Articles of manufacture and methods for manufacturing laminate structures including inorganically filled sheets

• US 5,830,548 A
• Filed: 04/09/1996
• Issued: 11/03/1998
• Est. Priority Date: 08/11/1992
• Status: Expired due to Term

• 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:
  US08/630,210
• Time in Patent Office: 938 Days
• Field of Search: 428/34.5, 428/35.6, 428/35.7, 428/36.4, 428/36.5, 428/53, 428/152, 428/182, 428/220, 428/312.4, 428/317.9, 428/339, 428/532, 428/906, 428/35.8, 428/36.6 , 428/36.91, 428/43, 428/116, 428/155, 428/323, 206/524.3, 206/524.7, 206/819
• US Class Current: 428/36.4
• 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 23/00 Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objectsB28B21/00 takes precedence; in units for prefabricated buildings B28B7/22
• 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 2043/463 : corrugated, patterned or embossed surface
• CPC Class Codes: B29C 2049/4608 : Nitrogen
• CPC Class Codes: B29C 2795/007 : after shaping
• 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 43/08 : with circular movement , e.g. mounted on rolls, turntables
• CPC Class Codes: B29C 43/22 : of articles of indefinite length
• 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 48/0011 : combined with compression moulding
• CPC Class Codes: B29C 48/0012 : combined with shaping by internal pressure generated in the material, e.g. foaming
• CPC Class Codes: B29C 48/0017 : combined with blow-moulding or thermoforming
• CPC Class Codes: B29C 48/0019 : combined with shaping by flattening, folding or bending
• CPC Class Codes: B29C 48/0022 : combined with cutting
• CPC Class Codes: B29C 48/07 : Flat, e.g. panels
• CPC Class Codes: B29C 48/08 : flexible, e.g. films
• CPC Class Codes: B29C 48/13 : Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
• CPC Class Codes: B29C 49/6605 : Heating the article, e.g. for hot fill
• CPC Class Codes: B29C 51/04 : Combined thermoforming and prestretching, e.g. biaxial stretching
• 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 67/24 : characterised by the choice of material
• 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 70/50 : for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
• 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 2105/04 : cellular or porous
• 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: B29L 2031/7132 : Bowls, Cups, Glasses
• CPC Class Codes: B31B 2105/0022 : Making boxes from tubular webs or blanks, e.g. with separate bottoms, including tube or bottom forming operations
• CPC Class Codes: B31B 50/32 : in circular paths
• CPC Class Codes: B31D 1/005 : making bottoms or caps
• CPC Class Codes: B32B 13/02 : with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 27/04 : as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/20 : using fillers, pigments, thixotroping agents
• 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: B65D 2565/385 : especially suited for or with means facilitating recycling
• 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 14/064 : Silica aerogel
• CPC Class Codes: C04B 14/10 : Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/106 : Kaolin
• CPC Class Codes: C04B 14/16 : porous, e.g. pumice
• CPC Class Codes: C04B 14/185 : expanded
• CPC Class Codes: C04B 14/20 : Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/22 : Glass ; Devitrified glass
• 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 14/42 : Glass
• CPC Class Codes: C04B 18/08 : Flue dust , i.e. fly ash
• CPC Class Codes: C04B 18/146 : Silica fume
• CPC Class Codes: C04B 20/0048 : Fibrous materials
• CPC Class Codes: C04B 2111/00612 : as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/802 : White cement
• CPC Class Codes: C04B 24/383 : Cellulose or derivatives thereof
• 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 28/04 : Portland cements
• CPC Class Codes: C04B 38/10 : by using foaming agents C04B38/02 takes precedenceor by using mechanical means, e.g. adding preformed foam
• CPC Class Codes: C08L 1/28 : Alkyl ethers
• CPC Class Codes: C08L 1/286 : substituted with acid radicals, e.g. carboxymethyl cellulose [CMC] C08L1/282 takes precedence
• 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: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10S 428/906 : Roll or coil
• CPC Class Codes: Y10T 428/1355 : Elemental metal containing [e.g., substrate, foil, film, coating, etc.]
• CPC Class Codes: Y10T 428/1372 : Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/1379 : Contains vapor or gas barrier, polymer derived from vinyl chloride or vinylidene chloride, or polymer containing a vinyl alcohol unit
• CPC Class Codes: Y10T 428/1393 : Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/15 : Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/24446 : Wrinkled, creased, crinkled or creped
• CPC Class Codes: Y10T 428/24471 : Crackled, crazed or slit
• CPC Class Codes: Y10T 428/24694 : Parallel corrugations
• CPC Class Codes: Y10T 428/249986 : Void-containing component contains also a solid fiber or solid particle
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate

Abstract

Compositions and methods for manufacturing composite laminate structures incorporating sheets having a moldable matrix are disclosed. Suitable compositions are prepared by mixing together a water dispersable organic binder, water, and appropriate additives (such as aggregates and fibers) 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 calendaring the sheet using a set of rollers. The calendered sheets are dried in an accelerated manner to form a substantially hardened sheet. The drying process is performed by heated rollers and/or a drying chamber. The inorganically filled 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 before or after being incorporated into composite laminate structures. Such composite laminate structures have especial utility in the mass production of containers, particularly food and beverage containers.

Claims

1. An article of manufacture having a laminate structure comprising an inorganically filled sheet and at least one other sheet laminated to the inorganically filled sheet, the inorganically filled sheet including an organic binder selected from the group consisting of polysaccharides, proteins, water soluble polymers, and mixtures and derivatives thereof, a fibrous material, and an inorganic aggregate filler in an amount in a range from about 20% to about 90% by weight of solids in the inorganically filled sheet, said inorganically filled sheet having a thickness less than about 1 cm.

2. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has physical characteristics which differ from the physical characteristics of the at least one other sheet.

3. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has chemical characteristics which differ from the chemical characteristics of the at least one other sheet.

4. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet and the at least one other sheet have physical and chemical properties which combine to produce a synergistic result in the laminate structure.

5. An article of manufacture as defined in claim 1, wherein the at least one other sheet creates a barrier to fluid within the laminate structure.

6. An article of manufacture as defined in claim 1, wherein the laminate structure is substantially impermeable to gas.

7. An article of manufacture as defined in claim 1, wherein the laminate structure provides a barrier to electromagnetic radiation.

8. An article of manufacture as defined in claim 1, wherein the at least one other sheet comprises a metallic material.

9. An article of manufacture as defined in claim 1, wherein the laminate structure provides a fire retardant barrier.

10. An article of manufacture as defined in claim 9, wherein the fire retardant barrier is essentially noncombustible.

11. An article of manufacture as defined in claim 1, wherein the organic binder comprises a cellulose-based material.

12. An article of manufacture as defined in claim 11, wherein the cellulose-based material is selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethyl-propylcellulose, and mixtures or derivatives thereof.

13. An article of manufacture as defined in claim 1, wherein the organic binder comprises a starch-based material.

14. An article of manufacture as defined in claim 13, wherein the starch-based material 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.

15. An article of manufacture as defined in claim 1, wherein the organic binder comprises a polysaccharide material selected from the group consisting of alginic acid, phycocolloids, agar, gum arabic, guar gum, locust bean gum, gum caraya, gum tragacanth, and mixtures or derivatives thereof.

16. An article of manufacture as defined in claim 1, wherein the organic binder comprises a protein-based material selected from the group consisting of prolamine, collagen, casein, and mixtures or derivatives thereof.

17. An article of manufacture as defined in claim 1, wherein the organic binder further comprises a synthetic organic material 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, ethyleneoxide polymers, polylactic acid, synthetic clay, latex, and mixtures or derivatives thereof.

18. An article of manufacture as defined in claim 1, wherein the organic binder has a concentration in a range from about 2% to about 40% by weight of total solids in the inorganically field sheet.

19. An article of manufacture as defined in claim 1, wherein the organic binder has a concentration in a range from about 5% to about 30% by weight of total solids in the inorganically filled sheet.

20. An article of manufacture as defined in claim 1, wherein the inorganic aggregate filler is selected from the group consisting of perlite, vermiculite, sand, gravel, rock, limestone, sandstone, glass beads, aerogel, xerogels, seagel, mica, clay, synthetic clay, alumina, fly ash, fumed silica, fused silica, tabular alumina, kaolin, microspheres, hollow glass spheres, porous ceramic spheres, gypsum dihydrate, calcium carbonate, calcium aluminate, cork, fiber glass, lightweight polymers, xonotlite, lightweight expanded clays, hydrated cement particles, unhydrated cement particles, pumice, exfoliated rock, and mixtures or derivatives thereof.

21. An article of manufacture as defined in claim 1, wherein the inorganic aggregate filler has a concentration in a range from about 30% to about 80% by weight of total solids in the inorganically filled sheet.

22. An article of manufacture as defined in claim 1, wherein the inorganic aggregate filler has a concentration in a range from about 40% to about 70% by weight of total solids in the inorganically filled sheet.

23. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet further comprises an organic aggregate.

24. An article of manufacture as defined in claim 23, wherein the organic aggregate is selected from the group consisting of seeds, starches, gelatins, agar materials, and mixtures or derivatives thereof.

25. An article of manufacture as defined in claim 23, wherein the organic aggregate is a light-weight polyethylene having a concentration between about 3% to about 6% by weight of total solids in the inorganically filled sheet.

26. An article of manufacture as defined in claim 1, wherein the fibrous material comprises organic fibers.

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

28. An article of manufacture as defined in claim 1, wherein the fibrous material comprises inorganic fibers.

29. An article of manufacture as defined in claim 28, 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.

30. An article of manufacture as defined in claim 1, wherein the fibrous material includes individual fibers having an average aspect ratio of at least about 10:

1.

31. An article of manufacture as defined in claim 1, wherein the fibrous material includes individual fibers having an average aspect ratio of at least about 100:

1.

32. An article of manufacture as defined in claim 1, wherein the fibrous material includes individual fibers having an average aspect ratio of at least about 200:

1.

33. An article of manufacture as defined in claim 1, wherein the fibrous material has a concentration in a range from about 0.2% to about 60% by weight of total solids in the inorganically filled sheet.

34. An article of manufacture as defined in claim 1, wherein the fibrous material has a concentration in a range from about 1% to about 40% by weight of total solids in the inorganically filled sheet.

35. An article of manufacture as defined in claim 1, wherein the fibrous material has a concentration in a range from about 5% to about 20% by weight of total solids in the inorganically filled sheet.

36. An article of manufacture as defined in claim 1, wherein the fibrous material comprises a mixture of different fibers having varying strengths and flexibilities.

37. An article of manufacture as defined in claim 1, wherein the fibrous material increases the flexibility of the inorganically filled sheet.

38. An article of manufactured as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially random orientation within the inorganically filled sheet.

39. An article of manufacture as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially unidirectional orientation within the inorganically filled sheet.

40. An article of manufacture as defined in claim 1, wherein the fibrous material comprises individual fibers which have a substantially bidirectional orientation within the inorganically filled sheet.

41. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet is water degradable.

42. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet is readily degradable into environmentally neutral components.

43. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a tensile strength in a range from about 0.05 MPa to about 70 MPa.

44. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a tensile strength in a range from about 5 MPa to about 40 MPa.

45. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a tensile strength to density ratio in a range from about 2 MPa-cm³ /g to about 200 MPa-cm³ /g.

46. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a tensile strength to density ratio in a range from about 3 MPa-cm³ /g to about 50 Mpa-cm³ /g.

47. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a maximum density of about 2 g/cm³.

48. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a density in a range from about 0.4 g/cm³ to about 1.5 g/cm³.

49. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet can elongate in a range from about 0.5% to about 8% without completely fracturing.

50. An article of manufacture as defined in claim 1, wherein at least one of the inorganically filled sheet and the one other sheet is corrugated.

51. An article of manufacture as defined in claim 1, wherein at least one of the inorganically filled sheet and the one other sheet is creped.

52. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has been compacted.

53. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has been calendared.

54. An article of manufacture as defined in claim 1, further comprising a coating on at least a portion of the inorganically filled sheet.

55. An article of manufacture as defined in claim 1, further comprising an adhesive between the inorganically filled sheet and the one other sheet.

56. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has been resin impregnated.

57. An article of manufacture as defined in claim 1, wherein the laminate structure further comprises a cavity within the laminate structure, wherein the cavity is formed by a structural element within the cavity.

58. An article of manufacture as defined in claim 57, wherein the cavity is formed between the inorganically filled sheet and the one other sheet.

59. An article of manufacture as defined in claim 57, wherein the cavity comprises a material selected from the group consisting of a fluid, a gas, a granular particulate material, a solid material, and mixtures thereof.

60. An article of manufacture as defined in claim 1, wherein the laminate structure further comprises:

means for adhering the inorganically filled sheet and the one other sheet together to form the laminate structure.

61. An article of manufacture as defined in claim 60, wherein the one other sheet is wet bond laminated to the inorganically filled sheet.

62. An article of manufacture as defined in claim 60, wherein the one other sheet is dry bond laminated to the inorganically filled sheet.

63. An article of manufacture as defined in claim 60, wherein the one other sheet is thermal bond laminated to the inorganically filled sheet.

64. An article of manufacture as defined in claim 60, wherein the one other sheet is cementitious bond laminated to the inorganically filled sheet.

65. An article of manufacture as defined in claim 1, wherein at least one of the inorganically filled sheet or the other sheet is porous.

66. An article of manufacture as defined in claim 1, wherein at least one of the inorganically filled sheet or the other sheet is impervious.

67. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet has a thickness less than about 3 mm.

68. An article of manufacture as defined in claim 1, wherein the laminate structure is mass producible.

69. An article of manufacture as defined in claim 1, wherein the inorganically filled sheet includes finely dispersed air voids.

70. An article of manufacture as defined in claim 1, wherein the laminate structure is fashioned into a container.

71. An article of manufacture as defined in claim 1, wherein the laminate structure has a tubular shape.

72. An article of manufacture as defined in claim 1, wherein the laminate structure is water degradable.

73. An article of manufacture as defined in claim 1, wherein the laminate structure includes a score cut.

74. An article of manufacture as defined in claim 1, wherein the laminate structure includes a perforation.

75. An article of manufacture as defined in claim 1, wherein the laminate structure comprises a continuous inorganically filled sheet that has been rolled onto a spool.

76. An article of manufacture as defined in claim 1, wherein the one other sheet is selected from the group consisting of metallic foils, textile fabrics, paper, paperboard, foam, sheets that form bonding with increased temperatures, inorganically filed sheets, plastics, and mixtures or derivatives thereof.

77. An article of manufacture as defined in claim 1, wherein the laminate structure is photosensitive.

78. An article of manufacture as defined in claim 1, wherein the laminate structure is translucent.

79. An article of manufacture as defined in claim 1, wherein the laminate structure is transparent.

80. An article of manufacture as defined in claim 1, wherein the laminate structure is water-proof.

81. An article of manufacture as defined in claim 1, wherein the laminate structure is oil resistant.

82. An article of manufacture as defined in claim 1, wherein the laminate structure is a barrier to flavor.

83. An article of manufacture as defined in claim 1, wherein the laminate structure is a barrier to odor.

84. An article of manufacture as defined in claim 1, wherein the laminate structure is a barrier to microwave radiation.

85. An article of manufacture as defined in claim 1, wherein the laminate structure is a barrier to electricity.

86. An article of manufacture as defined in claim 1, wherein the laminate structure is an electrical insulator.

87. An article of manufacture as defined in claim 1, wherein the laminate structure is an electrical conductor.

88. An article of manufacture as defined in claim 1, wherein the laminate structure is a barrier to sound.

89. An article of manufacture as defined in claim 1, wherein the laminate structure is a thermal insulation barrier.

90. An article of manufacture as defined in claim 1, wherein the laminate structure is an abrasion resistant barrier.

91. An article of manufacture as defined in claim 1, wherein the laminate structure is a barrier to biological agents.

92. An article of manufacture as defined in claim 1, wherein at least one of the inorganically filled sheet or the one other sheet comprise a cellular structure.

93. An article of manufacture as defined in claim 1, wherein the one other sheet is selected from the group consisting of a polyolefin, ethylvinyl alcohol, a polyester, a co-polymerized polyester, a polyamide, aluminum foil, caulking polymer layers, polyethylene terephthalate, polyurethane elastomers, polyethylene, polyvinylchloride film, polybutylene terephthalate, and mixtures or derivatives thereof.

94. An article of manufacture as defined in claim 1, wherein the laminate structure is coated with a conductive ink so that the laminate structure has an anti-static quality.

95. An article of manufacture as defined in claim 1, wherein the laminate structure is glossy.

96. An article of manufacture having a laminate structure produced by the process comprising the steps of:

providing an inorganically filled sheet including an organic binder selected from the group consisting of polysaccharides, proteins, water soluble polymers, and mixtures and derivatives thereof, a fibrous material, and an inorganic aggregate filler in an amount in a range from about 20% to about 90% by weight of solids in the inorganically filled sheet, said inorganically filled sheet having a thickness less than about 1 cm;

providing at least one other sheet to be laminated to the inorganically filled sheet;

applying an adhesive to one of the inorganically filled sheet or the at least one other sheet;

placing the inorganically filled sheet and the at least one other sheet together; and

pressing the inorganically filled sheet and the at least one other sheet together.

97. An article of manufacture as defined in claim 96, further including the step of applying heat to the inorganically filled sheet and the at least one other sheet subsequent to the pressing step.

98. An article of manufacture as defined in claim 96, further including the step of corrugating at least one of the inorganically filled sheet or the one other sheet prior to placing the inorganically filled sheet and the one other sheet together.

99. An article of manufacture as defined in claim 96, further including the step of coating at least one of the inorganically filled sheet or the one other sheet prior to placing the inorganically filled sheet and the one other sheet together.

100. An article of manufacture as defined in claim 96, further including the step of fashioning the laminate structure into a container.

101. An article of manufacture as defined in claim 96, further including the step of perforating the laminate structure to facilitate bending of the laminate structure.

102. An article of manufacture having a laminate structure produced by the process comprising the steps of:

providing an inorganically filled sheet wound on a spool and including an organic binder selected from the group consisting of polysaccharides, proteins, water soluble polymers, and mixtures and derivatives thereof, an inorganic aggregate filler in an amount in a range from about 20% to about 90% by weight of solids in the inorganically filled sheet, and a substantial quantity of starch, said inorganically filled sheet having a thickness less than about 1 cm;

providing at least one other sheet to be laminated to the inorganically filled sheet;

removing at least a portion of the inorganically filled sheet from the spool;

pressing the portion of the inorganically filled sheet and the at least one other sheet together; and

heating the inorganically filled sheet and the at least one other sheet together in order to form a thermoformed bond therebetween.

103. An article of manufacture as defined in claim 102, further including the step of fashioning the laminate structure into a container.

104. An article of manufacture as defined in claim 102, further including the step of perforating the laminate structure to facilitate bending of the laminate structure.

105. An article of manufacture as defined in claim 102, further including the step corrugating at least one of the portion of the inorganically filled sheet or the one other sheet prior to pressing the portion of the inorganically filled sheet and the one other sheet together.

106. An article of manufacture as defined in claim 102, further including the step of coating at least one of the portion of the inorganically filled sheet or the one other sheet prior to pressing the portion of the inorganically filled sheet and the one other sheet together.

107. An article of manufacture having a laminate structure comprising:

(a) a starch-bound sheet, including;

(i) a binding matrix including starch and a cellulosic ether, the starch having a concentration in a range from about 5% to about 90% by weight of total solids in the starch-bound sheet, the cellulosic ether having a concentration in a range from about 0.5% to about 10% by weight of total solids in the starch-bound sheet;

(ii) a fibrous material substantially homogeneously dispersed throughout the binding matrix and having a concentration of at least 3% by weight of total solids in the starch-bound sheet; and

(iii) an inorganic aggregate filler having a concentration in a range from about 0% to about 90% by weight of total solids in the starch-bound sheet;

wherein the starch-bound sheet has a thickness less than about 1 cm and a density greater than about 0.5 g/cm³ ; and

(b) at least one other sheet laminated to the starch-bound sheet.

108. An article of manufacture as defined in the claim 107, wherein the starch has a concentration in a range from about 15% to about 75% by weight of total solids in the starch-bound sheet.

109. An article of manufacture as defined in claim 107, wherein the starch has a concentration in a range from about 30% to about 70% by weight of total solids in the starch-bound sheet.

110. An article of manufacture as defined in claim 107, wherein the starch comprises unmodified potato starch.

111. An article of manufacture as defined in claim 107, wherein the starch comprises unmodified corn starch.

112. An article of manufacture as defined in claim 107, wherein the starch comprises unmodified waxy corn starch.

113. An article of manufacture as defined in claim 107, wherein the cellulosic ether has a concentration in a range from about 1% to about 5% by weight of total solids in the starch-bound sheet.

114. An article of manufacture as defined in claim 107, wherein the cellulosic ether has a concentration in a range from about 2% to about 4% by weight of total solids in the starch-bound sheet.

115. An article of manufacture as defined in claim 107, wherein the cellulosic ether is selected from the group consisting of methylhydroxyethylcellulose, hydroxymethylethylcellulose, carboxymethylcellulose, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxyethyl-propylcellulose, and mixtures or derivatives thereof.

116. An article of manufacture as defined in claim 107, wherein the binding matrix further includes a protein-based binder selected from the group consisting of prolamine, collagen, gelatin, glue, casein, and mixtures or derivatives thereof.

117. An article of manufacture as defined in claim 107, wherein the binding matrix further includes 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.

118. An article of manufacture as defined in claim 107, wherein the binding matrix further includes a synthetic organic binder 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, latex, and mixtures or derivatives thereof.

119. An article of manufacture as defined in claim 107, wherein the inorganic aggregate filler has a concentration in a range from about 20% to about 80% by weight of total solids in the starch-bound sheet.

120. An article of manufacture as defined in claim 107, wherein the inorganic aggregate filler has a concentration in a range from about 30% to about 70% by weight of total solids in the starch-bound sheet.

121. An article of manufacture as defined in claim 107, wherein the inorganic aggregate filler is selected from the group consisting of clay, gypsum, calcium carbonate, mica, silica, alumina, sand, gravel, sandstone, limestone, and mixtures or derivatives thereof.

122. An article of manufacture as defined in claim 107, wherein the inorganic aggregate filler comprises individual particles that are size optimized in order to achieve a predetermined natural particle packing density.

123. An article of manufacture as defined in claim 107, wherein the natural particle packing density of the inorganic aggregate filler is at least about 0.65.

124. An article of manufacture as defined in claim 107, wherein the inorganic aggregate filler comprises a lightweight aggregate selected from the group consisting of perlite, vermiculite, hollow glass spheres, porous ceramic spheres, pumice, and mixtures thereof.

125. An article of manufacture as defined in claim 107, wherein the fibrous material has a concentration in a range from about 5% to about 30% by weight of total solids in the starch-bound sheet.

126. An article of manufacture as defined in claim 107, wherein the fibrous material has a concentration in a range from about 7% to about 20% by weight of total solids in the starch-bound sheet.

127. An article of manufacture as defined in claim 107, wherein the fibrous material comprises organic fibers selected from the group consisting of hemp fibers, cotton fibers, bagasse fibers, abaca fibers, flax, southern pine fibers, southern hardwood fibers, and mixtures thereof.

128. An article of manufacture as defined in claim 107, wherein the fibrous material comprises inorganic fibers selected from the group consisting of glass fibers, silica fibers, ceramic fibers, carbon fibers, metal fibers, and mixtures thereof.

129. An article of manufacture as defined in claim 107, wherein the fibrous material includes individual fibers having an average aspect ratio of at least about 10:

1.

130. An article of manufacture as defined in claim 107, wherein the fibrous material includes individual fibers having an average aspect ratio of at least about 100:

1.

131. An article of manufacture as defined in claim 107, wherein the fibrous material includes a mixture of different fibers having varying strengths and flexibilities.

132. An article of manufacture as defined in claim 107, wherein the fibrous material comprises individual fibers which have a substantially random orientation within the starch-bound sheet.

133. An article of manufacture as defined in claim 107, wherein the fibrous material comprises individual fibers which have a substantially unidirectional orientation within the starchbound sheet.

134. An article of manufacture as defined in claim 107, wherein the fibrous material comprises individual fibers which have a substantially bidirectional orientation within the starchbound sheet.

135. An article of manufacture as defined in claim 107, wherein the starch-bound sheet has a tensile strength to density ratio in a range from about 2 MPa•

cm³ /g to about 500 MPa•

cm³ /g.

136. An article of manufacture as defined in claim 107, wherein the starch-bound sheet has a tensile strength to density ratio in a range from about 5 MPa•

cm³ /g to about 150 MPa•

cm³ /g.

137. An article of manufacture as defined in claim 107, wherein the starch-bound sheet has a tensile strength in a range from about 0.05 MPa to about 100 Mpa.

138. An article of manufacture as defined in claim 107, wherein the starch-bound sheet has a tensile strength in a range from about 5 MPa to about 80 MPa.

139. An article of manufacture as defined in claim 107, wherein the starch-bound sheet has a density greater than about 1 g/cm³.

140. An article of manufacture as defined in claim 107, wherein the starch-bound sheet has a density greater than about 1.5 g/cm³.

141. An article of manufacture as defined in claim 107, wherein the starch-bound sheet can elongate in a range from about 0.5% to about 12% without completely fracturing.

142. An article of manufacture as defined in claim 107, wherein the starch-bound sheet is water degradable.

143. An article of manufacture as defined in claim 107, wherein at least one of the starch-bound sheet and the other sheet is corrugated.

144. An article of manufacture as defined in claim 107, wherein at least one of the starch-bound sheet and the other sheet is creped.

145. An article of manufacture as defined in claim 107, wherein at least one of the starch-bound sheet and the other sheet further includes a coating.

146. An article of manufacture as defined in claim 107, wherein the one other sheet is selected from the group consisting of metallic foils, textile fabrics, paper, paperboard, foam, sheets that form bonding with increased temperatures, inorganically filed sheets, plastics, and mixtures or derivatives thereof.