Panels including renewable components and methods for manufacturing
View Patent ↗A panel includes about 0.1% to about 95% by weight of a renewable component. The panel has at least one of a CAC value of at least about 25, an NRC value of at least about 0.25 and an STC of at least about 25. A method for manufacturing such panels is also provided.
1. A panel for use as a building material comprising:
said panel being formed from an aqueous slurry including an inorganic fiber component, starch, water and a renewable component, about 0.1% to about 95% by weight of the panel, after removal of the water, being of the renewable component; wherein said panel has at least one of a Ceiling Attenuation Class value of at least about 25, a Noise Reduction Coefficient value of at least about 0.25 and a Sound Transmission Class value of at least about 25.
2. The panel of claim 1 wherein said renewable component comprises rice hulls.
3. The panel of claim 1 having an estimated Noise Reduction Coefficient value of at least about 0.20.
4. The panel of claim 1 having an air flow resistivity of less than about 8 mPa·s/m 2 .
5. The panel of claim 1 having an Modulus of Rupture value of at least about 80 psi.
6. The panel of claim 1 having a bulk density between about 7 lbs/ft 3 and about 30 lbs/ft 3 .
7. The panel of claim 1 having a thickness of between about 0.2 inches to about 1.5 inches.
8. The panel of claim 1 that sags less than about 1.5 inches in a 90% RH humidity chamber.
9. The panel of claim 1 having a flame spread index of less than about 25.
10. The panel of claim 1 having a smoke development index of less than about 50.
11. The panel of claim 1 wherein said renewable component includes less than about 5% by weight of particles that are retained by a mesh screen with openings of about 0.312 inches.
12. The panel of claim 1 wherein said renewable component includes less than about 5% by weight of particles that are retained by a mesh screen with openings of about 0.132 inches.
13. The panel of claim 1 wherein said renewable component includes less than about 5% by weight of particles that are retained by a mesh screen with openings of about 0.022 inches.
14. The panel of claim 1 wherein a bulk density of said renewable component is between 5 and 50 lbs/ft 3 .
15. A panel for use as a building material comprising:
said panel being formed from an aqueous slurry including an inorganic fiber component, starch, water and a renewable component, about 0.1% to about 95% by weight of the panel, after removal of the water, being of the renewable component, the renewable component being reduced in size such that no more than 5% by weight of the renewable component is retained by a mesh screen with openings of about 0.312 inches; wherein said panel has at least one of a Ceiling Attenuation Class value of at least about 25, a Noise Reduction Coefficient value of at least about 0.25 and a Sound Transmission Class value of at least about 25.