Building panel

Abstract

An acoustic building panel and a method of manufacturing an acoustic building panel are described, the acoustic building panel comprising a body comprising inorganic fibers, biochar, and a flame retardant. In some embodiments, the weight ratio of the biochar to the flame retardant may be from about 1: 1 to about 6: 1. In some embodiments, the flame retardant may include an active filler flame retardant.

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 are believed to be the primary cause of global warming and ocean acidification. Building products and materials used to form such building products are contributors to CO2 emissions. Therefore, there is a need for new building products that help reduce or eliminate CO2 emissions. Furthermore, such new building products should be developed without sacrificing the fire resistance, 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, an acoustic building panel may include a body. The body may include inorganic fibers, biochar, and a flame retardant, wherein the content of the inorganic fibers ranges from about 5% to about 75% by weight based on the total weight of the body; the content of the biochar ranges from about 5% to about 50% by weight or about 10% to about 40% by weight based on the total weight of the body; and the content of the flame retardant ranges from about 1% to about 30% by weight based on the total weight of the body. The weight ratio of the biochar to the flame retardant may range from about 1:1 to about 6:1.

[0003] According to some embodiments, an acoustic building panel may include a body. The body may include: inorganic fibers, biochar, and a flame retardant, wherein the inorganic fibers are present in an amount ranging from about 5% to about 75% by weight based on the total weight of the body; the amount of biochar is present in an amount ranging from about 5% to about 50% by weight based on the total weight of the body; and the amount of flame retardant is present in an amount ranging from about 1% to about 30% by weight based on the total weight of the body. The flame retardant may include colemanite.

[0004] According to some embodiments, a ceiling system may include a supporting structure and at least one of the above-described acoustic building panels mounted to the supporting structure.

[0005] According to some embodiments, a method of making an acoustic building panel may include mixing inorganic fibers, a binder, biochar, a flame retardant, and a liquid carrier 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. The body may be substantially free of the liquid carrier. The weight ratio of the biochar to the flame retardant may range from about 1:1 to about 6:1.

[0006] According to some embodiments, a method of making an acoustic building panel may include mixing inorganic fibers, a binder, biochar, a flame retardant, and a liquid carrier 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. The body may be substantially free of the liquid carrier. The flame retardant may include colemanite.

[0007] 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

[0008] 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 is a cross-sectional view of a building panel according to some embodiments of the invention, the cross-sectional view being taken along Figure 1 II line in; and Figure 3 is a ceiling system including building panels according to some embodiments of the invention.

[0009] Figure 4A and Figure 4B Controlling the heat release rate of the panel and the panel mass is shown.

[0010] Figure 5A and 5B The heat release rate and panel mass of a first exemplary building panel according to some embodiments of the invention are shown.

[0011] Fig. 6A and 6B Shown is the heat release rate and panel mass of a second exemplary building panel according to some embodiments of the invention.

[0012] Fig. 7A and 7B The heat release rate and panel mass of a third exemplary building panel according to some embodiments of the invention are shown. DETAILED DESCRIPTION

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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" refers to less than about 0.1% by weight based on the total reference value.

[0018] Reference Figure 1 According to some embodiments of the present invention, the building panel 100 may include a first major surface 111 opposite to the second major surface 112, and the ceiling panel 100 may also include a side surface 113 extending between the first major surface 111 and the second major surface 112, thereby defining the perimeter of the ceiling panel 100.

[0019] refer to Figure 3In 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.).

[0020] 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.

[0021] 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.

[0022] Now refer to Figure 1 and Figure 2 .like Figure 1 and Figure 2 As shown, in some embodiments, the building panel 100 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.

[0023] 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.

[0024] In some embodiments, 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.

[0025] 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 .

[0026] In some embodiments, the body 120 may include fibers 130. The fibers 130 may include fiber components. In some embodiments, the fiber components may include organic fibers, inorganic fibers, and combinations thereof. In some embodiments, the body 120 may also include biochar. In some embodiments, the body 120 may also include a flame retardant. In some embodiments, the body 120 may also include fillers and / or additives. In some embodiments, the body 120 may also include an adhesive.

[0027] The fiber component of fiber 130 can be organic fiber, inorganic fiber or its mixture. Non-limiting examples of inorganic fiber include mineral wool (also called slag wool), rock wool, asbestos, glass fiber and polymer fiber. Non-limiting examples of polymer fiber include polyester fiber, polyethylene fiber, aramid fiber (e.g. aramid fiber) and polypropylene fiber. Non-limiting examples of organic fiber include cellulose fiber visible to the naked eye (e.g. paper fiber-such as newspaper, hemp fiber, jute fiber, flax fiber, wood fiber or other natural fiber), protein fiber (e.g. sheep wool) and combination thereof. Depending on the specific type of material, the fiber component can be hydrophilic (e.g., cellulose fiber visible to the naked eye) or hydrophobic (e.g., glass fiber, mineral wool, rock wool, asbestos).

[0028] The fiber component may be present in an amount ranging from about 10% to about 80% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween. For example, in some embodiments, the fiber component may be present in an amount ranging from about 10% to about 80% by weight, from about 15% to about 80% by weight, from about 20% to about 80% by weight, from about 25% to about 80% by weight, from about 30% to about 80% by weight, from about 35% to about 80% by weight, from about 40% to about 80% by weight, from about 45% to about 80% by weight, from about 50% to about 80% by weight, from about 5 ... From about 60 wt % to about 80 wt %, from about 65 wt % to about 80 wt %, from about 70 wt % to about 80 wt %, from about 75 wt % to about 80 wt %, from about 10 wt % to about 75 wt %, from about 15 wt % to about 75 wt %, from about 20 wt % to about 75 wt %, from about 25 wt % to about 75 wt %, from about 30 wt % to about 75 wt %, from about 35 wt % to about 75 wt %, from about 40 wt % to about 75 wt %, from about 45 wt % to about 75 wt %, and from about 50 wt %. % to about 75% by weight, about 55% by weight to about 75% by weight, about 60% by weight to about 75% by weight, about 65% by weight to about 75% by weight, about 70% by weight to about 75% by weight, about 10% by weight to about 70% by weight, about 15% by weight to about 70% by weight, about 20% by weight to about 70% by weight, about 25% by weight to about 70% by weight, about 30% by weight to about 70% by weight, about 35% by weight to about 70% by weight, about 40% by weight to about 70% by weight, about 45% by weight to about 70% by weight, about 50% by weight to about 70% by weight, about 55% by weight to about 70% by weight, about 60% by weight to about 70% by weight, about 65% by weight to about 70% by weight, about 10% by weight to about 65% by weight, about 15% by weight to about 65% by weight, about 20% by weight to about 65% by weight, about 25% by weight to about 70% by weight, about 30% by weight to about 70% by weight, about 35% by weight to about 70% by weight, about 40% by weight to about 70% by weight, about 45% by weight to about 70% by weight, about 50% by weight to about 70% by weight, about 55% by weight to about 70% by weight, about 60% by weight to about 70% by weight, about 65% by weight to about 70% by weight, %, about 35 wt % to about 65 wt %, about 40 wt % to about 65 wt %, about 45 wt % to about 65 wt %, about 50 wt % to about 65 wt %, about 55 wt % to about 65 wt %, about 60 wt % to about 65 wt %, about 10 wt % to about 60 wt %, about 15 wt % to about 60 wt %, about 20 wt % to about 60 wt %, about 25 wt % to about 60 wt %, about 30 wt % to about 60 wt %, about 35 wt % to about 60 wt %, about 40 wt % to about 60 wt %, about 45 wt % to about 60 wt %, about 50 wt % to about 60 wt %, about 55 wt % to about 60 wt %, about 10 wt % to about 55 wt %, about 15 wt % to about 55 wt %, about 20 wt % to about 5 ...55 wtFrom about 35% to about 55% by weight, from about 40% to about 55% by weight, from about 45% to about 55% by weight, from about 50% to about 55% by weight, from about 10% to about 50% by weight, from about 15% to about 50% by weight, from about 20% to about 50% by weight, from about 25% to about 50% by weight, from about 30% to about 50% by weight, from about 35% to about 50% by weight, from about 40% to about 50% by weight, from about 45% to about 50% by weight, from about 10% to about 45% by weight, from about 15% to about 45% by weight, from about 20% to about 45% by weight, from about 25% to about 45% by weight, from about 30% to about 45% by weight, from about 35% to about 45% by weight, from about 40% to about 45% by weight %, about 20 wt % to about 40 wt %, about 25 wt % to about 40 wt %, about 30 wt % to about 40 wt %, about 35 wt % to about 40 wt %, about 10 wt % to about 35 wt %, about 15 wt % to about 35 wt %, about 20 wt % to about 35 wt %, about 25 wt % to about 35 wt %, about 30 wt % to about 35 wt %, about 10 wt % to about 30 wt %, about 15 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 25 wt % to about 30 wt %, about 10 wt % to about 25 wt %, about 15 wt % to about 25 wt %, about 20 wt % to about 25 wt %, about 10 wt % to about 20 wt %, about 15 wt % to about 20 wt %, about 10 wt % to about 15 wt %, or any other suitable value and subrange therebetween.

[0029] The phrase "dry weight" refers to the weight of the reference component without any weight of carrier. Therefore, when calculating the weight percentage of a dry component, the calculation should be based only on the solid components (e.g., fibers, binders, biochar, flame retardants, fillers, additives, etc.), and should exclude any amount of residual carrier that may still be present in a wet state (e.g., water, VOC solvents), which will be discussed further herein. According to the present invention, the phrase "dry state" can 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.

[0030] In some embodiments, the fiber component can be an inorganic fiber, such as mineral wool, wherein the inorganic fiber can be present in an amount ranging from about 5% to about 75% by weight, based on the total weight of the body 120, including all weight percentages and subranges therebetween. For example, in some embodiments, the inorganic fiber can be present in an amount ranging from about 5% to about 75% by weight, about 10% to about 75% by weight, about 15% to about 75% by weight, about 20% to about 75% by weight, about 25% to about 75% by weight, about 30% to about 75% by weight, about 35% to about 75% by weight, about 40% to about 75% by weight, about 45% to about 75% by weight, about 50% to about 75% by weight, about 55% to about 75% by weight, about 60% to about 75% by weight, about 65% to about 75% by weight, about 70% to about 75% by weight, based on the total weight of the body 120. %, about 5 wt % to about 70 wt %, about 10 wt % to about 70 wt %, about 15 wt % to about 70 wt %, about 20 wt % to about 70 wt %, about 25 wt % to about 70 wt %, about 30 wt % to about 70 wt %, about 35 wt % to about 70 wt %, about 40 wt % to about 70 wt %, about 45 wt % to about 70 wt %, about 50 wt % to about 70 wt %, about 55 wt % to about 70 wt %, about 60 wt % to about 70 wt %, about 65 wt % to about 70 wt %, about 5 wt % to about 65 wt %, about 10 wt % to about 65 wt %, about 15 wt % to about 65 wt %, about 20 % to about 65 wt%, about 25 wt% to about 65 wt%, about 30 wt% to about 65 wt%, about 35 wt% to about 65 wt%, about 40 wt% to about 65 wt%, about 45 wt% to about 65 wt%, about 50 wt% to about 65 wt%, about 55 wt% to about 65 wt%, about 60 wt% to about 65 wt%, about 5 wt% to about 60 wt%, about 10 wt% to about 60 wt%, about 15 wt% to about 60 wt%, about 20 wt% to about 60 wt%, about 25 wt% to about 60 wt%, about 30 wt% to about 60 wt%, about 35 wt% to about 60 wt%, about 40 wt% to about 60 wt %, about 45 wt % to about 60 wt %, about 50 wt % to about 60 wt %, about 55 wt % to about 60 wt %, about 5 wt % to about 55 wt %, about 10 wt % to about 55 wt %, about 15 wt % to about 55 wt %, about 20 wt % to about 55 wt %, about 25 wt % to about 55 wt %, about 30 wt % to about 55 wt %, about 35 wt % to about 55 wt %, about 40 wt % to about 55 wt %, about 45 wt % to about 55 wt %, about 50 wt % to about 55 wt %, about 5 wt % to about 50 wt %, about 10 wt % to about 50 wt %, about 15 wt % to about 50 wt %,From about 20% to about 50% by weight, from about 25% to about 50% by weight, from about 30% to about 50% by weight, from about 35% to about 50% by weight, from about 40% to about 50% by weight, from about 45% to about 50% by weight, from about 5% to about 45% by weight, from about 10% to about 45% by weight, from about 15% to about 45% by weight, from about 20% to about 45% by weight, from about 25% to about 45% by weight, from about 30% to about 45% by weight, from about 35% to about 45% by weight, from about 40% to about 45% by weight, from about 5% to about 40% by weight, from about 10% to about 45% by weight, from about 15% to about 45% by weight, from about 20% to about 45% by weight, from about 25% to about 45% by weight, %, about 10 wt % to about 35 wt %, about 15 wt % to about 35 wt %, about 20 wt % to about 35 wt %, about 25 wt % to about 35 wt %, about 30 wt % to about 35 wt %, about 5 wt % to about 30 wt %, about 10 wt % to about 30 wt %, about 15 wt % to about 30 wt %, about 20 wt % to about 30 wt %, about 25 wt % to about 30 wt %, about 5 wt % to about 25 wt %, about 10 wt % to about 25 wt %, about 15 wt % to about 25 wt %, about 20 wt % to about 25 wt %, about 5 wt % to about 20 wt %, about 10 wt % to about 20 wt %, about 15 wt % to about 20 wt %, about 5 wt % to about 15 wt %, about 10 wt % to about 15 wt %, about 5 wt % to about 10 wt %, or any other suitable weight percentage and subranges therebetween.

[0031] In some embodiments, the fiber component may further include macroscopic cellulose fibers, such as recycled newspapers. In some embodiments, the content of cellulose fibers ranges from 3% to about 25% by weight (including all weight percentages and sub-ranges therebetween) based on the total weight of the main body 120. In some embodiments, the content of cellulose fibers ranges from about 3% to about 25% by weight, about 5% to about 25% by weight, about 10% to about 25% by weight, about 15% to about 25% by weight, about 20% to about 25% by weight, 3% to about 20% by weight, about 5% to about 20% by weight, about 10% to about 20% by weight, about 15% to about 20% by weight, 3% to about 15% by weight, about 5% to about 15% by weight, about 10% to about 15% by weight, 3% to about 10% by weight, about 5% to about 10% by weight, 3% to about 5% by weight, or any other suitable weight percentage based on the total weight of the main body 120 and the sub-ranges therebetween.

[0032] 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.

[0033] In some embodiments, the biochar may be present in an amount ranging from about 5% to about 50% 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 may be present in an amount ranging from about 5% to about 50% by weight, about 10% to about 50% by weight, about 15% to about 50% by weight, about 20% to about 50% by weight, about 25% to about 50% by weight, about 30% to about 50% by weight, about 35% to about 50% by weight, about 40% to about 50% by weight, about 45% to about 50% by weight, about 50 ... %, about 10 wt % to about 45 wt %, about 15 wt % to about 45 wt %, about 20 wt % to about 45 wt %, about 25 wt % to about 45 wt %, about 30 wt % to about 45 wt %, about 35 wt % to about 45 wt %, about 40 wt % to about 45 wt %, about 5 wt % to about 40 wt %, about 10 wt % to about 40 wt %, about 15 wt % to about 40 wt %, about 20 wt % to about 40 wt %, about 25 wt % to about 40 wt % %, about 30 wt % to about 40 wt %, about 35 wt % to about 40 wt %, about 5 wt % to about 35 wt %, about 10 wt % to about 35 wt %, about 15 wt % to about 35 wt %, about 20 wt % to about 35 wt %, about 25 wt % to about 35 wt %, about 30 wt % to about 35 wt %, about 5 wt % to about 30 wt %, about 10 wt % to about 30 wt %, about 15 wt % to about 30 wt %, about 20 wt % to about 30 wt %, From about 25 wt % to about 30 wt %, from about 5 wt % to about 25 wt %, from about 10 wt % to about 25 wt %, from about 15 wt % to about 25 wt %, from about 20 wt % to about 25 wt %, from about 5 wt % to about 20 wt %, from about 10 wt % to about 20 wt %, from about 15 wt % to about 20 wt %, from about 5 wt % to about 15 wt %, from about 10 wt % to about 15 wt %, from about 5 wt % to about 10 wt %, or any other suitable value and subrange therebetween. In some embodiments, the biochar content ranges from about 10 wt % to about 40 wt %, based on the total dry weight of the body 120, including all values ​​and subranges therebetween.

[0034] In some embodiments, the biochar may have a density of about 3 pounds per cubic foot (pcf) to about 36 pcf. For example, in some embodiments, the biochar may have a density of about 3 pounds per cubic foot (pcf) to about 36 pcf, about 5 pcf to about 36 pcf, about 10 pcf to about 36 pcf, about 15 pcf to about 36 pcf, about 20 pcf to about 36 pcf, about 25 pcf to about 36 pcf, about 30 pcf to about 36 pcf, about 3 pcf to about 30 pcf, about 5 pcf to about 30 pcf, about 10 pcf to about 30 pcf, about 15 pcf to about 30 pcf, about 20 pcf to about 30 pcf, about 25 pcf to about 30 pcf, about 3 pcf to about About 25 pcf, about 5 pcf to about 25 pcf, about 10 pcf to about 25 pcf, about 15 pcf to about 25 pcf, about 20 pcf to about 25 pcf, about 3 pcf to about 20 pcf, about 5 pcf to about 20 pcf, about 10 pcf to about 20 pcf, about 15 pcf to about 20 pcf, about 3 pcf to about 15 pcf, about 5 pcf to about 15 pcf, about 10 pcf to about 15 pcf, about 3 pcf to about 10 pcf, about 5 pcf to about 10 pcf, about 3 pcf to about 5 pcf, or any other suitable value or sub-range therebetween.

[0035] In some embodiments, the biochar may have a density of about 3 pounds per cubic foot (pcf) to a density of about 18 pcf. For example, in some embodiments, the biochar may 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 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.

[0036] 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 biochar can have an average particle size 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 ...4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4.5 mm to about 5 mm, about 4 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 3 mm to about 4 mm, about 3.5 mm to about 4 mm, about 0.1 mm to about 3.5 mm , 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 1 mm to about 2.5 mm, about 1.5 mm to about 2.5 mm, about 2 mm to about 2.5 mm, about 0.1 mm to about 2 mm, about 0.5 mm to about 2 mm, about 1 mm to about 2 mm, about 1.5 mm to about 2 mm, about 0.1 mm to about 1.5 mm, about 0.5 mm to about 1.5 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.

[0037] Surprisingly, it was found that adding one or more flame retardants according to the present invention can impart enhanced self-extinguishing properties to the biochar-containing body 120 and the resulting building panels. The self-extinguishing properties may unexpectedly reduce the smoldering of the body 120 in high heat environments. That is, reduce the combustion of the body 120 in the absence of an open flame.

[0038] In some embodiments, the body 120 may include a flame retardant in an amount ranging from about 1 wt % to about 25 wt %, for example, from about 5 wt % to about 20 wt %, based on the total dry weight of the body 120, including all values ​​and sub-ranges therebetween. For example, in some embodiments, the body 120 may include a flame retardant in an amount ranging from about 1 wt % to about 25 wt %, from about 5 wt % to about 25 wt %, from about 10 wt % to about 25 wt %, from about 15 wt % to about 25 wt %, from about 20 wt % to about 25 wt %, from about 1 wt % to about 20 wt %, from about 10 wt % to about 20 wt %, from about 15 wt % to about 20 wt %, from about 1 wt % to about 15 wt %, from about 5 wt % to about 15 wt %, from about 10 wt % to about 15 wt %, from about 1 wt % to about 10 wt %, from about 5 wt % to about 10 wt %, from about 1 wt % to about 5 wt %, or any other suitable value and sub-range therebetween.

[0039] 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.

[0040] 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.

[0041] Non-limiting examples of 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.

[0042] 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.

[0043] In some embodiments, the fibers 130 of the present invention may include inorganic fibers and organic fibers in a weight ratio ranging from about 1:2 to about 15:1, including all values ​​and subranges therebetween. For example, in some embodiments, the fibers 130 of the present invention may include inorganic fibers and organic fibers in a weight ratio ranging from about 1:2 to about 15:1, from about 1:1 to about 15:1, from about 3:1 to about 15:1, from about 5:1 to about 15:1, from about 7:1 to about 15:1, from about 9:1 to about 15:1, from about 11:1 to about 15:1, from about 13:1 to about 15:1, from about 1:2 to about 13:1, from about 1:1 to about 13:1, from about 3:1 to about 13:1, from about 5:1 to about 13:1, from about 7:1 to about 13:1, from about 9:1 to about 13:1, from about 11:1 to about 13:1, from about 1:2 to about 11:1 1, about 1:1 to about 11:1, about 3:1 to about 11:1, about 5:1 to about 11:1, about 7:1 to about 11:1, about 9:1 to about 11:1, about 1:2 to about 9:1, about 1:1 to about 9:1, about 3:1 to about 9:1, about 5:1 to about 9:1, about 7:1 to about 9:1, about 1:2 to about 7:1, about 1:1 to about 7:1, about 3:1 to about 7:1, about 5:1 to about 7:1, about 1:2 to about 5:1, about 1:1 to about 5:1, about 3:1 to about 5:1, about 1:2 to about 3:1, about 1:1 to about 3:1, about 1:2 to about 1:1, or any other suitable values ​​and subranges therebetween.

[0044] In some embodiments, the weight ratio of fiber 130 to biochar may be from about 1:1 to about 10:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of fiber 130 to biochar may be about 1:1 to about 10:1, about 2:1 to about 10:1, about 3:1 to about 10:1, about 4:1 to about 10:1, about 5:1 to about 10:1, about 6:1 to about 10:1, about 7:1 to about 10:1, about 8:1 to about 10:1, about 9:1 to about 10:1, about 1:1 to about 9:1, about 2:1 to about 9:1, about 3:1 to about 9:1, about 4:1 to about 10:1, about 5:1 to about 9:1, about 6:1 to about 10:1, about 7:1 to about 10:1, about 8:1 to about 10:1, about 9:1 to about 10:1, about 1:1 to about 9:1, about 2:1 to about 9:1, about 3:1 to about 9:1, about 4:1 to about 10:1, about 5:1 to about 9:1, about 6:1 to about 10:1, about 7:1 to about 10:1, about 8:1 to about 10:1, The invention relates to a method of producing an aqueous phase-enhanced sodium-hydrogen phosphate-doped ...

[0045] In some embodiments, the weight ratio of inorganic fiber to biochar may be from about 1:1 to about 8:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of inorganic fiber to biochar may be from about 1:1 to about 8:1, from about 2:1 to about 8:1, from about 3:1 to about 8:1, from about 4:1 to about 8:1, from about 5:1 to about 8:1, from about 6:1 to about 8:1, from about 7:1 to about 8:1, from about 1:1 to about 7:1, from about 2:1 to about 7:1, from about 3:1 to about 7:1, from about 4:1 to about 7:1, from about 5:1 to about 8:1, from about 6:1 to about 8:1, from about 7:1 to about 8:1, 1 , about 2:1 to about 4:1, about 3:1 to about 4:1, about 1 :1 to about 3:1, about 2:1 to about 3:1, about 1 :1 to about 2:1, or any other suitable values ​​and subranges therebetween.

[0046] In some embodiments, the weight ratio of organic fiber to biochar may be from about 1:2 to about 1:10, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of organic fiber to biochar is from about 1:2 to about 1:10, from about 1:3 to about 1:10, from about 1:4 to about 1:10, from about 1:5 to about 1:10, from about 1:6 to about 1:10, from about 1:7 to about 1:10, from about 1:8 to about 1:10, from about 1:9 to about 1:10, from about 1:2 to about 1:9, from about 1:3 to about 1:9, from about 1:4 to about 1:9, from about 1:5 to about 1:9, from about 1:6 to about 1:9, from about 1:7 to about 1:9, from about 1:8 to about 1:9, 4 to about 1:8, about 1:5 to about 1:8, about 1:6 to about 1:8, about 1:7 to about 1:8, about 1:2 to about 1:7, about 1:3 to about 1:7, about 1:4 to about 1:7, about 1:5 to about 1:7, about 1:6 to about 1:7, about 1:2 to about 1:6, about 1:3 to about 1:6, about 1:4 to about 1:6, about 1:5 to about 1:6, about 1:2 to about 1:5, about 1:3 to about 1:5, about 1:4 to about 1:5, about 1:2 to about 1:4, about 1:3 to about 1:4, about 1:2 to about 1:3, or any other suitable values ​​and subranges therebetween.

[0047] In some embodiments, the weight ratio of biochar to flame retardant can be about 1:1 to about 6:1, such as about 1:1 to about 4:1, including all values ​​and subranges therebetween. The building panels described herein can allow for a high weight ratio of biochar to flame retardant to keep manufacturing costs low while maintaining ideal fire performance. For example, in some embodiments, the weight ratio of biochar to flame retardant can be about 1:1 to about 6:1, about 2:1 to about 6:1, about 3:1 to about 6:1, about 4:1 to about 6:1, about 5:1 to about 6:1, about 1:1 to about 5:1, about 2:1 to about 5:1, about 3:1 to about 5:1, about 4:1 to about 5:1, about 1:1 to about 4:1, about 2:1 to about 4:1, about 3:1 to about 4:1, about 1:1 to about 3:1, about 2:1 to about 3:1, about 1:1 to about 2:1, or any other suitable value and subrange therebetween.

[0048] In some embodiments, the weight ratio of the fiber to the flame retardant may be from about 4:1 to about 16:1, such as from about 4:1 to about 12:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of the fiber to the flame retardant may be from about 4:1 to about 16:1, from about 5:1 to about 16:1, from about 6:1 to about 16:1, from about 7:1 to about 16:1, from about 8:1 to about 16:1, from about 9:1 to about 16:1, from about 10:1 to about 16:1, from about 11:1 to about 16:1, from about 12:1 to about 16:1, from about 13:1 to about 16:1, from about 14:1 to about 16:1, from about 15:1 to about 16:1, from about 4:1 to about 15:1, from about 5:1 to about 15:1, from about 6:1 to about 15:1, from about 7:1 to about 15:1, from about 8:1 to about 15:1, from about 9:1 to about 15:1 1, about 10:1 to about 15:1, about 11:1 to about 15:1, about 12:1 to about 15:1, about 13:1 to about 15:1, about 14:1 to about 15:1, about 4:1 to about 14:1, about 5:1 to about 14:1, about 6:1 to about 14:1, about 7:1 to about 14:1, about 8:1 to about 14:1, about 9:1 to about 14:1, about 10:1 to about 14:1, about 11:1 to about 14:1, about 12:1 to about 14:1, about 13:1 to about 14:1, about 4:1 to about 13:1, about 5:1 to about 13:1, about 6:1 to about 13:1, about 7:1 to about 13:1, about 8:1 to about 13:1, about 9:1 to about 13:1, about 10:1 to about 13:1, about 11:1 to about 13:1, about 12:1 to about 13:1, 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 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 11:1, about 8:1 to about 11:1, about 9:1 to about 11:1, about 10:1 to about 11:1, The invention relates to an embodiment of the present invention that is suitable for use in the present invention and / or any suitable value or subrange thereof. The invention relates to an embodiment of the present invention that is suitable for use in the present invention and / or any suitable value or subrange therebetween.

[0049] In some embodiments, the weight ratio of the inorganic fiber to the flame retardant may be from about 2:1 to about 15:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of the inorganic fiber to the flame retardant may be from about 2:1 to about 15:1, from about 3:1 to about 15:1, from about 4:1 to about 15:1, from about 5:1 to about 15:1, from about 6:1 to about 15:1, from about 7:1 to about 15:1, from about 8:1 to about 15:1, from about 9:1 to about 15:1, from about 10:1 to about 15:1, from about 11:1 to about 15:1, from about 12:1 to about 15:1, from about 13:1 to about 15:1, from about 14:1 to about 15:1, from about 2:1 to about 14:1, from about 3:1 to about 14:1, from about 4:1 to about 14:1 1, about 5:1 to about 14:1, about 6:1 to about 14:1, about 7:1 to about 14:1, about 8:1 to about 14:1, about 9:1 to about 14:1, about 10:1 to about 14:1, about 11:1 to about 14:1, about 12:1 to about 14:1, about 13:1 to about 14:1, about 2:1 to about 13:1, about 3:1 to about 13:1, about 4:1 to about 13:1, about 5:1 to about 13:1, about 6:1 to about 13:1, about 7:1 to about 13:1, about 8:1 to about 13:1, about 9:1 to about 13:1, about 10:1 to about 13:1,about 11:1 to about 13:1, about 12:1 to about 13:1, about 2:1 to about 12:1, 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 2:1 to about 11:1, 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 11:1, about 8:1 to about 11:1, about 9:1 to about 11:1, about 10:1 to about 11:1, about 2:1 to about 10:1, about 3:1 to about 10:1, about 4:1 to about 10:1, about 5:1 to about 10:1, about 6:1 to about 10:1, about 7:1 to about 10:1, about 8:1 to about 10: 1, about 9:1 to about 10:1, about 2:1 to about 9:1, about 3:1 to about 9:1, about 4:1 to about 9:1, about 5:1 to about 9:1, about 6:1 to about 9:1, about 7:1 to about 9:1, about 8:1 to about 9:1, about 2:1 to about 8:1, about 3:1 to about 8:1, about 4:1 to about 8:1, about 5:1 to about 8:1, about 6:1 to about 8:1, about 7:1 to about 8:1, about 2:1 to about 7:1, about 3:1 to about 8:1 :1 to about 7:1, about 4:1 to about 7:1, about 5:1 to about 7:1, about 6:1 to about 7:1, about 2:1 to about 6:1, about 3:1 to about 6:1, about 4:1 to about 6:1, about 5:1 to about 6:1, about 2:1 to about 5:1, about 3:1 to about 5:1, about 4:1 to about 5:1, about 2:1 to about 4:1, about 3:1 to about 4:1, about 2:1 to about 3:1, or any other suitable values ​​and subranges therebetween. ,

[0050] In some embodiments, the weight ratio of the organic fiber to the flame retardant may be from about 1:1 to about 5:1, including all values ​​and subranges therebetween. For example, in some embodiments, the weight ratio of the organic fiber to the flame retardant may be from about 1:1 to about 5:1, from about 2:1 to about 5:1, from about 3:1 to about 5:1, from about 4:1 to about 5:1, from about 1:1 to about 4:1, from about 2:1 to about 4:1, from about 3:1 to about 4:1, from about 1:1 to about 3:1, from about 2:1 to about 3:1, from about 1:1 to about 2:1, or any other suitable value and subrange therebetween.

[0051] In some embodiments, the body 120 may further include an adhesive. Non-limiting examples of adhesives 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.

[0052] In some embodiments, the binder may be present in an amount ranging from about 3% to about 15% by weight, based on the total dry weight of the body 120, including all values ​​and sub-values ​​therebetween. For example, in some embodiments, the binder may be present in an amount ranging from about 3% to about 15% by weight, from about 6% to about 15% by weight, from about 9% to about 15% by weight, from about 12% to about 15% by weight, from about 3% to about 12% by weight, from about 6% to about 12% by weight, from about 9% to about 12% by weight, from about 3% to about 9% by weight, from about 6% to about 9% by weight, from about 3% to about 6% by weight, or any other suitable value and sub-range therebetween, based on the total dry weight of the body 120.

[0053] In some embodiments, the binder may include a starch-based polymer. In some embodiments, the starch-based polymer may be present in an amount ranging from about 3% to about 10% by weight based on the total dry weight of the body 120, including all values ​​and subranges therebetween. For example, in some embodiments, the starch-based polymer may be present in an amount ranging from about 3% to about 10% by weight, from about 5% to about 10% by weight, from about 7% to about 10% by weight, from about 9% to about 10% by weight, from about 3% to about 9% by weight, from about 5% to about 9% by weight, from about 7% to about 9% by weight, from about 3% to about 7% by weight, from about 5% to about 7% by weight, from about 3% to about 5% by weight, or any other suitable value and subranges therebetween, based on the total dry weight of the body 120.

[0054] In some embodiments, the body 120 may further 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.

[0055] In some embodiments, the filler content ranges from about 2 wt % to about 60 wt %, such as about 2 wt % to about 50 wt %, including all values ​​and subranges therebetween, based on the total dry weight of the body 120. For example, in some embodiments, the filler content ranges from about 2 wt % to about 60 wt %, about 5 wt % to about 60 wt %, about 10 wt % to about 60 wt %, about 15 wt % to about 60 wt %, about 20 wt % to about 60 wt %, about 25 wt % to about 60 wt %, about 30 wt % to about 60 wt %, about 35 wt % to about 60 wt %, about 40 wt % to about 60 wt %, about 45 wt % to about 60 wt %, about 50 wt % to about 60 wt %, about 55 wt % to about 60 wt %, about 2 wt % to about 55 wt %, about 5 wt % to about 55 wt %, about 10 wt % to about 60 wt %, about 15 wt % to about 60 wt %, about 20 wt % to about 60 wt %, about 25 wt % to about 60 wt %, about 30 wt % to about 60 wt %, about 35 wt % to about 60 wt %, about 40 wt % to about 60 wt %, about 45 wt % to about 60 wt %, about 50 wt % to about 60 wt %, about 55 wt % to about 60 wt %, about 2 wt % to about 55 wt %, about 5 wt about 55 wt %, about 15 wt % to about 55 wt %, about 20 wt % to about 55 wt %, about 25 wt % to about 55 wt %, about 30 wt % to about 55 wt %, about 35 wt % to about 55 wt %, about 40 wt % to about 55 wt %, about 45 wt % to about 55 wt %, about 50 wt % to about 55 wt %, about 2 wt % to about 50 wt %, about 5 wt % to about 50 wt %, about 10 wt % to about 50 wt %, about 15 wt % to about 50 wt %, about 20 wt % to about 50 wt %, about 25 wt % to about 50 wt %, about 30 wt % to about 50 wt %, about 35 wt % to about 50 wt %, about 40 % to about 50% by weight, about 45% to about 50% by weight, about 2% to about 45% by weight, about 5% to about 45% by weight, about 10% to about 45% by weight, about 15% to about 45% by weight, about 20% to about 45% by weight, about 25% to about 45% by weight, about 30% to about 45% by weight, about 35% to about 45% by weight, about 40% to about 45% by weight, about 2% to about 40% by weight, about 5% to about 40% by weight, about 10% to about 40% by weight, about 15% to about 40% by weight, about 20% to about 40% by weight, about 25% to about 40% by weight, From about 30% to about 40% by weight, from about 35% to about 40% by weight, from about 2% to about 35% by weight, from about 5% to about 35% by weight, from about 10% to about 35% by weight, from about 15% to about 35% by weight, from about 20% to about 35% by weight, from about 25% to about 35% by weight, from about 30% to about 35% by weight, from about 2% to about 30% by weight, from about 5% to about 30% by weight, from about 10% to about 30% by weight, from about 15% to about 30% by weight, from about 20% to about 30% by weight, from about 25% to about 35% by weight, from about 30% to about 35% by weight, from about 2% to about 30% by weight, from about 5% to about 30% by weight, from about 10% to about 30% by weight, from about 15% to about 30% by weight, from about 20% to about 30% by weight, from about 25% to about 30% by weight, from about 2% to about 25% by weight, from about 5% to about 25% by weight,From about 10% to about 25% by weight, from about 15% to about 25% by weight, from about 20% to about 25% by weight, from about 2% to about 20% by weight, from about 5% to about 20% by weight, from about 10% to about 20% by weight, from about 15% to about 20% by weight, from about 2% to about 15% by weight, from about 5% to about 15% by weight, from about 10% to about 15% by weight, from about 2% to about 10% by weight, from about 5% to about 10% by weight, from about 2% to about 5% by weight, or any other suitable values ​​and subranges therebetween.

[0056] In some embodiments, the filler may be perlite, which may be present in an amount ranging from about 5 wt % to about 60 wt % based on the total weight of the body 120 , including all amounts and subranges therebetween.For example, in some embodiments, the perlite content ranges from about 5% to about 60% by weight, about 10% to about 60% by weight, about 15% to about 60% by weight, about 20% to about 60% by weight, about 25% to about 60% by weight, about 30% to about 60% by weight, about 35% to about 60% by weight, about 40% to about 60% by weight, about 45% to about 60% by weight, about 50% to about 60% by weight, about 55% to about 60% by weight, about 5% to about 55% by weight, about 10% to about 55% by weight, about 15% to about 55% by weight, about 20% to about 5 ... %, about 25 wt % to about 55 wt %, about 30 wt % to about 55 wt %, about 35 wt % to about 55 wt %, about 40 wt % to about 55 wt %, about 45 wt % to about 55 wt %, about 50 wt % to about 55 wt %, about 5 wt % to about 50 wt %, about 10 wt % to about 50 wt %, about 15 wt % to about 50 wt %, about 20 wt % to about 50 wt %, about 25 wt % to about 50 wt %, about 30 wt % to about 50 wt %, about 35 wt % to about 50 wt %, about 40 wt % to about 50 wt %, about 45 wt % to about 50 wt %, about 5 wt % to about 45 wt %, about 10 wt % to about 45 wt %, about 15 wt % to about 50 wt %, About 45% by weight, about 20% by weight to about 45% by weight, about 25% by weight to about 45% by weight, about 30% by weight to about 45% by weight, about 35% by weight to about 45% by weight, about 40% by weight to about 45% by weight, about 5% by weight to about 40% by weight, about 10% by weight to about 40% by weight, about 15% by weight to about 40% by weight, about 20% by weight to about 40% by weight, about 25% by weight to about 40% by weight, about 30% by weight to about 40% by weight, about 35% by weight to about 40% by weight, about 5% by weight to about 35% by weight, about 10% by weight to about 35% by weight, about 15% by weight to about 35 ...35% by weight, about 25% by weight to about 35% by weight %, about 30 weight % to about 35 weight %, about 5 weight % to about 30 weight %, about 10 weight % to about 30 weight %, about 15 weight % to about 30 weight %, about 20 weight % to about 30 weight %, about 25 weight % to about 30 weight %, about 5 weight % to about 25 weight %, about 10 weight % to about 25 weight %, about 15 weight % to about 25 weight %, about 20 weight % to about 25 weight %, about 5 weight % to about 20 weight %, about 10 weight % to about 20 weight %, about 15 weight % to about 20 weight %, about 5 weight % to about % to about 15 weight %, about 10 weight % to about 15 weight %, about 5 weight % to about 10 weight %, or any other suitable values ​​and subranges therebetween.

[0057] In some embodiments, the body 120 may include one or more additives. Non-limiting examples of additives include defoamers, wetting agents, bactericides, dispersants, 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.

[0058] 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.

[0059] 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.

[0060] 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.

[0061] According to the present invention, porosity refers to: % Porosity = [V 总 –(V 粘合剂 +V 纤维 +V 生物炭 +V 阻燃剂 +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. 阻燃剂V refers to the total volume occupied by the flame retardant 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.

[0062] In some embodiments, the building panel 100 including the porous body 120 can exhibit sufficient airflow so that the building panel 100 has 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. The rating is the average of the sound absorption coefficients in four ⅓ octave bands (250, 500, 1000, and 2000 Hz), where, for example, a system with an NRC of 0.90 has approximately 90% of the sound absorption capacity of an ideal sound absorber. Higher NRC values ​​indicate that the material provides better sound absorption and reduced sound reflections.

[0063] The building panels 100 of the present invention may exhibit a NRC of at least about 0.5. In some embodiments, 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.

[0064] The body 120 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.

[0065] In some embodiments, the bulk density of the body 120 in a dry state may be about 0.04 g / cm 3 To about 0.6g / cm 3 The bulk density is, for example, 0.048 g / cm 3 to about 0.577g / cm 3 , including all integers and subranges therebetween. For example, in some embodiments, the bulk density of the body 120 in a dry state may be about 0.04 g / cm 3 To about 0.6g / cm 3 , about 0.045g / cm 3 To about 0.6g / cm 3 , about 0.05g / cm 3 To about 0.6g / cm 3 , about 0.075g / cm 3 To about 0.6g / cm 3 , about 0.1g / cm 3 To about 0.6g / cm 3 , about 0.15g / cm 3To about 0.6g / cm 3 , about 0.2g / cm 3 To about 0.6g / cm 3 , about 0.25g / cm 3 To about 0.6g / cm 3 , about 0.30g / cm 3 To about 0.6g / cm 3 , about 0.35g / cm 3 To about 0.6g / cm 3 , about 0.4g / cm 3 To about 0.6g / cm 3 , about 0.45g / cm 3 To about 0.6g / cm 3 , about 0.5g / cm 3 To about 0.6g / cm 3 , about 0.55g / cm 3 To about 0.6g / cm 3 , about 0.04g / cm 3 To about 0.55g / cm 3 , about 0.045g / cm 3 To about 0.55g / cm 3 , about 0.05g / cm 3 To about 0.55g / cm 3 , about 0.075g / cm 3 To about 0.55g / cm 3 , about 0.1g / cm 3 To about 0.55g / cm 3 , about 0.15g / cm 3 To about 0.55g / cm 3 , about 0.2g / cm 3 To about 0.55g / cm 3 , about 0.25g / cm 3 To about 0.55g / cm 3 , about 0.3g / cm 3 To about 0.55g / cm 3 , about 0.35g / cm 3 To about 0.55g / cm 3 , about 0.4g / cm 3 To about 0.55g / cm 3 , about 0.45g / cm 3 To about 0.55g / cm 3 , about 0.5g / cm 3 To about 0.55g / cm 3 , about 0.04g / cm 3To about 0.5g / cm 3 , about 0.045g / cm 3 To about 0.5g / cm 3 , about 0.05g / cm 3 To about 0.5g / cm 3 , about 0.075g / cm 3 To about 0.5g / cm 3 , about 0.1g / cm 3 To about 0.5g / cm 3 , about 0.15g / cm 3 To about 0.5g / cm 3 , about 0.2g / cm 3 To about 0.5g / cm 3 , about 0.25g / cm 3 To about 0.5g / cm 3 , about 0.3g / cm 3 To about 0.5g / cm 3 , about 0.35g / cm 3 To about 0.5g / cm 3 , about 0.4g / cm 3 To about 0.5g / cm 3 , about 0.45g / cm 3 To about 0.5g / cm 3 , about 0.04g / cm 3 To about 0.45g / cm 3 , about 0.045g / cm 3 To about 0.45g / cm 3 , about 0.05g / cm 3 To about 0.45g / cm 3 , about 0.075g / cm 3 To about 0.45g / cm 3 , about 0.1g / cm 3 To about 0.45g / cm 3 , about 0.15g / cm 3 To about 0.45g / cm 3 , about 0.2g / cm 3 To about 0.45g / cm 3 , about 0.25g / cm 3 To about 0.45g / cm 3 , about 0.3g / cm 3 To about 0.45g / cm 3 , about 0.35g / cm 3 To about 0.45g / cm 3 , about 0.4g / cm 3To about 0.45g / cm 3 , about 0.04g / cm 3 To about 0.4g / cm 3 , about 0.045g / cm 3 To about 0.4g / cm 3 , about 0.05g / cm 3 To about 0.4g / cm 3 , about 0.075g / cm 3 To about 0.4g / cm 3 , about 0.1g / cm 3 To about 0.4g / cm 3 , about 0.15g / cm 3 To about 0.4g / cm 3 , about 0.2g / cm 3 To about 0.4g / cm 3 , about 0.25g / cm 3 To about 0.4g / cm 3 , about 0.3g / cm 3 To about 0.4g / cm 3 , about 0.35g / cm 3 To about 0.4g / cm 3 , about 0.04g / cm 3 To about 0.35g / cm 3 , about 0.045g / cm 3 To about 0.35g / cm 3 , about 0.05g / cm 3 To about 0.35g / cm 3 , about 0.075g / cm 3 To about 0.35g / cm 3 , about 0.1g / cm 3 To about 0.35g / cm 3 , about 0.15g / cm 3 To about 0.35g / cm 3 , about 0.2g / cm 3 To about 0.35g / cm 3 , about 0.25g / cm 3 To about 0.35g / cm 3 , about 0.3g / cm 3 To about 0.35g / cm 3 , about 0.04g / cm 3 To about 0.3g / cm 3 , about 0.045g / cm 3 To about 0.3g / cm 3 , about 0.05g / cm 3To about 0.3g / cm 3 , about 0.075g / cm 3 To about 0.3g / cm 3 , about 0.1g / cm 3 To about 0.3g / cm 3 , about 0.15g / cm 3 To about 0.3g / cm 3 , about 0.2g / cm 3 To about 0.3g / cm 3 , about 0.25g / cm 3 To about 0.3g / cm 3 , about 0.04g / cm 3 To about 0.25g / cm 3 , about 0.045g / cm 3 To about 0.25g / cm 3 , about 0.05g / cm 3 To about 0.25g / cm 3 , about 0.075g / cm 3 To about 0.25g / cm 3 , about 0.1g / cm 3 To about 0.25g / cm 3 , about 0.15g / cm 3 To about 0.25g / cm 3 , about 0.2g / cm 3 To about 0.25g / cm 3 , about 0.04g / cm 3 To about 0.2g / cm 3 , about 0.045g / cm 3 To about 0.2g / cm 3 , about 0.05g / cm 3 To about 0.2g / cm 3 , about 0.075g / cm 3 To about 0.2g / cm 3 , about 0.1g / cm 3 To about 0.2g / cm 3 , about 0.15g / cm 3 To about 0.2g / cm 3 , about 0.04g / cm 3 To about 0.15g / cm 3 , about 0.045g / cm 3 To about 0.15g / cm 3 , about 0.05g / cm 3 To about 0.15g / cm 3 , about 0.075g / cm 3To about 0.15g / cm 3 , about 0.1g / cm 3 To about 0.15g / cm 3 , about 0.04g / cm 3 To about 0.1g / cm 3 , about 0.045g / cm 3 To about 0.1g / cm 3 , about 0.05g / cm 3 To about 0.1g / cm 3 , 0.075g / cm 3 To about 0.1g / cm 3 , about 0.04g / cm 3 To about 0.075g / cm 3 , about 0.045g / cm 3 To about 0.075g / cm 3 , about 0.05g / cm 3 To about 0.075g / cm 3 , about 0.04g / cm 3 To about 0.05g / cm 3 , about 0.045g / cm 3 To about 0.05g / cm 3 , or any other suitable values ​​and sub-ranges therebetween.

[0066] The term "bulk density" refers to the total volume V of the body 420. 总 The density is measured. Therefore, the bulk density is the density of the total volume V 总 density measurement, which includes the volume occupied by the components that make up the skeleton of the body 120 (i.e., V 粘合剂 + V 纤维 +V 生物炭 + V 阻燃剂 + V 填料 / 添加剂 +) and voids formed within the body 120 due to the porous nature of the body 120.

[0067] The main body 120 in a dry state may have a thickness of about 0.5 g / cm 3 To about 2.5g / cm 3 The skeleton density is within the range of about 1 g / cm 3 To about 2.2g / cm 3 , including all integers and subranges therebetween. For example, in some embodiments, the skeletal density of the body 120 in a dry state may be about 0.5 g / cm 3 To about 2.5g / cm 3 , about 1g / cm 3 To about 2.5g / cm 3, about 1.25g / cm 3 To about 2.5g / cm 3 , about 1.5g / cm 3 To about 2.5g / cm 3 , about 1.75g / cm 3 To about 2.5g / cm 3 , about 2g / cm 3 To about 2.5g / cm 3 , about 0.5g / cm 3 To about 2.25g / cm 3 , about 1g / cm 3 To about 2.25g / cm 3 , about 1.25g / cm 3 To about 2.25g / cm 3 , about 1.5g / cm 3 To about 2.25g / cm 3 , about 1.75g / cm 3 To about 2.25g / cm 3 , about 2g / cm 3 To about 2.25g / cm 3 , about 0.5g / cm 3 To about 2g / cm 3 , about 1g / cm 3 To about 2g / cm 3 , about 1.25g / cm 3 To about 2g / cm 3 , about 1.5g / cm 3 To about 2g / cm 3 , about 1.75g / cm 3 To about 2g / cm 3 , about 0.5g / cm 3 To about 1.75g / cm 3 , about 1g / cm 3 To about 1.75g / cm 3 , about 1.25g / cm 3 To about 1.75g / cm 3 , about 1.5g / cm 3 To about 1.75g / cm 3 , about 0.5g / cm 3 To about 1.5g / cm 3 , about 1g / cm 3 To about 1.5g / cm 3 , about 1.25g / cm 3 To about 1.5g / cm 3 , about 0.5g / cm 3 To about 1.25g / cm3 , about 1g / cm 3 To about 1.25g / cm 3 , or any other suitable values ​​and sub-ranges therebetween.

[0068] The term "skeleton density" refers to the volume occupied by the components constituting the skeleton of the body 120 (i.e., V 粘合剂 +V 纤维 +V 生物炭 + V 阻燃剂 +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.

[0069] 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.

[0070] 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, flame retardants, 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 surface treatment. 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.

[0071] The following examples were prepared according to certain embodiments of the present invention. The present invention is not limited to the embodiments described herein.

[0072] Example Experiments were conducted to evaluate the effectiveness of selected flame retardants in preventing smoldering in certain biochar-containing building panels. Three building panels (Example 1, Example 2, and Example 3) according to embodiments of the present invention were prepared. The building panels (Example 1, Example 2, and Example 3) each contained different weight ratios of biochar and flame retardant. A control panel (Comparative Example 1) containing only biochar but no flame retardant was also prepared. Each panel contained a body made from the formulation listed in Table 1 below, with each amount listed being a weight percent (wt %).

[0073] Table 1 The panels were tested in a cone calorimeter using the modified cone method ASTM E1354. Specifically, heat was applied only during the first 180 seconds of the test. Heat release and mass loss were measured for each panel. Figure 4A and 4B The heat release rate and panel mass of a control panel (Comparative Example 1) are shown. Figure 5A and 5B The heat release rate and panel mass of a first exemplary building panel (Example 1) having a 1:1 weight ratio of biochar to flame retardant are shown. Fig. 6A and 6B The heat release rate and panel mass of a second exemplary building panel (Example 2) having a biochar to flame retardant weight ratio of 2:1 are shown. Fig. 7A and 7B The heat release rate and panel mass of a third exemplary building panel (Example 3) having a biochar to flame retardant weight ratio of 4:1 are shown.

[0074] The inventors have found that adding different concentrations of flame retardant can successfully prevent the smoldering phenomenon observed on the control panel. Figure 4A and 4B As shown in Figure 1, when the heat supply was turned off at 180 seconds, the control panel (Comparative Example 1) continued to release heat and the panel mass continued to decrease, both of which indicated smoldering. Adding different concentrations of colemanite as a flame retardant to the exemplary panels (Examples 1, 2, and 3) effectively prevented the panels from releasing heat shortly after the heat source was turned off, as shown in Figure 1. Figure 5A , 6A and 7A, and the panel quality is maintained, as shown in Figure 5B , 6B In other words, the exemplary building panels (Example 1, Example 2, and Example 3) do not continue to burn (smolder) in the absence of a flame.

[0075] As demonstrated, embodiments described herein provide acoustic building panels that include a body formed in part from biochar to reduce carbon dioxide emissions while eliminating any potential smoldering issues that may arise from the addition of biochar to certain biochar-containing building panels.

[0076] Collection of exemplary clauses Exemplary clause 1. 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 5 weight % to about 75 weight % based on the total weight of the body, the content of the biochar ranges from about 5 weight % to about 50 weight % based on the total weight of the body, and the content of the flame retardant ranges from about 1 weight % to about 30 weight % based on the total weight of the body, wherein the weight ratio of the biochar to the flame retardant is about 1:1 to about 6:1.

[0077] Exemplary clause 2. The acoustic building panel of Exemplary clause 1, wherein the inorganic fibers comprise mineral wool.

[0078] Exemplary clause 3. The acoustic building panel of any one of exemplary clauses 1 to 2, wherein the flame retardant comprises an active filler flame retardant.

[0079] Exemplary clause 4. The acoustic building panel of any one of exemplary clauses 1 to 3, wherein the flame retardant decomposes endothermically.

[0080] Exemplary clause 5. The acoustic building panel of any one of exemplary clauses 1 to 4, wherein the flame retardant decomposes endothermically at an elevated temperature in a range of about 200°C to about 325°C.

[0081] Exemplary clause 6. The acoustic building panel of any one of exemplary clauses 1 to 5, wherein the flame retardant releases water (H2O) upon decomposition.

[0082] Exemplary clause 7. The acoustic building panel of any one of exemplary clauses 1 to 6, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrated or calcined clay, calcium carbonate, talc, or feldspar.

[0083] Exemplary clause 8. The acoustic building panel of any one of exemplary clauses 1 to 7, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0084] Exemplary clause 9. The acoustic building panel of any one of exemplary clauses 1 to 8, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0085] Exemplary clause 10. The acoustic building panel of any one of exemplary clauses 1 to 9, wherein the body further comprises organic fibers, the organic fibers being present in an amount ranging from about 3 wt % to about 25 wt % based on the total weight of the body.

[0086] Exemplary clause 11. The acoustic building panel of any one of exemplary clauses 1 to 10, wherein the body further comprises a binder, the binder being present in an amount ranging from about 3 wt % to about 15 wt % based on the total weight of the body.

[0087] Exemplary clause 12. The acoustic building panel of Exemplary clause 11, 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.

[0088] Exemplary clause 13. The acoustic building panel of any one of exemplary clauses 1 to 12, wherein the body further comprises a filler, the filler being present in an amount ranging from about 2 wt % to about 60 wt % based on the total weight of the body.

[0089] Exemplary clause 14. The acoustic building panel of Exemplary clause 13, 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.

[0090] Exemplary clause 15. The acoustic building panel of any one of exemplary clauses 1 to 14, wherein the body has a porosity of about 80% to about 95%.

[0091] Exemplary clause 16. The acoustic building panel of any one of exemplary clauses 1 to 15, wherein the body has a g / cm 3 To about 0.6g / cm 3 The volume density of .

[0092] Exemplary clause 17. The acoustic building panel of any one of exemplary clauses 1 to 16, wherein the body has a g / cm 3 To about 2.5g / cm 3 The skeleton density.

[0093] Exemplary clause 18. An acoustic building panel according to any of exemplary clauses 1 to 17, 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 measured between the first major surface and the second major surface.

[0094] Exemplary Clause 19. An acoustic building panel comprising: a body, the body comprising inorganic fibers, biochar, and a flame retardant; the content of the inorganic fibers ranges from about 5 weight % to about 75 weight % based on the total weight of the body, the content of the biochar ranges from about 5 weight % to about 50 weight % based on the total weight of the body, and the content of the flame retardant ranges from about 1 weight % to about 30 weight % based on the total weight of the body; wherein the flame retardant comprises colemanite.

[0095] Exemplary clause 20. The acoustic building panel of Exemplary clause 19, wherein the inorganic fibers include mineral wool.

[0096] Exemplary clause 21. The acoustic building panel of any one of exemplary clauses 19 to 20, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

[0097] Exemplary clause 22. The acoustic building panel of any one of exemplary clauses 19 to 21, wherein the flame retardant decomposes endothermically at an elevated temperature in a range of about 200°C to about 325°C.

[0098] Exemplary clause 23. The acoustic building panel of any one of exemplary clauses 19 to 22, wherein the flame retardant releases water (H2O) upon decomposition.

[0099] Exemplary clause 24. The acoustic building panel of any one of exemplary clauses 19 to 23, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0100] Exemplary clause 25. The acoustic building panel of any one of exemplary clauses 19 to 24, wherein the body further comprises organic fibers in an amount ranging from about 3 wt % to about 25 wt % based on the total weight of the body.

[0101] Exemplary clause 26. The acoustic building panel of any one of exemplary clauses 19 to 25, wherein the body further comprises a binder in an amount ranging from about 3 wt % to about 15 wt % based on the total weight of the body.

[0102] Exemplary clause 27. The acoustic building panel of clause 26 of exemplary embodiment, 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.

[0103] Exemplary clause 28. The acoustic building panel of any one of exemplary clauses 19 to 27, wherein the body further comprises a filler, the filler being present in an amount ranging from about 2 wt % to about 60 wt % based on the total weight of the body.

[0104] Exemplary clause 29. An acoustic building panel according to any of exemplary clauses 19 to 28, 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.

[0105] Exemplary clause 30. The acoustic building panel of any one of exemplary clauses 19 to 29, wherein the body has a porosity of about 80% to about 95%.

[0106] Exemplary clause 31. The acoustic building panel of any one of exemplary clauses 19 to 30, wherein the body has a 3 To about 0.6g / cm 3 The volume density of .

[0107] Exemplary clause 32. The acoustic building panel of any one of exemplary clauses 19 to 31, wherein the body has a g / cm 3 To about 2.5g / cm 3 The skeleton density.

[0108] Exemplary clause 33. An acoustic building panel according to any of exemplary clauses 19 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.

[0109] Exemplary clause 34. A ceiling system comprising: a support structure; and at least one acoustic building panel according to any one of exemplary clauses 1 to 33 mounted to the support structure.

[0110] Exemplary clause 35. A method of making an acoustic building panel, comprising: mixing inorganic fibers, a binder, biochar, a flame retardant, and a liquid carrier 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, wherein the weight ratio of the biochar to the flame retardant is about 1:1 to about 6:1.

[0111] Exemplary clause 36. The method of exemplary clause 35, wherein the blend further comprises an organic fiber material, and wherein the organic fiber material is present in an amount ranging from about 3 wt % to about 25 wt % based on the total weight of the body.

[0112] Exemplary clause 37. The method of any of exemplary clauses 35 to 36, wherein the inorganic fibers comprise mineral wool, and wherein the inorganic fibers are present in an amount ranging from about 5 wt % to about 75 wt % based on the total weight of the body.

[0113] Exemplary clause 38. The method of any one of exemplary clauses 35 to 37, wherein the flame retardant comprises an active filler flame retardant, and wherein the flame retardant is present in an amount ranging from about 1 wt % to about 30 wt % based on the total weight of the body.

[0114] Exemplary clause 39. The method of any one of exemplary clauses 35 to 38, wherein the flame retardant decomposes endothermically.

[0115] Exemplary clause 40. The method of any one of exemplary clauses 35 to 39, wherein the flame retardant decomposes endothermically at an elevated temperature in a range of about 200°C to about 325°C.

[0116] Exemplary clause 41. The method of any one of exemplary clauses 35 to 40, wherein the flame retardant releases water (H2O) upon decomposition.

[0117] Exemplary clause 42. The method of any one of Exemplary clauses 35 to 41, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrated or calcined clay, calcium carbonate, talc, or feldspar.

[0118] Exemplary clause 43. The method of any one of exemplary clauses 35 to 42, wherein the flame retardant has an average particle size in a range from about 1 μm to about 100 μm.

[0119] Exemplary clause 44. The method of any one of exemplary clauses 35 to 43, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0120] Exemplary clause 45. The method of any one of exemplary clauses 35 to 44, wherein the binder is present in an amount ranging from about 3 wt % to about 15 wt % based on the total weight of the body.

[0121] Exemplary clause 46. The method of exemplary clause 45, wherein the adhesive 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.

[0122] Exemplary clause 47. The method of any one of exemplary clauses 35 to 46, wherein the blend further comprises a filler, and wherein the filler is present in an amount ranging from about 2 wt % to about 60 wt % based on the total weight of the body.

[0123] Exemplary clause 48. The method of Exemplary clause 47, 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.

[0124] Exemplary clause 49. The method of any one of exemplary clauses 35 to 48, wherein the body has a porosity of about 80% to about 95%.

[0125] Exemplary clause 50. The method of any one of exemplary clauses 35 to 49, wherein the body has a g / cm 3 To about 0.6g / cm 3 The volume density of .

[0126] Exemplary clause 51. A method according to any one of exemplary clauses 35 to 50, wherein the body has a g / cm 3 To about 2.5g / cm 3 The skeleton density.

[0127] Exemplary clause 52. The method of any one of exemplary clauses 35 to 51, 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.

[0128] Exemplary clause 53. The method of any one of Exemplary clauses 35 to 52, wherein the liquid carrier comprises water.

[0129] Exemplary clause 54. A method of making an acoustic building panel, comprising: mixing inorganic fibers, a binder, biochar, a flame retardant, and a liquid carrier 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 major surface and the second major surface, wherein the body is substantially free of the liquid carrier, wherein the flame retardant comprises colemanite.

[0130] Exemplary clause 55. The method of exemplary clause 54, wherein the blend further comprises an organic fiber material, and wherein the organic fiber material is present in an amount ranging from about 3 wt % to about 25 wt % based on the total weight of the body.

[0131] Exemplary clause 56. The method of any of exemplary clauses 54 to 55, wherein the inorganic fibers comprise mineral wool, and wherein the inorganic fibers are present in an amount ranging from about 5 wt % to about 75 wt % based on the total weight of the body.

[0132] Exemplary clause 57. The method of any one of exemplary clauses 54 to 56, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 30 wt % based on the total weight of the body.

[0133] Exemplary clause 58. The method of any one of exemplary clauses 54 to 57, wherein the flame retardant decomposes endothermically at an elevated temperature in a range of about 200°C to about 325°C.

[0134] Exemplary clause 59. The method of any one of exemplary clauses 54 to 58, wherein the flame retardant releases water (H2O) upon decomposition.

[0135] Exemplary clause 60. The method of any one of exemplary clauses 54 to 59, wherein the flame retardant has an average particle size in a range from about 1 μm to about 100 μm.

[0136] Exemplary clause 61. The method of any one of exemplary clauses 54 to 60, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

[0137] Exemplary clause 61. The method of any one of exemplary clauses 54 to 61, wherein the binder is present in an amount ranging from about 3 wt % to about 15 wt % based on the total weight of the body.

[0138] Exemplary clause 63. The method of exemplary clause 62, wherein the adhesive 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.

[0139] Exemplary clause 64. The method of any one of exemplary clauses 54 to 63, wherein the blend further comprises a filler, and wherein the filler is present in an amount ranging from about 2 wt % to about 60 wt % based on the total weight of the body.

[0140] Exemplary clause 65. The method of exemplary clause 64, 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.

[0141] Exemplary clause 66. The method of any one of exemplary clauses 54 to 65, wherein the body has a porosity of about 80% to about 95%.

[0142] Exemplary clause 67. The method of any one of exemplary clauses 54 to 66, wherein the body has a g / cm 3 To about 0.6g / cm 3 The volume density of .

[0143] Exemplary clause 68. A method according to any one of exemplary clauses 54 to 67, wherein the body has a g / cm 3 To about 2.5g / cm 3 of bone density.

[0144] Exemplary clause 69. The method of any of exemplary embodiments 54 to 68, 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.

[0145] Exemplary clause 70. The method of any one of exemplary clauses 54 to 69, wherein the liquid carrier comprises water.

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 5 wt % to about 75 wt % based on the total weight of the body; biochar, the biochar being present in an amount ranging from about 5 wt % to about 50 wt % based on the total weight of the body; and A flame retardant, wherein the content of the flame retardant ranges from about 1 weight % to about 30 weight % based on the total weight of the main body, wherein the weight ratio of the biochar to the flame retardant is about 1:1 to about 6:

1.

2. An acoustic building panel comprising: A subject, the subject comprising: Inorganic fibers, the inorganic fibers being present in an amount ranging from about 5 wt % to about 75 wt % based on the total weight of the body; Biochar; the biochar is present in an amount ranging from about 5 wt % to about 50 wt % based on the total weight of the body; and a flame retardant, wherein the flame retardant is present in an amount ranging from about 1 wt % to about 30 wt % based on the total weight of the body; The flame retardant comprises colemanite.

3. The acoustic building panel of claim 1, wherein the inorganic fibers comprise mineral wool.

4. The acoustic building panel according to any one of claims 1 to 2, wherein the flame retardant comprises an active filler flame retardant.

5. The acoustic building panel according to any one of claims 1 to 3, wherein the flame retardant decomposes endothermically.

6. The acoustic building panel according to any one of claims 1 to 4, wherein the flame retardant decomposes endothermically at an elevated temperature in the range of about 200°C to about 325°C.

7. The acoustic building panel according to any one of claims 1 to 5, wherein the flame retardant releases water (H2O) upon decomposition.

8. The acoustic building panel according to any one of claims 1 to 6, wherein the flame retardant comprises at least one of colemanite, aluminum hydroxide, magnesium hydroxide, boehmite, hydrated or calcined clay, calcium carbonate, talc or feldspar.

9. The acoustic building panel according to any one of claims 1 to 7, wherein the flame retardant has an average particle size of about 1 μm to about 100 μm.

10. The acoustic building panel according to any one of claims 1 to 8, wherein the biochar has an average particle size of about 0.1 mm to about 5 mm.

11. The acoustic building panel according to any one of claims 1 to 9, wherein the body further comprises organic fibers in an amount ranging from about 3 wt% to about 25 wt%, based on the total weight of the body.

12. The acoustic building panel according to any one of claims 1 to 10, wherein the body further comprises a binder in an amount ranging from about 3 wt% to about 15 wt% based on the total weight of the body.

13. The acoustic building panel of claim 11, wherein The adhesive includes at least one of starch-based polymers, polyvinyl alcohol (PVOH), latex, polysaccharide polymers, cellulose polymers, protein solution polymers, acrylic polymers, polymaleic anhydride, or epoxy resins.

14. The acoustic building panel according to any one of claims 1 to 12, wherein the body further comprises a filler, the filler being present in an amount ranging from about 2 wt% to about 60 wt%, based on the total weight of the body.

15. The acoustic building panel of claim 13, 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, pigments, zinc oxide, or zinc sulfate.

16. The acoustic building panel of any one of claims 1 to 14, wherein the body has a porosity of about 80% to about 95%.

17. The acoustic building panel according to any one of claims 1 to 15, wherein the body has a g / cm 3 To about 0.6g / cm 3 The volume density of .

18. The acoustic building panel according to any one of claims 1 to 16, wherein the body has a g / cm 3 To about 2.5g / cm 3 The skeleton density.

19. 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 measured between the first major surface and the second major surface.

20. A method of making an acoustic building panel, comprising: mixing inorganic fibers, a binder, biochar, a flame retardant, and a liquid carrier 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; The weight ratio of the biochar to the flame retardant is about 1:1 to about 6:

1.

21. A method of making an acoustic building panel, comprising: mixing inorganic fibers, a binder, biochar, a flame retardant, and a liquid carrier to form a blend; as well as 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; The flame retardant comprises colemanite.

22. A method according to any one of claims 35 to 52, wherein the liquid carrier comprises water.

23. A ceiling system comprising: Support structure; and At least one acoustic building panel according to any one of claims 1 to 33 is mounted to the supporting structure.

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