Building panel

Abstract

A building panel having a body including an inorganic material in an amount ranging from about 1% to about 99% by weight based on the total weight of the body and a biochar in an amount ranging from about 1% to about 40% by weight based on the total weight of the body is described. In some embodiments, the inorganic material may include inorganic fibers. In some embodiments, the inorganic material may include inorganic particles. In some embodiments, the building panel may further include a flame retardant in an amount ranging from about 1% to about 15% by weight based on the total weight of the body.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a PCT international application, claiming priority to U.S. Provisional Patent Application No. 63 / 342,229, filed on May 16, 2022, the entire disclosure of which is incorporated herein by reference. Background Art

[0001] Carbon dioxide (CO2) emissions have been identified as a major contributor to global warming and ocean acidification phenomena. CO2 is a byproduct of combustion that creates operational, economic, and environmental issues. Increased atmospheric concentrations of CO2 and other greenhouse gases are expected to promote greater heat storage in the atmosphere, leading to increased surface temperatures and rapid climate change. Building products and materials used to form such building products are contributors to CO2 emissions. Therefore, new building products that help reduce or eliminate CO2 emissions are needed. In addition, such new building products should be developed without sacrificing the mechanical and / or acoustic performance characteristics required of such building products to achieve the desired functionality. Summary of the invention

[0002] According to some embodiments, the present invention may include an acoustic building panel, including a body, the body including inorganic fibers and biochar, wherein the content of the inorganic fibers ranges from about 60.0 wt% to about 90.0 wt% based on the total weight of the body, and the content of the biochar ranges from about 10.0 wt% to about 40.0 wt% based on the total weight of the body, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0003] According to some embodiments, the present invention may include an acoustic building panel comprising a body, the body comprising inorganic fibers and biochar; wherein the body has a relative humidity of about 0.03 g / cm 3 To about 0.25g / cm 3 The volume density of .

[0004] According to some embodiments, the present invention may include an acoustic building panel comprising: a body comprising inorganic fibers and biochar; wherein the body has a porosity of about 80.0% to about 95.0%.

[0005] According to some embodiments, the present invention may include a method of making an acoustic building panel, the method comprising: mixing a liquid carrier, inorganic fibers, biochar, and a binder to form a blend; shaping and drying the blend into a body having a first major surface opposite to a second major surface and a side surface extending between the first and second major surfaces; wherein the body is substantially free of the liquid carrier.

[0006] According to some embodiments, the present invention may include an acoustic building panel comprising: a body, the body comprising inorganic fibers, biochar, and a flame retardant, wherein the content of the inorganic fibers ranges from about 60.0 wt % to about 90.0 wt % based on the total weight of the body; and the content of the biochar ranges from about 10.0 wt % to about 40.0 wt % based on the total weight of the body.

[0007] According to some embodiments, the present invention may include a method of making an acoustic building panel, the method comprising: mixing a liquid carrier, inorganic fibers, biochar, a flame retardant, and a binder to form a blend; and shaping and drying the blend into a body having a first major surface opposite to a second major surface and a side surface extending between the first and second major surfaces; wherein the body is substantially free of the liquid carrier.

[0008] According to some embodiments, the present invention may include a building panel, comprising: a body, the body comprising an inorganic material, biochar and a flame retardant: the content of the inorganic material ranges from about 1 weight % to about 99 weight % based on the total weight of the body, wherein the inorganic material comprises an alkaline earth metal compound; the content of the biochar ranges from about 10 weight % to about 40 weight % based on the total weight of the body; the content of the flame retardant ranges from about 1 weight % to about 15 weight % based on the total weight of the body, wherein the flame retardant comprises an active filler flame retardant.

[0009] According to some embodiments, the present invention may include a method for manufacturing an acoustic building panel, the method comprising: mixing an inorganic material, biochar, a flame retardant, and a liquid carrier to form a blend; and molding and hardening the blend into a body having a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface; wherein: the inorganic material comprises an alkaline earth metal compound; the flame retardant comprises an active filler flame retardant; the content of the inorganic material ranges from about 1 weight % to about 99 weight % based on the total weight of the hardened body; the content of the biochar ranges from about 10 weight % to about 40 weight % based on the total weight of the hardened body; and the content of the flame retardant ranges from about 1 weight % to about 15 weight % based on the total weight of the hardened body.

[0010] According to some embodiments, the present invention may include a building panel comprising: a body, the body comprising an inorganic material, biochar and a flame retardant, wherein the content of the inorganic material ranges from about 1 weight % to about 99 weight % based on the total weight of the body; the content of the biochar ranges from about 1 weight % to about 40 weight % based on the total weight of the body; the content of the flame retardant ranges from about 1 weight % to about 15 weight % based on the total weight of the body, wherein the flame retardant comprises an active filler flame retardant.

[0011] According to some embodiments, the present invention may include a ceiling system comprising: a support structure; and at least one of the previously discussed building panels.

[0012] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter.It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention will become more fully understood through the detailed description and accompanying drawings, in which: Figure 1 is a top perspective view of a building panel according to some embodiments of the present invention; Figure 2 yes Figure 1 A cross-sectional view of a building panel taken along Figure 1 The II line shown in; Figure 3 is a ceiling system comprising building panels according to some embodiments of the present invention; Figure 4 is a top perspective view of a building panel according to some embodiments of the invention; and Figure 5 yes Figure 4 A cross-sectional view of a building panel taken along Figure 4 The V line shown in . DETAILED DESCRIPTION

[0014] The following description of the preferred embodiment is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0015] As used throughout, ranges are used as shorthand for describing each value within a range. Any value within the range may be selected as the endpoint of the range. In addition, all references cited herein are incorporated herein by reference in their entirety. In the event that a definition in the present invention conflicts with a definition in the cited reference, the present invention shall prevail.

[0016] The description of the illustrative embodiments according to the principles of the present invention is intended to be read in conjunction with the accompanying drawings, which are considered part of the entire written description. In the description of the embodiments of the present invention disclosed herein, any reference to direction or orientation is merely for convenience of description and is not intended to limit the scope of the present invention in any way. Relative terms such as "lower", "higher", "horizontal", "vertical", "above", "below", "upward", "downward" and "top" and "bottom" and their derivatives (e.g., "horizontally", "downwardly", "upwardly") should be interpreted as referring to the orientation as described or as shown in the drawings discussed. These relative terms are only for convenience of description and do not require that the device be constructed or operated in a specific orientation unless explicitly stated.

[0017] Unless expressly stated otherwise, terms such as "attached," "fixed," "connected," "coupled," and "interconnected" refer to a relationship in which structures are fixed or connected to each other, directly or indirectly through intermediate structures, as well as removable or rigid connections or relationships. In addition, the features and benefits of the present invention are described by reference to exemplary embodiments. Therefore, the present invention should obviously not be limited to the exemplary embodiments illustrating some possible non-limiting feature combinations, which may exist alone or in other feature combinations; the scope of the present invention is defined by the appended claims.

[0018] Unless otherwise indicated, all percentages and amounts expressed herein and elsewhere in the specification are understood to refer to weight percentages. The amounts given are based on the effective weight of the material. According to the present invention, the term "about" refers to + / - 5% of the reference value. According to the present invention, the term "substantially free" is less than about 0.1% by weight based on the total reference value.

[0019] Reference Figure 1 In some embodiments, the building panel 100 may include a first major surface 111 opposite to a second major surface 112 , and the ceiling panel 100 may further include a side surface 113 extending between the first major surface 111 and the second major surface 112 , thereby defining a perimeter of the ceiling panel 100 .

[0020] refer to Figure 3 In some embodiments, the present invention may further include a building system 1 - also referred to as a ceiling system 1, which includes one or more building panels 100 installed in an interior space, whereby the interior space includes a general space 3 and an effective room environment 2. The general space 3 provides space for mechanical lines 9 (e.g., HVAC, plumbing, etc.) within the building. The effective space 2 provides space for building occupants during normal expected use of the building (e.g., in an office building, the effective space will be occupied by offices containing computers, lights, etc.).

[0021] The ceiling system 1 may include a ceiling supporting grid 6 and at least one building panel 100 supported by the ceiling supporting grid 6, the building panel 100 having a first major surface 111 opposite to a second major surface 112, and the second major surface 112 faces upward and the first major surface 111 faces downward.

[0022] In the installed state, the building panel 100 can be supported in the interior space by one or more parallel support struts 5. Each support strut 5 may include an inverted T-shaped bar having a horizontal flange 31 and a vertical web 32. The ceiling system 1 may also include a plurality of first struts and a plurality of second struts substantially parallel to each other, the second struts being substantially perpendicular to the first struts (not shown). In some embodiments, the plurality of second struts intersect with the plurality of first struts to form an intersecting ceiling support grid 6. The entire space 3 exists above the ceiling support grid, and the effective room environment 2 exists above the ceiling support grid 6. In the installed state, the first major surface 111 of the building panel 100 faces the effective room environment 2, and the second major surface 112 of the building panel 100 faces the entire space 3.

[0023] Now refer to Figure 1 and Figure 2 .like Figure 1 and Figure 2 As shown, in some embodiments, the building panel 100 of the present invention can have a panel thickness t0 measured from the first major surface 111 to the second major surface 112. The panel thickness t0 can be in the range of about 12 mm to about 40 mm, including all values ​​and sub-ranges therebetween. The building panel 100 can have a length of about 30 cm to about 310 cm, including all values ​​and sub-ranges therebetween. The building panel 100 can have a width of about 10 cm to about 125 cm, including all values ​​and sub-ranges therebetween.

[0024] In some embodiments, the building panel 100 may include a body 120 having an upper surface 122 opposite to a lower surface 121 and a body side surface 123 extending between the upper surface 122 and the lower surface 121, thereby defining a perimeter of the body 120. The body 120 may have a body thickness t1 extending from the upper surface 122 to the lower surface 121. The body thickness t1 may range from about 12 mm to about 40 mm, including all values ​​and sub-ranges therebetween.

[0025] The first major surface 111 of the building panel 100 may include the lower surface 121 of the body 120. The second major surface 112 of the building panel 100 may include the upper surface 122 of the body 120. When the first major surface 111 of the building panel 100 includes the lower surface 121 of the body 120 and the second major surface 112 of the building panel 100 includes the upper surface 122 of the body 120, the panel thickness t0 is substantially equal to the body thickness t1.

[0026] As discussed in greater detail herein, in some embodiments, the body 120 may be porous, thereby allowing airflow through the body 120 between the upper surface 122 and the lower surface 121 .

[0027] In some embodiments, the body 120 may be composed of fibers 130, and the fibers 130 may include fiber components. The fiber components may include organic fibers, inorganic fibers, and combinations thereof. The body may also include biochar. In some embodiments, the body 120 may also include fillers and / or additives. The body 120 may also include a binder.

[0028] The first fiber component of fiber 130 can be an organic fiber, an inorganic fiber, or a mixture thereof. Non-limiting examples of inorganic fibers include mineral wool (also known as slag wool), rock wool, asbestos, glass fibers, and polymer fibers. Non-limiting examples of polymer fibers include polyester fibers, polyethylene fibers, aramid fibers (e.g., aramid fibers), and polypropylene fibers. Non-limiting examples of organic fibers include cellulose fibers visible to the naked eye (e.g., paper fibers-such as newspaper, hemp fibers, jute fibers, flax fibers, wood fibers, or other natural fibers), protein fibers (e.g., sheep wool), and combinations thereof. Depending on the specific type of material, the first fiber component can be hydrophilic (e.g., cellulose fibers visible to the naked eye) or hydrophobic (e.g., glass fibers, mineral wool, rock wool, asbestos).

[0029] The fiber component may be present in an amount ranging from about 25% to about 95% by weight based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In some embodiments, the fiber component may be present in an amount ranging from about 55% to about 95% by weight based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In some embodiments, the fiber component may be present in an amount ranging from about 60% to about 90% by weight based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In some embodiments, the fiber component may be present in an amount ranging from about 63% to about 75% by weight based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween.

[0030] The phrase "dry weight" refers to the weight of a reference component without the weight of any carrier. Therefore, when calculating the weight percentage of a dry component, the calculation should be based only on the solid components (e.g., binder, filler, biochar, fiber, additives, etc.), and should exclude any amount of residual carrier (e.g., water, VOC solvents) that may still be present in a wet state, as will be discussed further herein. According to the present invention, the phrase "dry state" may also be used to refer to a component that is substantially free of carrier, as compared to the term "wet state", which refers to a component that still contains various amounts of carrier, as discussed further herein.

[0031] In some embodiments, the fiber component can be an inorganic fiber, such as mineral wool, wherein the inorganic fiber is present in an amount ranging from about 55% to about 90% by weight based on the total weight of the body 120, including all weight percentages and subranges therebetween. In some embodiments, the fiber component can be an inorganic fiber, such as mineral wool, wherein the inorganic fiber is present in an amount ranging from about 60% to about 90% by weight based on the total weight of the body 120 (including all weight percentages and subranges therebetween). In some embodiments, the fiber component can be an inorganic fiber, such as mineral wool, wherein the inorganic fiber is present in an amount ranging from about 60% to about 75% by weight based on the total weight of the body 120, including all weight percentages and subranges therebetween. In some embodiments, the fiber component can be substantially free of inorganic fibers. In some embodiments, the fiber component is present in an amount ranging from 0% to about 90% by weight or from 0% to about 85% by weight based on the total weight of the body 120, including all weight percentages and subranges therebetween.

[0032] In some embodiments, the fiber component may further include macroscopic cellulose fibers, such as recycled newspapers. In some embodiments, the cellulose fibers are present in an amount ranging from 0.1 wt % to about 5.0 wt % (including all weight percentages and subranges therebetween) based on the total weight of the body 120. In some embodiments, the fiber component may further include cellulose fibers in an amount ranging from about 0.5 wt % to about 3.0 wt %.

[0033] In some embodiments, the body 120 may further include biochar. The term "biochar" is interchangeable with the term "biocoal" and refers to pyrolyzed biomass. The production of biochar removes carbon dioxide directly from the atmosphere through plant uptake, thereby actually reducing atmospheric carbon dioxide levels. With this in mind, since biochar is a negative carbon material, i.e., its production removes CO2 from the atmosphere, creating an acoustic panel composed in part of a body formed from biochar helps reduce carbon emissions, thereby mitigating the potential for global warming.

[0034] In some embodiments, the biochar can have a density of about 3 pounds per cubic foot (pcf) to about 18 pcf. For example, in some embodiments, the biochar can have a density of about 3 pcf to about 18 pcf, about 5 pcf to about 18 pcf, about 7 pcf to about 18 pcf, about 9 pcf to about 18 pcf, about 11 pcf to about 18 pcf, about 13 pcf to about 18 pcf, about 15 pcf to about 18 pcf, about 17 pcf to about 18 pcf, about 3 pcf to about 17 pcf, about 5 pcf to about 17 pcf, about 7 pcf to about 17 pcf, about 9 pcf to about 17 pcf, about 11 pcf to about 17 pcf, about 13 pcf to about 17 pcf, about 15 pcf to about 17 pcf, about 3 pcf to about 15 pcf, about 5 pcf to about 15 pcf, about 7 pcf to about 17 pcf, about 15pcf, about 9pcf to about 15pcf, about 11pcf to about 15pcf, about 13pcf to about 15pcf, about 3pcf to about 13pcf, about 5pcf to about 13pcf, about 7pcf to about 13pcf, about 9pcf to about 13pcf, about 11pcf to about 13pcf, about 3pcf to about 11pcf, about 5pcf to about 11pcf, about 7pcf to about 11pcf, about 9pcf to about 11pcf, about 3pcf to about 9pcf, about 5pcf to about 9pcf, about 7pcf to about 9pcf, about 3pcf to about 7pcf, about 5pcf to about 7pcf, about 3pcf to about 5pcf, or any other suitable value or sub-range therebetween.

[0035] The biochar can be processed to a specific particle size distribution. The biochar can have an average particle size of about 0.1 mm to about 5 mm, including all sizes and subranges therebetween. For example, in some embodiments, the average particle size of the biochar can be about 0.1 mm to about 5 mm, about 0.5 mm to about 5 mm, about 1 mm to about 5 mm, about 1.5 mm to about 5 mm, about 2 mm to about 5 mm, about 2.5 mm to about 5 mm, about 3 mm to about 5 mm, about 3.5 mm to about 5 mm, about 4 mm to about 5 mm, about 4.5 mm to about 5 mm, about 0.1 mm to about 4.5 mm, about 0.5 mm to about 4.5 mm, about 1 mm to about 4.5 mm, about 1.5 mm to about 4.5 mm, about 2 mm to about 4.5 mm, about 2.5 mm to about 4.5 mm, about 3 mm to about 4.5 mm, about 3.5 mm to about 4.5 mm, about 4 mm to about 4.5 mm, about 0.1 mm to about 4 mm, about 0.5 mm to about 4 mm, about 1 mm to about 4 mm, about 1.5 mm to about 4 mm, about 2 mm to about 4 mm, about 2.5 mm to about 4 mm, about 3mm to about 4mm, about 3.5mm to about 4mm, about 0.1mm to about 3.5mm, about 0.5mm to about 3.5mm, about 1mm to about 3.5mm, about 1.5mm to about 3.5mm, about 2mm to about 3.5mm, about 2.5mm to about 3.5mm, about 3mm to about 3.5mm, about 0.1mm to about 3mm, about 0.5mm to about 3mm, about 1mm to about 3mm, about 1.5mm to about 3mm, about 2mm to about 3mm, about 2.5mm to about 3mm, about 0.1mm to about 2.5mm, about 0.5mm to about 2.5mm, about 1mm to about 2.5mm, about 1.5mm to about 2.5mm, about 2mm to about 2.5mm, about 0.1mm to about 2mm, about 0.5mm to about 2mm, about 1mm to about 2mm, about 1.5mm to about 2mm, about 0.1mm to about 2mm, about 0.5mm to about 2mm, about 1mm to about 2mm, about 1.5mm to about 2mm mm, about 1 mm to about 1.5 mm, about 0.1 mm to about 1 mm, about 0.5 mm to about 1 mm, about 0.1 mm to about 0.5 mm, or any other suitable value or sub-range therebetween. In some embodiments, the biochar may have an average particle size of about 0.2 mm to about 5 mm, including all sizes and sub-ranges therebetween. In some embodiments, the biochar may have an average particle size of about 0.5 mm to about 5 mm, including all sizes and sub-ranges therebetween. In some embodiments, the biochar may have an average particle size of about 1.5 mm to about 4 mm, including all sizes and sub-ranges therebetween. In some embodiments, the biochar may have an average particle size of about 2.5 mm to about 3.5 mm, including all sizes and sub-ranges therebetween. In some embodiments, the biochar may have an average particle size of about 2 mm to about 3 mm, including all sizes and sub-ranges therebetween. In some embodiments, the biochar may have an average particle size of less than 2 mm.

[0036] In some embodiments, the biochar may include a first biochar component and a second biochar component. The first biochar component may have a first particle size and the second biochar component may have a second particle size, wherein the first particle size and the second particle size are not equal. In some embodiments, the first particle size may be in the range of about 2.5 mm to about 5 mm, including all sizes and subranges therebetween. In some embodiments, the second particle size may be in the range of about 0.1 mm to about 2 mm, including all sizes and subranges therebetween. In some embodiments, the second particle size may be less than 2.0 mm.

[0037] In some embodiments, the biochar may be present in an amount ranging from about 10% to about 40% by weight based on the total dry weight of the body 120 , including all values ​​and subranges therebetween. For example, in some embodiments, the biochar content can range from about 10% to about 40% by weight, about 13% to about 40% by weight, about 17% to about 40% by weight, about 20% to about 40% by weight, about 23% to about 40% by weight, about 27% to about 40% by weight, about 30% to about 40% by weight, about 33% to about 40% by weight, about 37% to about 40% by weight, about 10% to about 37% by weight, about 13% to about 37% by weight, about 17% to about 37% by weight, about 20% to about 37% by weight, about 23% to about 37% by weight, about 27% to about 37% by weight, about 30% to about 37% by weight, about 33% to about 37% by weight, about 10% to about 33% by weight, about 13% to about 37% by weight, about 17% to about 37% by weight, about 20% to about 37% by weight, about 23% to about 37% by weight, about 27% to about 37% by weight, about 30% to about 37% by weight, about 33% to about 37% by weight, about 10% to about 33% by weight, about 13% to about 33% by weight, about 17% to about 33% by weight, about 20% to about 33% by weight %, about 23 wt % to about 33 wt %, about 27 wt % to about 33 wt %, about 30 wt % to about 33 wt %, about 10 wt % to about 30 wt %, about 13 wt % to about 30 wt %, about 17 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 23 wt % to about 30 wt %, about 27 wt % to about 30 wt %, about 10 wt % to about 27 wt %, about 13 wt % to about 27 wt %, about 17 wt % to about 27 wt %, about 20 wt % to about 27 wt %, about 23 wt % to about 27 wt %, about 10 wt % to about 23 wt %, about 13 wt % to about 23 wt %, about 17 wt % to about 23 wt %, about 20 wt % to about 23 wt %, about 10 wt % to about 20 wt %, about 13 wt % to about 20 wt %, about 17 wt % to about 20 wt %, about 10 wt % to about 17 wt %, about 13 wt % to about 17 wt %. In some embodiments, the biochar may be present in an amount ranging from about 10% to about 30% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween. In some embodiments, the biochar may be present in an amount ranging from about 15% to about 25% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween. In some embodiments, the biochar may be present in an amount ranging from about 18% to about 23% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween. In some embodiments, the biochar may be present in an amount ranging from about 19% to about 20% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween.

[0038] The fibers 130 of the present invention may include inorganic fibers and organic fibers in a weight ratio of about 1:5 to about 27:1, including all ratios and subranges therebetween. In some embodiments, the fibers 130 of the present invention may include inorganic fibers and organic fibers in a weight ratio of about 1:1 to about 27:1, including all ratios and subranges therebetween. In some embodiments, the fibers 130 of the present invention may include inorganic fibers and organic fibers in a weight ratio of about 15:1 to about 27:1, including all ratios and subranges therebetween. In some embodiments, the fibers 130 of the present invention may include an inorganic fiber component and organic fibers in a weight ratio of about 18:1 to about 25:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of inorganic fibers to organic fibers may be about 20:1 to about 23:1, including all ratios and subranges therebetween.

[0039] The weight ratio of fiber 130 to biochar can be from about 1.5:1 to about 6.0:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar can be from 2.0:1 to about 5.5:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar can be from about 2.5:1 to about 5.5:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar can be from about 3:1 to about 5:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar can be present in a weight ratio of about 3:1 to about 4:1, including all ratios and subranges therebetween.

[0040] The weight ratio of inorganic fiber to biochar can be from about 2:1 to about 5.5:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of inorganic fiber to biochar can be from about 2.5:1 to about 5:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of inorganic fiber to biochar can be from about 3:1 to about 5:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar can be from about 3:1 to about 4:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar can be from about 3.1:1 to about 3.9:1, including all ratios and subranges therebetween.

[0041] The weight ratio of organic fiber to biochar may be about 0.1:1 to about 0.3:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar may be about 0.1:1 to about 0.2:1, including all ratios and subranges therebetween. In some embodiments, the weight ratio of fiber 130 to biochar may be about 0.15:1.

[0042] The body 120 may further include an adhesive. Non-limiting examples of the adhesive may include starch-based polymers, polyvinyl alcohol (PVOH), latex, polysaccharide polymers, cellulose polymers, protein solution polymers, acrylic polymers, polymaleic anhydride, epoxy resins, or a combination of two or more thereof.

[0043] The binder may be present in an amount ranging from about 1% to about 20% by weight based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In a preferred embodiment, the binder may be present in an amount ranging from about 5% to about 15% by weight based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In a non-limiting embodiment, the binder may include a starch-based polymer, and the amount of the starch-based polymer may range from about 6% to about 12% by weight based on the total dry weight of the body 120 (including all weight percentages and sub-ranges therebetween).

[0044] The body 120 may also include a filler. Non-limiting examples of fillers may include powders of calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, perlite, polymers, gypsum, wollastonite, expanded perlite, calcite, aluminum trihydrate, pigments, zinc oxide, or zinc sulfate.

[0045] The filler may be present in an amount ranging from about 1.0 wt % to about 30.0 wt % based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In some embodiments, the filler may be present in an amount ranging from about 1.0 wt % to about 20.0 wt % based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. In some embodiments, the filler may be present in an amount ranging from about 5.0 wt % to about 18.0 wt % based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween.

[0046] In a preferred embodiment, the filler may be perlite, and the perlite is present in an amount ranging from about 5 wt % to about 17 wt % based on the total weight of the body 120, including all amounts and subranges therebetween.

[0047] In some embodiments, the body 120 may further include a filler including calcium carbonate, the calcium carbonate content range being about 0.25 wt % to 13 wt %, based on the total weight of the body 120, including all amounts and subranges therebetween. In some embodiments, the calcium carbonate content range may be about 0.5 wt % to about 8 wt %, based on the total dry weight of the body 120, including all values ​​and subranges therebetween. In some embodiments, the calcium carbonate content range is about 1.0 wt % to about 3.0 wt %, based on the total dry weight of the body 120, including all values ​​and subranges therebetween.

[0048] In some embodiments, body 120 can be substantially free of fillers.

[0049] In some embodiments, the body 120 may include one or more additives. Non-limiting examples of additives include defoamers, wetting agents, biocides, dispersants, flame retardants, etc. The additives may be present in an amount ranging from about 0.01 wt % to about 30 wt % based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween.

[0050] In some embodiments, the body 120 may include a flame retardant. In some embodiments, the flame retardant may be present in an amount ranging from about 1% to about 15% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween. For example, in some embodiments, the flame retardant may be present in an amount ranging from about 1% to about 15% by weight, about 3% to about 15% by weight, about 5% to about 15% by weight, about 7% to about 15% by weight, about 9% to about 15% by weight, about 11% to about 15% by weight, about 13% to about 15% by weight, about 1% to about 13% by weight, about 3% to about 13% by weight, about 5% to about 13% by weight, about 7% to about 15% by weight, about 9% to about 15% by weight, about 11% to about 13% by weight, about 13% to about 15% by weight, about 1% to about 13% by weight, about 3% to about 13% by weight, about 5% to about 13% by weight, about 7% to about 13% by weight, about 9% to about 13% by weight, about 11% to about 13% by weight, based on the total dry weight of the body 120. %, about 1 wt % to about 11 wt %, about 3 wt % to about 11 wt %, about 5 wt % to about 11 wt %, about 7 wt % to about 11 wt %, about 9 wt % to about 11 wt %, about 1 wt % to about 9 wt %, about 3 wt % to about 9 wt %, about 5 wt % to about 9 wt %, about 7 wt % to about 9 wt %, about 1 wt % to about 7 wt %, about 3 wt % to about 7 wt %, about 5 wt % to about 7 wt %, about 1 wt % to about 5 wt %, about 3 wt % to about 5 wt %, or about 1 wt % to about 3 wt %, or any other suitable value or sub-range therebetween.

[0051] In some embodiments, the flame retardant may have an average particle size of about 1 μm to about 100 μm, including all values ​​and sub-ranges therebetween. For example, in some embodiments, the flame retardant may have an average particle size of about 1 μm to about 100 μm, about 25 μm to about 100 μm, about 50 μm to about 100 μm, about 75 μm to about 100 μm, about 1 μm to about 75 μm, about 25 μm to about 75 μm, about 50 μm to about 75 μm, about 1 μm to about 50 μm, about 25 μm to about 50 μm, about 1 μm to about 25 μm, or any other suitable value or sub-range therebetween.

[0052] In some embodiments, the flame retardant may include an active filler flame retardant. In some embodiments, the term active filler flame retardant may refer to a flame retardant that can decompose at a high temperature of about 200°C to about 325°C. Depending on the specific active filler flame retardant, in some embodiments, the active filler flame retardant may decompose at a high temperature of about 200°C to about 325°C, about 225°C to about 325°C, about 250°C to about 325°C, about 275°C to about 325°C, about 300°C to about 325°C, 200°C to about 300°C, about 225°C to about 300°C, about 250°C to about 300°C, about 275°C to about 300°C, 200°C to about 275°C, about 225°C to about 275°C, about 250°C to about 275°C, 200°C to about 250°C, about 225°C to about 250°C, 200°C to about 225°C, or any other suitable value or sub-range therebetween. In some embodiments, the active filler flame retardant can decompose endothermically and absorb heat from the environment. Therefore, in some embodiments, the active filler flame retardant can act as a heat sink. In some embodiments, upon decomposition, the flame retardant can release water (H2O), such as water vapor.

[0053] Non-limiting examples of flame retardants or active filler flame retardants may include colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, feldspar, or a combination of two or more thereof.

[0054] As described above, the phrase "dry weight" as used herein refers to the weight of the reference component without the weight of any carrier. It should be noted that the term "carrier" refers to a liquid carrier that is not part of the aqueous component, such as some of the aqueous flame retardants discussed above. During the drying or hardening process, such a liquid carrier is able to evaporate from the mixture or blend in a temperature range of about 60°C to about 200°C, as further discussed herein. However, during such drying or hardening process, the aqueous compound does not lose its hydration. Therefore, when calculating the weight percentage of the aqueous component, such as the weight percentage of the flame retardant in the dry state, the calculation is based on the weight of the aqueous component (including hydration that may not evaporate during the drying or hardening process) and the weight of the body 120 without any liquid carrier that can evaporate from the body 120 during the drying or hardening process.

[0055] In some embodiments, the body 120 may further include a flocculant. Non-limiting examples of flocculants include ionic flocculants, such as cationic polyacrylamide. The flocculant may be present in an amount ranging from about 0.01 wt % to about 1.0 wt % based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween.

[0056] The body 120 can be porous, thereby allowing airflow through the body 120 between the upper surface 122 and the lower surface 121, as further described herein. The porosity of the body 120 can allow airflow through the body 120 under atmospheric conditions, so that the building panel 100 can be used as an acoustic ceiling panel, which requires properties related to noise reduction and sound attenuation properties, as further discussed.

[0057] Specifically, in some embodiments, the body 120 of the present invention may have a porosity of about 60% to about 98%, including all values ​​and sub-ranges therebetween. In some embodiments, the body 120 may have a porosity of about 75% to 95%, including all values ​​and sub-ranges therebetween. In some embodiments, the body 120 may have a porosity of about 80% to 95%, including all values ​​and sub-ranges therebetween. In some embodiments, the body 120 may have a porosity of about 85% to 95%, including all values ​​and sub-ranges therebetween. In some embodiments, the body 120 may have a porosity of about 90% to 95%, including all values ​​and sub-ranges therebetween.

[0058] According to the present invention, porosity refers to: % Porosity = [V 总 –(V 粘合剂 +V 纤维 +V 生物炭 +V 填料 / 添加剂 )] / V 总 Where V 总 V refers to the total volume of the body 120 defined by the upper surface 122, the lower surface 121 and the body side surface 123, 粘合剂 V refers to the total volume occupied by the adhesive in the body 120. 纤维 V refers to the total volume occupied by the fibers 130 in the body 120. 生物炭 V refers to the total volume occupied by the biochar in the body 120. 填料 / 添加剂 Refers to the total volume occupied by fillers and additives in the body 120. Therefore, % porosity indicates the amount of free volume within the body 120.

[0059] The building panels 100 of the present invention including the porous body 120 can exhibit sufficient airflow to provide the building panels 100 with the ability to reduce the amount of reflected sound in a room. The reduction in the amount of reflected sound in a room is represented by a Noise Reduction Coefficient (NRC) rating as described in the American Society for Testing and Materials (ASTM) test method C423. This rating is a measure of the noise reduction coefficient (NRC) rating in four ⅓ octave bands (250, 500, 1000 and 2000). The average value of the sound absorption coefficient (NRC) at 100 Hz, where, for example, a system with an NRC of 0.90 has about 90% of the sound absorption capacity of an ideal absorber. Higher NRC values ​​indicate that the material provides better sound absorption and reduced sound reflection.

[0060] The building panels 100 of the present invention exhibit a NRC of at least about 0.5. In a preferred embodiment, the building panels 100 of the present invention may have a NRC of about 0.60 to about 0.99, including all values ​​and subranges therebetween.

[0061] The body 100 may also exhibit an airflow resistance measured between the upper surface 122 and the lower surface 121 of about 200 MKS Rayls to about 40,000 MKS Rayls, including all airflow resistances and subranges therebetween, where the MKS Rayls are measured in units of Pa*s / m.

[0062] The main body 120 in a dry state may have a thickness of about 0.03 g / cm 3 To about 0.25g / cm 3 The term "bulk density" refers to the volume density relative to the total volume V of the body 120. 总 The measured density. Therefore, the bulk density is the total volume V 总 Density measurement, total volume V 总 The volume occupied by the components constituting the skeleton of the body 120 (ie, (V 粘合剂 +V 纤维 +V 生物炭 +V 填料 / 添加剂 ) and voids within the body 120 due to the porous nature of the body 120.

[0063] In some embodiments, the body 120 in a dry state may have a g / cm 3 To about 0.25g / cm 3 In some embodiments, the body 120 may have a bulk density of about 0.18 g / cm 3 To about 0.21g / cm 3 In some embodiments, the body 120 in a dry state may have a bulk density of about 0.03 g / cm 3 To about 0.05g / cm 3 The bulk density is within the range , including all integers and subranges therebetween.

[0064] In some embodiments, the bulk density of the body 120 in a dry state may be about 0.03 g / cm 3 To about 0.25g / cm 3, about 0.05g / cm 3 To about 0.25g / cm 3 , about 0.07g / cm 3 to about 0.25 g / cm 3 , about 0.09g / cm 3 To about .25g / cm 3 , about 0.11g / cm 3 to about 0.25 g / cm 3 , about 0.13g / cm 3 To about 0.25g / cm 3 , about 0.15g / cm 3 To about 0.25g / cm 3 , about 0.17g / cm 3 To about 0.25g / cm 3 , about 0.19g / cm 3 To about 0.25g / cm 3 , about 0.21g / cm 3 To about 0.25g / cm 3 , about 0.23g / cm 3 To about 0.25g / cm 3 , about 0.03g / cm 3 To about 0.23g / cm 3 , about 0.05g / cm 3 To about 0.23g / cm 3 , about 0.07g / cm 3 To about 0.23g / cm 3 , about 0.09g / cm 3 To about 0.23g / cm 3 , about 0.11g / cm 3 To about 0.23g / cm 3 , about 0.13g / cm 3 To about 0.23mg / cm 3 , about 0.15g / cm 3 To about 0.23g / cm 3 , about 0.17g / cm 3 To about 0.23g / cm 3 , about 0.19g / cm 3 To about 0.23g / cm 3 , about 0.21g / cm 3 To about 0.23g / cm 3 , about 0.03g / cm 3 To about 0.21g / cm 3 , about 0.07g / cm 3To about 0.21g / cm 3 , about 0.09g / cm 3 To about 0.21g / cm 3 , about 0.11g / cm 3 To about 0.21g / cm 3 , about 0.13g / cm 3 To about 0.21g / cm 3 , about 0.15g / cm 3 To about 0.21g / cm, about 0.17g / cm 3 To about 0.21g / cm 3 , about 0.19g / cm 3 To about 0.21g / cm 3 , about 0.03g / cm 3 To about 0.19g / cm 3 , about 0.05g / cm 3 To about 0.19g / cm 3 , about 0.07g / cm 3 To about 0.19g / cm 3 , by about 0.09g / cm 3 To about 0.19g / cm 3 g / cm 3 , about 0.11g / cm 3 To about 0.19g / cm 3 , about 0.13g / cm 3 To about 0.19g / cm 3 , about 0.15g / cm 3 To about 0.19g / cm 3 , about 0.17g / cm 3 To about 0.19g / cm 3 , about 0.03g / cm 3 To about 0.17g / cm 3 , about 0.05g / cm 3 To about 0.17g / cm 3 , about 0.07g / cm 3 To about 0.17g / cm 3 , about 0.09g / cm 3 To about 0.17g / cm 3 , about 0.11g / cm 3 To about 0.17g / cm 3 , about 0.13g / cm 3 To about 0.17g / cm 3 , about 0.15g / cm 3 To about 0.17g / cm 3, about 0.03g / cm 3 To about 0.15g / cm 3 , about 0.05g / cm 3 To about 0.15g / cm 3 , about 0.07g / cm 3 To about 0.15g / cm 3 , about 0.09g / cm 3 To about 0.15g / cm 3 , about 0.11g / cm 3 To about 0.15g / cm 3 , about 0.13g / cm 3 To about 0.15g / cm 3 , about 0.03g / cm 3 To about 0.13g / cm 3 , about 0.05g / cm 3 To about 0.13g / cm 3 , about 0.07g / cm 3 To about 0.13g / cm 3 , about 0.09g / cm 3 To about 0.13g / cm 3 , about 0.11g / cm 3 To about 0.13g / cm 3 , about 0.03g / cm 3 To about 0.11g / cm 3 , about 0.05g / cm 3 To about 0.11g / cm 3 , about 0.07g / cm 3 To about 0.11g / cm 3 , about 0.09g / cm 3 To about 0.11g / cm 3 , about 0.03g / cm 3 To about 0.09g / cm 3 , about 0.05g / cm 3 To about 0.09g / cm 3 , about 0.07g / cm 3 To about 0.09g / cm 3 , about 0.03g / cm 3 To about 0.07g / cm 3 , about 0.05g / cm 3 To about 0.07g / cm 3 , about 0.03g / cm 3 To about 0.05g / cm 3 , or any other suitable value or sub-range therebetween.

[0065] The main body 120 in a dry state may have a g / cm 3 To about 2.7g / cm 3 The term "skeleton density" refers to the volume occupied by the components constituting the skeleton of the main body 120 (i.e., (V 粘合剂 +V 纤维 +V 生物炭 +V 填料 / 添加剂 ) without taking into account the volume occupied by voids within the body 120 due to the porous nature of the body 120. In some embodiments, the skeletal density of the body can be about 0.73 g / cm 3 to about 2.7 g / cm 3 , including all values ​​and subranges therebetween.

[0066] In some embodiments, the skeleton density of the body 120 in a dry state may be about 0.35 g / cm 3 To about 2.7g / cm 3 , about 0.7g / cm 3 To about 2.7g / cm 3 , about 1g / cm 3 To about 2.7g / cm 3 About 1.35g / cm 3 To about 2.7g / cm 3 , about 1.7g / cm 3 To about 2.7g / cm 3 , about 2g / cm 3 To about 2.7g / cm 3 , about 2.35g / cm 3 To about 2.7g / cm 3 , about 0.35g / cm 3 To about 2.35g / cm 3 , about 0.7g / cm 3 To about 2.35g / cm 3 , about 1g / cm 3 To about 2.35g / cm 3 , about 1.35g / cm 3 To about 2.35g / cm 3 , about 1.7g / cm 3 To about 2.35g / cm 3 , about 2g / cm 3 To about 2.35g / cm 3 , about 0.35g / cm 3 About 2g / cm 3 , about 0.7g / cm 3 About 2g / cm3 , about 1g / cm 3 About 2g / cm 3 , about 1.35g / cm 3 About 2g / cm 3 , about 1.7g / cm 3 About 2g / cm 3 , about 0.35g / cm 3 To about 1.7g / cm 3 , about 0.7g / cm 3 To about 1.7g / cm 3 , about 1g / cm 3 To about 1.7g / cm 3 , about 1.35g / cm 3 To about 1.7g / cm 3 , about 0.35g / cm 3 To about 1.35g / cm 3 , about 0.7g / cm 3 To about 1.35g / cm 3 , about 1g / cm 3 To about 1.35g / cm 3 , about 0.35g / cm 3 About 1g / cm 3 , about 0.7g / cm 3 About 1g / cm 3 , about 0.35g / cm 3 to about 0.7 g / cm 3 , or any other suitable value or sub-range therebetween.

[0067] According to the present invention, it has surprisingly been found that the addition of biochar leads to a lower global warming potential (“ GWP ”) without sacrificing the density, porosity and airflow resistance necessary for the building panel to be used as an acoustic building panel in building system 1.

[0068] Although not shown, the building panel 100 of the present invention may further include a scrim attached to at least one of the lower surface 121 or the upper surface 122 of the body 120, and the scrim may be a non-woven scrim formed of glass fibers. In such an embodiment, the first major surface 111 of the building panel 100 may include the scrim.

[0069] In some embodiments, the body 120 can be formed according to a standard wet-laid process that uses an aqueous medium or liquid carrier (e.g., water) to transport the body components and form the body components into a desired structure. The basic process includes first blending various body components (such as fibers, adhesives, biochar, fillers, additives, etc.) into an aqueous slurry (i.e., wet state), conveying the slurry to a forming station, and distributing the slurry on a moving porous screen to form a uniform mat of desired size and thickness. Remove the liquid carrier and dry the mat (i.e., dry state). The dry mat can be made into the body by cutting, stamping, coating and / or laminating the surface of the tile. The wet body 120 can be heated at a high temperature in the range of about 60°C to about 200°C (including all values ​​and sub-ranges therebetween) to dry the body 120 from a wet state to a dry state.

[0070] Now refer to Figure 4 , shows a building panel 400 according to another embodiment of the present invention. Similar to building panel 100, building panel 400 can be used to build or be incorporated into building system 1. The building panel may include inorganic materials, including but not limited to inorganic particles, biochar, flame retardants, fibers, etc.

[0071] In some embodiments, the building panel 400 may include a first major surface 411 opposite to a second major surface 412 , and the building panel 400 may further include a side surface 413 extending between the first major surface 411 and the second major surface 412 , thereby defining a perimeter of the building panel 400 .

[0072] In some embodiments, the building panel 400 may have a panel thickness measured from the first major surface 411 to the second major surface 412. The panel thickness may range from about 0.4" to about 1", including all values ​​and subranges therebetween. The building panel 400 may have a panel thickness of about 12 " to about 72" in length, including all values ​​and subranges therebetween. The building panel 400 can have a width of about 12" to about 30", including all values ​​and subranges therebetween.

[0073] refer to Figure 5 In some embodiments, the building panel 400 may include a body 420 having an upper surface 422 opposite to a lower surface 421 and a body side surface 423 extending between the upper surface 422 and the lower surface 421. The body 420 may have a body thickness extending from the upper surface 422 to the lower surface 421. The body thickness may range from about 0.4" to about 1. ", including all values ​​and subranges in between.

[0074] The first major surface 411 of the building panel 400 may include a lower surface 421 of the body 420. The second major surface 412 of the building panel 400 may include an upper surface 422 of the body 420. When the first major surface 411 of the building panel 400 includes the lower surface 421 of the body 420 and the second major surface 412 of the building panel 400 includes the upper surface 422 of the body 420, the panel thickness is substantially equal to the body thickness.

[0075] In some embodiments, the body 420 may include inorganic materials, including but not limited to inorganic particles. In some embodiments, the content of inorganic materials may range from about 1 wt % to about 99 wt % (for calcined bodies) based on the total dry weight of the body 420, including all values ​​and subranges therebetween. For example, in some embodiments, the content of inorganic materials such as inorganic particles may range from about 1 wt % to about 99 wt %, about 10 wt % to about 99 wt %, about 20 wt % to about 99 wt %, about 30 wt % to about 99 wt %, about 40 wt % to about 99 wt %, about 50 wt % to about 99 wt %, about 60 wt % to about 99 wt %, about 70 wt % to about 99 wt %, about 80 wt % to about 99 wt %, about 90 wt % to about 99 wt %, about 1 wt % to about 90 wt %, about 10 wt % to about 90 wt %, about From about 20% to about 90% by weight, from about 30% to about 90% by weight, from about 40% to about 90% by weight, from about 50% to about 90% by weight, from about 60% to about 90% by weight, from about 70% to about 90% by weight, from about 80% to about 90% by weight, from about 1% to about 80% by weight, from about 10% to about 80% by weight, from about 20% to about 80% by weight, from about 30% to about 80% by weight, from about 40% to about 80% by weight, from about 50% to about 80% by weight, from about 60% to about 80% by weight, from about 70% to about 80% by weight , about 1 wt % to about 70 wt %, about 10 wt % to about 70 wt %, about 20 wt % to about 70 wt %, about 30 wt % to about 70 wt %, about 40 wt % to about 70 wt %, about 50 wt % to about 70 wt %, about 60 wt % to about 70 wt %, about 1 wt % to about 60 wt %, about 10 wt % to about 60 wt %, about 20 wt % to about 60 wt %, about 30 wt % to about 60 wt %, about 40 wt % to about 60 wt %, about 50 wt % to about 60 wt %, about 1 wt % to about 50 wt %, about 10 wt % to about 50 wt %, , about 20 wt % to about 50 wt %, about 30 wt % to about 50 wt %, about 40 wt % to about 50 wt %, about 1 wt % to about 40 wt %, about 10 wt % to about 40 wt %, about 20 wt % to about 40 wt %, about 30 wt % to about 40 wt %, about 1 wt % to about 30 wt %, about 10 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 1 wt % to about 20 wt %, about 10 wt % to about 20 wt %, about 1 wt % to about 10 wt %, or any other suitable value or sub-range therebetween, based on the total dry weight of the body 420.

[0076] In some embodiments, the inorganic particles may have an average particle size of about 0.1 μm to about 5 mm, including all values ​​and subranges therebetween. For example, in some embodiments, the inorganic particles may have an average particle size of about 0.1 μm to about 5 mm, about 0.5 μm to about 5 mm, about 1 μm to about 5 mm, about 1.5 μm to about 5 mm, about 2 μm to about 5 mm, about 3 μm to about 5 mm, about 4 μm to about 5 μm, about 0.1 μm to about 4 mm, about 0.5 μm to about 4 mm, about 1 μm to about 4 mm, about 1.5 μm to about 4 mm, about 2 μm to about 4 mm, about 3 μm to about 4 mm, about 0.1 μm to about 3 mm, about 0.5 μm to about 4 mm, about 1 μm to about 4 mm, about 1.5 μm to about 4 mm, about 2 μm to about 4 mm, about 3 μm to about 4 mm, about 0.1 μm to about 3 mm, about 0.5 μm to about 4 mm, about 1.5 μm to about 4 mm, about 2 μm to about 4 mm, about 3 ... To about 3 mm, about 1 μm to about 3 mm, about 1.5 μm to about 3 mm, about 2 μm to about 3 mm, about 0.1 μm to about 2 mm, about 0.5 μm to about 2 mm, about 1 μm to about 2 mm, about 1.5 μm to about 2 mm, about 0.1 μm to about 1.5 mm, about 0.5 μm to about 1.5 mm, about 1 μm to about 1.5 mm, about 0.1 μm to about 1 mm, about 0.5 μm to about 1 mm, about 0.1 μm to about 0.5 mm, or any other suitable value or sub-range therebetween.

[0077] In some embodiments, the inorganic material may include one or more alkaline earth metal compounds. In some embodiments, the alkaline earth metal compound may include at least one of an alkaline earth metal oxide, an alkaline earth metal sulfate, or a combination thereof. In some embodiments, the alkaline earth metal compound may include at least one of a calcium compound, a magnesium compound, or a combination thereof. In some embodiments, the alkaline earth metal compound may include at least one of calcium sulfate, magnesium sulfate, magnesium oxide, or a combination thereof.

[0078] In some embodiments, the alkaline earth metal compound may include a calcium compound. In some embodiments, the calcium compound may include calcium sulfate. In some embodiments, the calcium compound may have an average particle size in the range of about 0.1 μm to about 2,000 μm, including all values ​​and subranges therebetween. For example, in some embodiments, the average particle size of the calcium compound may range from about 0.1 μm to about 2000 μm, from about 100 μm to 2000 μm, from about 500 μm to 200 μm, from 1000 μm to 2000 μm, from 1500 μm to 1000 μm, from 0.1 μm to 1500 μm, from 100 μm to 500 μm, from 500 μm to 1500 μm, from about 0.1 μm to about 100 μm, from about 0.1 μm to about 2,000 μm. About 1500 μm, about 100 μm to about 1500 μm, about 500 μm to about 1500 μm, about 1000 μm to about 1500 μm, about 0.1 μm to about 1000 μm, about 100 μm to about 1000 μm, about 500 μm to about 1000 μm, about 0.1 μm to about 500 μm, about 100 μm to about 500 μm, about 0.1 μm to about 100 μm, or any other suitable value or sub-range therebetween.

[0079] In some embodiments, the calcium compound may be present in an amount ranging from about 1 wt % to about 90 wt % based on the total dry weight of body 420 , including all values ​​and subranges therebetween. For example, in some embodiments, the calcium compound may be present in an amount ranging from about 1 wt % to about 90 wt %, from about 10 wt % to about 90 wt %, from about 20 wt % to about 90 wt %, from about 30 wt % to about 90 wt %, from about 40 wt % to about 90 wt %, from about 50 wt % to about 90 wt %, from about 60 wt % to about 90 wt %, from about 70 wt % to about 90 wt %, from about 80 wt % to about 90 wt %, from about 1 wt % to about 80 wt %, from about 10 wt % to about 80 wt %, from about 20 wt % to about 80 wt %, from about 30 wt % to about 80 wt %, from about 40 wt % to about 80 wt %, from about 50 wt % to about 80 wt %, from about 60 wt % to about 80 wt %, from about 70 wt % to about 80 wt %, from about 1 wt % to about 70 wt %, from about 20 wt % to about 70 wt %, from about 30 wt % to about 70 wt %, from about 40 wt % to about 70 wt %. %, about 50 wt % to about 70 wt %, about 60 wt % to about 70 wt %, about 1 wt % to about 60 wt %, about 10 wt % to about 60 wt %, about 20 wt % to about 60 wt %, about 30 wt % to about 60 wt %, about 40 wt % to about 60 wt %, about 50 wt % to about 60 wt %, about 1 wt % to about 50 wt %, about 10 wt % to about 50 wt %, about 20 wt % to about 50 wt %, about 30 wt % to about 50 wt %, about 40 wt % to about 50 wt %, about 1 wt % to about 40 wt %, about 10 wt % to about 40 wt %, about 20 wt % to about 40 wt %, about 30 wt % to about 40 wt %, about 1 wt % to about 30 wt %, about 10 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 1 wt % to about 20 wt %, about 10 wt % to about 20 wt %, about 1 wt % to about 10 wt %, or any other suitable value or sub-range therebetween.

[0080] In some embodiments, the alkaline earth metal compound may include a magnesium compound. In some embodiments, the content of the magnesium compound may range from about 0% to about 75% by weight based on the total dry weight of the body 420, including all values ​​and subranges therebetween. For example, in some embodiments, the content of the magnesium compound may range from about 0% to about 75% by weight, about 10% to about 75% by weight, about 20% to about 75% by weight, about 30% to about 75% by weight, about 50% to about 75% by weight, about 60% to about 75% by weight, about 70% to about 75% by weight, about 0% to about 70% by weight, about 10% to about 70% by weight, about 20% to about 70% by weight, about 30% to about 70% by weight, about 40% to about 70% by weight, about 50% to about 70% by weight, about 60% to about 75% by weight, about 70% to about 75% by weight, about 0% to about 70% by weight, about 10% to about 70% by weight, about 20% to about 70% by weight, about 30% to about 70% by weight, about 40% to about 70% by weight, about 50% to about 70% by weight, about 60% to about 70% by weight, about %, about 0 wt % to about 60 wt %, about 10 wt % to about 60 wt %, about 20 wt % to about 60 wt %, about 30 wt % to about 60 wt %, about 40 wt % to about 60 wt %, about 50 wt % to about 60 % to about 50 wt %, about 10 wt % to about 50 wt %, about 20 wt % to about 50 wt %, about 30 wt % to about 50 wt %, about 40 wt % to about 50 wt %, about 0 wt % to about 40 wt %, about 10 wt % to about 40 wt %, about 20 wt % to about 40 wt %, about 30 wt % to about 40 wt %, about 0 wt % to about 30 wt %, about 10 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 0 wt % to about 20 wt %, about 0 wt % to about 10 wt %, or any other suitable value or sub-range therebetween.

[0081] In some embodiments, the magnesium compound may have an average particle size of about 0.5 μm to about 1000 μm, including all values ​​and subranges therebetween. For example, the magnesium compound may have an average particle size of about 0.5 μm to about 1000 μm, about 250 μm to about 1000 μm, about 500 μm to about 1000 μm, about 750 μm to about 1000 μm, about 0.5 μm to about 750 μm, about 250 μm to about 750 μm, about 500 μm to about 750 μm, about 0.5 μm to about 500 μm, about 250 μm to about 500 μm, about 0.5 μm to about 250 μm, or any other suitable value or subrange therebetween.

[0082] In some embodiments, the magnesium compound may include at least one of magnesium oxide, magnesium sulfate, or a combination thereof. In some embodiments, the content of magnesium oxide may range from about 0% to about 50% by weight based on the total dry weight of the body 420, including all values ​​and subranges therebetween. For example, in some embodiments, the content of magnesium oxide may range from about 0% to about 50% by weight, about 10% to about 50% by weight, about 20% to about 50% by weight, about 30% to about 50% by weight, about 40% to about 50% by weight, about 0% to about 40% by weight, about 10% to about 40% by weight, about 20% to about 40% by weight, about 30% to about 40% by weight, based on the total dry weight of the body 420. % to about 30 wt %, about 10 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 0 wt % to about 20 wt %, about 10 wt % to 20 wt %, 0 wt % to 10 wt %, or any other suitable value or sub-range therebetween.

[0083] In some embodiments, the average particle size of the magnesium oxide is from about 0.5 μm to about 1000 μm, including all values ​​and sub-ranges therebetween. For example, in some embodiments, the average particle size of the magnesium oxide can be from about 0.5 μm to about 1000 μm, from about 250 μm to about 1000 μm, from about 500 μm to about 1000 μm, from about 750 μm to about 1000 μm, from about 0.5 μm to about 750 μm, from about 250 μm to about 750 μm, from about 500 μm to about 750 μm, from about 0.5 μm to about 500 μm, from about 250 μm to about 500 μm, from about 0.5 μm to about 250 μm, or any other suitable value or sub-range therebetween.

[0084] In some embodiments, the magnesium sulfate content can range from about 0 wt % to about 20 wt %, including all values ​​and sub-ranges therebetween, based on the total dry weight of the body 420. For example, in some embodiments, the magnesium sulfate content can range from about 0 wt % to about 20 wt %, about 5 wt % to about 20 wt %, about 10 wt % to about 20 wt %, about 15 wt % to about 20 wt %, about 0 wt % to about 15 wt %, about 5 wt % to about 15 wt %, about 10 wt % to about 15 wt %, about 0 wt % to about 10 wt %, about 5 wt % to about 10 wt %, about 0 wt % to about 5 wt %, or any other suitable value or sub-range therebetween, based on the total dry weight of the body 420.

[0085] In some embodiments, building panel 400 may include gypsum board, and the inorganic material of body 420 may include calcium sulfate. In some embodiments, building panel 400 may include cement-based panels, and the inorganic material of body 420 may include at least one of magnesium oxide, magnesium sulfate, or other cement materials.

[0086] In some embodiments, the inorganic material of the body 420 may further include a metal silicate. In some embodiments, the metal silicate may include at least one of an alkali metal silicate, wherein the alkali metal portion includes at least one of sodium, potassium, or lithium. The content of the alkali metal silicate may range from about 0 wt % to about 30 wt % based on the total dry weight of the body 420, including all values ​​and sub-ranges therebetween. In some embodiments, the alkali metal silicate may have an average particle size of about 0.1 μm to about 150 μm, including all values ​​and sub-ranges therebetween.

[0087] In some embodiments, the inorganic material of the body 420 may further include at least one of limestone, calcined gypsum, aluminum sulfate, zinc sulfate, zinc oxide, aluminum oxide, aluminum oxide, titanium oxide, aluminum silicate, montmorillonite, or bentonite. In some embodiments, including but not limited to building panels based on cement materials, the inorganic material of the body 420 may further include at least one of silicon dioxide, volcanic ash, calcium oxide, calcium hydroxide, calcium silicate, calcium ferrous silicate, metakaolin, nepheline syenite, alabaster, or asphalt.

[0088] In some embodiments, body 420 can further include biochar, similar to the biochar described above with reference to body 120. In some embodiments, the biochar can be present in an amount ranging from about 10% to about 40% by weight based on the total dry weight of body 420, including all values ​​and subranges therebetween. For example, in some embodiments, the biochar content can range from about 10% to about 40% by weight, about 13% to about 40% by weight, about 17% to about 40% by weight, about 20% to about 40% by weight, about 23% to about 40% by weight, about 27% to about 40% by weight, about 30% to about 40% by weight, about 33% to about 40% by weight, about 37% to about 40% by weight, about 10% to about 37% by weight, about 13% to about 37% by weight, about 17% to about 37% by weight, about 20% to about 37% by weight, about 23% to about 37% by weight, about 27% to about 37% by weight, about 30% to about 37% by weight, about 33% to about 37% by weight, about 10% to about 33% by weight, about 13% to about 37% by weight, about 17% to about 37% by weight, about 20% to about 37% by weight, about 23% to about 37% by weight, about 27% to about 37% by weight, about 30% to about 37% by weight, about 33% to about 37% by weight, about 10% to about 33% by weight, about 13% to about 33% by weight, about 17% to about 33% by weight, about 20% to about 33% by weight, about 23% to about 33% by weight %, about 27 wt % to about 33 wt %, about 30 wt % to about 33 wt %, about 10 wt % to about 30 wt %, about 13 wt % to about 30 wt %, about 17 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 23 wt % to about 30 wt %, about 27 wt % to about 30 wt %, about 10 wt % to about 27 wt %, about 13 wt % to about 27 wt %, about 17 wt % to about 27 wt %, about 20 wt % to about 27 wt %, about 23 wt % to about 27 wt %, about 10 wt % to about 23 wt %, about 13 wt % to about 23 wt %, about 17 wt % to about 23 wt %, about 20 wt % to about 23 wt %, about 10 wt % to about 20 wt %, about 13 wt % to about 20 wt %, about 17 wt % to about 20 wt %, about 10 wt % to about 17 wt %, about 13 wt % to about 17 wt %, about 10 wt % to about 13 wt %, or any other suitable value or sub-range therebetween.

[0089] In some embodiments, the biochar can have an average particle size in the range of about 0.1 mm to about 5 mm, including all sizes and subranges therebetween. For example, in some embodiments, the biochar can have an average particle size in the range of about 0.1 mm to about 5 mm, about 0.5 mm to about 5 mm, about 1 mm to about 5 mm, about 1.5 mm to about 5 mm, about 2 mm to about 5 mm, about 2.5 mm to about 5 mm, about 3 mm to about 5 mm about 3.5 mm to about 5 mm, about 4 mm to about 5 mm, about 4.5 mm to about 5 mm, about 0.1 mm to about 4.5 mm, about 0.5 mm to about 4.5 mm, about 1 .... 5mm, about 2mm to about 4.5mm, about 2.5mm to about 4.5mm, about 3mm to about 4.5mm, about 3.5mm to about 4.5mm, about 4mm to about 4.5mm, about 0.1mm to about 4mm, about 0.5mm to about 4mm, about 1mm to about 4mm, about 1.5mm to about 4mm, about 2mm to about 4mm, about 2.5mm to about 4mm, about 3mm to about 4mm, about 3.5mm to about 4mm, about 0.1mm to about 3.5mm, about 0.5mm to about 3.5mm m, about 1 mm to about 3.5 mm, about 1.5 mm to about 3.5 mm, about 2 mm to about 3.5 mm, about 2.5 mm to about 3.5 mm, about 3 mm to about 3.5 mm, about 0.1 mm to about 3 mm, about 0.5 mm to about 3 mm, about 1 mm to about 3 mm, about 1.5 mm to about 3 mm, about 2 mm to about 3 mm, about 2.5 mm to about 3 mm, about 0.1 mm to about 2.5 mm, about 0.5 mm to about 2.5 mm, about 1 mm to about 2.5 mm, about 1.5 mm to about 2 .5mm, about 2mm to about 2.5mm, about 0.1mm to about 2mm, about 0.5mm to about 2mm, about 1mm to about 2mm, about 1.5mm to about 2mm, about 0.1mm to about 1.5mm, about 0.5mm to about 1.5mm, about 1mm to about 1.5mm, about 0.5mm to about 1.5mm, about 1mm to about 1.5mm, about 0.1mm to about 1mm, about 0.5mm to about 1mm, about 0.1mm to about 0.5mm, or any other suitable value or sub-range therebetween.

[0090] In some embodiments, the biochar can have a density of about 3 pounds per cubic foot (pcf) to about 18 pcf. For example, in some embodiments, the biochar can range from about 3 pcf to about 18 pcf, about 5 pcf to about 18 pcf, about 7 pcf to about 18 pcf, about 9 pcf to about 18 pcf, about 11 pcf to about 18 pcf, about 13 pcf to about 18 pcf, about 15 pcf to about 18 pcf, about 17 pcf to about 18 pcf, about 3 pcf to about 17 pcf, about 5 pcf to about 17 pcf, about 7 pcf to about 17 pcf, about 9 pcf to about 17 pcf, about 11 pcf to about 17 pcf, about 13 pcf to about 17 pcf, about 15 pcf to about 17 pcf, about 3 pcf to about 17 pcf, about 5 pcf to about 17 pcf, about 7 pcf to about 17 pcf, about 9 pcf to about 17 pcf, about 11 pcf to about 17 pcf, about 13 pcf to about 17 pcf, about 15 pcf to about 17 pcf, about 3 pcf to about 15 pcf, about 5 pcf to about 15 pcf, about 7 pcf to about 15pcf, about 9pcf to about 15pcf, about 11pcf to about 15pcf, about 13pcf to about 15pcf, about 3pcf to about 13pcf, about 5pcf to about 13pcf, about 7pcf to about 13pcf, about 9pcf to about 13pcf, about 11pcf to about 13pcf, about 3pcf to about 11pcf, about 5pcf to about 11pcf, about 7pcf to about 11pcf, about 9pcf to about 11pcf, about 3pcf to about 9pcf, about 5pcf to about 9pcf, about 7pcf to about 9pcf, about 3pcf to about 7pcf, about 5pcf to about 7pcf, about 3pcf to about 5pcf, or any other suitable value or sub-range therebetween.

[0091] In some embodiments, body 420 may further include a flame retardant, similar to the flame retardant discussed above with reference to body 120. In some embodiments, the flame retardant may include an active filler flame retardant, similar to the flame retardant discussed above with reference to body 120. In some embodiments, the flame retardant may decompose endothermically. In some embodiments, the flame retardant may decompose endothermically at an elevated temperature of about 200° C. to about 325° C. Depending on the specific flame retardant, in some embodiments, the flame retardant can decompose at an elevated temperature of about 200°C to about 325°C, about 225°C to about 325°C, about 250°C to 325°C, about 275°C to about 325°C, about 300°C to about 325°C, 200°C to about 300°C, about 225°C to about 300°C, about 250°C to 300, about 275°C to 300, 200°C to 275°C, about 225°C to 275°C, about 250°C to about 275°C, 200°C to about 250°C, about 225°C to about 250°C, 200°C to about 225°C, or any other suitable value or sub-range therebetween. In some embodiments, upon decomposition, the flame retardant can release water (H2O), such as water vapor. In some embodiments, the flame retardant may include at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, feldspar, or a combination of two or more thereof.

[0092] In some embodiments, the flame retardant may be present in an amount ranging from about 1 wt % to about 15 wt %, including all values ​​and subranges therebetween, based on the total dry weight of the body 420. For example, in some embodiments, the flame retardant may be present in an amount ranging from about 1 wt % to about 15 wt %, from about 3 wt % to about 15 wt %, from about 5 wt % to about 15 wt %, from about 7 wt % to about 15 wt %, from about 9 wt % to about 15 wt %, from about 11 wt % to about 15 wt %, from about 13 wt % to about 15 wt %, from about 1 wt % to about 13 wt %, from about 3 wt % to about 13 wt %, from about 5 wt % to about 13 wt %, from about 7 wt % to about 13 wt %, from about 9 wt % to about 13 wt %, from about 11 wt % to about 13 wt %, from about 1 wt % to about 13 wt %, from about 1 % to about 11 wt %, about 3 wt % to about 11 wt %, about 5 wt % to about 11 wt %, about 7 wt % to about 11 wt %, about 9 wt % to about 11 wt %, about 1 wt % to about 9 wt %, about 3 wt % to about 9 wt %, about 5 wt % to about 9 wt %, about 7 wt % to about 9 wt %, about 1 wt % to about 7 wt %, about 3 wt % to about 7 wt %, about 5 wt % to about 7 wt %, about 1 wt % to about 5 wt %, about 3 wt % to about 5 wt %, or about 1 wt % to about 3 wt %, or any other suitable value or subrange therebetween, based on the total dry weight of the body 420.

[0093] In some embodiments, the flame retardant may have an average particle size of about 1 μm to about 100 μm, including all values ​​and sub-ranges therebetween. For example, in some embodiments, the average particle size of the flame retardant may be about 1 μm to about 100 μm, about 25 μm to about 100 μm, about 50 μm to about 100 μm, about 75 μm to about 100 μm, about 1 μm to about 75 μm, about 25 μm to about 75 μm, about 50 μm to about 75 μm, about 1 μm to about 50 μm, about 25 μm to about 50 μm, about 1 μm to about 25 μm, or any other suitable value or sub-range therebetween.

[0094] In some embodiments, the body 420 may further include fibers. In some embodiments, the fibers may include organic fibers. The organic fibers may be present in an amount ranging from about 4% to about 30% by weight based on the total dry weight of the body 420, including all values ​​and subranges therebetween. For example, in some embodiments, the organic fibers may be present in an amount ranging from about 4% to about 30% by weight, from about 8% to about 30% by weight, from about 12% to about 30% by weight, from about 16% to about 30% by weight, from about 20% to about 30% by weight, from about 24% to about 30% by weight, from about 28% to about 30% by weight, from about 4% to about 28% by weight, from about 8% to about 28 ...12% to about 30% by weight, from about 12% to about 30% by weight, from about 16% to about 30% by weight, from about 12% to about 30% by weight, from about 12% to about 30% by weight, from about 16% to about 30% by weight, from about 12% to about 30% by weight, from about 12 wt %, about 12 wt % to about 28 %, about 16 wt % to about 28 wt %, about 20 wt % to about 28 wt %, about 24 wt % to about 28 wt %, about 4 wt % to about 24 wt %, about 8 wt % to about 24 wt %, about 12 wt % to about 24 wt %, about 20 wt % to about 24 wt %, about 4 wt % to about 20 wt %, about 8 wt % to about 20 wt %, about 12 wt % to about 20 %, about 16 wt % to about 20 wt %, about 4 wt % to about 16 wt %, about 8 wt % to about 16 wt %, about 12 wt % to about 16 wt %, about 4 wt % to about 12 wt %, about 8 wt % to about 12 wt %, about 4 wt % to 8 wt %, or any other suitable value or sub-range therebetween. In some embodiments, the organic fibers may include macroscopic cellulose fibers (e.g., paper fibers - such as newspaper, hemp fibers, jute fibers, flax fibers, wood fibers, or other natural fibers), protein fibers (e.g., sheep wool), and combinations thereof.

[0095] In some embodiments, the fiber may further include inorganic fibers. The content range of the inorganic fibers can be about 1% by weight to about 80% by weight based on the total dry weight of the body 420, including all values ​​and sub-ranges therebetween. For example, in some embodiments, the content range of the inorganic fibers can be about 1% by weight to about 80% by weight based on the total dry weight of the body 420, about 10% by weight to about 80% by weight, about 20% by weight to about 80% by weight, about 40% by weight to about 80% by weight, about 60% by weight to about 80% by weight, about 1% by weight to about 60% by weight, about 10% by weight to about 60% by weight, about 20% by weight to about 60% by weight, about 40% by weight to about 60% by weight, about 1% by weight to about 40% by weight, about 10% by weight to about 40% by weight, about 20% by weight to about 40% by weight, about 1% by weight to about 20% by weight, about 1% by weight to about 20% by weight, or any other suitable value or sub-range therebetween. In some embodiments, the inorganic fibers may include mineral wool (also known as slag wool), rock wool, asbestos, glass fibers, polymer fibers, and combinations thereof. Non-limiting examples of polymer fibers include polyester fibers, polyethylene fibers, aromatic polyamide fibers (e.g., aramid fibers), polypropylene fibers, and combinations thereof.

[0096] In some embodiments, the weight ratio of inorganic material, such as inorganic particles, to biochar can be about 1.5:1 to about 6:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of inorganic material, such as inorganic particles, to biochar can be about 1.5:1 to about 6:1, about 2:1 to about 6:1, about 2.5:1 to about 6:1, about 3:1 to about 6:1, about 3.5:1 to about 6:1, about 4:1 to about 6:1, about 4.5:1 to about 6:1, about 5:1 to 6:1, about 5.5:1 to 6:1, about 1.5:1 to 5.5:1; about 1.5:1 to 5.5:1; 2:1 to 5.5:1:, about 2.5:1 to about 5.5:1, about 3:1 to about 5.5:1, about 3.5:1 to about 5.5:1, about 4:1 to about 5.5:1, about 4.5:1 to about 5.5:1, about 5:1 to about 5.5:1, about 1.5:1 to about 5:1, about 2:1 to about 5:1, about 2.5:1 to about 5:1, about 3:1 to about 5:1, about 3.5:1 to about 5:1 1, about 4:1 to about 5:1, about 4.5:1 to about 5:1, about 1.5:1 to about 4.5:1, about 2:1 to about 4.5:1, about 2.5:1 to about 4.5:1, about 3:1 to about 4.5:1, about 3.5:1 to about 4.5:1, about 4:1 to about 4.5:1, about 1.5:1 to about 4:1, about 2:1 to about 4:1, about 2.5:1 to about 4:1, about 3:1 to about 1 to 4:1, about 3.5:1 to 4:1, about 1.5:1 to 3.5:1; about 2:1 to 3.5:1, about 2.5:1 to about 3.5:1, about 3:1 to about 3.5:1, about 1.5:1 to about 3:1, about 2:1 to about 3:1, about 2.5:1 to about 3:1, about 1.5:1 to about 2.5:1, about 2:1 to about 2.5:1, or any other suitable value or subrange therebetween.

[0097] In some embodiments, the weight ratio of inorganic material (such as inorganic particles) to biochar can be about 2:1 to about 4:1, including all values ​​and subranges therebetween. In some embodiments, the weight ratio of inorganic material (e.g., inorganic particles) to biochar is about 2.5:1 to about 3.5:1, including all values ​​and subranges therebetween. Lower ratios of inorganic material to biochar (or higher biochar content) allow for greater carbon emissions reductions to be achieved without negatively affecting the mechanical and / or acoustic properties of the building panels.

[0098] In some embodiments, the weight ratio of inorganic material, such as inorganic particles, to flame retardant may be from about 3:1 to about 12:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of the inorganic material (such as inorganic particles) to the flame retardant can be about 3:1 to about 12:1, about 4:1 to about 12:1, about 5:1 to about 12:1, about 6:1 to about 12:1, about 7:1 to about 12:1, about 8:1 to about 12:1, about 9:1 to about 12:1, about 10:1 to about 12:1, about 11:1 to about 12:1, about 3:1 to about 11:1, about 4:1 to about 11:1, about 5:1 to about 11:1, about 6:1 to about 11:1, about 7:1 to about 12:1, about 8:1 to about 12:1, about 9:1 to about 12:1, about 10:1 to about 12:1, about 11:1 to about 12:1, about 3:1 to about 11:1, about 4:1 to about 11:1, about 5:1 to about 11:1, about 6:1 to about 11:1, about 7:1 to about 12:1, about 8:1 to about 11:1, about 9:1 to about 11:1, about The invention relates to a method for producing an aqueous phase-enhanced sodium-ion battery comprising: a molecular weight of at least about 50 μm, a molecular weight of at least about 100 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 60 μm, a molecular weight of at least about 80 μm, a molecular weight of at least about 100 μm, a molecular weight of at least about 200 μm, a molecular weight of at least about 300 μm, a molecular weight of at least about 400 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 60 μm, a molecular weight of at least about 80 μm, a molecular weight of at least about 200 μm, a molecular weight of at least about 300 μm, a molecular weight of at least about 400 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 60 μm, a molecular weight of at least about 300 μm, a molecular weight of at least about 400 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 60 μm, a molecular weight of at least about 60 μm, a molecular weight of at least about 300 μm, a molecular weight of at least about 400 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about 50 μm, a molecular weight of at least about

[0099] In some embodiments, the weight ratio of the inorganic material (such as inorganic particles) to the flame retardant can be from about 4:1 to about 8:1, including all values ​​and subranges therebetween. In some embodiments, the weight ratio of the inorganic material (such as inorganic particles) to the flame retardant can be from about 5:1 to about 7:1, including all values ​​and subranges therebetween.

[0100] In some embodiments, the weight ratio of biochar to flame retardant may be from about 1.5:1 to about 4:1, including all values ​​and subranges therebetween. The building panels described herein may allow for high weight ratios of biochar to flame retardant to keep manufacturing costs low while maintaining desired fire resistance. In some embodiments, the weight ratio of biochar to flame retardant may be from about 1:1 to about 20:1, including all values ​​and subranges therebetween.

[0101] For example, in some embodiments, the weight ratio of biochar to flame retardant can be about 1:1 to about 20:1, about 1.5:1 to about 20:1, about 2:1 to about 20:1, about 2.5:1 to about 20:1, about 3:1 to about 20:1, about 3.5:1 to about 20:1, about 4:1 to about 20:1, about 5:1 to about 20:1, about 7.5:1 to about 20:1, about 10:1 to about 20:1, about 15:1 to about 20:1, 1:1 to about 15:1, about 1.5:1 to about 15:1, about 2:1 to about 15:1, about 2.5:1 to about 20:1, about 3:1 to about 20:1, about 3.5:1 to about 20:1, about 4:1 to about 20:1, about 5:1 to about 20:1, about 7.5:1 to about 20:1, about 10:1 to about 20:1, about 15:1 to about 20:1, about 1:1 to about 15:1, about 1.5:1 to about 15:1, about 2:1 to about 15:1, about 2.5:1 to about 15:1, or about 3. 1 to about 15:1, about 3.5:1 to about 15:1, about 4:1 to about 15:1, about 5:1 to about 15:1, about 7.5:1 to about 15:1, about 10:1 to about 15:1, 1:1 to about 10:1, about 1.5:1 to about 10:1, about 2:1 to about 10:1, about 2.5:1 to about 10:1, about 3:1 to about 10:1, about 3.5:1 to about 10:1, about 4:1 to about 10:1, about 5:1 to about 10:1, about 7.5:1 to about 10:1, about 10:1 to about 10:1, 1:1 to about 7.5:1, about 1.5:1 to about 10:1. 5:1, about 2:1 to about 7.5:1, about 2.5:1 to about 7.5:1, about 3:1 to about 7.5:1, about 3.5:1 to about 7.5:1, about 4:1 to about 7.5:1, about 5:1 to about 7.5:1, 1:1 to about 5:1, about 1.5:1 to about 5:1, about 2:1 to about 5:1, about 2.5:1 to about 5:1, about 3:1 to about 5:1, about 3.5:1 to about 5:1, about 4:1 to about 5:1, 1:1 to about 4:1, about 1.5:1 to about 4:1, about 2:1 to about 4:1, about 2.5:1 to about 4:1, about 3:1 to about 4:1: 1, about 3.5:1 to about 4:1, 1:1 to about 3.5:1, about 1.5:1 to about 3.5:1, about 2:1 to about 3.5:1, about 2.5:1 to about 3.5:1, about 3:1 to about 3.5:1, 1:1 to about 3:1, about 1.5:1 to about 3:1, about 2:1 to about 3:1, about 2.5:1 to about 3:1, 1:1 to about 2.5:1, about 1.5:1 to about 2.5:1, about 2:1 to about 2.5:1, about 1:1 to about 2:1, about 1.5:1 to about 2:1, 1:1 to about 1.5:1, or any other suitable value or subrange therebetween.

[0102] In some embodiments, body 420 can have airflow properties that can allow building panel 400 to function as an acoustic building panel. In some embodiments, adding biochar to acoustic building panels can have a neutral or positive effect on acoustic performance due to the porous nature and high skeletal density of biochar.

[0103] In some embodiments, perforations may be formed in the body 420 to further enhance the airflow characteristics and acoustic performance of the building panel 400. In some embodiments, the body 420 may include a plurality of perforations extending continuously from an upper surface 422 to a lower surface 421 of the body 420, forming an air channel that provides fluid communication through the body 420 between the upper surface 422 and the lower surface 421.

[0104] In some embodiments, the average diameter of the perforations may be in the range of about 0.5 mm to about 100 mm, including all values ​​and sub-ranges therebetween. For example, in some embodiments, the diameter of the perforations may range from, for example, about 0.5 mm to about 50 mm, about 0.5 mm to about 40 mm, about 0.5 mm to about 30 mm, about 0.5 mm to about 20 mm, about 0.5 mm to about 10 mm, about 0.5 mm to about 8 mm, about 0.5 mm to about 6 mm, about 0.5 mm to about 4 mm, about 0.5 mm to about 2 mm, or about 0.5 mm to about 1 mm to achieve the desired acoustic performance and / or any other desired properties. In some embodiments, the perforations may have a uniform size (e.g., diameter). In some embodiments, the perforations may have an uneven, varying size.

[0105] In some embodiments, the perforations may be present at a perforation density (number of perforations per unit area) of about 1 perforation per square foot to about 100 perforations per square foot, including all values ​​and subranges therebetween. For example, in some embodiments, the perforations may have a perforation density of about 1 perforation per square foot to about 100 perforations per square foot, about 25 perforations per square foot to about 100 perforations per square foot, about 50 perforations per square foot to about 100 perforations per square foot, about 75 perforations per square foot to about 100 perforations per square foot, 1 perforation per square foot to about 75 perforations per square foot, about 25 perforations per square foot to about 75 perforations per square foot, about 50 perforations per square foot to about 75 perforations per square foot, 1 perforation per square foot to about 50 perforations per square foot, about 25 perforations per square foot to about 50 perforations per square foot, 1 perforation per square foot to about 25 perforations per square foot, or any other suitable value or subrange therebetween.

[0106] In some embodiments, the body 420 can exhibit an airflow resistance in the range of about 200 MKS Rayleigh to about 40,000 MKS Rayleigh, measured between the upper surface 422 and the lower surface 421, including all values ​​and subranges therebetween. In some embodiments, the building panel 400 can exhibit an airflow resistance in the range of about 200 MKS Rayleigh to about 40,000 MKS Rayleigh, measured between the first major surface 411 and the second major surface 412, including all values ​​and subranges therebetween. In some embodiments, the building panel 400 can exhibit an NRC of at least about 0.5 measured between the first major surface 411 and the second major surface 412. In some embodiments, the building panel 400 can exhibit an NRC of about 0.60 to about 0.99 measured between the first major surface 411 and the second major surface 412, including all values ​​and subranges therebetween.

[0107] The main body 420 in a dry state may have a relative humidity of about 0.03 g / cm 3 To about 0.25g / cm 3 The term "bulk density" refers to the volume density relative to the total volume V of the body 420. 总 The density measured, where V 总 The volume defined by the panel length, panel width and panel thickness. 总 Included is the volume occupied by the skeleton of the body 420 (i.e., the volume occupied by the material forming the body 420 , including inorganic particles, biochar, flame retardants, organic fibers, etc.) and the volume occupied by voids created by perforations extending through the body 420 of the building panel 400 .

[0108] In some embodiments, the bulk density of the body 420 in a dry state may be about 0.03 g / cm 3 To about 0.25g / cm 3 , about 0.05g / cm 3 To about 0.25g / cm 3 , about 0.07g / cm 3 To about 0.25g / cm 3 , about 0.09g / cm 3 To about 0.25g / cm 3 , about 0.11g / cm 3 To about 0.25g / cm 3 , about 0.13g / cm 3 To about 0.25g / cm 3 , about 0.15g / cm 3 To about 0.25g / cm 3 , about 0.17g / cm 3 To about 0.25g / cm3 , about 0.19g / cm 3 To about 0.25g / cm 3 , about 0.21g / cm 3 To about 0.25g / cm 3 , about 0.23g / cm 3 To about 0.25g / cm 3 , about 0.03g / cm 3 To about 0.23g / cm 3 , about 0.05g / cm 3 To about 0.23g / cm 3 , about 0.07g / cm 3 To about 0.23g / cm 3 , about 0.09g / cm 3 To about 0.23g / cm 3 , about 0.11g / cm 3 To about 0.23g / cm 3 , about 0.13g / cm 3 To about 0.23g / cm 3 , about 0.15g / cm 3 To about 0.23g / cm 3 , about 0.17g / cm 3 To about 0.23g / cm 3 , about 0.19g / cm 3 To about 0.23g / cm 3 , about 0.21g / cm 3 To about 0.23g / cm 3 , about 0.03g / cm 3 To about 0.21g / cm 3 , about 0.05g / cm 3 To about 0.21g / cm 3 , about 0.07g / cm 3 To about 0.21g / cm 3 , about 0.09g / cm 3 To about 0.21g / cm 3 , about 0.11g / cm 3 To about 0.21g / cm 3 , about 0.13g / cm 3 To about 0.21g / cm 3 , about 0.15g / cm 3 To about 0.21g / cm 3 , about 0.17g / cm 3 To about 0.21g / cm 3 , about 0.19g / cm 3To about 0.21g / cm 3 , about 0.03g / cm 3 To about 0.19g / cm 3 , about 0.05g / cm 3 To about 0.19g / cm 3 , about 0.07g / cm 3 To about 0.19g / cm 3 , about 0.09g / cm 3 To about 0.19g / cm 3 , about 0.11g / cm 3 To about 0.19g / cm 3 , about 0.13g / cm 3 To about 0.19g / cm 3 , about 0.15g / cm 3 To about 0.19g / cm 3 , about 0.17g / cm 3 To about 0.19g / cm 3 , about 0.03g / cm 3 To about 0.17g / cm 3 , about 0.05g / cm 3 To about 0.17g / cm 3 , about 0.07g / cm 3 To about 0.17g / cm 3 , about 0.09g / cm 3 To about 0.17g / cm 3 , about 0.11g / cm 3 To about 0.17g / cm 3 , about 0.13g / cm 3 To about 0.17g / cm 3 , about 0.15g / cm 3 To about 0.17g / cm 3 , about 0.03g / cm 3 To about 0.15g / cm 3 , about 0.05g / cm 3 To about 0.15g / cm 3 , about 0.07g / cm 3 To about 0.15g / cm 3 , about 0.09g / cm 3 To about 0.15g / cm 3 , about 0.11g / cm 3 To about 0.15g / cm 3 , about 0.13g / cm 3 To about 0.15g / cm 3 , about 0.03g / cm3 To about 0.13g / cm 3 , about 0.05g / cm 3 To about 0.13g / cm 3 , about 0.07g / cm 3 To about 0.13g / cm 3 , about 0.09g / cm 3 To about 0.13g / cm 3 , about 0.11g / cm 3 To about 0.13g / cm 3 , about 0.03g / cm 3 To about 0.11g / cm 3 , about 0.05g / cm 3 To about 0.11g / cm 3 , about 0.07g / cm 3 To about 0.11g / cm 3 , about 0.09g / cm 3 To about 0.11g / cm 3 , about 0.03g / cm 3 To about 0.09g / cm 3 , about 0.05g / cm 3 To about 0.09g / cm 3 , about 0.07g / cm 3 To about 0.09g / cm 3 , about 0.03g / cm 3 To about 0.07g / cm 3 , about 0.05g / cm 3 To about 0.07g / cm 3 , about 0.03g / cm 3 To about 0.05g / cm 3 , or any other suitable value or sub-range therebetween.

[0109] The main body 420 in a dry state may have a relative humidity of about 1 g / cm 3 To about 2.6g / cm 3 The term "skeletal density" refers to the total volume V of the body 420 relative to the body 420. 总 The density measured, where V 总 Defined by the volume created by the panel length, panel width and panel thickness minus the volume occupied by the void created by the perforations 200.

[0110] In some embodiments, the skeleton density of the body 420 in a dry state may be about 1 g / cm 3 to about 2.6 g / cm 3, about 1.3 g / cm 3 to about 2.6 g / cm 3 , about 1.6 g / cm 3 to about 2.6 g / cm 3 , about 2 g / cm 3 to about 2.6 g / cm 3 , about 2.3 g / cm 3 to about 2.6 g / cm 3 , about 1 g / cm 3 to about 2.3 g / cm 3 , about 1.6 g / cm 3 to about 2.3 g / cm 3 , about 2 g / cm 3 to about 2.3 g / cm 3 , about 1 g / cm 3 to about 2 g / cm 3 , about 1.3 g / cm 3 to about 2 g / cm 3 , about 1.6 g / cm 3 About 2g / cm 3 , about 1g / cm 3 to about 1.6 g / cm 3 , about 1.3 g / cm 3 To 1.6 g / cm 3 , or about 1 g / cm 3 To 1.3 g / cm 3 , or any other suitable value or sub-range therebetween.

[0111] In some embodiments, building panel 400 can be manufactured according to the following method. In some embodiments, inorganic particles, biochar, flame retardant, fiber (e.g., organic fiber), and liquid carrier (e.g., water) can be mixed to form a blend. The liquid carrier can be present in an amount ranging from about 94% to about 99% by weight based on the total weight of the blend, including all values ​​and subranges therebetween.

[0112] The blend may be formed or processed into a wet web. The wet web may then be heated at an elevated temperature of about 100° C. to about 200° C. (including all values ​​and subranges therebetween) to dry or harden and cut to size to form a dry body 420.

[0113] In some embodiments, during the molding process, a mold may be used. In some embodiments, the mold may include a structure or geometry that will create through holes or perforations in the body 420.

[0114] In some embodiments, the body 420 may be formed without perforations during the above process, and the perforations may be subsequently formed or machined into the body 420 by drilling, punching, or any suitable method.

[0115] The following examples were prepared according to the invention. The invention is not limited to the examples described herein.

[0116] Example Experiment 1 A first experiment was conducted to test the effect on the strength and porosity of panels according to the invention. Each panel comprised a body formed from the formulation listed in Table 1 below, each amount listed being a weight percent (wt %).

[0117] Table 1 The average particle size of Biochar 1 is about 2 mm to about 3 mm. The average particle size of Biochar 2 is less than 2 mm.

[0118] Each panel was then tested for bulk density, skeletal density, porosity and strength (modulus). The results are listed in Table 2 below.

[0119] Table 2 As shown in Table 2, the addition of biochar resulted in the host exhibiting improved strength as evidenced by an increase in the modulus of rupture. Surprisingly, when the porosity of the host was increased (>90%), the bulk density of the material did not change. Furthermore, the partial / complete replacement of perlite in the building panels of Examples 1-3 reflects a carbon negative product when compared to the building panel of Comparative Example 1.

[0120] Thus, the subject of the invention provides an improvement in panel strength without reducing airflow characteristics, thereby allowing the panel to maintain its acoustic properties. The increase in strength without changing density results in an acoustic panel with excellent sag resistance.

[0121] Experiment 2 A second experiment was conducted to further test the porosity and carbon reduction of panels according to the present invention. The panels of Comparative Example 2, Example 4 and Example 5 were formed using water recycled from previous board manufacturing. Each panel of this experiment included a body formed from the formulation listed in Table 3 below, with each amount listed being a weight percent (wt %).

[0122] Table 3 Then based on kg CO2 / kg material testing of each board's skeletal density, porosity and global warming potential (" GWP ”). The results are listed in Table 4 below.

[0123] Table 4 As shown in Table 4, the addition of biochar resulted in no material change in the bulk in terms of skeletal density or porosity when the building panels of Comparative Example 2 were compared, while the partial / complete replacement of perlite in the building panels of Examples 4 and 5 reflected a negative carbon product.

[0124] Collection of exemplary clauses Exemplary Clauses 1. An acoustic building panel, comprising: a body, the body comprising: inorganic fibers and biochar, wherein the content of the inorganic fibers ranges from about 60.0 wt% to about 90.0 wt% based on the total weight of the body, and the content of the biochar ranges from about 10.0 wt% to about 40.0 wt% based on the total weight of the body, wherein the biochar has an average particle size in the range of about 0.1 mm to about 5 mm.

[0125] Exemplary clause 2. The acoustic building panel of Exemplary clause 1, wherein the biochar is present in an amount ranging from about 18 wt % to about 23 wt % based on the total weight of the body.

[0126] Exemplary clause 3. The acoustic building panel of any one of exemplary clauses 1 to 2, wherein the inorganic fibers comprise mineral wool.

[0127] Exemplary clause 4. The acoustic building panel of any one of exemplary clauses 1 to 3, wherein the body further comprises an organic fiber material.

[0128] Exemplary clause 5. The acoustic building panel of Exemplary clause 4, wherein the organic fiber material is present in an amount ranging from about 1.0 wt % to about 10.0 wt % based on the total weight of the body.

[0129] Exemplary clause 6. An acoustic building according to any one of exemplary clauses 1 to 5, wherein the body further comprises a filler selected from the group consisting of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0130] Exemplary clause 7. The acoustic building panel of any one of exemplary clauses 1 to 6, wherein the body further comprises starch.

[0131] Exemplary clause 8. The acoustic building panel of Exemplary clause 7, wherein the starch is present in an amount ranging from about 5.0 wt % to about 15.0 wt % based on the total weight of the body.

[0132] Exemplary clause 9. The acoustic building panel 8 of any one of exemplary clauses 1 to 8, wherein the body has a porosity of about 80% to about 95%.

[0133] Exemplary clause 10. The acoustic building panel of any one of exemplary clauses 1 to 9, wherein the body has a g / cm 3 To about 0.25g / cm 3 The volume density of .

[0134] Exemplary clause 11. An acoustic building panel 10 according to any of exemplary clauses 1 to 10, wherein the body has a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface, and the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls.

[0135] Exemplary clause 12. The acoustic building panel 11 of any one of exemplary clauses 1 to 11, wherein the body further comprises a flame retardant.

[0136] Exemplary clause 13. The acoustic building panel of Exemplary clause 12, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

[0137] Exemplary clause 14. The acoustic building panel of any one of exemplary clauses 12 and 13, wherein the flame retardant comprises an active filler flame retardant.

[0138] Exemplary clause 15. The acoustic building panel of any one of exemplary clauses 12 to 14, wherein the flame retardant decomposes endothermically.

[0139] Exemplary clause 16. The acoustic building panel of any one of exemplary clauses 12 to 15, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0140] Exemplary clause 17. The acoustic building panel of any one of exemplary clauses 12 to 16, wherein the flame retardant releases water (H2O) upon decomposition.

[0141] Exemplary clause 18. The acoustic building panel of any one of exemplary clauses 12 to 17, wherein the flame retardant has an average particle size of 1 μm to about 100 μm.

[0142] Exemplary clause 19. The acoustic building panel of any one of exemplary clauses 12 to 18, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0143] Exemplary clause 20. An acoustic building panel comprising: a body comprising inorganic fibers and biochar; wherein the body has a 3 To about 0.25g / cm 3 The volume density of .

[0144] Exemplary clause 21. The acoustic building panel of Exemplary clause 20, wherein the weight ratio of the inorganic fibers to the biochar is about 3:1 to about 5:1.

[0145] Exemplary clause 22. The acoustic building panel of Exemplary clause 21, wherein the weight ratio of the inorganic fibers to the biochar is about 3.1:1 to about 4.5:1.

[0146] Exemplary clause 23. The acoustic building panel of any one of exemplary clauses 20 to 22, wherein the body has a skeletal density of about 0.35 g / cm 3 To about 2.7g / cm 3 .

[0147] Exemplary clause 24. The acoustic architectural inlay of any of Exemplary clauses 20 to 23, wherein the inorganic fibers are present in an amount ranging from about 60.0 wt % to about 90.0 wt % based on the total weight of the body.

[0148] Exemplary clause 25. The acoustic building panel of any of exemplary clauses 20 to 24, wherein the biochar is present in an amount ranging from about 10.0 wt % to about 40.0 wt % based on the total weight of the body.

[0149] Exemplary clause 26. The acoustic building panel of any one of exemplary clauses 20 to 25, wherein the inorganic fibers comprise mineral wool.

[0150] Exemplary clause 27. An acoustic building panel according to any of exemplary clauses 20 to 26, wherein the body further comprises a filler selected from the group consisting of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0151] Exemplary clause 28. The acoustic building panel of any one of exemplary clauses 20 to 27, wherein the body further comprises starch.

[0152] Exemplary clause 29. The acoustic building panel 28 of exemplary clause 28, wherein the starch is present in an amount ranging from about 5.0 wt % to about 15.0 wt % based on the total weight of the body.

[0153] Exemplary clause 30. The acoustic building panel of any of exemplary clauses 20 to 29, wherein the body further comprises an organic fiber material.

[0154] Exemplary clause 31. The acoustic building panel 30 of exemplary clause 31, wherein the organic fiber material is present in an amount ranging from about 1.0 wt % to about 10.0 wt % based on the total weight of the body.

[0155] Exemplary clause 32. An acoustic building panel according to any of exemplary clauses 20 to 31, wherein the body has a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface, and the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls.

[0156] Exemplary clause 33. The acoustic building panel of any one of exemplary clauses 20 to 32, wherein the body further comprises a flame retardant.

[0157] Exemplary clause 34. The acoustic building panel of exemplary clause 33, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

[0158] Exemplary clause 35. The acoustic architectural panel of any one of Exemplary clauses 33 to 34, wherein the flame retardant comprises an active filler flame retardant.

[0159] Exemplary clause 36. The acoustic building panel of any one of exemplary clauses 33 to 35, wherein the flame retardant decomposes endothermically.

[0160] Exemplary clause 37. The acoustic building panel of any one of exemplary clauses 33 to 36, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0161] Exemplary clause 38. The acoustic building panel of any one of exemplary clauses 33 to 37, wherein the flame retardant releases water (H2O) upon decomposition.

[0162] Exemplary clause 39. The acoustic architectural panel of any of exemplary clauses 33 to 38, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0163] Exemplary clause 40. The acoustic building panel of any one of exemplary clauses 33 to 39, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0164] Exemplary clause 41. An acoustic building panel, comprising: a body comprising inorganic fibers and biochar; wherein the body has a porosity of about 80.0% to about 95.0%.

[0165] Exemplary clause 42. The acoustic building panel 41 of exemplary clause 41, wherein the weight ratio of the inorganic fibers to the biochar is about 3:1 to about 5:1.

[0166] Exemplary clause 43. The acoustic architectural inlay of any of exemplary clauses 41 to 42, wherein the inorganic fibers are present in an amount ranging from about 60.0 wt % to about 90.0 wt % based on the total weight of the body.

[0167] Exemplary clause 44. The acoustic building panel of any of exemplary clauses 41 to 43, wherein the biochar is present in an amount ranging from about 10.0 wt % to about 40.0 wt % based on the total weight of the body.

[0168] Exemplary clause 45. The acoustic building panel of any one of exemplary clauses 41 to 44, wherein the inorganic fibers comprise mineral wool.

[0169] Exemplary clause 46. An acoustic building panel according to any of exemplary clauses 41 to 45, wherein the body further comprises a filler selected from the group consisting of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0170] Exemplary clause 47. The acoustic building panel of Exemplary clause 46, wherein the perlite is present in an amount ranging from about 5.0 wt % to about 20.0 wt % based on the total weight of the body.

[0171] Exemplary clause 48. The acoustic building panel of any one of exemplary clauses 41 to 47, wherein the body further comprises starch.

[0172] Exemplary clause 49. The acoustical building panel of exemplary clause 48, wherein the starch is present in an amount ranging from about 5.0 wt % to about 15.0 wt % based on the total weight of the body.

[0173] Exemplary clause 50. The acoustic building panel of any one of exemplary clauses 41 to 49, wherein the body further comprises an organic fiber material.

[0174] Exemplary clause 51. The acoustic building panel of exemplary clause 50, wherein the organic fiber material is present in an amount ranging from about 1.0 wt % to about 10.0 wt % based on the total weight of the body.

[0175] Exemplary clause 52. An acoustic building panel according to any of exemplary clauses 41 to 51, wherein the body has a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface, and the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls.

[0176] Exemplary clause 53. The acoustic building panel of any one of exemplary clauses 41 to 52, wherein the body further comprises a flame retardant.

[0177] Exemplary clause 54. The acoustic building panel of exemplary clause 53, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

[0178] Exemplary clause 55. The acoustic building panel of any of exemplary clauses 53 to 54, wherein the flame retardant comprises an active filler flame retardant.

[0179] Exemplary clause 56. The acoustic building panel of any one of exemplary clauses 53 to 55, wherein the flame retardant decomposes endothermically.

[0180] Exemplary clause 57. The acoustic building panel of any one of exemplary clauses 53 to 56, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0181] Exemplary clause 58. The acoustic architectural panel of any of exemplary clauses 53 to 57, wherein the flame retardant releases water (H2O) upon decomposition.

[0182] Exemplary clause 59. The acoustic building panel of any one of exemplary clauses 53 to 58, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0183] Exemplary clause 60. The acoustic building panel of any one of exemplary clauses 53 to 59, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0184] Exemplary clause 61. A ceiling system comprising: a support structure; and at least one acoustic building panel according to any one of exemplary clauses 1 to 60 mounted on the support structure.

[0185] Exemplary clause 62. A method of making an acoustic building panel, comprising: mixing a liquid carrier, inorganic fibers, biochar, and a binder to form a blend; and shaping and drying the blend into a body having a first major surface opposite a second major surface and a side surface extending between the first major surface and the second major surface, wherein the body is substantially free of the liquid carrier.

[0186] Exemplary clause 63. The method of exemplary clause 62, wherein the blend further comprises a filler selected from the group consisting of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigments, zinc oxide, zinc sulfate, and combinations thereof.

[0187] Exemplary clause 64. The method of any one of exemplary clauses 62 to 63, wherein the blend further comprises an organic fiber material.

[0188] Exemplary clause 65. The method of any one of exemplary clauses 62 to 64, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0189] Exemplary clause 66. The method of any one of exemplary clauses 62 to 65, wherein the weight ratio of the inorganic fiber to the biochar in the blend is from about 3:1 to about 5:1.

[0190] Exemplary clause 67. The method of any one of exemplary clauses 62 to 66, wherein the body has a porosity of about 80.0% to about 95.0%.

[0191] Exemplary clause 68. The method of any one of exemplary clauses 62 to 67, wherein the blend further comprises a flocculant.

[0192] Exemplary clause 69. The method of any one of exemplary clauses 62 to 68, wherein the blend further comprises a flame retardant.

[0193] Exemplary clause 70. The method of exemplary clause 69, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

[0194] Exemplary clause 71. The method of any one of exemplary clauses 69 to 70, wherein the flame retardant comprises an active filler flame retardant.

[0195] Exemplary clause 72. The method of any one of exemplary clauses 69 to 71, wherein the flame retardant decomposes endothermically.

[0196] Exemplary clause 73. The method of any one of exemplary clauses 69 to 72, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0197] Exemplary clause 74. The method of any one of exemplary clauses 69 to 73, wherein the flame retardant releases water (H2O) upon decomposition.

[0198] Exemplary clause 75. The method of any one of exemplary clauses 69 to 74, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0199] Exemplary clause 76. The method of any one of exemplary clauses 69 to 75, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0200] Exemplary clause 77. An acoustic building panel, comprising: a body, the body comprising inorganic fibers, biochar, and a flame retardant, wherein the content of the inorganic fibers ranges from about 60.0 weight % to about 90.0 weight % based on the total weight of the body; the content of the biochar ranges from about 10.0 weight % to about 40.0 weight % based on the total weight of the body.

[0201] Exemplary clause 78. The acoustic building panel of exemplary clause 77, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

[0202] Exemplary clause 79. The acoustic building panel of any one of exemplary clauses 77 to 78, wherein the flame retardant comprises an active filler flame retardant.

[0203] Exemplary clause 80. The acoustic building panel of any one of exemplary clauses 77 to 79, wherein the flame retardant decomposes endothermically.

[0204] Exemplary clause 81. The acoustic building panel of any one of exemplary clauses 77 to 80, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0205] Exemplary clause 82. The acoustic building panel of any one of exemplary clauses 77 to 81, wherein the flame retardant releases water (H2O) upon decomposition.

[0206] Exemplary clause 83. The acoustic building panel of any one of exemplary clauses 77 to 82, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0207] Exemplary clause 84. The acoustic building panel of any one of exemplary clauses 77 to 83, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0208] Exemplary clause 85. The acoustic building panel of any one of exemplary clauses 77 to 84, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0209] Exemplary clause 86. The acoustic building panel of any one of exemplary clauses 77 to 85, wherein the body further comprises a filler.

[0210] Exemplary clause 87. The acoustic building panel of exemplary clause 86, wherein the filler is present in an amount ranging from about 5.0 wt % to about 20.0 wt % based on the total weight of the body.

[0211] Exemplary clause 88. An acoustic building panel according to any of exemplary clauses 86 to 87, wherein the filler comprises at least one of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigment, zinc oxide or zinc sulfate.

[0212] Exemplary clause 89. The acoustic building panel of any one of exemplary clauses 77 to 88, wherein the inorganic fibers comprise at least one of mineral wool, rock wool, asbestos, glass fibers, or polymer fibers.

[0213] Exemplary clause 90. The acoustic building panel of any one of exemplary clauses 77 to 89, wherein the body further comprises an organic fiber material.

[0214] Exemplary clause 91. The acoustic building panel of clause 90, wherein the organic fiber material is present in an amount ranging from about 1 wt % to about 10 wt % based on the total weight of the body.

[0215] Exemplary clause 92. The acoustic building panel of any one of exemplary clauses 90 to 91, wherein the organic fibrous material comprises at least one of macroscopic cellulosic fibers or protein fibers.

[0216] Exemplary clause 93. An acoustic building panel 77 according to any one of exemplary clauses 77 to 92. As described in 92, the body also includes an adhesive.

[0217] Exemplary clause 94. The acoustic building panel of exemplary clause 93, wherein the binder is present in an amount ranging from about 1 wt % to about 20 wt % based on the total weight of the body.

[0218] Exemplary clause 95. The acoustic building panel of any one of exemplary clauses 93 to 94, wherein the binder comprises at least one of a starch-based polymer, polyvinyl alcohol (PVOH), latex, a polysaccharide polymer, a cellulosic polymer, a protein solution polymer, an acrylic polymer, polymaleic anhydride, or an epoxy resin.

[0219] Exemplary clause 96. The acoustic building panel of any one of exemplary clauses 93 to 95, wherein the adhesive comprises starch.

[0220] Exemplary clause 97. The acoustic building panel of any one of exemplary clauses 77 to 96, wherein the body has a porosity of about 80% to about 95%.

[0221] Exemplary clause 98. The acoustic building panel of any one of exemplary clauses 77 to 97, wherein the body has a g / cm3 3 To about 0.25g / cm3 3 The volume density of .

[0222] Exemplary clause 99. The acoustic building panel of any one of exemplary clauses 77 to 98, wherein the body has a skeletal density of about 0.35 g / cm 3 to about 2.7 g / cm 3 .

[0223] Exemplary clause 100. An acoustic building panel according to any of exemplary clauses 77 to 98, wherein the body has a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface, and the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls.

[0224] Example clause 101. A ceiling system comprising: a support structure; and at least one acoustic building panel 77 according to any one of the example clauses. To 100 Mounted on a supporting structure.

[0225] Exemplary clause 102. A method of making an acoustic building panel, comprising: mixing a liquid carrier, inorganic fibers, biochar, a flame retardant, and a binder to form a blend; and shaping and drying the blend into a body having a first major surface opposite a second major surface and a side surface extending between the first and second major surfaces, wherein the body is substantially free of the liquid carrier.

[0226] Exemplary clause 103. The method of exemplary clause 102, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

[0227] Exemplary clause 104. The method of any one of exemplary clauses 102 to 103, wherein the flame retardant comprises an active filler flame retardant.

[0228] Exemplary clause 105. The method of exemplary clause 104, wherein the active filler flame retardant decomposes endothermically.

[0229] Exemplary clause 106. The method of exemplary clause 104, wherein the active filler flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0230] Exemplary clause 107. The method of any one of exemplary clauses 105 to 106, wherein the active filler flame retardant releases water (H2O) upon decomposition.

[0231] Exemplary clause 108. The method of any one of exemplary clauses 102 to 107, wherein the active filler flame retardant has an average particle size of about 1 μm to about 100 μm.

[0232] Exemplary clause 109. The method of any one of exemplary clauses 102 to 108, wherein the active filler flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0233] Exemplary clause 110. The method of any one of exemplary clauses 102 to 109, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0234] Exemplary clause 111. The method of any one of exemplary clauses 102 to 110, wherein the blend further comprises a filler.

[0235] Exemplary clause 112. The method of exemplary clause 111, wherein the filler is present in an amount of about 5.0 wt % to about 20.0 wt % based on the total weight of the body.

[0236] Exemplary clause 113. The method of any one of exemplary clauses 111 to 112, wherein the filler comprises at least one of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigment, zinc oxide, or zinc sulfate.

[0237] Exemplary clause 114. The method of any one of exemplary clauses 102 to 113, wherein the inorganic fibers comprise at least one of mineral wool, rock wool, asbestos, glass fibers, or polymer fibers.

[0238] Exemplary clause 115. The method of any one of exemplary clauses 102 to 111, wherein the blend further comprises an organic fiber material.

[0239] Exemplary clause 116. The method of exemplary clause 115, wherein the organic fiber material is present in an amount ranging from about 1 wt % to about 10 wt % based on the total weight of the body.

[0240] Exemplary clause 117. The method of any one of exemplary clauses 115 to 116, wherein the organic fibrous material comprises at least one of macroscopic cellulosic fibers or protein fibers.

[0241] Exemplary clause 118. The method of any one of exemplary clauses 102 to 117, wherein the binder is present in an amount ranging from about 1 wt % to about 20 wt % based on the total weight of the body.

[0242] Exemplary clause 119. The method of any one of exemplary clauses 102 to 118, wherein the binder comprises at least one of a starch-based polymer, polyvinyl alcohol (PVOH), latex, a polysaccharide polymer, a cellulosic polymer, a protein solution polymer, an acrylic polymer, polymaleic anhydride, or an epoxy resin.

[0243] Exemplary clause 120. The method of any one of exemplary clauses 102 to 119, wherein the binder comprises starch.

[0244] Exemplary clause 121. The method of any one of exemplary clauses 102 to 120, wherein the blend further comprises a flocculant.

[0245] Exemplary clause 122. The method of any one of exemplary clauses 102 to 121, wherein the liquid carrier comprises water.

[0246] Exemplary clause 123. The method of any one of exemplary clauses 102 to 122, wherein the body has a porosity of about 80% to about 95%.

[0247] Exemplary clause 124. The method of any one of exemplary clauses 102 to 123, wherein the body has a g / cm 3 To about 0.25g / cm 3 The volume density of .

[0248] Exemplary clause 125. The method of any one of exemplary clauses 102 to 124, wherein the body has a skeletal density of about 0.35 g / cm 3 To about 2.7g / cm 3 .

[0249] Exemplary clause 126. A method according to any of exemplary clauses 102 to 125, wherein the body has a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface, and the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls.

[0250] Exemplary clause 127. A building panel comprising: a body, the body comprising an inorganic material, biochar, and a flame retardant, wherein the inorganic material is present in an amount ranging from about 1 wt % to about 99 wt % based on the total weight of the body, wherein the inorganic material comprises an alkaline earth metal compound; the biochar is present in an amount ranging from about 1 wt % to about 40 wt % based on the total weight of the body; the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body, wherein the flame retardant comprises an active filler flame retardant.

[0251] Exemplary clause 128. The method of the building panel of exemplary clause 127, wherein the alkaline earth metal compound comprises at least one of a calcium compound or a magnesium compound.

[0252] Exemplary clause 129. The building panel of any of exemplary clauses 127-128, wherein the alkaline earth metal compound comprises at least one of an alkaline earth metal oxide or an alkaline earth metal sulfate.

[0253] Exemplary clause 130. The building panel of any of exemplary clauses 127 to 129, wherein the alkaline earth metal compound comprises at least one of calcium sulfate, magnesium sulfate, or magnesium oxide.

[0254] Exemplary clause 131. The building panel of any of exemplary clauses 127 to 130, wherein the inorganic material comprises inorganic particles having an average particle size of about 0.1 μm to about 5 mm.

[0255] Exemplary clause 132. The building panel of any one of exemplary clauses 127 to 131, wherein the flame retardant decomposes endothermically.

[0256] Exemplary clause 133. The building panel of any of exemplary clauses 127 to 132, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0257] Exemplary clause 134. The building panel of any of exemplary clauses 127 to 133, wherein the flame retardant releases water (H2O) upon decomposition.

[0258] Exemplary clause 135. The building tile of any of exemplary clauses 127 to 134, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrated or calcined clay, calcium carbonate, talc, or feldspar.

[0259] Exemplary clause 136. The building panel according to any of exemplary clauses 127 to 135, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0260] Exemplary clause 137. The building panel of any one of exemplary clauses 127 to 136, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0261] Exemplary clause 138. The building panel of any one of exemplary clauses 127 to 137, wherein the biochar has a density of about 3 pcf to about 18 pcf.

[0262] Exemplary clause 139. The building panel of any of exemplary clauses 127 to 138, wherein the weight ratio of the inorganic material to the biochar is from about 1.5:1 to about 6:1, optionally from about 2:1 to about 4:1, or optionally from about 2.5:1 to about 3.5:1.

[0263] Exemplary clause 140. The building panel of any one of exemplary clauses 127 to 139, wherein the weight ratio of the inorganic material to the flame retardant is about 3:1 to about 12:1, optionally about 4:1 to about 8:1, or optionally about 5:1 to about 7:1.

[0264] Exemplary clause 141. The building panel of any one of exemplary clauses 127 to 140, wherein the weight ratio of the biochar to the flame retardant is about 1:1 to about 20:1, optionally about 1.5:1 to about 4:1.

[0265] Exemplary clause 142. The building panel of any one of exemplary clauses 127 to 141, wherein the body exhibits an NRC value of about 0.6 to about 0.99.

[0266] Exemplary clause 143. The building panels of any of exemplary clauses 127 to 142, wherein the body comprises a first major surface opposite a second major surface and a plurality of perforations extending from the first major surface to the second major surface of the body.

[0267] Exemplary clause 144. The building panels of exemplary clause 143, wherein the plurality of perforations have an average diameter in the range of about 0.5 mm to about 100 mm.

[0268] Exemplary clause 145. The building panel of any one of exemplary clauses 143-144, wherein the plurality of perforations has a perforation density of about 1 perforation per square foot to about 100 perforations per square foot.

[0269] Exemplary clause 146. The building panels of any of exemplary clauses 143 to 145, wherein the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls measured between the first major surface and the second major surface.

[0270] Exemplary clause 147. The building panel of any one of exemplary clauses 143 to 146, wherein the body has a g / cm 3 To about 0.25g / cm 3 The volume density of .

[0271] Exemplary clause 148. The building panel of any one of exemplary clauses 143 to 147, wherein the skeletal density of the body is about 1 gcm 3 To about 2.6g / cm 3 .

[0272] Exemplary clause 149. A ceiling system comprising: a support structure; and at least one building panel according to any one of exemplary clauses 127 to 148 mounted on the support structure.

[0273] Exemplary clause 150. A method of manufacturing building panels, comprising: mixing an inorganic material, biochar, a flame retardant, and a liquid carrier to form a blend; and shaping and hardening the blend into a body having a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface; wherein the inorganic material comprises an alkaline earth metal compound; the flame retardant comprises an active filler flame retardant; the content of the inorganic material ranges from about 1 weight % to about 99 weight % based on the total weight of the hardened body; the content of the biochar ranges from about 10 weight % to about 40 weight % based on the hardened body; and the content of the flame retardant ranges from about 1 weight % to about 15 weight % based on the hardened body.

[0274] Exemplary clause 151. The method of exemplary clause 150, wherein the alkaline earth metal compound comprises at least one of a calcium compound or a magnesium compound.

[0275] Exemplary clause 152. The method of any one of exemplary clauses 150 to 151, wherein the alkaline earth metal compound comprises at least one of an alkaline earth metal oxide or an alkaline earth metal sulfate.

[0276] Exemplary clause 153. The method of any one of exemplary clauses 150 to 152, wherein the alkaline earth metal compound comprises at least one of calcium sulfate, magnesium sulfate, or magnesium oxide.

[0277] Exemplary clause 154. The method of any one of exemplary clauses 150 to 153, wherein the inorganic material comprises inorganic particles having an average particle size of about 0.1 μm to about 5 mm.

[0278] Exemplary clause 155. The method of any one of exemplary clauses 150 to 154, wherein the flame retardant decomposes endothermically.

[0279] Exemplary clause 156. The method of any one of exemplary clauses 150 to 155, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0280] Exemplary clause 157. The method of any one of exemplary clauses 150 to 156, wherein the flame retardant releases water (H2O) upon decomposition.

[0281] Exemplary clause 158. The method of any one of exemplary clauses 150 to 157, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc, or feldspar.

[0282] Exemplary clause 159. The method of any one of exemplary clauses 150 to 158, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0283] Exemplary clause 160. The method of any one of exemplary clauses 150 to 159, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0284] Exemplary clause 161. The method of any one of exemplary clauses 150 to 160, wherein the biochar has a density of about 3 pcf to about 18 pcf.

[0285] Exemplary clause 162. The method of any one of exemplary clauses 150 to 161, wherein the weight ratio of the inorganic material to the biochar is about 1.5:1 to about 6:1, optionally about 2:1 to about 4:1, or optionally about 2.5:1 to about 3.5:1.

[0286] Exemplary clause 163. The method of any one of exemplary clauses 150 to 162, wherein the weight ratio of the inorganic material to the flame retardant is from about 3:1 to about 12:1, optionally from about 4:1 to about 8:1, or optionally from about 5:1 to about 7:1.

[0287] Exemplary clause 164. The method of any one of exemplary clauses 150 to 163, wherein the weight ratio of the biochar to the flame retardant is from about 1:1 to about 20:1, optionally from about 1.5:1 to about 4:1.

[0288] Exemplary clause 165. The method of any one of exemplary clauses 150 to 164, wherein the body exhibits an NRC value of about 0.6 to about 0.99.

[0289] Exemplary clause 166. The method of any one of exemplary clauses 150 to 165, further comprising forming a plurality of perforations extending from the first major surface to the second major surface of the body.

[0290] Exemplary clause 167. The method of exemplary clause 166, wherein an average diameter of the plurality of perforations is in a range from about 0.5 mm to about 100 mm.

[0291] Exemplary clause 168. The method of any of exemplary clauses 166 to 167, wherein the plurality of perforations has a perforation density of about 1 perforation per square foot to about 100 perforations per square foot.

[0292] Exemplary clause 169. The method of any one of exemplary clauses 166 to 168, wherein the body exhibits an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls measured between the first major surface and the second major surface.

[0293] Exemplary clause 170. The method of any one of exemplary clauses 166 to 169, wherein the body has a g / cm 3 To about 0.25g / cm 3 The volume density of .

[0294] Exemplary clause 171. The method of any one of exemplary clauses 166 to 170, wherein the body has a skeletal density of about 1 gcm 3 To about 2.6g / cm 3 .

[0295] Exemplary clause 172. The method of any one of exemplary clauses 166 to 171, wherein the liquid carrier comprises water.

[0296] Exemplary clause 173. A building panel comprising: a body, the body comprising an inorganic material, biochar, and a flame retardant, wherein the inorganic material is present in an amount ranging from about 1 wt % to about 99 wt % based on the total weight of the body, the biochar is present in an amount ranging from about 1 wt % to about 40 wt % based on the total weight of the body, and the flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body, wherein the flame retardant comprises an active filler flame retardant.

[0297] Exemplary clause 174. The building panel of exemplary clause 173, wherein the inorganic material comprises an alkaline earth metal compound.

[0298] Exemplary clause 175. The building panel of exemplary clause 174, wherein the alkaline earth metal compound comprises at least one of a calcium compound or a magnesium compound.

[0299] Exemplary clause 176. The building panel of any of exemplary clauses 174 to 175, wherein the alkaline earth metal compound comprises at least one of an alkaline earth metal oxide or an alkaline earth metal sulfate.

[0300] Exemplary clause 177. The building panel of any of exemplary clauses 174 to 176, wherein the alkaline earth metal compound comprises at least one of calcium sulfate, magnesium sulfate, or magnesium oxide.

[0301] Exemplary clause 178. The building panel of exemplary clause 173, wherein the inorganic material comprises inorganic fibers.

[0302] Exemplary clause 179. The building panel of exemplary clause 178, wherein the inorganic fibers are present in an amount ranging from about 60.0 wt. % to about 90.0 wt. % based on the total weight of the body.

[0303] Exemplary clause 180. The building panel of any of exemplary clauses 178 to 179, wherein the inorganic fibers comprise mineral wool.

[0304] Exemplary clause 181. The building panel of any of exemplary clauses 173 to 180, wherein the flame retardant decomposes endothermically.

[0305] Exemplary clause 182. The building panel of any one of exemplary clauses 173 to 181, wherein the flame retardant decomposes endothermically at an elevated temperature of about 200°C to about 325°C.

[0306] Exemplary clause 183. The building panel of any of exemplary clauses 173 to 182, wherein the flame retardant releases water (H2O) upon decomposition.

[0307] Exemplary clause 184. The building panel of any of exemplary clauses 173 to 183, wherein the flame retardant has an average particle size of 1 μm to about 100 μm.

[0308] Exemplary clause 185. The building panel of any one of exemplary clauses 173 to 184, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrated or calcined clay, calcium carbonate, talc, or feldspar.

Claims

1. An acoustic building panel comprising: A subject, the subject comprising: Inorganic fibers, the inorganic fibers being present in an amount ranging from about 60.0 wt % to about 90.0 wt % based on the total weight of the body; and Biochar, the biochar being present in an amount ranging from about 10.0 wt % to about 40.0 wt % based on the total weight of the body; Wherein, the biochar has an average particle size ranging from about 0.1 mm to about 5 mm.

2. An acoustic building panel comprising: The subject, which includes: Inorganic fibers; and Biochar; wherein the body has about 0.03g / cm 3 To about 0.25g / cm 3 The volume density of .

3. An acoustic building panel comprising: A subject, the subject comprising: Inorganic fibers; and Biochar; Wherein, the body has a porosity of about 80.0% to about 95.0%.

4. A method of making an acoustic building panel, comprising: mixing a liquid carrier, an inorganic fiber, a biochar, and a binder to form a blend; and The blend is shaped and dried into a body having a first major surface opposite a second major surface and a side surface extending between the first major surface and the second major surface, wherein the body is substantially free of the liquid carrier.

5. The acoustic building panel according to any one of claims 1 to 4, wherein The body also includes a flame retardant.

6. An acoustic building panel comprising: A subject, the subject comprising: Inorganic fibers, the inorganic fibers being present in an amount ranging from about 60.0 wt % to about 90.0 wt % based on the total weight of the body; Biochar, the biochar present in an amount ranging from about 10.0 wt % to about 40.0 wt % based on the total weight of the body; and Flame retardant.

7. A method of making an acoustic building panel, comprising: mixing a liquid carrier, an inorganic fiber, a biochar, a flame retardant, and a binder to form a blend; and The blend is shaped and dried into a body having a first major surface opposite a second major surface and a side surface extending between the first major surface and the second major surface, wherein the body is substantially free of a liquid carrier.

8. A building panel comprising: A subject, the subject comprising: an inorganic material, the inorganic material being present in an amount ranging from about 1 wt % to about 99 wt % based on the total weight of the host, wherein the inorganic material comprises an alkaline earth metal compound; biochar, the biochar being present in an amount ranging from about 1 wt % to about 40 wt % based on the total weight of the body; and A flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the main body, wherein the flame retardant comprises an active filler flame retardant.

9. A method of manufacturing a building panel, comprising: mixing an inorganic material, a biochar, a flame retardant, and a liquid carrier to form a blend; as well as shaping and hardening the blend into a body having a first major surface opposite to a second major surface and a side surface extending between the first major surface and the second major surface; in: The inorganic material includes an alkaline earth metal compound; The flame retardant includes an active filler flame retardant; The inorganic material is present in an amount ranging from about 1 wt % to about 99 wt % based on the total weight of the hardened body; The biochar is contained in an amount ranging from about 10 wt % to about 40 wt % based on the total weight of the hardened body; and The flame retardant may be included in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the hardened body.

10. A building panel comprising: A subject, the subject comprising: an inorganic material, wherein the content of the inorganic material ranges from about 1 wt % to about 99 wt % based on the total weight of the host; biochar, the biochar being present in an amount ranging from about 1 wt % to about 40 wt % based on the total weight of the body; and A flame retardant is present in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the main body, wherein the flame retardant comprises an active filler flame retardant.

11. The acoustic building panel according to any one of claims 1 to 10, wherein The biochar may be present in an amount ranging from about 18 wt % to about 23 wt % based on the total weight of the body.

12. The acoustic building panel according to any one of claims 1 to 5, wherein The inorganic fibers include mineral wool.

13. The acoustic building panel according to any one of claims 1 to 12, wherein The body further comprises an organic fiber material, optionally in an amount ranging from about 1.0 wt % to about 10.0 wt % based on the total weight of the body; optionally, the body further comprises a filler selected from the group consisting of perlite, calcium carbonate, limestone, titanium dioxide, sand, barium sulfate, clay, mica, dolomite, silica, talc, wollastonite, calcite, aluminum trihydrate, pigments, zinc oxide, zinc sulfate, and combinations thereof; and optionally, the body further comprises starch, in an amount ranging from about 5.0 wt % to about 15.0 wt % based on the total weight of the body.

14. The acoustic building panel according to any one of claims 1 to 13, wherein The flame retardant decomposes endothermally at a high temperature of about 200°C to about 325°C.

15. The acoustic building panel according to any one of claims 1 to 16, wherein The body has a thickness of about 0.03 g / cm 3 To about 0.25g / cm 3 The volume density of .

16. The acoustic building panel according to any one of claims 1 to 17, wherein The body has a first major surface opposite a second major surface and a side surface extending between the first major surface and the second major surface, the body exhibiting an airflow resistance of about 200 MKS Rayls to about 40,000 MKS Rayls.

17. The acoustic building panel according to any one of claims 5 to 7, wherein The flame retardant may be included in an amount ranging from about 1 wt % to about 15 wt % based on the total weight of the body.

18. The acoustic building panel of any one of claims 5 to 1919, wherein The flame retardant includes an active filler flame retardant.

19. The acoustic building panel according to any one of claims 5 to 20, wherein The flame retardant decomposes endothermally.

20. The acoustic building panel according to any one of claims 5 to 21, wherein The flame retardant decomposes endothermally at a high temperature of about 200°C to about 325°C.

21. The acoustic building panel according to any one of claims 5 to 22, wherein The flame retardant releases water (H2O) when decomposing.

22. The acoustic building panel according to any one of claims 5 to 23, wherein The flame retardant has an average particle size of about 1 μm to about 100 μm.

23. The acoustic building panel according to any one of claims 5 to 24, wherein The flame retardant includes at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrous or calcined clay, calcium carbonate, talc or feldspar.

24. The acoustic building panel of claim 8, wherein The alkaline earth metal compound comprises at least one of a calcium compound or a magnesium compound, optionally wherein the alkaline earth metal compound comprises at least one of an alkaline earth metal oxide or an alkaline earth metal sulfate; optionally wherein the alkaline earth metal compound comprises at least one of calcium sulfate, magnesium sulfate or magnesium oxide and optionally wherein the inorganic material comprises inorganic particles having an average particle size of about 0.1 μm to about 5 mm.

25. A ceiling system comprising: Support structure; as well as At least one building panel according to any of claims 1 to 3, 5, 6, 8 and 10 to 25 mounted on the supporting structure.

Images