wherein the second sheet is selected from the group consisting of organic polymer sheets, metal foil sheets, fiber sheets, ceramic sheets, ionomer sheets, elastomeric sheets, plastic sheets, cellophane sheets, nylon sheets, wax sheets, metallized film sheets, and combinations thereof.

53. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet is corrugated.

54. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet is creped.

55. An article of manufacture as defined in claim 1, further including a coating on at least a portion of the hydraulically settable sheet.

56. An article of manufacture as defined in claim 55, wherein the coating increases the ability of the hydraulically settable matrix to resist penetration of water into the hydraulically settable sheet.

57. An article of manufacture as defined in claim 55, wherein the coating enhances the ability of the hydraulically settable sheet to be liquid-tight.

58. An article of manufacture as defined in claim 55, wherein the coating enhances the ability of the hydraulically settable sheet to be pressure-tight.

59. An article of manufacture as defined in claim 55, wherein the coating increases the ability of the hydraulically settable sheet to resist penetration of grease or oils into the hydraulically settable sheet.

60. An article of manufacture as defined in claim 55, wherein the coating increases the flexibility of the hydraulically settable sheet.

61. An article of manufacture having a hydraulically settable sheet as defined in claim 55, wherein the coating is safe for use with foods or beverages.

62. An article of manufacture having a hydraulically settable matrix as defined in claim 55, wherein the coating comprises a biodegradable material.

63. An article of manufacture having a hydraulically settable matrix as defined in claim 55, wherein the coating is selected from the group consisting of edible oils, melamine, polyvinyl chloride, polyvinyl alcohol, polyvinyl acetate, polyacrylate, hydroxypropylmethylcellulose, polyethylene glycol, acrylics, polyurethane, polylactic acid, starch, soy bean protein, polyethylene, synthetic polymers, waxes, elastomers, and mixtures or derivatives thereof.

64. An article of manufacture having a hydraulically settable matrix as defined in claim 55, wherein the coating is selected from the group consisting of sodium silicate, calcium carbonate, aluminum oxide, silicon oxide, clay, kaolin, ceramic, and mixtures or derivatives thereof.

65. An article of manufacture as defined in claim 1, wherein a surface of the article includes an indicia.

66. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet includes a score cut.

67. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet includes a score.

68. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet includes a perforation.

69. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet includes a slot.

70. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet is translucent.

71. An article of manufacture as defined in claim 1, wherein the hydraulically settable sheet is opaque.

72. An article of manufacture as defined in claim 1, wherein the article of manufacture is a container.

73. An article of manufacture as defined in claim 1, wherein the article of manufacture is a food or beverage container.

74. An article of manufacture as defined in claim 1, wherein the article of manufacture comprises a packaging container.

75. An article of manufacture as defined in claim 1, wherein the article of manufacture includes a seam.

76. An article of manufacture as defined in claim 1, wherein the article of manufacture includes mechanical interlocking devices.

77. An article of manufacture as defined in claim 1 wherein the article is a cup.

78. An article of manufacture as defined in claim 1, wherein the article is a two piece cup comprising a sidewall and a bottom portion.

79. An article of manufacture as defined in claim 78, wherein the sidewall has a seam.

80. An article of manufacture as defined in claim 78, further including a seam between the sidewall and the bottom portion.

81. An article of manufacture as defined in claim 78, wherein the cup includes a lip so as to strengthen the cup.

82. An article of manufacture as defined in claim 77, wherein the cup is a pleated cup.

83. An article of manufacture as defined in claim 77, wherein the cup is a cone cup.

84. An article of manufacture as defined in claim 1, wherein the article of manufacture is a hinged clam-shell container.

85. An article of manufacture as defined in claim 1, wherein the article of manufacture is a carton.

86. An article of manufacture as defined in claim 1, wherein the article of manufacture is a milk carton.

87. An article of manufacture as defined in claim 1, wherein the article of manufacture is a fruit juice container.

88. An article of manufacture as defined in claim 1, wherein the article of manufacture is a container derived from a laminated sheet.

89. An article of manufacture as defined in claim 88, wherein the laminated container is in the form of a corrugated box.

90. An article of manufacture as defined in claim 1 wherein the article of manufacture is a fast-food carryout box.

91. An article of manufacture as defined in claim 1, wherein the article of manufacture is a french fry container.

92. An article of manufacture as defined in claim 1, wherein the article of manufacture is a carrier for beverage containers.

93. An article of manufacture as defined in claim 1, wherein the article of manufacture is a box.

94. An article of manufacture as defined in claim 1, wherein the article of manufacture is a bag.

95. An article of manufacture as defined in claim 1, wherein the article of manufacture is an envelope.

96. An article of manufacture as defined in claim 1, wherein the article of manufacture is a tube.

97. An article of manufacture as defined in claim 96, wherein the tube comprises a convoluted hydraulically settable sheet.

98. An article of manufacture as defined in claim 96, wherein the tube comprises a spiral wound hydraulically settable sheet.

99. An article of manufacture as defined in claim 96, further comprising continuous fibers wrapped around the tube.

100. An article of manufacture as defined in claim 96, further comprising continuous fibers woven around the tube.

101. An article of manufacture as defined in claim 96, further comprising continuous fibers integral in the hydraulically settable sheet comprising the tube.

102. An article of manufacture as defined in claim 96, further comprising closure means for engaging an open end of the tube.

103. An article of manufacture as defined in claim 102, wherein the tube has at least one open end engaged by the closure means, the tube being selected from the group consisting of a can, a frozen juice concentrate container, a potato chip container, an ice cream container, a salt container, a detergent container, a motor oil container, and a mailing tube.

104. An article of manufacture as defined in claim 96, wherein the tube comprises a tube having two open ends, the tube being selected from the group consisting of a straw, a sleeve, and a sheet roll.

105. An article of manufacture as defined in claim 1, wherein the article of manufacture is a plate.

106. An article of manufacture as defined in claim 1, wherein the article of manufacture is a platter.

107. An article of manufacture as defined in claim 1, wherein the article of manufacture is a tray.

108. An article of manufacture as defined in claim 1, wherein the article of manufacture is a bowl.

109. An article of manufacture as defined in claim 1, wherein the article of manufacture is an egg carton.

110. An article of manufacture as defined in claim 1, wherein the article of manufacture is a lid.

111. An article of manufacture as defined in claim 1, wherein the article of manufacture is a rigid setup box.

112. An article of manufacture as defined in claim 111, further comprising a cover sheet wrapped around the rigid setup box.

113. An article of manufacture as defined in claim 111, wherein the rigid setup box has a box body and a lid.

114. An article of manufacture as defined in claim 1, wherein the article of manufacture is a carded packaging container having a support card and a cover.

115. An article of manufacture as defined in claim 114, wherein the cover is a translucent hydraulically settable sheet.

116. An article of manufacture as defined in claim 114, wherein the cover includes a plastic cover.

117. An article of manufacture as defined in claim 116, wherein the cover includes a rigid blister.

118. An article of manufacture as defined in claim 116, wherein the cover includes a plastic skin cover.

119. An article of manufacture as defined in claim 1, wherein the article of manufacture is a pouch.

120. An article of manufacture as defined in claim 1, wherein the article of manufacture is a container and a liner.

121. An article of manufacture as defined in claim 1, wherein the article of manufacture is a magazine.

122. An article of manufacture as defined in claim 1, wherein the article of manufacture is a book cover.

123. An article of manufacture as defined in claim 1, wherein the article of manufacture is a notebook.

124. An article of manufacture as defined in claim 1, wherein the article of manufacture is substantially flat.

125. An article of manufacture as defined in claim 1, wherein the article of manufacture is substantially curved.

126. An article of manufacture as defined in claim 1, wherein the article of manufacture has an oval cross-section.

127. An article of manufacture as defined in claim 1, wherein the article of manufacture has a rectangular cross-section.

128. An article of manufacture as defined in claim 1, wherein the article of manufacture has an triangular cross-section.

129. An container comprising at least a portion of a substantially hardened hydraulically settable sheet, the sheet being formed from a hydraulically settable mixture comprising a hydraulically settable binder, rheology-modifying agent, fibers, and water, wherein the fibers are substantially homogeneously dispersed throughout the hydraulically settable sheet such that the sheet can be bent, folded or rolled to significantly mechanically deform the sheet after the hydraulically settable sheet has been substantially dried during formation of the container without complete rupture of the hydraulically settable sheet, said hydraulically settable sheet having a maximum thickness of about 1 cm.

130. A container as defined in claim 129, wherein the container comprises a food container.

131. A container as defined in claim 129, wherein the container comprises a beverage container.

132. A container as defined in claim 129, wherein the container comprises a packaging container.

133. A container as defined in claim 129, wherein the hydraulically settable sheet has been convoluted into a desired shape of the container.

134. A container as defined in claim 129, wherein the hydraulically settable sheet has been spiral wound into a desired shape of the container.

135. An article of manufacture comprising at least a portion of a substantially dried hydraulically settable sheet, the sheet being formed from a hydraulically settable mixture comprising a hydraulically settable binder, water, an aggregate material, fibers, and a rheology-modifying agent, wherein the fibers are substantially homogeneously dispersed throughout the hydraulically settable sheet such that the sheet can be bent, folded or rolled to significantly mechanically deform the sheet after the hydraulically settable sheet has been substantially dried during fashioning of the article of manufacture without complete rupture of the hydraulically settable sheet, said hydraulically settable sheet having a maximum thickness of about 5 mm.

136. An article of manufacture as defined in claim 135, wherein the hydraulically settable sheet has been convoluted into the desired shape of the article.

137. An article of manufacture as defined in claim 135, wherein the article comprises a food or beverage container.

138. An article of manufacture as defined in claim 135, wherein the article of manufacture comprises a box.

139. An container comprising at least a portion of a substantially dried hydraulically settable sheet, the sheet being formed from a hydraulically settable mixture comprising a hydraulically settable binder, water, an aggregate material, fibers, and a rheology-modifying agent, wherein the fibers are substantially homogeneously dispersed throughout the hydraulically settable sheet such that the sheet can be bent, folded or rolled to significantly mechanically deform the sheet after the hydraulically settable sheet has been substantially dried during fashioning of the container without complete rupture of the hydraulically settable sheet, said hydraulically settable sheet having a maximum thickness of about 1 cm.

140. A container as defined in claim 139, wherein the container further includes a coating on at least a portion of the hydraulically settable sheet.

141. A container as defined in claim 139, wherein the container comprises a cup.

142. A container as defined in claim 139, wherein the container comprises a box.

143. An article of manufacture comprising at least a portion of a substantially hardened hydraulically settable sheet, the sheet being formed from a hydraulically settable mixture comprising a hydraulically settable binder, rheology-modifying agent, fibers, and water, the hydraulically settable sheet being characterized in that it can be bent, folded or rolled to significantly mechanically deform the sheet after the hydraulically settable sheet has been substantially dried and during formation of the article of manufacture without complete rupture of the hydraulically settable sheet, the hydraulically settable sheet being corrugated.

144. An article of manufacture comprising at least a portion of a substantially hardened hydraulically settable sheet, the sheet being formed from a hydraulically settable mixture comprising a hydraulically settable binder, rheology-modifying agent, fibers, and water, the hydraulically settable sheet being characterized in that it can be bent, folded or rolled to significantly mechanically deform the sheet after the hydraulically settable sheet has been substantially dried and during formation of the article of manufacture without complete rupture of the hydraulically settable sheet, wherein the article is a carton.