JP2011518266A - Panels containing renewable components and manufacturing methods - Google Patents

Abstract

A panel comprising from about 0.1% to about 95% by weight of renewable components, having a CAC value of at least about 25, an NRC value of at least about 0.25, and an STC value of at least about 25. In an embodiment, based on a dry panel, the renewable component is about 0.1% to about 95% by weight, the fiber is 0.1% to 95% by weight, and the binder is 1% to 30% by weight. It is out. The renewable component optionally has a particle size distribution with a residue of 5% or less on a mesh screen having an aperture of 0.312 inches and a content of 5% or less passing through a mesh screen having an aperture of 0.059 inches. A method for manufacturing this panel is also proposed.

Description

  The present invention relates to a panel for the building industry that contains renewable components and improves acoustic and physical properties. A method for manufacturing the panel is also provided.

  Panels used as tiles and walls fall into the building materials category and give architectural value such as sound absorption and attenuation and practical functions inside the building. Generally, a panel such as a sound insulation panel is used in the field of suppressing noise. Examples of these areas are department stores, hospitals, hotels, auditoriums, airports, restaurants, libraries, classrooms, theaters and cinemas, and residences.

  In order to provide architectural value and practical function, for example, the sound insulation panels are substantially flat and hang on a typical inner wall grid or similar structure. Therefore, sound insulation panels often have a certain level of hardness and stiffness measured by the breaking modulus ("MOR"). In order to obtain desired acoustic characteristics, the sound insulation panel has sound absorption and propagation attenuation.

  Sound absorption is typically measured by the noise attenuation factor (“NRC”) described in ASTM-C423. NRC is expressed by a number between 0 and 1.00, and indicates a portion where sound is absorbed and reaches. A sound insulation panel with an NRC value of 0.60 absorbs 60% of the bumped sound and reflects 40%.

  Another test method is estimated NRC (“eNRC”), which uses an impedance tube as described in ASTM-C384.

  The ability to reduce sound propagation is measured by the ceiling panel attenuation class (“CAC”) value described in ASTM-E1414. The CAC value is measured in decibels ("dB") and represents the amount of sound attenuation as the sound propagates through the material. For example, a sound insulation panel with a CAC of 40 lowers the transmitted sound by 40 decibels. Similarly, sound propagation attenuation can also be measured with the sound propagation class ("STC") described in ASTM-E413 and E90. For example, a panel with an STC of 40 will lower the transmitted sound by 40 decibels.

  Sound insulation panels manufactured in accordance with various industry standards and building codes have Class A fire resistance standards. According to ASTM-E84, a flame spread index of 25 or less and a smoke index of 50 or less are required.

  Airflow resistance, a measure of the porosity of the mat, is tested according to the revised ASTM-C423 and C386 standards. In addition, the sound insulation panel's MOR, hardness, and sag are tested by ASTM C367. Increasing the porosity of the base mat improves sound absorption, but it is not measured by specific industry standards or building codes.

  Currently, most sound insulation panels or tiles are manufactured using the water felt process, favored in the industry, due to its speed and efficiency. The water felt process forms a base mat using a method similar to papermaking. One form of this process is described in U.S. Patent No. 5,637,049 to Baig and is shown here for reference.

  First, a water slurry in which mineral wool and lightweight agglomerates are thinly dispersed is supplied onto a moving wire having a small hole in a long net paper machine type mat forming apparatus. Water flows out of the slurry by gravity and optionally further dehydrated by vacuum suction and / or pressing means. Next, the dehydrated base mat that still retains water is dried in a heated furnace or kiln to remove any remaining moisture. The dry mat is finished to obtain a panel of a predetermined size, appearance and acoustic properties. Finishes include surface polishing, cutting, perforation / grooving, roll / spray coating, edge cutting and / or laminating panels with woven fabric or screens.

  A typical sound insulation panel base mat is a composition of inorganic fibers, cellulose fibers, binders and fillers. As is known in the industry, inorganic fibers are either mineral wool (slag wool, rock wool and stone wool) or glass fiber.

  Mineral wool is formed by first melting slag or rock wool at 1300 ° C. (2372 ° F.) to 1650 ° C. (3002 ° F.). The molten mineral is then spun into a wool with a continuous air stream on a fiberized spinning machine. Inorganic fibers are hard and provide bulk and porosity to the base mat.

  Conversely, cellulose fibers function as structural elements and provide strength to wet and dry base mats. The strength is due to the fact that cellulose fibers form many hydrogen bonds with the various components in the base mat. This hydrogen bond is a result of the hydrophilic nature of the cellulose fiber.

  A typical base mat binder used is starch. Typical starches used in sound insulation panels are unmodified, non-gelatinized starch granules that are dispersed in an aqueous panel slurry and generally distributed homogeneously in the base mat. The starch granules are gelatinized when heated and dissolve to give an adhesive force to the panel components. Starch gives not only the flexural strength of the sound insulation panel but also the hardness and rigidity of the panel.

  In panel compositions with high concentrations of inorganic fibers, latex binder is used as the main binder material.

  Typical base mat fillers are both heavy and lightweight inorganic materials. The main function of the filler is to give bending strength and contribute to the hardness of the panel. The term “filler” is used throughout this specification, which means that each filler has unique properties and / or characteristics, such as stiffness, hardness, sagging, absorption and attenuation during sound propagation in the panel. May be affected.

  Examples of heavy fillers are calcium carbonate, clay or gypsum. An example of a lightweight filler is expanded perlite.

  Expanded pearlite as a filler has the advantage of being bulky, thereby reducing the amount of filler required for the base mat.

  One drawback of expanded perlite is that perlite particles fill the holes in the base mat and seal its surface, which reduces the panel's ability to absorb sound. In addition, expanded perlite is relatively fragile and fragile during the manufacturing process. In general, the greater the amount of expanded perlite used, the worse the sound absorption characteristics of the sound insulation panel.

  The expansion of perlite consumes a great deal of energy. Expanded perlite is formed by heating perlite ore into an expansion tower and heating to about 950 ° C. (1750 ° F.). The water in the pearlite structure becomes steam, and its expansion causes the pearlite to “pop” like popcorn, reducing it to a density of about one tenth of the unexpanded material. Expanded perlite with reduced bulk density flows upward in the expansion tower and is collected by the filter device. This process uses a relatively large amount of energy to heat all of the pearlite to a temperature sufficient to evaporate the water in the pearlite.

  Looking at recent trends in the building industry, it is environmentally friendly, that is, manufactured in a process that reduces global warming, acidification, smog, water eutrophication, solid waste, primary energy consumption and / or drainage An improved product is desired.

Naturally growing renewable materials can be used to produce environmentally friendly building materials. A widely used renewable material in the construction industry is wood but does not absorb sound.
Similarly, there are large amounts of agricultural and by-products, wood and furniture industry waste, which are readily available, but have limited use in the construction of building materials.

  In order to use renewable materials that grow naturally, it is necessary to extract the fibers. This is done by pulping ligno-cellulose materials such as wood, firewood, bamboo, etc. and breaking these plant materials into individual fiber cells either chemically or mechanically.

  Common chemical pulping methods use sodium sulfate, sodium hydroxide, sodium sulfite and dissolve lignin from about 150 ° C. (302 ° F.) to about 180 ° C. (356 ° F.), so fiber biomass Is reduced by about 40 to 60%.

  In contrast, the thermomechanical pulping method exposes wood chips to high temperatures (about 130 ° C. (266 ° F.), high pressure (about 3 to 4 atmospheres (304 to 405 kPa)) to soften the lignin and machine the fiber cells. I am hitting out.

  Cleavage of the lignin bond causes defibration of the raw material, resulting in a loss of biomass of about 5-10%. Chemical and thermomechanical pulping processes require a great deal of energy to make ligno-cellulose materials into individual fibers. Furthermore, the loss of a large amount of biomass increases the cost of raw materials.

Several US patents teach the use of renewable materials in building materials. Patent Document 2 discloses a method of manufacturing a structural panel having a non-constant length, which is made of an organic particle-based material mainly composed of rice husk and a binder. Because of the need for structural integrity, the process requires a combination of high temperature and high pressure to form a sufficiently strong panel.
The resulting panel has a relatively low sound absorption value due to its high density and low porosity. Thermal and sound shielding properties are achieved by having holes.

  Patent Document 3 discloses a process for producing a cement-waste composite using rice husk as waste. Rice husks are heated to approximately 600 ° C. (1112 ° F.) in the absence of oxygen to form microparticles.

  U.S. Patent No. 6,099,077 discloses a sound-absorbing porous panel formed from a cemented material that is cured, aqueous, and foamed. This panel has improved durability and moisture resistance, and has good sound insulation performance. Rice husk is added to increase the overall hardness of the foamable cement panel.

US Pat. No. 5,911,818 US Pat. No. 6,322,731 US Pat. No. 5,851,281 US Pat. No. 6,443,258

Provided is a panel used as a building material with improved acoustic and physical properties. This panel contains renewable components such as rice husk and improves sound insulation performance without relatively changing CAC or STC.
In addition, NRC is improved by maintaining or enhancing the panel's other physical performance, including MOR, hardness, airflow resistance, and sagging.

  In one embodiment, the panel of the present invention includes from about 0.1% to about 95% renewable components by weight. The panel has a CAC value of at least about 25, an NRC value of at least about 0.25, and an STC value of at least about 25.

  In another embodiment of the panel of the present invention, the panel core comprises from about 0.1% to about 95% ground renewable components and from about 0.1% of one or more fibers, by weight of the dry panel. About 95%, one or more binders from about 1% to about 30%, and one or more fillers from about 3% to about 80%.

  The pulverized renewable component has a particle size distribution in which 5% or less of particles remain on a mesh screen having an opening of about 0.312 inches and 5% or less of particles pass through a mesh screen of about 0.059 inches. have.

  In another embodiment, a method of manufacturing a panel used as a building material includes forming an aqueous slurry of about 0.1% to about 95% renewable components and water. Next, a base mat is formed from the slurry using a wire with small holes. Water is removed from the base mat and the base mat is finished to produce a panel used as a building material. Panels produced by this method have a CAC value of at least about 25 and an NRC value of at least about 0.25.

  At least one other embodiment is a method of manufacturing a panel used as a building material, the step of selecting a ground renewable component, about 0.1% to about 95% by weight, ground renewable Mixing the ingredients, about 1% to about 50% by weight fiber, about 1% to about 30% by weight binder, about 3% to about 80% by weight filler with water to form an aqueous slurry. And a step of forming a base mat from an aqueous slurry on a small hole wire, and a step of removing water from the base mat to finish the base mat.

  Renewable components are separated into the above particle size distribution. Panels produced in this way have a CAC value of at least about 25 and an NRC value of at least about 0.25.

  The production of renewable components requires less energy than other filler materials, so it is advantageous to add ground or ground renewable components. The renewable component is preferably pulverized or directly put into the sound insulation panel. This process consumes energy only when the renewable component is crushed or sieved, and uses less energy than expanded perlite.

  Another advantage of using renewable materials is that biomass can be produced without significant loss. Ground or crushed renewable materials retain the bulk structure and are not subject to chemical changes or changes in the chemical structure such as defibration. Biomass retention is the efficient use of purchased raw materials, thus reducing costs.

  Choosing different fillers for use in building panels can be undesirable because it changes the properties of the panels. However, the use of the renewable components of the present invention reduces energy and material costs while maintaining or improving other physical properties of the panel.

The products, methods and compositions described herein are intended to apply to panels used as building materials. In particular, the panels can be used as inner wall panel products, sound insulation panels or tiles.
The following discussion is directed to a sound insulation panel as one embodiment of the invention. However, this is not intended to limit the present invention.

  The fibers are in the sound insulation panel as inorganic fibers, organic fibers, or combinations thereof. The inorganic fiber is mineral wool, slag wool, rock wool, stone wool, glass fiber, or a combination thereof.

  The inorganic fibers are stiff and become the bulk of the base mat, making the base mat porous. Inorganic fibers are present in the sound insulation panel from about 0.1% to about 95% by weight of the panel. In at least one embodiment of the sound insulation panel, mineral wool is used as the preferred fiber.

  Cellulose fibers are examples of organic fibers that function as structural elements and provide strength to both wet and dry base mats. The strength is a result of the hydrophilic nature of the cellulose fiber and depends on making hydrogen bonds with the various components in the base mat. Cellulose fibers in the base mat are about 1% to about 50%, preferably about 5% to about 40%, and most preferably about 10% to about 30%, based on the weight of the panel. One preferred cellulose fiber is derived from recycled newspaper.

  The panel contains at least one component that can be regenerated. Renewable components are defined as wood or non-wood, or part of wood or non-wood. These renewable components are preferably ligno-cellulose containing cellulose and lignin. The source of these materials is waste or by-products from the farming, agricultural, forestry and / or building industries.

  Rice husk or husk is an example of a renewable component. Examples of other renewable ingredients are wheat husk, oat husk, rye stalk, cotton seed husk, coconut husk, corn straw, corn ear, rice straw, wheat straw, barley straw, oat straw, rye straw, bagasse ), Cocoon, African spatula (Espart), Sabai, flax (flax), kenaf (kenaf), jute, hemp (hemp), ramie, Manila hemp (abaca), sisal (sisal) ), Sawdust, bamboo, wood chips, sorghum straw, sunflower seeds, buckwheat shells, nut shells including peanut shells and walnut shells, and the like, and combinations thereof Not a thing.

  The renewable component is preferably reduced in size before mixing with the other panel components. The renewable material passes through a mesh screen with a mesh opening of 0.312 inches (2.5 mesh defined by ASTM sieve chart) and a mesh screen with a mesh opening of 0.0059 inches (100 mesh defined by ASTM sieve chart). It is preferable to make the particle size remaining in ().

  In some embodiments, the renewable components are used as received or obtained from the supplier. The use of the term “renewable component” is intended to refer to granulates that are either whole or reduced in size by methods known in the art and include those that are subdivided, cut, crushed, or crushed. is doing.

  In order to reduce the particle size, a desired size is obtained by a mechanical process such as pulverization or crushing. In at least one embodiment, a hammer mill type device is used.

  Optionally, the renewable component can be sieved through a screen of a specific mesh size to obtain the desired particle size distribution. The large particle portion that cannot pass through the desired maximum screen is removed and reprocessed until it passes through the screen.

  In one embodiment, the ground rice husk is first sieved through a # 30 mesh screen to remove large particles and then sieved through a # 80 mesh screen to remove small particles. The rice husk that passed through the # 30 mesh screen and remained on the # 80 mesh screen is used in the production of the sound insulation panel. In this embodiment, no material passed through the # 80 mesh screen is used in the panel.

  The # 30 mesh screen has a 0.022 inch or 0.55 mm aperture. The # 80 mesh screen has an opening of 0.007 inches or 180 μm.

  In another embodiment, treated rice husks obtained directly from a rice mill are used in the manufacture of sound insulation panels.

  The particle size distribution of the sieved renewable material is optionally at least about 95% particles passing through a # 30 mesh screen of a US sieve set and no more than about 5% particles passing through a # 80 mesh screen.

  As mentioned in the background art, expanded perlite is a material often used for building panels. When used for interior wall panels, expanded perlite tends to create a structure without interconnecting holes. By crushing or crushing the renewable material into the sound insulation panel, the structure of the expanded perlite is inhibited, thereby increasing the number of communication holes. Panels containing crushed renewable components and pearlite are more porous and sound absorbing than panels containing pearlite without crushed or crushed renewable components.

  It was observed that the larger the particle size of the renewable component, the higher the acoustic absorption value. In either embodiment, the optimum particle size distribution depends on the desired acoustic absorption value.

The particle size distribution of the renewable component should be considered as related to other components such as fibers, expanded perlite, etc. to form a homogeneous and homogeneous slurry.
The formation of a uniform slurry leads to the production of a homogeneous and uniform base mat. The particle size distribution is preferably selected to maintain or improve the physical strength of the panel.

  In some embodiments, the renewable component has no more than about 5% by weight of particles remaining on a # 6 mesh screen.

  In another embodiment, the renewable component used has no more than about 5% particles remaining on a # 20 mesh screen. In yet another embodiment, the crushed or crushed renewable component has no more than about 5% of particles remaining on the # 30 mesh screen.

Preferably, the renewable component has a bulk density of about 5 to about 50 lbs / ft ³ (80 to 800 kg / m ³ ), preferably about 10 to 40 lbs / ft ³ (160 to 640 kg / m ³ ), most preferably about It is in the range of 20 to about 35 lbs / ft ³ (320 to 560 kg / m ³ ).

  The # 6 mesh screen has a 0.132 inch or 3.35 mm opening, the # 20 screen mesh has a 0.0312 inch or 800 μm opening, and the # 30 screen mesh has a 0.022 inch or 0 opening. Opening of .55 mm.

  The starch is optionally placed in the base mat as a binder. A typical starch is dispersed in an aqueous slurry with unmodified, non-gelatinized starch granules so that it is evenly distributed in the base mat. The base mat is heated, the starch granules are gelatinized and dissolved, and combined with the panel components. Starch not only increases the bending strength of the sound insulation panel, but also improves the hardness and rigidity of the panel.

  The base mat optionally includes starch in the range of about 1% to about 30%, more preferably about 3% to about 15%, and most preferably about 5% to about 10% by weight of the panel.

  Typical base mat fillers are both light and heavy minerals. Examples of heavy fillers are calcium carbonate, clay or gypsum. Other fillers may be used in the sound insulation panel. In some embodiments, calcium carbonate is used in the range of about 0.5% to about 10% by weight of the panel. Calcium carbonate can also be used in the range of about 3% to about 8% by weight of the panel.

  An example of a lightweight filler is expanded perlite. Expanded perlite is bulky and can reduce the amount of filler used in the base mat. The main function of the filler is to improve the flexural strength and hardness of the panel.

  Although the term “filler” is used throughout the specification, it is understood that each filler has unique properties and / or characteristics and affects panel stiffness, strength, sagging, sound absorption and attenuation.

  The expanded perlite in the base mat in this embodiment ranges from about 5% to about 80%, more preferably from about 10% to about 60%, most preferably from about 20% to about 40% by weight of the panel. It is.

  In one preferred embodiment, the base mat includes renewable ingredients, mineral wool, expanded perlite, starch, calcium carbonate and / or clay.

  One preferred renewable component is ground rice husk. The proportion of renewable components ranges from about 0.1% to about 95% by weight of the panel, more preferably from about 5% to about 60%, and most preferably from about 7% to about 40%.

  Another optional component in the sound insulation panel is clay, which typically improves fire resistance. When exposed to fire, the clay does not burn and sinters. The sound insulation panel optionally includes clay in the range of about 0% to about 10%, preferably about 1% to about 5% by weight of the panel.

  Many types of clay are used, including Spins Clay in Glason, Tennessee, Ball Clay, and Old Hickory Clay in Hickory, Kentucky. However, it is not limited to this.

  A flocculant is also optionally added to the sound insulation panel. The flocculant is preferably used in the range of about 0.1% to about 3%, more preferably about 0.1% to about 2% by weight of the panel.

  Useful flocculants include, but are not limited to, aluminum chloride hydrate, aluminum sulfate, calcium oxide, ferric chloride, ferrous sulfate, polyacrylamide, sodium aluminate, sodium silicate.

  In one embodiment of creating a base mat for a sound insulation panel, an aqueous slurry is created by mixing renewable ingredients, mineral wool, expanded perlite, cellulose fiber, starch, calcium carbonate, clay and flocculant with water. Is done.

  The mixing operation is preferably carried out in a batch or continuous mode in a stock chest. The amount of water added is such that the total solids or consistency is in the range of about 1% to about 8%, preferably about 2% to about 6%, more preferably about 3% to about 5% by consistency. To.

  When a homogeneous slurry is formed containing the above components, the slurry is transferred to a head box and the slurry material is allowed to flow constantly. The slurry flowing out of the headbox is spread on a moving, small hole wire to form a wet base mat. First, water flows out of the wire by gravity. In certain embodiments, it is contemplated that a low vacuum pressure can be used in conjunction with, or after, the gravity flow of water from the slurry. Further, optionally, additional water is removed by squeezing and / or vacuum dewatering, as is done by one skilled in the art. The remaining water is typically evaporated in a furnace or kiln.

The formed base mat preferably has a bulk density of about 7 to about 30 lbs / ft ³ (112 to 480 kg / m ³ ), more preferably about 8 to 25 lbs / ft ³ (128 to 400 kg / m ³ ), most preferably Is from about 9 to about 20 lbs / ft ³ (144 to 320 kg / m ³ ).

  The formed base mat is then cut and finished into a sound insulation panel known to those skilled in the art. Preferred finishing operations include surface polishing, coating, drilling, grooving, edge adjustment, and / or packaging.

  Drilling and grooving greatly contribute to improving the acoustic absorption value of the base mat. A perforation operation creates a number of holes on the surface of the base mat with a constant depth and density (number of perforations per unit area).

  The perforation is performed by pressing a plate having a predetermined number of needles on the base mat. Grooving can be achieved, for example, by creating a uniquely shaped recess on the surface of the base mat using a roll with a certain form of metal plate.

  The drilling and grooving steps create openings in the base mat surface and its internal structure, thereby allowing air to move in and out of the panel. The opening in the base mat also allows sound to enter the core of the base mat and be absorbed.

  Furthermore, the sound insulation panel is optionally laminated with woven fabric or cloth. This sound insulation panel can be cut by hand using a universal knife.

The formed sound insulation panel preferably has a bulk density of about 9 to about 32 lbs / ft ³ (144 to 513 kg / m ³ ), more preferably about 10 to about 27 lbs / ft ³ (160 to 433 kg / m ³ ), most Preferably from about 11 to about 22 lbs / ft ³ (176 to 352 kg / m ³ ).

  In addition, the panel preferably has a thickness of about 0.2 to 1.5 inches (5 to 38 mm), more preferably about 0.3 to 1.0 inches (8 to 25 mm), most preferably about 0.5 inches to about 0.75 inches (13 to 19 mm).

  A sound insulation panel comprising at least one renewable component preferably has an NRC value of at least about 0.25 and a CAC value of at least about 25. Furthermore, the sound insulation panel has an eNRC value of at least about 0.15.

  In addition, the sound insulation panel has a MOR value of at least about 80 psi, a hardness of at least about 100 lbf, and a maximum sag of 1.5 inches (38 mm) in a 90% RH humidity room.

  Furthermore, this sound insulation panel has a flame spreading index of about 25 or less and a smoke generation index of about 50 or less. The sound insulation panel also has an STC of at least about 25.

  Rice husks were obtained from Riceland Industries, Johannesburg, Arkansas, which threshed rice grains and separated rice grains from rice husks.

Rice husk is sieved with # 6 mesh screen, # 10 mesh screen (0.066 inch or 1.7 mm opening), # 16 mesh screen (0.039 inch or 1 mm opening), and # 30 mesh screen. Divided. The grain size distribution of rice husks is about 18.3% residue on # 10 mesh screen, about 58.0% residue on # 16 mesh screen, about 20.1% residue on # 30 mesh screen, Passing through a # 30 mesh screen was about 3.6%. The bulk density of the rice husk was about 8.51 lbs / ft ³ (136 kg / m ³ ).

  As noted in Table 1, panel ingredients, various amounts of perlite and rice husk were mixed with water to make a slurry with a consistency of about 4.5%.

  While stirring water, each component was added in the order of newspaper pulp, starch, calcium carbonate, crushed rice husk, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant by weight of the slurry was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

  A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to a constant thickness to remove more water and harden the base mat structure. The wet base mat was further dehydrated to a high vacuum pressure (5-9 ″ Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove residual moisture.

  In the following examples, about 10% mineral wool by weight of the panel was used with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate. The amount of perlite and rice husk is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat having a high weight ratio of rice husk has a low air flow resistance value, indicating that the base mat is more porous. Therefore, the base mat with more rice husks is a better acoustic absorber and is reflected in the holeless eNRC value.

  Rice husks were obtained from Riceland Industries, Johannesburg, Arkansas, which threshed rice grains and separated rice grains from rice husks.

  The rice husk was further crushed in a Fritz mill equipped with a screen with a hole of diameter 0.109 ″ (0.028 m). The rice husk was crushed until everything passed through the screen. Were added and pulverized, and separated using screens having openings of 0.079 "and 0.050" (0.002 m and 0.0013 m, respectively).

The bulk density of the above sample is about 14.62 lbs by passing through screen openings of 0.109 "(0.028 m), 0.079" (0.002 m) and 0.050 "(0.0013 m), respectively. / Ft ³ (234 kg / m ³ ), 16.31 lbs / ft ³ (261 kg / m ³ ) and 21.77 lbs / ft ³ (349 kg / m ³ ).

  As noted in Table 2, the panel ingredients, various amounts of perlite and rice husk were mixed with water to form a slurry with a consistency of about 4.5%.

  While stirring water, each component was added in the order of newspaper pulp, starch, calcium carbonate, crushed rice husk, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant by weight of the slurry was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

  A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to a constant thickness to remove more water and harden the base mat structure. The wet base mat was further dehydrated to a high vacuum pressure (5-9 ″ Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove residual moisture.

  In Table 2, about 10% mineral wool by weight of the panel was used with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate. The amount of perlite and rice husk is shown below. The properties of the obtained dry base mat are also shown in the table.

  A base mat having a rice husk that can pass through a screen with a large mesh opening is a better acoustic absorber and reflects a higher eNRC value.

  Rice husks were obtained from Rice Hull Specialties of Stuttgart, Arkansas, which is milling rice husks from a rice mill.

The ground rice husk was first sieved through a # 20 mesh screen to remove large particles and then through a # 80 mesh screen to remove small particles. The ground rice husk that passed through the # 20 mesh screen and remained on the # 80 mesh screen was used to form the base mat. Its bulk density was approximately 22.96 lbs / ft ³ (368 kg / m ³ ).

  As noted in Table 3, panel ingredients, varying amounts of perlite and rice husk were mixed with water to form a slurry with a consistency of about 4.5%.

    While stirring water, each component was added in the order of newspaper pulp, starch, calcium carbonate, crushed rice husk, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant by weight of the slurry was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

  A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to a constant thickness to remove more water and harden the base mat structure. The wet base mat was further dehydrated to a high vacuum pressure (5-9 ″ Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove residual moisture.

  In Table 3, about 10% mineral wool by panel weight was used with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate by panel weight. The amount of perlite and rice husk is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, all three samples in the example were tested with the test No. 1 in Example 1. It was a more porous and acoustically higher absorber than the controls 1 and 2.

  Rice husks were obtained from Rice Hull Specialties, Inc., Stuttgart, Arkansas, which is milling rice husks from a rice mill.

The ground rice husk was first sieved through a # 30 mesh screen to remove large particles and then through a # 80 mesh screen to remove small particles. The ground rice hulls that passed through the # 30 mesh screen and remained on the # 80 mesh screen were used to make the base mat. The bulk density was about 28.56 lbs / ft ³ (457 kg / m ³ ).

  In a stock chest, a panel component having the composition shown in Table 4 and water were mixed to produce a slurry.

  In addition to the ingredients in Table 4, a 20% recycled (or “broken”) soundproof panel was added by weight of the panel. The reused soundproof panel is a panel of a damaged product, a non-standard product, or a final pulverized product. The reused soundproofing panels have the same composition but need not be the same. The consistency of the slurry was about 3.0%.

  The homogeneous slurry consisting of the ingredients in Table 4 was transferred to the headbox to allow the slurry material to flow constantly. The slurry that flowed out of the head box was spread on a wire with a small hole to form a wet base mat. First, water was poured from the wire by gravity. Under the wire, a low vacuum pressure (4 "Hg (100mmHg)) was applied to remove water. After the base mat was squeezed between two rollers, a high vacuum pressure (7-15" Hg (178-381mmHg) was applied under the wire. )) To remove further water. Residual moisture and moisture in the base mat were evaporated in a kiln. After drying, the base mat is cut, polished, rolled, sprayed, perforated and 2 ′ × 4 ′ (0.61 m × 1.22 m) or 2 ′ × 2 ′ (0.61 m × 0. 61m) A sound insulation panel having a good appearance was used. Table 5 shows the properties of the base mat.

  Table 6 shows the properties of the finished sound insulation panel.

  Rice husks were obtained from Rice Hull Specialties, Inc., Stuttgart, Arkansas, which is milling rice husks from a rice mill.

The ground rice husks were first screened through a # 20 mesh screen to remove large particles and then through a # 80 mesh screen to remove small particles. The ground rice husks that passed through the # 20 mesh screen and remained on the # 80 mesh screen were used to form the base mat. Its bulk density was about 24.37 lbs / ft ³ (390 kg / m ³ ). The panel components and water having the composition shown in Table 7 were mixed in a stock chest to form a slurry.

  In addition to the ingredients in Table 7, 15% more broken panels (by panel weight) were added.

  The consistency of the slurry was about 3.0%. The homogeneous slurry containing the ingredients in Table 7 was transferred to a headbox and the slurry material was flushed out uniformly. The slurry that flowed out of the head box was spread on a wire with a small hole to form a wet base mat. First, water was poured from the wire by gravity. Further dewatering was performed with a low vacuum pressure (1 "Hg (25mmHg)) under the wire. After compressing the base mat between two rollers, a high vacuum pressure (5-9" Hg (127-229mmHg) under the wire was applied. The water and moisture remaining in the wet base mat were evaporated in the kiln.

After drying, the base mat is cut, rolled, sprayed, perforated, grooved,
A sound-insulating panel of 2 ′ × 4 ′ (0.61 m × 1.22 m) or 2 ′ × 2 ′ (0.61 m × 0.61 m) was produced. Table 8 shows the properties of the base mat.

  Table 9 shows the properties of the final sound insulation panel.

  Buckwheat husks were obtained from Zafu Store, Houston, Texas.

The buckwheat husks were further crushed in a Fritz mill equipped with a screen with a hole of 0.05 "(1.27 mm) in diameter. All the buckwheat husks were crushed until they passed through the screen. About 24.5 lbs / ft ³ (392 kg / m ³ ) The particle size distribution of the crushed buckwheat husks was 21.0% residue on 20 mesh and 47.4% residue on 30 mesh. The residue on the 40 mesh was 21.0%, the residue on the 50 mesh was 5.6%, the residue on the 100 mesh was 2.8%, and the amount passed through the 100 mesh was 2.3%. It was.

  The panel ingredients listed in Table 10, various amounts of perlite, and buckwheat chaff were mixed with water to form a slurry with a consistency of about 4.5%.

  While stirring the water, each component was added in the order of newspaper pulp, starch, calcium carbonate, ground buckwheat husk, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

  A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to remove more water to harden the base mat structure. Finally, the wet base mat was Further dehydration was carried out under high vacuum pressure (5-9 "Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 10, panels were formed using about 10% mineral wool by weight with about 19% newspaper fiber, about 8% starch, and about 6% calcium carbonate. The amount of perlite and buckwheat husk is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat including the crushed buckwheat husk is a better acoustic absorber than the control product (test No. 1) and has a high eNRC value.

  Wood sawdust used as a pine tree nursery was obtained from American Wood Fiber Inc. of Columbia, Maryland.

The wood planer was further ground in a Fritz mill equipped with a screen with a hole of 0.05 "(1.27 mm) in diameter. The wood planer was ground until everything passed through the screen. The bulk density was about 8.9 lbs / ft ³ (143 kg / m ³ ) The particle size distribution of the ground wood sawdust was 5.5% residue on 20 mesh and residue on 30 mesh. 37.6%, the residue on 40 mesh is 24.3%, the residue on 50 mesh is 13.6%, the residue on 100 mesh is 12.6%, and the amount passing through 100 mesh is 6. 4%.

  The panel ingredients listed in Table 11, various amounts of perlite, and wood plank were mixed with water to give a slurry with a consistency of about 4.5%. While stirring water, each component was added in the order of newsprint pulp, starch, calcium carbonate, crushed wood plank, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

    A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mmHg)) to remove more water. The wet base mat was then pressed to a certain thickness to remove more water and harden the base mat structure. The wet base mat was further dehydrated to a high vacuum pressure (5-9 ″ Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 11, panels were formed using about 10% mineral wool by weight with about 19% newspaper fiber, about 8% starch, and about 6% calcium carbonate. The amount of perlite and wood plank is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat containing the pulverized wood kana scrap is a better acoustic absorber than the control product (test No. 1), and has a high eNRC value.

  Wheat straw was obtained from Galusha Farm, Warrenville, Illinois.

The wheat straw was further ground in a Fritz mill equipped with a screen with a hole of 0.05 "(1.27 mm) in diameter. The wheat straw was ground until most of the material passed through the screen. Bulk of ground wheat straw The density was about 7.7 lbs / ft ³ (123 kg / m ³ ) The particle size distribution of the ground wheat straw was 3.6% residue on 20 mesh and 25 residue on 30 mesh. .3%, residue on 40 mesh is 25.4%, residue on 50 mesh is 19.8%, residue on 100 mesh is 17.1%, and amount passed through 100 mesh is 8.9 %Met.

  The panel ingredients listed in Table 12, various amounts of perlite, and wheat straw were mixed with water to form a slurry with a consistency of about 4.5%.

  While stirring the water, each component was added in the order of newspaper pulp, starch, calcium carbonate, ground wheat straw, mineral wool, and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

  A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mmHg)) to remove more water. The wet base mat was then pressed to a certain thickness to remove more water and harden the base mat structure. The wet base mat was further dehydrated to a high vacuum pressure (5-9 ″ Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 12, about 10% mineral wool by weight of the panel was used with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate to form a panel. The amount of perlite and wheat straw is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat containing pulverized wheat straw is a better acoustic absorber than the control product (Test No. 1), and is indicated by a high eNRC value.

  Sawdust was obtained from ZEP (ZEP), Carterville, Georgia.

Its bulk density was about ^{24.0lbs / ft 3 (384kg / m} 3). The sawdust particle size distribution is 9.0% residue on 20 mesh, 24.3% residue on 30 mesh, 22.7% residue on 40 mesh, and residue on 50 mesh. 19.1%, the residue on 100 mesh was 21.4%, and the amount passed through 100 mesh was 3.6%.

  The panel ingredients listed in Table 13, various amounts of perlite, and sawdust were mixed with water to produce a slurry with a consistency of about 4.5%. While stirring the water, each component was added in the order of newsprint pulp, starch, calcium carbonate, sawdust, mineral wool, and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

    A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to remove more water to harden the base mat structure. Finally, the wet base mat was Further dehydration was carried out under high vacuum pressure (5-9 "Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 13, about 10% mineral wool by weight of the panel was used with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate to form a panel. The amount of pearlite and sawdust is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat including saw dust is a better acoustic absorber than the control product (test No. 1), and is indicated by a high eNRC value.

  Milled corn ears were obtained from Kramer Industries Inc. of Piscataway, NJ.

The bulk density of the ground corn ears was about 18.5 lbs / ft ³ (296 kg / m ³ ). The particle size distribution of the ground corn ear is 0.0% residue on 20 mesh, 0.1% residue on 30 mesh, 1.6% residue on 40 mesh, and residue on 50 mesh The fraction was 94.1%, the residue on 100 mesh was 4.1%, and the fraction passed through 100 mesh was 0.2%.

  The panel ingredients listed in Table 14, various amounts of perlite, and ground corn ears were mixed with water to form a slurry with a consistency of about 4.5%.

  While stirring the water, each component was added in the order of newspaper pulp, starch, calcium carbonate, ground corn ear, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

    A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to remove more water to solidify the base mat structure. Finally, the wet base mat was Further dehydration was performed at a high vacuum pressure (5 to 9 "Hg (127 to 229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

    In Table 14, panels were formed using about 10% mineral wool by weight with about 19% newspaper fiber, about 8% starch, and about 6% calcium carbonate. The amount of pearlite and ground corn ears is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat containing corn ears is a better acoustic absorber than the control product (Test No. 1), and is indicated by a high eNRC value.

  Ground walnut shells were obtained from Kramer Industries, Inc., Piscataway, NJ.

The bulk density of the ground walnut shell was about 44.2 lbs / ft ³ (708 kg / m ³ ). The particle size distribution of the crushed walnut shell is 0.0% residue on 20 mesh, 0.0% residue on 30 mesh, 3.9% residue on 40 mesh, residue on 50 mesh The minute was 72.5%, the residue on 100 mesh was 23.2%, and the amount passed through 100 mesh was 0.3%.

  The panel ingredients listed in Table 15, various amounts of perlite, and ground walnut shells were mixed with water to give a slurry with a consistency of about 4.5%.

  While stirring water, each component was added in the order of newsprint pulp, starch, calcium carbonate, ground walnut shell, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

    A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to remove more water to solidify the base mat structure. Finally, the wet base mat was Further dehydration was performed at a high vacuum pressure (5 to 9 "Hg (127 to 229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 15, panels were formed using about 10% mineral wool by weight with about 19% newspaper fiber, about 8% starch, and about 6% calcium carbonate. The amount of pearlite and ground walnut shell is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat including the pulverized walnut shell is a better acoustic absorber than the control product (test No. 1), and has a high eNRC value.

  Peanut shells were obtained from a local food store. The peanut shell was further ground in a Fritz mill equipped with a screen with a hole of 0.05 "(1.27 mm) in diameter. The peanut shell was ground until everything passed through the screen.

The bulk density of the ground peanut shell was 15.2 lbs / ft ³ (243 kg / m ³ ). The particle size distribution of the ground peanut shell is 0.2% residue on 20 mesh, 13.1% residue on 30 mesh, 31.5% residue on 40 mesh, residue on 50 mesh The minute was 19.8%, the residue on 100 mesh was 29.2%, and the amount passed through 100 mesh was 6.1%.

  The panel ingredients listed in Table 16, various amounts of perlite, and ground peanut shells were mixed with water to give a slurry with a consistency of about 4.5%.

  While stirring water, each component was added in the order of newspaper pulp, starch, calcium carbonate, ground peanut shell, mineral wool, and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

    A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to remove more water to solidify the base mat structure. Finally, the wet base mat was Further dehydration was carried out under high vacuum pressure (5-9 "Hg (127-229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 16, panels were formed using about 10% mineral wool by weight with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate. The amount of pearlite and ground peanut shells are shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat including the pulverized peanut shell is a better acoustic absorber than the control product (Test No. 1), and has a high eNRC value.

  Sunflower seed husks were obtained from Archer Daniels Midland, North Dakota.

The bulk density of the ground sunflower seeds was about 12.4 lbs / ft ³ (199 kg / m ³ ). The particle size distribution of ground sunflower seed husk is 0.1% residue on 20 mesh, 8.9% residue on 30 mesh, 30.3% residue on 40 mesh, 50 mesh above The residue was 29.3%, the residue on 100 mesh was 23.9%, and the amount passed through 100 mesh was 7.5%.

  The panel ingredients listed in Table 17, various amounts of perlite, and ground sunflower seed husk were mixed with water to produce a slurry with a consistency of about 4.5%.

  While stirring water, each component was added in the order of newspaper pulp, starch, calcium carbonate, ground sunflower seed shell, mineral wool and expanded perlite. The slurry was stirred for about 2 minutes. At the end of stirring, about 0.1% flocculant was added to the slurry. The slurry was then poured into a forming box measuring 14 ″ × 14 ″ × 30 ″ (0.36 m × 0.36 m × 0.76 m).

  A glass fiber woven fabric supported by a metal grid was placed on the bottom of the molding box, and the slurry water was allowed to flow out naturally, leaving most of the solid content. The mold box was brought to a low vacuum pressure (1 "Hg (25 mm Hg)) to remove more water. The wet base mat was then pressed to remove more water to solidify the base mat structure. Finally, the wet base mat was Further dehydration was performed at a high vacuum pressure (5 to 9 "Hg (127 to 229 mmHg)). The formed base mat was dried in an oven or kiln at 315 ° C. (600 ° F.) for 30 minutes and 149 ° C. (300 ° F.) for 3 hours to remove the remaining moisture.

  In Table 17, about 10% mineral wool by weight of the panel was used with about 19% newsprint fiber, about 8% starch, and about 6% calcium carbonate to form a panel. The amount of perlite and ground sunflower seed shells is shown below. The properties of the obtained dry base mat are also shown in the table.

  As described above, the base mat including the ground sunflower seed husk is a better acoustic absorber than the control product (Test No. 1), and has a high eNRC value.

  While particular embodiments of panels used as building materials containing renewable components have been shown and described, those skilled in the art can make changes and modifications without departing from the scope described in the following claims. Will.

Claims (10)

  A panel used as a building material comprising from about 0.1% to about 95% renewable components by weight, having a CAC value of at least about 25, an NRC value of at least about 0.25, and an STC value of A panel characterized in that it is at least about 25. The renewable component is
Rice husk, buckwheat husk, nut shell including peanut shell and walnut shell, wheat husk, oat husk, rye husk, cotton seed husk, coconut husk, corn straw, corn ear, sunflower seed, rice straw,
Wheat straw, barley straw, oat straw, rye straw, African spider (Espart), sorghum straw, straw, bamboo, sisal, sabai, ramie, bagasse, The panel of claim 1, wherein the panel is flax, kenaf, jute, hemp, manila heba, sawdust, wood chips, or a combination thereof.   The panel of claim 1, wherein the eNRC is at least about 0.20.   The panel of claim 1, wherein the MOR value is at least about 80 psi.   The panel of claim 1 having a flame spread index of about 25 or less.   The renewable component is particles that pass through a mesh screen having an aperture of about 0.312 inches (8000 microns) and remain on the mesh screen having an aperture of about 0.0059 inches (655 microns). Item 1. The panel according to Item 1.   The composition of claim 1, further comprising from about 0.1% to about 95% of one or more fibers and from about 1% to about 30% of one or more binders by weight of the dry panel. panel. A method for manufacturing a panel according to claim 1,
Selecting a renewable component;
Combining the renewable component with one or more fibers, a binder, and water to form an aqueous slurry;
Forming a base mat from the aqueous slurry on a wire with small holes;
A method for producing a panel, comprising: removing water from the base mat; and finishing the base mat.   The renewable ingredients include rice husk, buckwheat husk, nut shell including peanut husk and walnut shell, wheat husk, oat husk, rye husk, cotton seed husk, coconut husk, corn husk, corn ear, sunflower seed, rice husk , Wheat straw, barley straw, oat straw, rye straw, African spider, Sorghum straw, straw, bamboo, sisal, sabai, ramie, bagasse 9. Flax, kenaf, jute, hemp, manila hemp, abaca, sawdust, wood chips, or a combination thereof. Panel manufacturing method.   The panel manufacturing method according to claim 8, further comprising the step of aligning the particle sizes of the renewable components.