# US 2009/0260918 A1 · Panels including renewable components and methods for manufacturing same

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2009/0260918 A1
- Document ID: US20090260918A1
- Status: Published application
- Kind: A1
- Application number: 12/414,313
- Filed: 2009-03-30
- Published: 2009-10-22
- Earliest claimed: 2008-04-18
- Assignees: USG Interiors, Inc.
- Inventors: Bangji Cao; Te Hua Lau; W. David Song; Martin W. Brown
- Web page: https://patentgrep.com/patent/US20090260918A1

## CPC

- E04B 1/86: slab-shaped
- C04B 28/26: Silicates of the alkali metals
- E04B 9/04: comprising slabs, {panels,} sheets or the like
- C04B 2111/52: Sound-insulating materials
- E04B 2001/745: {Vegetal products, e.g. plant stems, barks}
- E04B 2001/746: {Recycled materials, e.g. made of used tires, bumpers or newspapers}
- Y02A 30/244: using natural or recycled building materials, e.g. straw, wool, clay or used tires
- Y02W 30/91: Use of waste materials as fillers for mortars or concrete
- E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001})
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- Y02A: TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

A panel includes about 0.1% to about 95% by weight of a ground renewable component. In an embodiment, the panel has at least one core comprising: from about 0.1% to about 95% by weight of the ground renewable component; from about 0.1% to about 95% by weight of one or more fibers; and from about 1% to about 30% by weight of one or more binders, all based on dry panel weight. In an embodiment, the ground renewable component has a particle size distribution whereby less than 5% of the particles are retained by a mesh screen with openings of about 0.312 inches and less than 5% of the particles pass through a mesh screen with openings of about 0.059 inches. A method for manufacturing such panels is also provided.

## Claims

### Claim 1

An acoustical panel having a panel core comprising:
from about 0.1% to about 95% by weight of a ground renewable component having a particle size distribution wherein less than 5% of ground renewable component particles are retained by a first mesh screen having openings of about 0.312 inches and less than 5% of the particles pass through a second mesh screen having openings of about 0.059 inches;
from about 0.1% to about 95% by weight of one or more fibers; and
from about 1% to about 30% by weight of one or more binders, all weights based on dry panel weight.

### Claim 2 (depends on 1)

The acoustical panel of claim 1 wherein said ground renewable component comprises rice hulls, buckwheat hulls, nut shells, including peanut and walnut shells, wheat chaff, oat husks, rye whisks, cotton seed hulls, coconut shells, corn bran, corn cobs, sunflower seeds, rice straw stalk, wheat straw stalk, barley straw stalk, oat straw stalk, rye straw stalk, Espart, sorghum stalks, reeds, bamboos, sisal, Sabai, ramie, bagasse, flax, kenaf, jute, hemp, abaca, saw dust, wood chips or combinations thereof.

### Claim 3

An acoustical panel having a panel core comprising:
from about 0.1% to about 95% by weight of a ground renewable component having a particle size distribution wherein less than 5% of ground renewable component particles are retained by a first mesh screen with openings of about 0.132 inches;
from about 0.1% to about 95% by weight of one or more fibers; and
from about 1% to about 30% by weight of one or more binders, all weights based on dry panel weight.

### Claim 4 (depends on 3)

The acoustical panel of claim 3 wherein said ground renewable component comprises rice hulls, buckwheat hulls, nut shells, including peanut and walnut shells, wheat chaff, oat husks, rye whisks, cotton seed hulls, coconut shells, corn bran, corn cobs, sunflower seeds, rice straw stalk, wheat straw stalk, barley straw stalk, oat straw stalk, rye straw stalk, Espart, sorghum stalks, reeds, bamboos, sisal, Sabai, ramie, bagasse, flax, kenaf, jute, hemp, abaca, saw dust, wood chips or combinations thereof.

### Claim 5 (depends on 1, 2, 3, 4)

The acoustical panel of claim 1, 2, 3 or 4 wherein said ground renewable component is present in amount of about 7% to about 40% by weight based on the dry panel weight.

### Claim 6 (depends on 1, 2, 3, 4)

The acoustical panel of claim 1, 2, 3 or 4 wherein said one or more fibers is selected from the group consisting of recycled paper fibers, mineral wool, glass wool, rock wool and combinations thereof.

### Claim 7 (depends on 1, 2, 3, 4)

A method of preparing the acoustical panel of claim 1, 2, 3 or 4, comprising:
selecting the ground renewable component;
sorting the ground renewable component to obtain the desired particle size distribution;
combining the ground renewable component, the fiber, and the binder with water;
forming an aqueous slurry;
forming a base mat on a foraminous wire from the slurry;
removing at least some of the water from the base mat; and
finishing said base mat to form the acoustical panel.

### Claim 8 (depends on 7)

The method of claim 7 wherein said combining step further comprises adding expanded perlite as one of at least one filler.