Biochar-based composite materials for carbon sequestration and use thereof for packaging and horticultural applications

Abstract

Disclosed are biochar-infused composite materials designed for applications in construction, packaging, and / or horticulture. The materials, integrating biochar into matrices of starch, paper, cardboard, molded pulp, peat moss, cellulose, chitosan, polylactic acid (PLA), gelatin, PLA (Polylactic Acid), pectin, agar, or other natural polymers, taken alone or in combinations, enhance key mechanical properties like rigidity, moisture resistance, and impact protection. These composites offer environmental benefits, such as carbon sequestration and pollutant absorption, contributing to long-term sustainability. Customizable biochar concentrations and particle sizes allow for application-specific optimization, making the materials versatile across industries. Packaging solutions not only protect products but also act as vehicles for distributing biochar globally, at no extra cost. Once the packaging has served its purpose, it can be composted to improve soil health and sequester carbon, thus supporting climate action goals. The use of starch further enhances biodegradability, aligning with the vision of promoting a circular economy.

Description

BIOCHAR-BASED COMPOSITE MATERIALS FOR CARBON SEQUESTRATION AND USE THEREOF FOR PACKAGING AND HORTICULTURAL APPLICATIONSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present patent application claims the benefits of priority of U.S. provisional application no. 63 / 693,374 filed on September 11, 2024, the content of which is enclosed herewith by reference.FIELD OF THE INVENTION

[0002] The present invention relates to biochar-based composite materials and method of using the same, in particular, but not limited to, in construction, packaging, and horticulture.BACKGROUND OF THE INVENTION

[0003] Biochar is a carbon-rich substance produced through the pyrolysis of biomass such as forestry residues, industrial waste, or municipal refuse. Biochar is known to hold exceptional potential for sequestering carbon, enhancing soil health, and improving the mechanical properties of composites.

[0004] Biochar has long been recognized for its ability to sequester carbon and enrich soils. Historically, biochar has been used primarily as a soil amendment, offering significant agricultural benefits such as improving soil fertility, water retention, and aeration. However, its versatility has spurred interest in its application in other industries, such as construction and packaging.

[0005] The new technology disclosed herein allows fully harnessing these capabilities and drive innovation across multiple industries, with a particular emphasis on environmental sustainability and circular economy principles.

[0006] While there have been advancements in the application of biochar, there remains a pressing need for a comprehensive approach that leverages its full potential across multiple industries.SUMMARY OF THE INVENTION

[0007] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter.

[0008] Broadly stated, in some embodiments, the present invention first relates to a composite material comprising: a polymeric matrix, and a given amount of biochar particles infused or combined with the polymeric matrix, wherein the given amount and / or size of the biochar particles are tailored to enhance the composite material’s physical properties, and wherein the biochar particles in the composite material allows for carbon sequestration when the material is used or subsequently composted.

[0009] According to a preferred embodiment, the size of the biochar particles comprises particles having a diameter ranging from about 0.1 mm to about 5.0 mm.

[0010] According to a preferred embodiment, the biochar is a bimodal biochar comprising a first portion of biochar particles having a diameter inferior to 0.2 mm and a second portion of biochar particles having a diameter of from about 0.3 to 3.0 mm.

[0011] According to a preferred embodiment, the polymeric matrix may comprise at least one natural polymer. Preferably, the at least one natural polymer comprises cellulose, starch, chitosan, gelatin, Polylactic Acid (PLA), pectin, agar or a mixture thereof.

[0012] According to a preferred embodiment, the polymeric matrix may comprise cellulose in a form of molded pulp, paper, carton or cardboard. More preferably, the composite material may be for use as packaging material with enhanced protection against moisture, shocks, and UV exposure, while offering secondary environmental benefits as a soil amendment after use.

[0013] According to a preferred embodiment, the composite material as disclosed herein may further comprise at least one additive selected from the group consisting of antimicrobial agents, moisture regulators, stabilizers (such as UV stabilizer), where theimpregnation of biochar with these polymers and / or additives enhances the mechanical properties, moisture absorption, and antimicrobial capabilities of the material, while facilitating a controlled release of nutrients and additives in agricultural or environmental applications.

[0014] According to a preferred embodiment, the biochar may be present in the matrix at a concentration ranging between 5% and 50% by weight of said composite material, said concentration being selected depending on specific mechanical and environmental properties of the composite material to be used.

[0015] According to a preferred embodiment, the size of the biochar particles may range from 0.1 mm to 5 mm. More preferably, the size of the biochar particles is selected for customizing the composite material’s physical properties comprising mechanical properties and strengths, moisture absorption management, and pollutant absorption capabilities depending on specific applications of the composite material.

[0016] According to a preferred embodiment, the composite material may be recyclable. More preferably, the recyclable composite material is repurposed into new materials (such as cardboard material) or converted back into biochar for further use in other applications, ensuring a closed-loop lifecycle.

[0017] According to a preferred embodiment, the composite material as disclosed herein may be in the form of biochar-infused layers. More preferably, one or more of said biochar- infused layers are laminated onto a substrate, preferably comprising oriented strand boards (OSBs) or plywood, to form recyclable construction panels.

[0018] According to a preferred embodiment, the one or more layers comprises 20 to 30% of biochar with printing / vanishing based on impregnated fine biochar comprising ethanol- water / PG / triacetin, for the release of pleasant odors and adsorption of VOCs and odor attenuation.

[0019] According to a preferred embodiment, the composite material may be a biochar- infused material combined with standard pulp layers in a hybrid structure, creating a composite that balances the benefits of biochar with traditional cardboard properties, such as flexibility and cost-effectiveness.

[0020] According to a preferred embodiment, the composite material as disclosed herein may be used in packaging applications, wherein the biochar is further capable of absorbing volatile organic compounds (VOCs) and odors during its initial use, and absorbing pollutants such as heavy metals when the material is composted into soil. More preferably, the biochar may be present at a concentration which is optimized to enhance the absorption capacity of VOCs and odors during the packaging's first lifecycle, and to maximize pollutant absorption in soil during its second lifecycle.

[0021] According to a preferred embodiment, the biochar is configured to adsorb volatile organic compounds (VOCs), tyre-wear derived chemicals such as 6PPD-quinone, and other toxic pollutants released by packaged goods during transport and storage.

[0022] According to a preferred embodiment, the biochar is infused with natural plant extracts such as balsam fir (e.g. Abies balsamea), cedar, or hydrosols, thereby combining pollutant adsorption with aromatic masking and antimicrobial action.

[0023] According to another aspect, the present invention relates to the use of the composite material as disclosed herein, for the manufacturing of a packaging material, the biochar-infused material providing enhanced protection against moisture, shocks, and UV exposure, while offering secondary environmental benefits as a soil amendment after use, and wherein the biochar allows for carbon sequestration when the material is used or composted. Preferably, during primary use of the packaging material, said packaging material protects both a packaged product and a consumer environment by reducing indoor VOC exposure upon unboxing. Preferably, the biochar is infused or incorporated into cardboard for creating boxes or other packaging components, with specific layers such as corrugated and flat liners enhanced by biochar to improve structural integrity, moisture resistance, and UV protection. More preferably, the cardboard comprises at least one corrugated layer over a flat liner, wherein the at least one corrugated layer of the cardboard contains a concentration of biochar configured to maximize rigidity and compression resistance, while the flat liner layer contains another concentration of biochar configured to optimize moisture resistance and durability.

[0024] According to a preferred embodiment, the boxes or other packaging components as disclosed herein is bonded using a biochar-infused water-based adhesive, which enhances the overall structural integrity and moisture resistance of the cardboard. Preferably, whereinthe biochar-infused water-based adhesive is configured to improve packaging durability and provide more sustainable solution for carbon sequestration in soils, free from chemical contaminants, when the composite material is composted or repurposed after use.

[0025] According to another aspect, the present invention relates to a construction panel comprising a composite material for construction applications, wherein the panel comprises a protective layer or paper made of biochar-infused composite material applied onto a substrate, such as oriented strand board (OSB), plywood, veneer, or other flat or corrugated panels, wherein the protective layer enhances the durability of the substrate by providing increased resistance to UV radiation and moisture, and contributes to carbon sequestration.

[0026] According to another aspect, the substrate comprises corrugated panels having ribs and grooves and further comprises extruded helical elements comprising biochar and starch and / or cellulose, the extruded helical elements being configured to be placed in said grooves before gluing a second liner, so as to fill a void formed by the grooves of the corrugated panels and support the ribs against collapse.

[0027] According to a preferred embodiment, the construction panel may further comprise additional layers of biochar-infused adhesives that enhance the overall structural integrity and moisture resistance of the panels. Preferably, the biochar-infused protective layer is further treated with or further comprise additives to enhance UV and moisture resistance, extending the longevity and structural integrity of the underlying substrate.

[0028] According to another aspect, the present invention relates to a composite material comprising biochar and starch, with or without additional additives such as chitosan, gelatin, or other natural biopolymers, where the formulation improves the mechanical properties of the composite material, such as impact resistance, moisture management, and antimicrobial properties, and wherein the material is designed for use in packaging applications, including packing peanuts, independent molded forms, or integrated within packaging materials such as cardboard or molded pulp.

[0029] According to a preferred embodiment, the biochar concentration may range between 5% and 50% by weight, and is optionally combined with starch to enhance structure and provide environmental benefits such as carbon sequestration and soil health improvement when the material is composted or used as a soil amendment.

[0030] According to a preferred embodiment, the biochar particles have a size range from 0.1 mm to 5 mm, allowing customization of the composite material’s mechanical properties, moisture management, and pollutant absorption capabilities depending on the specific application.

[0031] According to a preferred embodiment, the composite material as disclosed herein is molded to form parts comprising, after pressing, extruded helical elements comprising biochar and starch and / or cellulose, the extruded helical elements being provided at areas comprising comers, edges and / or grooves in order to enhance shock absorption during a fall, without excess thickness.

[0032] According to another aspect, the present invention relates to packing peanuts, such as spiral-shaped packing peanuts, made from the composite material as disclosed herein, where the spiral shape increases air content, enhancing shock absorption, moisture absorption, and optimizing the distribution of biochar and other additives in the material. Preferably, the helical geometry provides progressive energy dissipation by sequential deformation of outer coils followed by inner coils of increasing diameter and rigidity, thereby optimizing cushioning efficiency while minimizing material usage.

[0033] According to a preferred embodiment, the shape also maximizes the efficiency of cushioning while minimizing material usage, and after dissolving in water, the biochar allows controlled absorption of additives, which can then be dried for transportation and reused in packaging.

[0034] According to a preferred embodiment, when the biochar is further enriched with starch and / or additives and placed in a soil, the (spiral-shaped) packing peanuts manage nutrients and moisture, contributing to improved soil fertility.

[0035] According to a preferred embodiment of the spiral-shaped packing peanuts, after partial dissolution of the starch or cellulose matrix, a fraction of biochar remains in solid form as an active residue, said residue providing carbon sequestration, microbial habitat, and controlled release of infused additives, thereby contributing to soil regeneration.

[0036] According to a preferred embodiment, the combination of spiral geometry and biochar residue provides a dual functionality of product cushioning during transport and regenerative soil amendment after use.

[0037] According to another aspect, the present invention relates to a biochar-infused composite material as disclosed herein, integrated into a matrix of paper, cardboard, molded pulp, peat moss, or a combination of these carbon materials, used for the manufacture of horticultural products such as pots and soil amendments, wherein the biochar enhances water retention, aeration, and nutrient availability in the soil, while also contributing to carbon sequestration.

[0038] According to a preferred embodiment, the biochar-infused composite material is configured to be composted after use, allowing the biochar to be released into soil, improving soil fertility, moisture retention capacity, and promoting the long-term survival and vigor of plants or seeds in agricultural and horticultural applications.

[0039] According to another aspect, the present invention relates to a method for packaging and transporting a product, comprising: a) providing a packaging made of a composite material comprising: a polymeric matrix, and a given amount of biochar particles, wherein the given amount and / or size of the biochar particles are tailored to enhance the composite material’s physical properties; b) transporting the product using said packaging for delivering the product to its final destination; and c) composting said packaging after delivery; wherein the biochar particles in the composite material allows for carbon sequestration when the composite material is used for packaging and transportation and subsequently composted.

[0040] According to a preferred embodiment of the method as disclosed herein, the product may be biochar used for horticulture applications.

[0041] According to a preferred embodiment of the method as disclosed herein, the biochar in the packaging and the packaging containing biochar are both conjointly used for horticulture applications.

[0042] According to another aspect, the present invention relates to a biodegradable horticulture ring comprising about 5 - 50% of the bimodal biochar composite as disclosed herein with fine infused biochar and aggregate, about 0.5-2% of chitosan, optionally 5-25% of CaCOs and about 10 - 40% of bark fibers grooved / micro-textured reliefs; formed second life process.

[0043] According to another aspect, the present invention relates to pellets comprising about 50% of material composite as disclosed herein, about 10 - 30% of a bimodal biochar having 30% of fines infused particles with a diameter inferior to 200 pm and about 70% of 0.5-1.5 mm particles, about 10 - 40% of peat, about 1% of chitosan, about 4% of starch, binders and optionally CaCOs.

[0044] According to another aspect, the present invention relates to the usse of the pellets as disclosed herein for the making of a litter for animals selected from poultry, equine / bovine, swine, and small animals or pets.

[0045] According to another aspect, the present invention relates to construction panel coating formulation comprising: about 40 - 75% of an acrylic water layer, about 10 - 30% of biochar material composite as claimed in claim 1, and about 5 - 25% of CaCOs, wherein the construction panel coating formulation is configured to be applied on a surface before drying and form a coating having a thickness of about 50 - 300 pm with a static coefficient of friction (ps) superior or equal to about 0.6.

[0046] All features of exemplary embodiments which are described in this disclosure and are not mutually exclusive can be combined with one another. Elements of one embodiment can be utilized in the other embodiments without further mention.

[0047] Other and further aspects and advantages of the present invention will be better understood upon the reading of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practice.BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The above and other aspects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:

[0049] Figure 1A is a 3D computer-generated view of an exemplary of a spiral-shaped packing peanut in accordance with a preferred embodiment; and

[0050] Figure IB is a schematic perspective view of the spiral-shaped packing peanut shown in Figure 1A in accordance with a preferred embodiment.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0051] The present technology is explained in greater detail below. This description is not intended to be a detailed catalog of all the different ways in which the technology may be implemented or all the features that may be added to the instant technology. For example, features illustrated with respect to one embodiment may be incorporated into other embodiments, and features illustrated with respect to a particular embodiment may be deleted from that embodiment. In addition, numerous variations and additions to the various embodiments suggested herein will be apparent to those skilled in the art considering the instant invention which variations and additions do not depart from the present technology. Hence, the following description is intended to illustrate some embodiments of the technology, and not to exhaustively specify all permutations, combinations, and variations thereof.

[0052] The terminology used herein is in accordance with definitions set out below.

[0053] As used herein % or wt.% means weight % unless otherwise indicated. When used herein % refers to weight % as compared to the total weight percent of the phase or composition that is being discussed.

[0054] By "about", it is meant that the value of a data disclosed herein can vary within a certain range depending on the margin of error of the method or device used to evaluate such data. A margin of error of 10% is generally accepted.

[0055] By “Infusion” or “Infused” (also known as pre-impregnation), it is meant that a load of biochar (preferably a fine biochar i.e. with particles < 200 pm) is charged into a carrier, preferably a food grade carrier, such as, but not limited to ethanol-water, propylene glycol, triacetin, hydrolats / natural extracts, etc. under agitation, ultrasound and / or vacuum / pressure cycle, then dry.

[0056] By “Combination” or “Combined”, it is meant preferably a mechanical mixing by which the biochar is incorporated into a matrix (for example molded pulp, paper / cardboard) providing structure, adsorption (e.g. water / VOCs), and drying aid.

[0057] By “static coefficient of friction (ps)” it is meant the dimensionless value representing the ratio of the maximum static friction force to the normal force pressing two surfaces together, just before they begin to slide. It determines the amount of force required to initiate movement between stationary objects and depends on the materials and surface conditions, not the contact area or speed. It is always greater than or equal to the kinetic coefficient of friction.

[0058] By “second life process” it is meant that a product, such as a biodegradable horticulture ring or any other products as disclosed herein, is not manufactured from new matter but from already used matter such as a packaging containing biochar.

[0059] Glossary of abbreviations- CEC: cation exchange capacity — quantity of cations (K+, Ca2+, NH4+, etc.) that a material / soil can retain / exchange (cmol(+) / kg).- VOC: volatile organic compounds (odors, solvents, aromas).- NIL: ammonia (litter odors).- PF AS: per- and polyfluoroalkyl substances.- PLA: polylactic acid.- OSB: oriented strand board.- UV: ultraviolet.- GRAS: Generally Recognized As Safe (US food safety).- PG: propylene glycol (food co-solvent).- MDF: Medium-Density Fiberboard- HDF : High-Density Fiberboard- D50: median particle size.- GC-MS / LC-MS / SPME: analytical tools (chromatography + mass spectrometry, solid-phase microextraction).- MIC: minimum inhibitory concentration.- CFU: colony-forming units.- ps: static coefficient of friction.

[0060] The description which follows, and the embodiments described therein are provided by way of illustration of an example of particular embodiments of principles and aspects of the present invention. These examples are provided for the purposes of explanation and not of limitation, of those principles of the invention. In the description that follows, like parts and / or steps are marked throughout the specification and the drawing with the same respective reference numerals.

[0061] Recently, laboratory trials by Swansea University, RSK Group, and Kier (2025) demonstrated that biochar completely removed microplastics from simulated highway runoff. No microplastics remained in solution after filtration through biochar columns, even at low concentrations. Biochar packaging according to the present invention can be used to capture polymeric residues and microplastics released during transport and disposal.

[0062] Also, researchers from the University of Washington (2025) identified 6PPD- quinone, a transformation product of a common tyre additive, as lethal to coho salmon within hours of exposure. Tyre and road-wear dust (about 3 million tonnes annually) is now recognized as airborne and linked to respiratory / endocrine risks in humans. Therefore, biochar packaging according to the present invention can serve as a protective barrier against VOCs and tyre-derived pollutants (e.g., phthalates, 6PPD-quinone), preventing harmful “first-burst” emissions indoors.

[0063] A key aspect of the present invention is its vision to maximize biochar's potential by embedding it into everyday products, thus creating dual-purpose materials. Traditionally, packaging has served a singular role: protecting products during transportation. However, the technology disclosed herein redefines packaging as a medium for environmental action and education. Once it fulfills its primary function, packaging enriched with biochar can be repurposed to improve soil quality in indoor plants, gardens, or agricultural land. In doing so, consumers not only benefit from enhanced soil health but are also educated on the longterm role of biochar in carbon sequestration and climate change mitigation.

[0064] The packaging sector is moving towards sustainable solutions, driven by the need to reduce environmental impact. Traditional packaging materials, such as paper and cardboard, tend to lose mechanical strength under humid conditions. Incorporating biochar into these materials enhances their moisture resistance and structural integrity, making themmore durable in various environments. Additionally, biochar-enriched packaging serves as a carbon sink, further contributing to global efforts to reduce greenhouse gas emissions.

[0065] In addition, the present technology provides biochar in water-based adhesives used, for instance, in the manufacturing of the packaging, providing as such an eco-friendly alternative to traditional chemical adhesives, reducing the environmental footprint of packaging.

[0066] In horticulture, biochar has proven benefits for soil health, notably in improving water retention, nutrient availability, and overall soil structure. Recent advances have focused on incorporating biochar into growing media, such as replacing traditional components like peat and perlite. This shift not only reduces the reliance on non-renewable resources but also improves plant growth and sustainability. Biochar-embedded horticultural products, such as biodegradable plant pots or soil amendments, can be designed to gradually release biochar into the soil, supporting carbon sequestration and soil regeneration.

[0067] The technology disclosed herein stems from the need to integrate biochar across various sectors and make it accessible to the broader population. By incorporating biochar into widely-used products such as packaging, construction materials, and horticultural substrates, we aim to distribute biochar globally at no additional cost. This model transforms everyday items into tools for combating climate change and improving soil health, while fostering widespread participation in sustainable practices.

[0068] The technology as disclosed herein provides new biochar-infused composite materials that enhance mechanical performance, increase durability under harsh conditions, and offer significant environmental benefits such as carbon sequestration and recyclability. By utilizing biochar derived from diverse sources, including, for instance, forest biomass, industrial residues, and municipal waste, the technology as disclosed herein underscores the importance of creating a circular economy where waste materials are transformed into valuable, sustainable products. This approach not only mitigates climate change but also aligns with the broader goal of creating a more sustainable society through biochar's widespread adoption and use.

[0069] The technology disclosed herein relates to the development of biochar-based composite materials preferably designed for use in construction, packaging, and horticulture. These composites incorporate biochar into matrices made from natural materials, such as,but not limited to, cardboard, molded pulp, starch, chitosan, gelatin, cellulose, PLA (Polylactic Acid), pectin, agar, and other natural polymers. The integration of biochar enhances the mechanical properties of these materials, including for instance increased rigidity, better shock absorption, better moisture management, and higher UV resistance, for naming a few, while offering significant environmental benefits such as carbon sequestration, recyclability, and biodegradability.

[0070] One of the key aspects of the present invention is its vision to redefine packaging beyond its primary function of product protection, transforming it into a vehicle for the global distribution of biochar at no additional cost. After its initial use, the packaging can be repurposed to improve soil quality in indoor plants, gardens, or lawns. This dual-purpose design helps educate consumers about the role biochar plays in long-term carbon sequestration, soil regeneration, and combating climate change.

[0071] Biochar-based composites as disclosed herein offer broad applications in construction by enhancing the durability and resilience of materials exposed to outdoor conditions, such as providing resistance to UV radiation and moisture. In packaging, combinations such as biochar with starch, chitosan, or PLA create lightweight, durable packaging with superior protection against shocks, moisture, and contamination. These new composite materials are ideal for shipping sensitive goods like electronics, perishable items, or fragile products. In horticulture, biochar-infused molded pulp or biodegradable polymers are used to create plant pots and soil supports that enhance soil health, retain water, and sequester carbon when composted.

[0072] The technology as disclosed herein extends its applications through innovative material combinations such as for instance: “Biochar + Agar + Natural Rubber” for high- impact cushioning, ideal for long-distance shipping or delicate electronics, or “Biochar + Polylactic acid (PLA) + Pectin”, which provides lightweight, rigid packaging with strong shock absorption and biodegradability. Both combinations maintain their second life by enhancing soil quality when composted. Other combinations of Biochar with natural polymers can be considered in the scope of the present invention.

[0073] Overall, the technology as disclosed herein introduces a versatile and sustainable approach across multiple industries, positioning packaging as a crucial tool for both product protection and environmental sustainability. It promotes a circular economy by transformingpost-use packaging into a resource for soil regeneration and carbon sequestration, furthering the mission of global biochar distribution and consumer education on environmental stewardship.Composite Material Composition

[0074] The composite materials described herein are preferably composed of biochar integrated (infused or combined) into various natural matrices such as cardboard, molded pulp, starch, cellulose, PLA (polylactic acid), pectin, agar, chitosan, gelatin, or any mixtures thereof. This integration offers multiple mechanical and environmental benefits, including:

[0075] Rigidity and Structural Integrity: Biochar may increase the rigidity and compression resistance of the composite, making it suitable for packaging and construction applications that require robust protection.

[0076] Moisture Management: The porous structure of biochar allows it to absorb excess moisture, enhancing the material’s performance in humid conditions. This is particularly valuable in packaging applications where moisture can compromise product integrity, and in construction materials that are exposed to varying environmental conditions.

[0077] Controlled release of organoleptic agents (smells / tastes) and functional agents (mild antimicrobials, anti-desiccation), odor attenuation in first life and agricultural benefits in second life.

[0078] Impact Resistance: Biochar-infused materials are preferably designed to absorb and dissipate shock energy, making them ideal for protecting fragile items during transportation.

[0079] Carbon Sequestration: A core advantage of the present technology is biochar's ability to sequester carbon. Each ton of biochar used in the composite can capture up to 3.67 tons of CO2, effectively reducing the carbon footprint of the material and contributing to global climate change mitigation efforts.

[0080] Zero Distribution Cost for Biochar: One of the most innovative aspects of the present technology is the seamless integration of biochar into the logistics of everyday product distribution. Incorporating biochar into packaging materials leverages global shipping networks to distribute biochar worldwide at no additional cost. Once the packagingreaches its destination, it can be composted, returning the biochar to the soil, where it improves soil quality and continues to sequester carbon.

[0081] Customization Through Biochar Concentration and Particle Size: The concentration of biochar in the composite material, whether in molded pulp, cardboard, or paper, can be adjusted or tuned to optimize the material's properties for specific applications. Higher concentrations of biochar can be used for packaging that needs extra moisture resistance or impact protection, while lower concentrations may be more appropriate for lighter packaging solutions.

[0082] In addition to biochar concentration, the particle size of an aggregate biochar can be tailored (ranging for example from 0.1 mm to 5 mm, preferably from 0.3 mm to 3 mm) to meet the mechanical demands of various applications. For instance, smaller particle sizes enhance the uniformity and structural integrity of the composite material, while larger particles improve the composite material’s ability to absorb pollutants and manage moisture.

[0083] Additives and Custom Blends: In addition to biochar, other natural additives like starch, chitosan (for antimicrobial properties), gelatin, and pectin can be incorporated into the composite materials to improve or modify their functionality. For instance, incorporating biochar helps to evenly distribute these additives within the matrix, improving the overall uniformity of the composite. The porous structure of biochar allows it to absorb and release additives like starch or gelatin over time when applied to the soil, providing controlled nutrient release and moisture retention, which is especially beneficial in horticultural and agricultural applications.

[0084] For example, combining biochar with chitosan may add antimicrobial properties, which can be highly advantageous for packaging sensitive products such as food or electronics. Similarly, adding gelatin may enhance the flexibility and durability of the material, making it more versatile in various applications.

[0085] Innovative Packaging Solutions: One specific example of innovation in packaging is the development of spiral-shaped packing peanuts. Made from biochar and starch, these packing peanuts are designed to maximize air content and shock absorption. The spiral shape increases the surface area, which further enhances cushioning properties while maintaining the lightweight nature of the material. After use, the peanuts can be dissolved in water, and the biochar can absorb starch and other materials as it dries out,releasing them slowly when applied to soil. This innovative packaging solution not only protects products during transport but also enhances soil health through its secondary life.

[0086] The biochar-starch combination can also be rehydrated for liquid applications, offering further versatility and sustainability in agricultural and horticultural settings. Additives like glycerin can be used to fine-tune the material’s performance, enhancing its flexibility, durability, and biodegradability.Biochar-Infused Composite Materials:

[0087] Materials: Examples of infused biochar according to a preferred embodiment of the invention.Biochar: from 5 to 50% w / w (per layer), particle size from 0.1 to 5 mm. Fine infused (e.g. particles < 200 pm) for release / odors / functional properties, and Aggregate (e.g. particles 0.3-3 mm) for structure / adsorption / drying.Matrices: cellulose, paper, cardboard, molded pulp; PLA; chitosan; pectin / alginate / agar / gelatin; starch.Additives: chitosan (0.5-2%, antimi crobial / elicitor film), glycerin / triacetin (0.2-1%, plasticity / fixation), eggshells (CaCOs 5-25%, rigidity / minerals), bark fibers (10-40%, co-binding lignin / flavors), peat (10-40%, capillarity / pH / natural antimicrobial).Packaging:

[0088] Molded Pulp for Protective Packaging: Biochar-enriched molded pulp as disclosed herein provides superior protection for products while offering a secondary environmental benefit. Once its primary function as protective packaging is fulfilled, it can be repurposed as a soil amendment. When composted, the biochar enhances soil structure, improves water retention, and boosts nutrient availability. This aligns with the broader vision of distributing biochar globally, offering environmental education on biochar’s long-term benefits for soil health and carbon sequestration.

[0089] Cardboard and Other Packaging Components: Biochar can be integrated into cardboard packaging to create more durable, eco-friendly components. The biochar-infused cardboard as disclosed herein enhances resistance to moisture, shocks, and UV exposure, which prolongs the life of the packaging and ensures better product protection during transport. These materials support the circular economy by extending their lifecycle, andonce discarded, they contribute to soil improvement by releasing biochar back into the environment.

[0090] Corrugated Layer: The corrugated layer of cardboard, which provides structural integrity and compression resistance, can be reinforced with molded pulp containing biochar. This biochar reinforcement creates a more robust structure while maintaining lightness, making the packaging efficient for transportation and protecting the product inside from impacts.

[0091] Example of corrugated layer: 10 to 20% biochar aggregate (particle sizes: 0.3-3 mm) providing compression and rigidity, favorizing drying, and increasing resistance to humid environments.

[0092] Flat Layer (Liner): The flat liner layer of the cardboard also benefits from biochar integration, particularly in terms of moisture resistance. This helps extend the material’s overall durability, which is especially useful in humid environments where packaging might otherwise degrade. The biochar-infused liner as disclosed herein provides an additional layer of protection, ensuring that the contents are shielded from environmental conditions.

[0093] Examples of flat liners: 20-30% total biochar (infused fine + fine aggregate fraction), with biochar vamish / inks (chitosan / glycerin / triacetin), providing odor reduction, moisture / UV barrier, and aromatic unpack.

[0094] Multilayer molded paste & densities: Layers with different contents and densities by adjusting the molding pressure to adapt the structure, absorption, moisture tolerance, surface smoothness (non-abrasive for electronics), and customize the product interface.

[0095] Hybrid Combination with Standard Pulp: A hybrid approach combining biochar-enriched molded pulp with traditional pulp layers maximizes both environmental and mechanical benefits. This combination balances biochar’s advantages, such as carbon sequestration and enhanced strength, while retaining the flexibility and cost-effectiveness of standard pulp. This layered approach allows manufacturers to create a composite material that leverages the best attributes of both components, resulting in functional, durable, and sustainable packaging.

[0096] Transport and Storage: Molded pulp packaging enriched with biochar as disclosed herein can be compressed for easier transport and storage, reducing logistical costsand environmental impact. Upon reaching the consumer, the packaging can be repurposed for horticultural applications, further extending its lifecycle. In gardening, biochar-enriched packaging serves as a soil enhancer, contributing to water retention and nutrient absorption, making it valuable even after its primary function has been fulfdled.

[0097] Spiral-Shaped Packing Peanuts: Figures 1 A and IB show a spiral-shaped packing peanut (100) optionally comprising biochar as disclosed herein. Extruded helical element is made from starch and / or cellulose, optionally fdled with biochar (fine and / or aggregate), extruded and then twisted, produced in continuous lengths and cut (e.g., 30 to 200 cm). The spiral-shaped packing peanut (100) has a size with preferably a length of about 5 cm and a width / diameter of about 1.5 cm. Other sizes can be considered without departing from the scope of the present invention.

[0098] The packing peanuts shaped in a spiral design maximize air content and shock absorption. Lightweight shock absorber / spacer in the corrugation hollows (between two corrugated sheets), improving shock absorption, specific rigidity, and capillarity (anticrushing, minimal weight). Local cohesion agent (“fiber coagulant”) can be used in the molded paste: strategic insertion (angles / comers, ribs) before pressing to densify locally, drain excess water, distribute stresses, and increase mechanical strength. Customizations: infused twist (release of aromas / functional properties), or high-porosity twist (local desiccation).

[0099] After use, the peanuts can be dissolved in water, and the biochar will absorb materials such as starch. Once dried, these materials will be released gradually into the soil, improving soil fertility. This biochar-starch mixture can also be rehydrated for liquid applications, adding versatility and sustainability to biochar-based packaging.

[0100] Unlike conventional biodegradable packing peanuts, which completely dissolve and lose utility after use, the spiral-shaped peanuts of the present invention provide two distinctive and synergistic technical effects: a. Progressive shock absorption — the helical geometry enables gradual and sequential dissipation of impact energy. The outer coils deform first, followed by inner coils of increasing diameter and rigidity, thereby optimizing cushioning efficiency while minimizing material usage.b. Active regenerative residue — after partial dissolution of the starch or cellulose matrix, a fraction of biochar remains in solid form. This biochar does not constitute waste but becomes an active agent for soil regeneration, providing long-term carbon sequestration, acting as a microbial habitat, and enabling controlled release of infused additives (nutrients, antimicrobials, aromas).Construction:

[0101] Panels and Boards: In the construction sector, biochar-enhanced composite materials as disclosed herein can be used as a coating or reinforcement for OSB (oriented strand board), plywood, and other flat or corrugated panels. The biochar-infused layers as disclosed herein provide superior resistance to UV radiation and moisture, extending the life of materials in exterior applications such as siding, roofing, and cladding. Additionally, biochar’s carbon-sequestering properties help reduce the overall carbon footprint of these construction materials.

[0102] Moisture and UV Resistance: Biochar’s porous structure as disclosed herein absorbs moisture, reducing the risk of degradation due to environmental exposure. Its carbon content also offers added protection against UV radiation, making it ideal for outdoor construction products where durability and sustainability are critical.Horticulture:

[0103] Pots and Soil Amendments: Biochar-infused molded pulp as disclosed herein can be used to create plant pots and soil support systems. Once placed in the soil, these products gradually release biochar, enhancing soil quality by improving water retention, aeration, and nutrient availability. This supports healthy plant growth and contributes to long-term carbon sequestration, aligning with sustainable gardening practices.

[0104] Sustainable Gardening: Biochar-enriched horticultural products as disclosed herein promote healthier plant growth while reducing the need for chemical fertilizers. These products not only enhance soil health but also address global environmental challenges like climate change by sequestering carbon. This dual purpose: plant support and carbon capture, makes biochar-infused gardening materials highly beneficial in both commercial and home gardening settings.Manufacturing and Processing of Biochar-Infused Composite Materials

[0105] The production of biochar-infused composite materials as disclosed herein preferably involves a series of specialized steps that integrate biochar into various base materials such as cardboard, molded pulp, starch, and other natural polymers like cellulose, PLA (Polylactic Acid), and agar. These processes can be tailored depending on the desired mechanical properties, environmental benefits, and application requirements of the final product. Below is a detailed description of the manufacturing and processing steps according to preferred embodiments of the present invention.1. Raw Material Preparation

[0106] The first stage in manufacturing preferably involves preparing the base materials and biochar. The base materials, including cardboard, molded pulp, starch, or other natural polymers such as those disclosed herein, are either pre-processed or sourced in bulk. The biochar, derived from biomass pyrolysis, must meet specific particle size requirements typically ranging from 0.1 mm to 5 mm, to ensure optimal integration into the composite matrix.

[0107] Biochar Characteristics:Particle Size: Fine biochar particles (0.1-5 mm) may ensure uniform distribution within the matrix, enhancing rigidity and mechanical performance.Surface Area and Porosity: The highly porous structure of biochar may increase its ability to absorb moisture and additives like starch or gelatin, which contributes to the functional qualities of the final product.2. Mixing and Integration

[0108] Premixing:Biochar is premixed with the base materials to ensure even distribution throughout the matrix. Depending on the desired properties, additives such as starch, chitosan, gelatin, or natural rubber may be included in the premixing phase to enhance performance factors like shock absorption, antimicrobial properties, or flexibility.

[0109] Customization:According to a preferred embodiment, the concentration of biochar, base materials, and additives can be tailored to meet specific functional needs. For instance, higher biocharconcentrations are used in applications requiring increased moisture resistance or impact protection, while lower concentrations might be used for less demanding applications.3. Dispersion and Coating

[0110] Uniform Dispersion:According to a preferred embodiment, the biochar can be uniformly dispersed within the matrix during mixing, which helps ensuring that its beneficial properties, such as moisture absorption, pollutant trapping, and carbon sequestration, are evenly distributed throughout the material. This uniform distribution is particularly crucial in packaging and construction materials, where consistent performance is required across all parts of the composite.

[0111] Surface Coating:According to a preferred embodiment, biochar is applied as a surface coating rather than being mixed into the core matrix. Surface coating biochar onto cardboard or molded pulp adds an additional protective layer, offering enhanced moisture resistance and environmental durability. This method is often used in construction materials, where surfaces are more exposed to external conditions like UV radiation and moisture.4. Forming and Shaping

[0112] After mixing and coating, the composite material may be processed into its desired shape through various forming methods, such as:

[0113] Extrusion: The composite mixture is extruded into shapes such as packing peanuts or protective inserts. This method allows for the precise shaping of biochar- enhanced materials, such as spiral-shaped peanuts, to maximize shock absorption and structural efficiency.

[0114] Molding: Molded pulp packaging is formed by pressing the biochar-infused slurry into molds. The use of biochar in this process improves the rigidity and impact resistance of the packaging while maintaining a lightweight structure.

[0115] Lamination: For applications such as construction panels, biochar-infused layers are laminated onto substrates like OSB or plywood. This process creates a robust composite panel with enhanced environmental resistance.5. Adhesive Integration

[0116] In the assembly of layered materials like cardboard or construction panels, biochar can be incorporated into water-based adhesives. These biochar-infused adhesives provide the following benefits:Environmental Sustainability: By replacing chemical-based adhesives, biochar- infused water-based adhesives reduce the environmental impact of manufacturing.Enhanced Moisture Resistance: The adhesive strengthens the composite material’s resistance to moisture penetration, a key property for applications in both packaging and outdoor construction.6. Compression and Drying

[0117] Once the materials are shaped or molded, the products may go through a compression and drying phase. This process may ensure that the biochar is securely integrated into the matrix and that any moisture present is expelled. The drying phase may also serve to lock in the structural benefits provided by biochar, ensuring the final product maintains its rigidity and performance.

[0118] Drying Techniques:Convection Drying: Used in large-scale manufacturing to efficiently remove moisture from molded pulp or cardboard components.Oven Drying: Utilized for smaller-scale production or specific products where controlled drying conditions are essential for maintaining biochar’s functional properties.Recyclability and Lifecycle:

[0119] End-of-Life Solutions: Biochar-infused composite materials offer significant end-of-life benefits. After their primary use, they can be recycled into new products or composted to return biochar to the soil, where it improves soil health. This closed-loop lifecycle minimizes waste and maximizes environmental contributions, from carbon sequestration to pollutant absorption.

[0120] Pollutant Absorption: Biochar’s unique properties extend beyond structural improvements. During packaging use, biochar can absorb volatile organic compounds (VOCs) and odors, making it ideal for sensitive products like food and electronics. After composting, biochar continues to contribute to environmental health by absorbing pollutants such as heavy metals, reducing soil contamination. When returned to the soil,biochar continues to offer benefits such as improving soil structure, nutrient retention, and even absorbing heavy metals, reducing their harmful impact on the environment.

[0121] This approach transforms every package into a tool for environmental improvement, promoting sustainable practices and global biochar distribution.

[0122] VOC and Pollutant Adsorption During Transport: In addition to cushioning and moisture management, the biochar-infused packaging material provides a unique benefit: the ability to absorb toxic volatile organic compounds (VOCs) and micropollutants released by the packaged product itself during storage and transport. Many consumer goods, especially those containing plastics or adhesives, release VOCs such as formaldehyde, phthalates, and tyre-derived degradation products (e.g., 6PPD- quinone). These emissions accumulate inside packaging and create a toxic “first-burst” effect upon unboxing, impacting indoor air quality. The biochar-infused packaging actively adsorbs these VOCs, preventing their release into the consumer’s environment. When biochar is further infused with natural extracts such as balsam fir (Abies balsamea), cedar, or other hydrosols, the packaging combines pollutant adsorption with aromatic masking and antimicrobial action. This dual strategy protects consumer health while enhancing the sensory experience.

[0123] Comparative Table (Packaging Baseline vs. Invention)EXAMPLES:

[0124] General processes:1. Post-oven + vacuum (infusion): heating / drying the biochar before preimpregnation thereof (carrier plus aromas / active ingredients) before vacuum / pressure (0.2-0.5 bar) and finally drying the composite (40-60 °C).2. Biochar varnishes / inks (liner): aqueous dispersion of biochar (particles < 50 pm) plus chitosan (0.5-2%) and glycerin / triacetin (0.2-1%).3. Biochar aqueous adhesives: biochar-loaded water-based glues (anti- humidity / odors).4. Densification (second life): grinding of post-use flows before palettization (diameter of about 4 - 12 mm) before drying / packaging.5. Helical twists: starch / cellulose ± biochar co-extrusion before twisting and then cutting, preferably using robotic / guided placement in molded pulp (comer areas) and corrugated pulp (flute bottoms) before pressing / assembling.

[0125] PACKAGING (Ex. 1-10) : cardboard / molded pulp 10-30% biochar (finely infused + aggregate), moisture control, odor reduction, biochar varnishes / inks (chitosan / glycerin / triacetin).

[0126] Ex. 1 — Molded pulp “egg trays” (base): Composition: 10 g of cellulose (egg tray), 4 g of biochar (0.1-2 mm). Effects: stiffness increased of about 20% vs. control, moisture tolerance (absorption / restitution), UV barrier (dark color).

[0127] Ex. 2 — Thin carton “cereal box” and chitosane: Composition: 12 g defibrated cardboard, 3.5 g biochar, 3 g chitosan. Effects: Mild antimicrobial, durability in humid environments (+24-36 hours), odor reduction (48 hours).

[0128] Ex. 3 — Cellulose and eggshells (CaCCh): Composition: 12 g cellulose, 10.6 g eggshells, 4 g biochar, 3 g chitosan. Effects: Compression increased of about 30%, mineralization (Ca) useful for compost.

[0129] Ex. 4 — Lightweight, rapidly biodegradable formulation (thin piece < 1 mm). Composition: 2.5 g cellulose, 1 g biochar, 1 g chitosan. Degradation: < 15 days in active industrial composting (>55°C, aeration); about 15-30 days in summer home composting; >30 days if piece is thicker or temperature is low.

[0130] Ex. 5 — Flexible composite (glycerin). Composition: 8 g cellulose, 3 g biochar, 2 g chitosan, 1 g glycerin. Effects: Increased flexibility, ideal for internal / multilayer liners.

[0131] Ex. 6 — Printed liner with “active scent” (coffee). Liner: about 25% w / w total biochar (structure + adsorption). Varnish / Ink (% on deposited solids 3-6 g / m2): biochar < 50 pm 5%, chitosan 1%, glycerin 0.5%, triacetin 0.5%, food-grade coffee extract 0.2% (option 0.2-0.4%). Effects: Aromatic release 48-72 hours, reduction of adhesive / solvent odors (adsorption + masking).

[0132] Ex. 6 — Printed liner with “active scent” (coffee). Liner: about 25% w / w total biochar (structure + adsorption). Vamish / Ink (% on deposited solids 3-6 g / m2): biochar < 50 pm 5%, chitosan 1%, glycerin 0.5%, triacetin 0.5%, food-grade coffee extract 0.2% (option 0.2-0.4%). Effects: Aromatic release 48-72 hours, reduction of adhesive / solvent odors (adsorption + masking).

[0133] Ex. 7 — Anti-desiccation meat (rose-lactic). Inner layer (solids): fine infused biochar (1-2% m / m rose hydrosol in biochar), chitosan 1-2%, glycerin 0.5-1%, lactic acid 0.5%. Effects: Anti-desiccation, gentle hygiene, odor reduction.

[0134] Ex. 8 — Anti-odor “electronics / pharmaceutical” liner. Liner: 20-30% biochar (infused fine + fine aggregate fraction); biochar / chitosan varnish. Effects: Adsorption of solvent / adhesive odors, non-abrasive surface.

[0135] Ex. 9 — Post-oven method (vacuum infusion). Carrier bath: water / ethanol or PG, agent 0.5-1.0% m / m of the bath; retention after drying: about 1-3% w / w of agent in the biochar. Integration: liner (10% biochar) + corrugated (12%). Effects: Controlled release, mechanical properties preserved.

[0136] Ex. 10 — “Red wine” liner (anthocyanins). Varnish (solids): anthocyanin extract 0.05-0.20%, triacetin 0.5%, biochar < 50 pm 5%, chitosan 1%. Effects: Light aromatic note on opening, improved UV barrier.

[0137] CONSTRUCTION (Ex. 15-17): Acrylic anti-slip coatings (bimodal biochar + CaCOs), UV shield, moisture resistant, matte finish, washable.

[0138] Ex. 15 — Non-slip acrylic coating (OSB, MDF, HDF Plywood, etc. / facing). Water-based acrylic about 60%, biochar 20% (bimodal), CaCOs shells 15%, additives 5%. Effects: Anti-slips (ps > 0.6), UV shield, abrasion increased.

[0139] Ex. 16 — “Fine grip” finish (wall panels). Acrylic 55%, biochar 25% (bimodal: about 30% fines < 100 pm + about 70% 0.3-1.0 mm), shells 10%, additives 10%. Effects: Micro-roughness increased, friction increased, scratch decreased.

[0140] Ex. 17 — Low-gloss topcoat. Acrylic 70%, biochar 15% (fines < 80 pm), shells 10%, additives 5%. Effects: Matte / anti-glare, UV shield, moderate slip resistance, washable.

[0141] HORTICULTURE (Ex. 18-25): rings formed from post-use packaging; maple, wood, and fir versions; mineralized ring (CaCOs); substrate pellets.

[0142] Ex. 18 — Ring formed from post-use packaging. Flow of crushed packaging with 1-2 mm biochar aggregate (10-15%) and 1-2% chitosan; molding of rings with a diameter of about 20-35 cm; drying at 60-80°C. Effects: Capillarity (grooves), vigor, reduced watering.

[0143] Ex. 19 — “Infused + combined” ring (terroir-coded). Fine infused biochar (maple hydrosol) 1-3% w / w in biochar with aggregate 0.5-2 mm (10%), cellulose and chitosan 1-2%; triacetin 0.5% (fixation). Effects: Moderate aromatic signature, antidesiccation, cation exchange capacity (CEC) increased.

[0144] Ex. 20 — Mineralized ring (CaCCU). Cellulose about 50-65%, biochar about 15-25%, (egg)shells about 10-20%, and chitosan about 1-3%. Effects: watering decreased, growth increased (young trees).

[0145] Ex. 21 — “Maple signature” strawberries. Infused fine biochar: about 1-3% w / w maple extract in biochar; triacetin about 0.3-0.5%, chitosan about 1%. Measurements: SPME-GC-MS soil + sensory panel (modulation not guaranteed, as effect difficult to measure in the short term).

[0146] Ex. 22 — “Woody” vine (test plot). Ring with wood extract (traces of vanillin / eugenol), chitosan 1-2%. Follow-up: LC-MS metabolome berries and sensory micro-vinification (R&D in progress).

[0147] Ex. 23 — Terroir-coded liner to ring: Coffee-infused / woody liner reshaped into a ring; measures VOC flow (SPME-GC-MS) & fruit aromas.

[0148] Ex. 24 — “Forest-boost” (fir tree). Cellulose / bark fibers about 60-70%, biochar about 15-25% (including about 5% fir-infused), shells about 5-10%. Effects: capillarity / CEC increased, initial terpene release, Ca returned to soil.

[0149] Ex. 25 — Horticultural substrat pellets (Peat option). Composite 40-50%, peat 30-40%, biochar 15-20% (0.5-1 mm), alginate 1-2%; fine infused biochar option (triacetin 0.3-0.5%). Effects: uniform capillarity, increased CEC.

[0150] LITTERS (Ex. 26-31): poultry, equine / bovine, swine, small animals (“mild aroma”), “forest-fresh” variant (fir tree), hybrid litter to substrate.

[0151] Ex. 26 — Poultry litter (particle diameter about 6-8 mm). Composite 50%, peat 25%, hybrid biochar 20% (30% fines < 200 pm infused + 70% 0.5-1.5 mm), chitosan 1%, starch 4%. Effects: absorption increased, NHa / odors decreased, low dust; compost: CEC increased.

[0152] Ex. 27 — Equine / Bovine litter (particle diameter about 8-12 mm, robust).Composite 50-60%, biochar 25-30%, lignosulfonate 1-3%, shells 5-10%. Effects: easier cleaning, dry surface.

[0153] Ex. 28 — Pig manure litter (particle diameter about 8-10 mm). Composite 45-55%, peat 20-30%, biochar 20-25%, chitosan 0.8-1.5%. Effects: odor decreased, mechanical stability.

[0154] Ex. 29 — Small animals’ litter (0 4-6 mm, “mild aroma”). Composite 65-75%, biochar 15-20% (infused fine fraction: hydrolat 0.10-0.20% on solids or 1- 2% m / m in biochar), triacetin 0.3-0.5%, glycerin 0.5-1%, starch 2-3%. Effects: slight odor masking, adequate agglomeration.

[0155] Ex. 30 — “Forest-fresh” (bark fibers + fir tree). Composite 45-55%, bark fibers 15-25%, biochar 20-25% (including 0.5-1.5% m / m oleoresin / hydrolate in fine biochar; net pellet load -0.05-0.30%), starch 2-3%, chitosan 1%. Effects: NHa / odors decreased, subtle forest aroma.

[0156] Ex. 31 — Hybrid litter to substrate: Composite 40-50%, peat 30-40%, biochar 15-20% (0.5-1 mm), alginate 1-2%. Effects: absorption in litter, then reuse in horticultural substrate, before composting.

[0157] PEANUT TWIST HELICAL REINFORCEMENTS (Ex. 32 to 33)

[0158] Ex. 32 — Corrugated with twists (groove filling). a. Principle & material: extruded helical element (starch and / or cellulose, ± biochar) produced in continuous length, then cut (e.g., 30 to 200 cm). b. Integration: the twist is placed in the flute voids before the second liner (or second wave) is glued on. The twist fills the void and supports the flute to prevent collapse under load and impact. c. This twist can be introduced into our biochar-based product or another conventional packaging product. d. This twist can also be used independently, as is currently the case to fill a box. e. Optional functions: i. Infused fine biochar (moisture control, aromatic note as required), ii. Aggregate biochar (micro-cushioning, drying aid), iii. Aqueous biochar adhesive for local fixing. f. Effects: shock absorption increased, specific rigidity increased, weight decreased (performance with little material) g. End of life: regenerative / recyclable / compostable.

[0159] Ex. 33 — Molded paste with insertion of twists (after pressing) a. Principle: after pressing / forming the molded paste part, targeted insertion of twists at angles / corners / grooves in recesses provided for in the design (housings, anchor bosses). b. Objective: to place localized shock absorbers at critical points (impact zones during a fall) to optimize packaging performance. Twist lengths are adapted as needed (short or long segments, e.g., 30 to 200 mm). c. Optional functions: i. Infused fine biochar twist (odor / moisture control), ii. Aggregate biochar twist (cushioning), iii. Aqueous biochar adhesive for post-pressing bonding.d. Effects: local cohesion increased, mechanical strength increased in targeted areas without overall excess thickness. e. End of life: recyclable / compostable with the molded pulp part.REGENERATIVE SECOND LIFE (Ex. 34 - 38)

[0160] Ex. 34 - Biodegradable horticultural ring:Composite: 5-50% biochar, finely infused + aggregate; cellulose / bark fibers; chitosan; CaCOs & peat options.Functions: water retention, capillarity, weed control, CEC increased, organoleptic modulation (maple / woody / fir / coffee), gentle hygiene.End of life: composting (stable C & mineral return).

[0161] Ex. 35 - Densified bedding (granules / pellets):Composite: 10 - 30% biochar (bimodal) + 10 - 40% peat + chitosan / binders; bark fiber & CaCOs options; pet-safe aromas (low-dose hydrolats).Functions: absorption increased, NFE / odors decreased, hygiene; regenerative compost.Sizes: diameter 4-6 mm (small animals), 6-8 mm (poultry), 8-12 mm (equine / bovine / porcine).

[0162] Ex. 36 - Horticultural substrates (pellets):Composite plus peat / biochar; homogeneous capillarity, increased CEC; pellets can be used for sowing / nursery, then composted.

[0163] Ex. 37 - Municipal reuse (collection & buildings):Integration into food waste bins for NHi / odors / VOC decreased; absorbent materials for waste / building premises; composting & return to soil; optimization of collection frequency.

[0164] Ex. 38 - Voluntary dissemination in soil — primary mission:The primary mission is to achieve soil regeneration everywhere: each package delivered carries biochar, free of charge for the planet. If the consumer throws the packaging into soil / garden / flowerbed / earth (tom, fragmented, or whole), the objective is achieved: adsorption of pollutants (e.g., PFAS, heavy metals), improvement of structure, CEC, and water retention. When the context does not allow for this (e.g., urban living, no access to soil), reuse (rings, bedding, substrates) and municipal collection offer added value before final composting.CONCLUSION:

[0165] The new technology as disclosed herein represents a groundbreaking approach to material design by integrating biochar into composite materials for use in packaging, construction, and horticulture. By focusing on sustainability, environmental stewardship, and material performance, this innovation contributes significantly to global climate change mitigation efforts. The dual-purpose use of packaging as a means for distributing biochar and improving soil quality further strengthens its environmental impact, helping to build a sustainable, circular economy.

[0166] The new technology as disclosed herein represents a groundbreaking approach to sustainable material development by integrating biochar into composite materials for construction, packaging, and horticulture. The dual-purpose nature of these materials allows them to fulfill their primary functions, such as protecting products, reinforcing structures, or supporting plant growth, while also contributing meaningfully to environmental sustainability.

[0167] The biochar-infused composites provide key mechanical enhancements, including increased rigidity, moisture resistance, and impact protection, making them highly suitable for diverse applications across industries. Moreover, biochar’s innovative use in these materials supports crucial environmental goals, such as carbon sequestration, pollutant absorption, and soil health improvement, effectively addressing global challenges like climate change and environmental degradation.

[0168] A core advantage of biochar is its long-term carbon sequestration ability. Biochar can store carbon for thousands of years, reducing atmospheric CO2 levels and playing a pivotal role in climate change mitigation. Additionally, by incorporating biochar into everyday materials, the composite material as disclosed herein opens up new opportunities for participation in carbon offset markets, offering not onlyenvironmental benefits but also potential economic incentives through the generation of carbon credits. This financial aspect enhances the scalability and appeal of biochar- infused products.

[0169] In addition to their primary functions, these new materials as disclosed herein may fit seamlessly into a circular economy model. They can be recycled, composted, or repurposed into new biochar-based products, minimizing waste and maximizing environmental benefits. The ability to return biochar to the soil through composting further extends its lifecycle and amplifies its positive environmental impact, contributing to improved soil quality and sustainable agricultural practices.

[0170] Moreover, as aforesaid, the customization of biochar concentration, particle size, and the incorporation of additives such as starch, chitosan, and natural polymers allow the composites to be tailored for specific applications. Whether enhancing the durability of construction panels, increasing moisture resistance in packaging, or improving plant growth in horticulture, this adaptability ensures that biochar-infused composites can be optimized for diverse functional and environmental goals.

[0171] In summary, the present invention sets a new benchmark for eco-friendly material innovation, offering a versatile solution that combines superior mechanical performance with long-lasting environmental benefits. By addressing the needs of the packaging, construction, and horticultural industries, the technology as disclosed herein supports global efforts to mitigate climate change, promote resource conservation, and advance sustainable practices. Its comprehensive integration of biochar across multiple sectors ensures a lasting positive impact on both the market and the environment.

[0172] While illustrative and presently preferred embodiments of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art.

Claims

CLAIMS1. A composite material comprising: a polymeric matrix, and a given amount of biochar particles infused or combined with the polymeric matrix, wherein the given amount and / or size of the biochar particles are tailored to enhance the composite material’s physical properties, and wherein the biochar particles in the composite material allows for carbon sequestration when the material is used or subsequently composted.

2. The composite material as claimed in claim 1, wherein the size of the biochar particles comprises particles having a diameter ranging from about 0.1 mm to about 5.0 mm.

3. The composite material as claimed in claim 2, wherein the biochar is a bimodal biochar comprising a first portion of biochar particles having a diameter inferior to 0.2 mm and a second portion of biochar particles having a diameter of from about 0.3 to 3 mm.

4. The composite material as claimed in any one of claims 1 to 3, wherein the polymeric matrix comprises at least one natural polymer.

5. The composite material as claimed in claim 4, wherein the at least one natural polymer comprises cellulose, starch, chitosan, gelatin, Polylactic Acid (PLA), pectin, agar or a mixture thereof.

6. The composite material as claimed in any one of claims 1 to 5, wherein the polymeric matrix comprises cellulose in a form of molded pulp, paper, carton or cardboard.

7. The composite material as claimed in any one of claims 1 to 6, for use as packaging material with enhanced protection against moisture, shocks, and UV exposure, while offering secondary environmental benefits as a soil amendment after use.

8. The composite material as claimed in any one of claims 1 to 7, further comprising at least one additive selected from the group consisting of antimicrobial agents, moisture regulators, stabilizers, UV stabilizer, where the impregnation of biochar with these polymers and / or additives enhances the mechanical properties, moisture absorption, and antimicrobial capabilities of the material, while facilitating a controlled release of nutrients and additives in agricultural or environmental applications.

9. The composite material as claimed in any one of claims 1 to 8, wherein the biochar is present in the matrix at a concentration ranging between 5% and 50% by weight of said composite material, said concentration being selected depending on specific mechanical and environmental properties of the composite material to be used.

10. The composite material as claimed in any of claims 1 to 9, wherein the composite material is recyclable.

11. The composite material as claimed in claim 10, wherein the recyclable composite material is repurposed into new materials or converted back into biochar for further use in other applications, ensuring a closed-loop lifecycle.

12. The composite material as claimed in any one of claims 1 to 11, in the form of biochar-infused layers.

13. The composite material as claimed in claim 12, wherein one or more of said biochar- infused layers are laminated onto a substrate comprising oriented strand boards (OSBs) or plywood, to form recyclable construction panels.

14. The composite material as claimed in claim 13, wherein the one or more layers comprises 20 to 30% of biochar with printing / vanishing based on impregnated fine biochar comprising ethanol-water / PG / triacetin, for the release of pleasant odors and adsorption of VOCs and odor attenuation.

15. The composite material as claimed in any one of claims 1 to 11, wherein the composite material is a biochar-infused material combined with standard pulp layers in a hybrid structure, creating a composite that balances the benefits of biochar with traditional cardboard properties.

16. The composite material as claimed any one of claims 1 to 11, used in packaging applications, wherein the biochar is further configured for absorbing volatile organic compounds (VOCs) and odors during its initial use, and absorbing pollutants when the material is composted into soil.

17. The composite material of any one of claims 1 to 16, wherein the biochar is configured to adsorb volatile organic compounds (VOCs), tyre-wear derived chemicals such as 6PPD-quinone, and other toxic pollutants released by packaged goods during transport and storage.

18. The composite material as claimed in claim 17, wherein the biochar is present at a concentration which is optimized to enhance the absorption capacity of VOCs and odors during the packaging's first lifecycle, and to maximize pollutant absorption in soil during its second lifecycle.

19. The composite material of any one of claims 1 to 18, wherein the biochar is infused with natural plant extracts such as balsam fir (Abies balsamed), cedar, or hydrosols, thereby combining pollutant adsorption with aromatic masking and antimicrobial action.

20. Use of the composite material as claimed in any one of claims 1 to 19, for the manufacturing of a packaging material, the biochar-infused material providing enhanced protection against moisture, shocks, and UV exposure, while offering secondary environmental benefits as a soil amendment after use, and wherein the biochar allows for carbon sequestration when the material is used or composted.

21. The use of claim 20, wherein during primary use of the packaging material, said packaging material protects both a packaged product and a consumer environment by reducing indoor VOC exposure upon unboxing.

22. The use of claim 20 or 21, wherein the biochar is infused or incorporated into cardboard for creating boxes or other packaging components, with specific layers including corrugated and flat liners enhanced by biochar to improve structural integrity, moisture resistance, and UV protection.

23. The use as claimed in claim 22, wherein the cardboard comprises at least one corrugated layer over a flat liner, wherein the at least one corrugated layer of thecardboard contains a concentration of biochar configured to maximize rigidity and compression resistance, while the flat liner layer contains another concentration of biochar configured to optimize moisture resistance and durability.

24. The use as claimed in claim 22 or 23, wherein the boxes or other packaging components is bonded using a biochar-infused water-based adhesive, which enhances the overall structural integrity and moisture resistance of the cardboard.

25. The use as claimed in claim 24, wherein the biochar-infused water-based adhesive is configured to improve packaging durability and to provide sustainable solutions for carbon sequestration in soils, free from chemical contaminants, when the composite material is composted or repurposed after use.

26. A construction panel comprising a composite material for construction applications, wherein the panel comprises a protective layer or paper made of biochar-infused composite material applied onto a substrate, wherein the protective layer enhances the durability of the substrate by providing increased resistance to UV radiation and moisture and contributes to carbon sequestration.

27. The construction panel as claimed in claim 26, wherein the substrate comprises oriented strand board (OSB), plywood, veneer, or other flat or corrugated panels.

28. The construction panel as claimed in claim 26, wherein the substrate comprises corrugated panels having ribs and grooves and further comprises extruded helical elements comprising biochar and starch and / or cellulose, the extruded helical elements being configured to be placed in said grooves before gluing a second liner, so as to fill a void formed by the grooves of the corrugated panels and support the ribs against collapse.

29. The construction panel as claimed in any one of claims 26 to 28, wherein the construction panel further comprises additional layers of biochar-infused adhesives that enhance the overall structural integrity and moisture resistance of the panels.

30. The construction panel as claimed in any one of claims 26 to 29, wherein the biochar- infused protective layer is further treated with or further comprise additives to enhance UV and moisture resistance, extending the longevity and structural integrity of the underlying substrate.

31. The construction panel as claimed in any one of claims 26 to 30, wherein the composite material is as defined in any one of claims 1 to 19.

32. A composite material comprising biochar and starch, with or without additional additives selected from chitosan, gelatin, and other natural biopolymers, wherein said composite material has a formulation for improving mechanical properties of the composite material, including impact resistance, moisture management, and antimicrobial properties, and wherein the composite material is designed for use in packaging applications or integrated within packaging materials.

33. The composite material of claim 32, wherein biochar concentration ranges between 5% and 50% by weight and is optionally combined with starch to enhance structure and provide environmental benefits such as carbon sequestration and soil health improvement when the material is composted or used as a soil amendment.

34. The composite material as claimed in claim 32 or 33, wherein the biochar particles have a size range from 0.1 mm to 5 mm, allowing customization of the composite material’s mechanical properties, moisture management, and pollutant absorption capabilities depending on the specific application.

35. The composite material as claimed in any one of claims 32 to 34, which is molded to form parts comprising, after pressing, extruded helical elements comprising biochar and starch and / or cellulose, the extruded helical elements being provided at areas comprising comers, edges and / or grooves in order to enhance shock absorption during a fall, without excess thickness.

36. Spiral-shaped packing peanuts made from the composite material as claimed in any one of claims 1 to 19 or any one of claims 32 to 31, where the spiral shape allowing increasing air content, enhancing shock absorption, absorbing moisture, and optimizing distribution of biochar and other additives in the material.

37. The spiral-shaped packing peanuts of claim 36, wherein the helical geometry provides progressive energy dissipation by sequential deformation of outer coils followed by inner coils of increasing diameter and rigidity, thereby optimizing cushioning efficiency while minimizing material usage.

38. The spiral-shaped packing peanuts as claimed in claim 36 or 37, wherein the spiral shape also maximizes the efficiency of cushioning while minimizing material usage, and after dissolving in water, the biochar allows controlled absorption of additives, which can then be dried for transportation and reused in packaging.

39. The spiral-shaped packing peanuts as claimed in any one of claim 36 to 38, wherein when the biochar is further enriched with starch and / or additives and placed in a soil, the spiral-shaped packing peanuts manage nutrients and moisture, contributing to improved soil fertility.

40. The spiral-shaped packing peanuts of claim 39, wherein after partial dissolution of the starch or cellulose matrix, a fraction of biochar remains in solid form as an active residue, said residue providing carbon sequestration, microbial habitat, and controlled release of infused additives, thereby contributing to soil regeneration.

41. The spiral-shaped packing peanuts of any one of claims 36 to 40, wherein the combination of spiral geometry and biochar residue provides a dual functionality of product cushioning during transport and regenerative soil amendment after use.

42. A biochar-infused composite material integrated into a matrix of paper, cardboard, molded pulp, peat moss, or a combination of these carbon materials, used for the manufacture of horticultural products such as pots and soil amendments, wherein the biochar enhances water retention, aeration, and nutrient availability in the soil, while also contributing to carbon sequestration.

43. The biochar-infused composite material as claimed in claim 42, wherein the composite material is configured to be composted after use, allowing the biochar to be released into soil, improving soil fertility, moisture retention capacity, and promoting the long-term survival and vigor of plants or seeds in agricultural and horticultural applications.

44. A method for packaging and transporting a product, comprising: a) providing a packaging made of a composite material comprising: a polymeric matrix, anda given amount of biochar particles, wherein the given amount and / or size of the biochar particles are tailored to enhance the composite material’s physical properties; b) transporting the product using said packaging for delivering the product to its final destination; and c) composting said packaging after delivery; wherein the biochar particles in the composite material allows for carbon sequestration when the composite material is used for packaging and transportation and subsequently composted.

45. The method as claimed in claim 44, wherein the product is biochar used for horticulture applications.

46. The method as claimed in claim 44 or 45, wherein the biochar in the packaging and the packaging containing biochar are both conjointly used for horticulture applications.

47. A biodegradable horticulture ring comprising:- about 5 - 50% of the bimodal biochar composite of claim 3 with fine infused biochar and aggregate,- about 0.5-2% of chitosan,- optionally 5-25% of CaCOs, and- about 10 - 40% of bark fibers grooved / micro-textured reliefs, wherein the biodegradable horticulture ring is formed from a second life process.

48. Pellets comprising about 50% of material composite as claimed in claim 1, about 10 to 30% of a bimodal biochar having 30% of fines infused particles with a diameter inferior to 200 pm and about 70% of 0.5-1.5 mm particles, about 10 - 40% of peat, about 1% of chitosan, about 4% of starch, binders and optionally CaCCh.

49. Use of the pellets of claim 48 for the making of a litter for animals selected from poultry, equine / bovine, swine, and small animals or pets.

50. A construction panel coating formulation comprising:- about 40 - 75% of an acrylic water layer, - about 10 - 30% of biochar material composite as claimed in claim 1, and- about 5 - 25% of CaCCh, wherein the construction panel coating formulation is configured to be applied on a surface before drying and form a coating having a thickness of about 50 - 300 pm with a static coefficient of friction (ps) superior or equal to about 0.6.

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