WO2022180087A1

WO2022180087A1 - Insulation material and method for production thereof

Info

Publication number: WO2022180087A1
Application number: PCT/EP2022/054508
Authority: WO
Inventors: Farid AKHTAR; Farid KHADIJAH
Original assignee: Hipor Materials Ab
Priority date: 2021-02-25
Filing date: 2022-02-23
Publication date: 2022-09-01

Abstract

The present disclosure concerns an insulation material with hierarchical porosity, wherein the insulation material comprises; i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binding system; iv) at least one type of functionalized inorganic nanoparticles, preferably silica or alumina, wherein the functional inorganic nanoparticles are forming a layer on the surface of the material;wherein the insulation material has a tailored open and closed porosity. The present disclosure also concerns a method for production thereof and use of a material for molding or extruding the material in form of sheets, panels, laminates and/or granulating lightweight granules as pumpable insulation material.

Description

INSULATION MATERIAL AND METHOD FOR PRODUCTION THEREOF

Technical Field

The present disclosure concerns insulation material and method for production thereof. Background

Heating, ventilation, and air conditioning of buildings make a great proportion of the world energy consumption. Thus, by improving the isolation and solar reflection of isolation materials may be one way of reducing the energy consumption and further to reduce CO2 emission when less heating is required for buildings. One solution would be thicker layers of insulation material. However, that would reduce the living space of the buildings or demand greater use of land to build the houses. Neither of those options are optimal, since there also is a demand for building cheaper houses and using less agricultural land to build houses. Further, as in many other areas, the construction of buildings has a great demand from the government and the public to reduce its environmental impact by not using fossil-based material. Moreover, the conventionally used materials are further connected to health risks for the workers producing the material and for the workers which later mounts the material. The insulation material which is commonly available on the market today includes glass wool, aerogels, expanded polystyrene, cellulose foams, polyurethane foams, insulation with added graphite and vacuum insulation panels.

Further, buildings and vehicles may need more than isolation. It may also need solar reflection to allow reflection of the sun light. This in conventionally solved by using two different layers of materials. A combination of isolation and solar reflection within one material would be a benefit in comparison with the prior art.

New materials and methods to produce environmentally friendly and yet efficient insulation materials are needed. Summary of Disclosure

An object of the present disclosure is to provide an insulation material with great insulation value and solar reflection. A further object of the present disclosure is to provide an insulation material with a surface countermining dirt pickup. A further object of the present disclosure is to provide an environmentally friendly insulation material. An even further object of the present disclosure is to provide an insulation material which is easy to assemble. A further objective of the present invention is to provide an insulation material being pumpable. This is a benefit when applying the insulation material where needed for instance when constructing and insulating a building on site. Being pumpable makes the material for the construction worker easy to handle and applying on the relevant site.

According to a first aspect of the present disclosure, there is provided an insulation material with hierarchical porosity, wherein the insulation material comprises; i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binding system; iv) at least one type of functionalized inorganic nanoparticles of silica or alumina wherein the insulation material has a tailored open and closed porosity. The functional inorganic nanoparticles are forming a layer on the surface of the material. Hereby an improved insulation material is provided. The insulation material has a high insulation value and solar reflection. The surface of the insulation material countermines dirt pickup. The insulation material may be made in an environmentally friendly way, such that it for instance may be recycled. The raw material of the material may be sustainable. Further, the insulation material may be prepared in forms which are easily installed.

The insulation material may be prepared into panels of various forms and shape. The insulation material may be prepared into granules. The insulation material may be pumpable. The hierarchical porosity may differ between panels. The porosity may be differed to adjust the material to the demands from the building. The combination of open and closed pores hinders heat transfer, by conduction, convection, and radiation, within the insulation material. This increases the insulation capacity of the material. Further, the solar reflection within the material may further increase the cooling effect of the buildings during summertime. The inorganic constituent may in one embodiment be an alumina or silica based mineral or a combination thereof. The inorganic constituent may be an alumina or silica. In one embodiment, the inorganic constituent may have a silica to alumina ratio no greater than about 4. In another embodiment the inorganic constituent may have a silica to alumina ratio no greater than about 1. The inorganic constituent has a nano-porosity with a pore width of 3- 30 nm. Further, the inorganic constituent may in one embodiment further comprise macropores with a pore width of greater than 50 nm, such as 0.5-5 pm. In one embodiment, the inorganic constituent may comprise nanoparticles or aggregates of nanoparticles, exhibiting a combination of textural mesopores and macropore, where the nanoparticles may have an average size not larger than about 200 nm. In another embodiment, the nanoparticles or aggregates of nanoparticles may exhibit a combination of textural mesopores and macropores may have an average size not larger than about 100 nm or in another embodiment not larger than about 20 nm. In one embodiment, the inorganic constituent may comprise 5 % inorganic oxide. The inorganic constituent countermines dirt pickup within the insulation material.

In one embodiment, the hollow polymer spheres may have a diameter of 5-80 pm. The hollow polymer spheres lower the density while having the same viscosity of the formulations as compared to competitive hollow glass microspheres. This also assists in making the material pumpable. Further the hollow polymer spheres reduce the thermal conductivity. Resilient thermoplastic microspheres reduce issues with shrinking, warping and cracking, while molding and subsequent processing. Further it compensates stresses while molding or forming and through temperature variations. It is an advantage compared to prior art including glass that the hollow polymer spheres can accommodate large internal stress and bear larger external load. Thus, the toughness of the materials containing hollow polymer spheres are larger than the toughness of the materials containing hollow glass spheres.

In yet another embodiment, the at least one polymer binding system may comprise at least one green polymer, such as polylactic acid (PLA)- polyethylene glycol (PEG).

Further, in one embodiment the polymer binding system may be epoxy based and comprise a hardener for the epoxy. The hardener for epoxy based binding system may be amines, acids, acid anhydrides, phenols, alcohols and thiols, and is preferably a mixture of polyamines. In one embodiment of the present disclosure, the polymer binder system further may comprise up to 10 % by weight of cellulose.

The at least one type of functionalized inorganic nanoparticles are preferably silica, alumina or aluminosilicates. The inorganic nanoparticles may be silica functionalized with silanes or any other type of functionalizing group. During production of the insulation material, the functionalized inorganic nanoparticles are migrating to the surface of the material. The functionalized inorganic nanoparticles are forming a layer at the surface or close to the surface of the material. The functionalized inorganic nanoparticles may have a size of 5-50 nm, such as 5-10 nm, 10-20 nm, 20-30 nm, 30-40 nm or 40-50 nm.

In an embodiment there is provided an insulation material with hierarchical porosity, wherein the insulation material comprises; i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binding system;

The insulation material may have a thermal conductivity of 0.028-0.035 W/mK in the temperature range of 20-100 °C in air at atmospheric pressure. The insulation material may further have a mechanical strength of 0.8 kPa - 8 MPa. The insulation material may further have a solar reflection in infrared light range of > 90% and may also have a solar reflection in visible light range of > 95%. The insulation material may also have a thermal stability of 1200 °C.

Compared to conventionally used isolation materials, such as mineral wool and plastic foams, the environmental impact of the present isolation material is reduced. The material may be tailored for the demand or preferences of the user. For instance, the polymer binder system may be chosen such that the resulting insulation panels has a customized combination of properties for thermal insulation, solar reflection, mechanical strength and recyclability demanded by the user. Further, the insulation material may easily be accustomed by new demands from for instance the government.

The insulation material may be made with bio-based raw material that may consist of sustainable raw materials such as cellulose, and naturally porous materials such as aluminum, silica and perlite. According to a second aspect of the present disclosure, there is provided a method for production of an insulation material with hierarchical porosity, wherein the method comprises the steps of: a) providing a slurry comprising: i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the slurry; iii) at least one polymer binder system; iv) at least one type of functionalized inorganic nanoparticles, preferably silica, alumina or aluminosilicate; b) polymerizing or curing, optionally molding, extruding or by shear force granulating the slurry; c) drying the slurry; wherein during drying or during curing, the functionalized inorganic nanoparticles are migrating to a surface of the material; wherein the insulation material has a tailored open and closed porosity.

The functionalized inorganic nanoparticles will diffuse to the surface/interphase of the material and countermine dirt pickup.

In one embodiment of the disclosure, the method may comprise a catalyst. The catalyst may speed up the polymerization of the slurry. In one embodiment of the disclosure, the drying is performed in 40-90 RH% at 30-55 °C for 20-30 hours followed by 80-110 °C for 1-3 hours, preferably 30-55 °C for 24 hours, followed by 100 °C for 2 hours.

In one embodiment, the drying is performed in 40-90 RH% at 80-110 °C for 3-4 hours, preferably 100 °C for 3,5 hours.

The method as disclosed herein provides an insulation material suitable for applications at a temperature of 50-120 °C.

Further, in one embodiment, the method may further comprise the steps of d) thermal treatment at 500-600 °C for up to 24 hours; and/or e) pre- sintering treatment at 700-1200 °C for up to 2 hours. The hollow polymer spheres may in one embodiment be sacrificed. During sacrificing, the structure of the hollow space of the hollow polymer spheres may be intact, but the polymer itself is sacrificed. This may enable the insulation material to be used at temperatures above 400 °C and even up to 1200 °C. In one embodiment of the present disclosure, there is provided a method for production of an insulation material with hierarchical porosity, wherein the method comprises the steps of a) providing a slurry comprising i) at least one inorganic constituent with nano-porosity; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the slurry; iii) epoxy; b) adding a hardener for curing of the slurry, wherein the insulation material has a tailored open and closed porosity.

In one embodiment of the present disclosure, the hardener for the epoxy based binding system may be amines, acids, acid anhydrides, phenols, alcohols and thiols, and is preferably a mixture of polyamines. The method as disclosed herein may produce an insulation material in various shaped and thicknesses. The process for constructing the present isolation material is lowered compared to that of conventional materials. The insulation material may be used in a flexible way and any modification to the material depending on the shape of the building, windows, electricity or heating installation or the like, is not needed. Further, the material may be processed into units with a size that is easy to handle, making it possible for the consumer do assemble it without having professional help. Further, the need for service of the buildings using the insulation material as disclosed herein may be decreased. The insulation material may be especially suitable for renovation of buildings, such that it may be suitable for renovate the buildings from the outside. According to a third aspect of the present disclosure, there is provided a use of a material for molding or extruding the material in form of sheets, panels, laminates and/or granulating the material to lightweight granules as pumpable insulation material.

The porosity of the material allows it to be pumpable. Being pumpable provides the material with a unique feature of being able to collect air inside the material, increasing the isolation. In conventional methods, air is used between sheets of isolation to get the isolating feature. However, with the present invention air can be trapped between the granules making it part of the insulation material.

Definitions

The term “nano-porosity” means a porosity with a pore width of less than 50 nm.

The term “macropores” means pore width greater than 50 nm. The term “hierarchical porosity” means that there are pores of different sizes with a pre-defined hierarchy.

The term “hollow polymer spheres” refers to a thermoplastic expandable polymer microsphere. Such thermoplastic expandable polymers often comprise acrylonitrile (ACN). One example is EXPANCEL™ manufactured by Nouryon AB, which comprises acrylonitrile. Acrylonitrile can be combined with one or more of vinylidene chloride (VDC), methacrylonitrile (MAN), methylacrylate (MA), methylmethacrylate (MMA) and methacrylic acid (MAA).

The term “polymer binding system” refers to a combination of polymers or prepolymers which may act as a binding system for the inorganic constituent and the hollow polymer spheres. Detailed description

The present disclosure concerns an insulation material with hierarchical porosity which has a high isolation value, solar reflection and is environmentally friendly, such that it for instance may be recycled. The raw material of the material is sustainable. Further, the isolation material may be prepared in forms which are easy to install.

The insulation material with hierarchical porosity according to the present disclosure comprises i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binding system; iv) at least one type of functionalized inorganic nanoparticles, preferably silica or alumina.

The functional inorganic nanoparticles are forming a layer on the surface of the material. wherein the insulation material has a tailored open and closed porosity.

The inorganic constituent with nano-porosity may be alumina or silica based mineral or a combination thereof. The inorganic constituent may also comprise perlite, which may comprise 70-75% silicon dioxide (S1O₂), 12-15% aluminium oxide (AI₂O3), 3-4% sodium oxide (Na₂0), 3-5% potassium oxide (K₂O), 0.5-2% iron oxide (Fe₂03), 0.2-0.7% magnesium oxide (MgO) and 0.5-1.5% calcium oxide (CaO). There may be a silica to alumina ratio of no greater than 4, such as no greater than 1 , 2 or 3. The alumina-based mineral may comprise 56-59 weight-% of the total weight of the insulation material.

For instance, the alumina-based mineral may comprise 56.8, 58 or 58.8 weight-% of the total weight of the insulation material. The silicon-based mineral may comprise 15-16 weight-% of the total weight of the insulation material. For instance, the silicon-based mineral may comprise 15, 15.4 or 15.7 weight-% of the total weight of the insulation material. Further, the inorganic constituent with nano-porosity may have a pore width of 3-10 nm, 10-20 nm or 20-30 nm. Even further, the inorganic constituent may comprise macropores with a pore width greater than 50 nm, such as 0.5-5 pm. For instance, 0.5-1 pm, 1-2 pm, 2-3 pm, 3-4 pm or 4-5 pm. Moreover, the inorganic constituent may comprise nanoparticles or aggregates of nano particles, exhibiting a combination of textural mesopores and macropore, where the nanoparticles have an average size not larger than about 200 nm, such as not larger than about 150 nm, 100 nm, 50 nm, 40 nm, 30, nm or 20 nm.

The hollow polymer spheres may comprise Expancel™. Expancel™ is a thermoplastic which is gas tight. The hollow polymer spheres may constitute acrylonitrile (ACN) in combination with any or a mixture of vinylidene chloride (VDC), methacrylonitrile (MAN), methylacrylate (MA), methylmethacrylate (MMA) or even methacrylic acid (MAA). The hollow polymer spheres may be pre-expanded. The hollow polymer spheres may be expanded during the process. The hollow polymer spheres may comprise 2-3 weight-% of the total weight of the insulation material. The hollow polymer spheres may comprise 2.5, 2.6, 2.7 or 2.8 weight-% of the total weight of the insulation material. The hollow polymer spheres may have a diameter of 5-80 pm, such as 5-20 pm, 20-40 pm, 40-60 pm or 60-80 pm. In one embodiment of the present disclosure, the hollow polymer spheres may be intact in the insulation material. In another embodiment of the present disclosure the hollow polymer spheres may be sacrificed. During sacrificing, the structure of the hollow space of the hollow polymer spheres may be intact, but the polymer itself is sacrificed. This may enable the insulation material to be used at temperatures above 400 °C and even up to 1200 °C.

The polymer binder system may comprise acrylic binders and dispersing agents. The polymer binder system may comprise methacrylamide (MAM) and N,N’-methylenebisacrylamide (MBAM) as acrylic binder. The polymer binder system may comprise ammonium polyacrylate (PAA) and polyvinyl pyrrolidone (PVP) as dispersing agent. PVP may be partly or completely replaced with sodium carboxymethyl acetate. Nanocellulose or fibers may be used as a polyumner binder. Cellulose may be added from 1-10 % depending on the viscosity of the system. In one embodiment of the present disclosure, the polymer binder system may comprise at least one green polymer, such as polylactic acid (PLA)-polyethylene glycol (PEG). Further, in one embodiment of the present disclosure, the polymer binder system may be epoxy-based. The constituents of the polymer binder system may be chosen to accommodate the need for thermal insulation, solar reflection, mechanical strength and recyclability at the site where the end- product is to be used. The MAM may comprise 1-6 weight-% of the total weight of the insulation material. For instance, the MAM may comprise 1 , 1.9, 2.1 , 3.8, 4.1 or 6 weight-% of the total weight of the insulation material.

Further, the MBAM may comprise 0.2-1.2 weight-% of the total weight of the insulation material. For instance, the MBAM may comprise 0.2, 0.4, 0.8 or 1.2 weight-% of the total weight of the insulation. The PAA may comprise 0.1 -0.6 weight-% of the total weight of the insulation material. The PAA may comprise 0.1 , 0.5 or 0.6 weight-% of the total weight of the insulation material.

The at least one type of functionalized inorganic nanoparticles are preferably silica, alumina, or aluminosilicate. The inorganic nanoparticles may be silica functionalized with silanes. During production of the insulation material, the functionalized inorganic nanoparticles are migrating to the surface of the material. The functionalized inorganic nanoparticles are forming a layer at the surface or close to the surface of the material. The functionalized inorganic nanoparticles may have a size of 5-50 nm. The present disclosure further concerns a method for production of an insulation material with hierarchical porosity, wherein the method comprises the steps of: a) providing a slurry comprising: i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binder system; iv) at least one type of functionalized inorganic nanoparticles, preferably silica, alumina, or aluminosilicate; b) polymerizing or curing, optionally molding, extruding or by shear force granulating the slurry; c) drying or curing the slurry; wherein during drying or curing, the functionalized inorganic nanoparticles are migrating to a surface of the material; wherein the insulation material has a tailored open and closed porosity.

During drying or curing, the functionalized nanoparticles are migrating to the surface of the material, such that the material get a surface which countermine dirt pickup.

The slurry may further comprise cellulose.

The slurry may further comprise a catalyst. The catalyst may help in initiating and accelerating the polymerization. Further, the drying may be performed in 40-90 RH% at 30-55 °C for

20-30 hours followed by 80-110 °C for 1-3 hours, preferably 30-55 °C for 24 hours, followed by 100 °C for 2 hours.

The drying may also be performed in 40-90 RH% at 80-110 °C for 3-4 hours, preferably 100 °C for 3,5 hours for a fast drying. Should an epoxy-based polymer binding system be used, curing may be performed at 50-80 °C for 1 ,5-3 hours, preferably 2 hours.

Even further, the method may further comprise the steps: d) thermal debinding at 500-600 °C for up to 24 hours; and/or e) pre-sintering treatment at 700-1200 °C for up to 2 hours. The additional steps d) and e) may provide an insulation material for high temperature application. Such as applications above 400 °C or even up to 1200 °C.

When performing the thermal debinding, the polymers within the insulation material, i.e. polymer binding system and the polymer shells of the hollow polymer spheres, are sacrificed, but the insulation material still remain intact and the pores provided by the hollow polymer spheres are maintained within the insulation material. When starting the thermal treatment, a heating rate of 1-10 °C/min may be used to reach the target temperature.

When pre-sintering the slurry, with or without a preceding thermal debinding step, the slurry is hardened, but again the pores are kept intact in the insulation material.

According to a third aspect of the present disclosure, there is provided a use of a material for molding or extruding the material in form of sheets, panels, laminates and/or granulating the material to lightweight granules as pumpable insulation material. Examples

By way of examples, and not limitation, the following examples identify a variety of compositions pursuant to the embodiments of the present disclosure.

Example 1 - General production procedure An insulation material as disclosed herein was produced according to below given general procedure: i) Providing a slurry comprising the three main components, inorganic constituent, hollow polymer spheres and polymer binding system, of the insulation material. A mixture of the polymer binding system was prepared by dissolving the polymer binding components, e.g. methacrylamid (MAM) and N, N - methylenebisacrylamid (MBAM), in water, preferably distilled water.

Thereafter a dispersion agent, e.g. ammonium polyacrylate (PAA), was added during mixing. The inorganic constituent(s) was/were slowly added to the mixture of the polymer binding system during continuous mixing. After having added half the amount of inorganic constituent(s), an anti-foaming agent (e.g. 1 -butanol) was added.

To ensure a homogenous slurry without any agglomerates of the inorganic constituents, the slurry was ground in order to break any of such agglomerates, but not to the extent that any of the inorganic constituent was ground. One example of such a grinding procedure may be ball mill grinding, wherein an amount of grinding balls in comparison with inorganic constituent preferably is close to 1:1.

A composition of an initiator, e.g. ammonium persulfate (APS), and hollow polymer spheres, e.g. Expancel™ , was prepared and added to the slurry during continuous mixing.

Thereafter a catalyst (i.e. TEMED™, or N, N, N, N-tetra- methylethylenediamine) was added to the slurry during mixing.

The slurry was then degassed to ensure that any air bubbles trapped therein was removed. After degassing the slurry was casted into molds. Addition of 1 -10 % by dry weight of functionalized inorganic particles. ii) Polymerizing the slurry. Polymerizing was made by thermally treating the molds containing the slurry for crosslinking the polymer binding system. Appropriate temperatures of course depend upon the polymer binding system used but may be for example be a temperature of at least 60 °C, at least 70 °C, or at least 80 °C under a time period of about 60 to 75 minutes. iii) Drying the slurry. Drying temperatures/time periods of course depends upon the material used and the size of the composition, but may for example be made, for a composition comprising alumina or a combination of alumina and silica as inorganic constituent, at a temperature of 35 to 55 °C for 20-30 h, preferably 24 hand then at 80-110 °C. preferably 100 °C for 1-3 h, preferably 100 °C for 2 h. Fast drying at 80-110 °C for 3-4 hours, preferably 100 °C for about 3,5 h, is also possible, but this needs to be adjusted and monitored not to effect the polymer binding system and the hollow polymer spheres within the insulation material. For a composition comprising silica the drying may be performed at 30-50 °C for 24 h, thereafter 100 °C for 2 h. Fast drying at 100 ° for about 3,5-4 h is also possible.

The method as decribed above results in a insulation material having a tailored open and closed porosity. Example 2 - Inorganic constituent comprising alumina

A insulation panel was made according to the process as outlined in Example 1. The polymer binder system was prepared by mixing 5.3 grams of MAM, 1.1 grams of MBAM and 1.6 grams of PAA in 100 grams of distilled water. Alumina was added in a total amount of 160 g. Further, 0.3 grams of APS was added to start the polymerization. The hollow polymer spheres were made from 7 grams of Expancel.

The polymerizing was made at at temperature of 70 °C for 75 minutes. The drying was performed at 25 °C for 24 hours, followed by 35 °C for another 24 hours and last 50 °C for 24 hours.

The result was an insulation panel with great insulating properties and solar reflecting properties.

Example 3 - Inorganic constituent comprising alumina

A insulation panel was made according to the process as outlined in Example 1. The polymer binder system was prepared by mixing 10.6 grams of MAM, 2.2 grams of MBAM and 1.6 grams of PAA in 100 grams of distilled water. Alumina was added in a total amount of 160 g. Further, 0.3 grams of APS was added to start the polymerization. The hollow polymer spheres were made from 7 grams of Expancel. 10 % by weight of functionalized aluminum particles was added to the composition.

The polymerizing was made at at temperature of 70 ° C for 75 minutes. The drying was performed at 100 °C for 4 hours.

Example 4 - Inorganic constituent comprising alumina

A insulation panel was made according to the process as outlined in Example 1. The polymer binder system was prepared by mixing 2.65 grams of MAM, 0.55 grams of MBAM and 1.6 grams of PAA in 100 grams of distilled water. Alumina was added in a total amount of 160 g. Further, 0.3 grams of APS was added to start the polymerization. The hollow polymer spheres were made from 7 grams of Expancel. 8 % by weight of functionalized silica particles was added to the composition.

The polymerizing was made at at temperature of 70 °C for 75 minutes. The drying was performed at 100 °C for 4 hours. The result was an insulation panel with great insulating properties and solar reflecting properties.

Example 5 - Inorganic constituent comprises silica

A insulation panel was made according to the process as outlined in Example 1. The polymer binder system was prepared by mixing 15.9 grams of MAM, 3.3 grams of MBAM and 0.3 grams of PAA in 200 grams of distilled water. Silica was added in a total amount of 40 g. Further, 0.3 grams of APS was added to start the polymerization. The hollow polymer spheres were made from 7 grams of Expancel. 2 % by weight of functionalized aluminosilicate particles was added to the composition.

The polymerizing was made at at temperature of 70 °C for 60 minutes. The drying was performed at 100 °C for 4 hours.

Example 6 - Inorganic constituent comprises silica

A insulation panel was made according to the process as outlined in Example 1. The polymer binder system was prepared by mixing 10.6 grams of MAM, 2.2 grams of MBAM and 0.3 grams of PAA in 200 grams of distilled water. Silica was added in a total amount of 40 g. Further, 0.3 grams of APS was added to start the polymerization. The hollow polymer spheres were made from 7 grams of Expancel. 6 % by weight of functionalized aluminum particles was added to the composition.

The polymerizing was made at at temperature of 70 °C for 60 minutes. The drying was performed at 30 °C for 24 hours followed by 100 °C for

2 hours. The result was an insulation panel with great insulating properties and solar reflecting properties.

Example 7 - Inorganic constituent comprises silica A insulation panel was made according to the process as outlined in

Example 1. The polymer binder system was prepared by mixing 5.3 grams of MAM, 1.1 grams of MBAM and 0.3 grams of PAA in 200 grams of distilled water. Silica was added in a total amount of 40 g. Further, 0.3 grams of APS was added to start the polymerization. The hollow polymer spheres were made from 7 grams of Expancel. 7 % by weight of functionalized silica particles was added to the composition.

The polymerizing was made at at temperature of 70 °C for 60 minutes. The drying was performed at 40 °C for 24 hours followed by 100 °C for 2 hours. The result was an insulation panel with great insulating properties and solar reflecting properties.

Example 8 - General production procedure using epoxy

An insulation material as disclosed herein was produced according to below given general procedure: a) Providing a slurry comprising the three main components, inorganic constituent, hollow polymer spheres and epoxy, of the insulation material.

A mixture of silica and epoxy was prepared. Thereafter, Expancel™ was added during continuously mixing. Thereafter, a hardener, for instance an amine, in a concentration of 1/5 of the amount of epoxy was added to the slurry to initiate the curing. The slurry was casted into molds. b) Curing the slurry. The curing was performed during vacuum and heating for 6 hours. c) Drying the slurry, by releasing the vacuum and continue heating until the slurry was dried out.

Heat and vacuum were applied at the same time for 20-120 minutes. Followed by a release of the vacuum, while keeping the heating for 30-40 minutes. Heating temperature for curing and drying are within the range of 50-80 °C.

Example 9 - Epoxy-based insulation material An insulation panel was made according to the process as outlined in

Example 8. 20 grams of silica was mixed with 130 grams of epoxy for 10 minutes. Thereafter, 5 grams of Expancel was added to the slurry during 1-5 minutes continuous mixing before 32.2 grams of the hardener was mixed into the slurry. 10 % by weight of functionalized aluminosilicate particles was added to the composition.

The slurry was casted into molds, and curing was initiated by vacuum and heating at a temperature of 60 °C for about 20 minutes until the slurry became rigid, thereafter the vacuum was released, but heating at a temperature of 60 °C continued for about 30-40 minutes in order to dry the slurry.

In another embodiment, the green body was cured under vacuum and heating (60 °C) for 1 hour, and thereafter dried at room temperature for 5 hours.

Example 10 - Granulated insulation material

An insulation material as disclosed herein was produced according to below given general procedure: a) Providing a slurry comprising the three main components, inorganic constituent, hollow polymer spheres and binder, of the insulation material.

A powder mixture of inorganic constituent and polymer binder was prepared through 1 hour of mixing. Thereafter, hollow polymer spheres were added together with distilled water, during continuously mixing during 30 min. As an alternative, the hollow polymer spheres may be added to the powder mixture during the first 1-hour mixing. 1-10 % by weight of functionalized inorganic particles was added to the composition. b) Extruding in an extruder or granulated by shear granulation of the slurry, into granules. c) Drying the granules, by releasing the vacuum and continue heating until the granules were dried out.

Heating under the temperature of 40 °C - 75 °C was applied for 1 -12 hours. Followed by an increased temperature to 100 °C for an additional 2-8 hours.

Example 11 - General production procedure of granules

A granulated insulation material was made according to the process outlined in Example 10. 500 grams of aluminum oxide was mixed with 10 grams of PAA for one hour. 170 grams of EPS was added to 146 grams of distilled water and the mixture was added to the former powder mixture. 10 % by weight of functionalized inorganic particles was added to the composition. The mixing continued for 30 minutes, whereafter the mixture was extruded using an extruder. The resulting granules was dried at 40 °C for 4 hours, followed by a 100 °C for 4 hours. The result was an insulation extrudates with great insulating properties with possibility to pump in characteristic.

Example 12 - General production procedure of granules

A granulated insulation material was made according to the process outlined in Example 10. 500 grams of aluminum oxide was mixed with 10 grams of PVP and 85 grams of EPS for one hour. 146 grams of distilled water was added to the powder mixture. 5 % by weight of functionalized silica particles was added to the composition. The mixing continued for 30 minutes, whereafter the mixture was extruded using an extruder. The resulting granules was dried at 40 °C for 8 hours, followed by a 100 °C for 2 hours.

The result was an insulation extrudates with great insulating properties with possibility to pump in characteristic. Example 13 - General production procedure of granules

A granulated insulation material was made according to the process outlined in Example 10. 500 grams of aluminum oxide was mixed with 10 grams of PVP and 85 grams of EPS for one hour. 146 grams of distilled water was added to the powder mixture. 2 % by weight of functionalized aluminum particles was added to the composition. The mixing continued for 30 minutes, whereafter the mixture was granulated using shear granulation. The resulting granules was dried at 75 °C for 6 hours, followed by a 100 °C for 2 hours. The result was an insulation extrudates with great insulating properties with possibility to pump in characteristic.

Example 14 - General production procedure of granules

A granulated insulation material was made according to the process outlined in Example 10. 500 grams of aluminum oxide was mixed with 10 grams of PAA for one hour. 170 grams of EPS was added to 146 grams of distilled water and the mixture was added to the former powder mixture. 4 % by weight of functionalized silica particles was added to the composition. The mixing continued for 30 minutes, whereafter the mixture was granulated using shear granulation. The resulting granules was dried at 50 °C for 12 hours, followed by a 100 °C for 2 hours.

The result was an insulation extrudates with great insulating properties with possibility to pump in characteristic.

Claims

1. An insulation material with hierarchical porosity, wherein the insulation material comprises; i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binding system; iv) at least one type of functionalized inorganic nanoparticles, of silica or alumina or aluminosilicate; wherein the insulation material has a tailored open and closed porosity.

2. The insulation material according to claim 1 , wherein the inorganic constituent is an oxide, preferably alumina or silica-based mineral, aluminum silicate or a combination thereof.

3. The insulation material according to any one of claims 1-2, wherein the inorganic constituent further comprises macropores with a pore width greater than 50 nm.

4. The insulation material according to any one of claims 1-3, wherein the hollow polymer spheres have a diameter of 5-80 pm.

5. The insulation material according to any one of claims 1-4, wherein the at least one polymer binding system comprises at least one green polymer.

6. The insulation material according to claim 1-5, wherein the polymer binding system is epoxy based, also comprising a hardener therefore.

7. The insulation material according to claim 2, wherein the inorganic constituent has a silica to alumina ratio no greater than about 4.

8. The insulation material according to claim 2, wherein the inorganic constituent has a silica to alumina ratio no greater than about 1.

9. The insulation material according to any one of claims 1-8, wherein the inorganic constituent comprises nanoparticles or aggregates of nano particles, exhibiting a combination of textural mesopores and macropore, where the nanoparticles have an average size not larger than about 200 nm.

10. The insulation material according to any one of claims 1 -9, wherein the inorganic constituent comprises nanoparticles or aggregates of nano particles, exhibiting a combination of textural mesopores and macropore, where the nanoparticles have an average size not larger than about 100 nm.

11. The insulation material according to any one of claims 1 -10, wherein the inorganic constituent comprises nanoparticles or aggregates of nano particles, exhibiting a combination of textural mesopores and macropore, where the nanoparticles have an average size not larger than about 20 nm.

12. The insulation material according to any one of claims 1-11, wherein the polymer binding system further comprises: v) up to 10 % by weight of cellulose.

13. A method for production of an insulation material with hierarchical porosity according to any one of claims 1-12, wherein the method comprises the steps of: a) providing a slurry comprising: i) at least one inorganic constituent with nano-porosity, having a pore width of 3-30 nm; ii) at least one type of hollow polymer spheres, wherein the hollow polymer spheres add closed pores to the insulation material; iii) at least one polymer binder system; iv) at least one type of functionalized inorganic nanoparticles, of silica or alumina or aluminosilicate; b) polymerizing, curing, optionally molding, extruding or by shear force granulating the slurry; c) drying the slurry; wherein during drying or during curing, the functionalized inorganic nanoparticles are migrating to a surface of the material; wherein the insulation material has a tailored open and closed porosity.

14. A method according to claim 14, wherein the slurry further comprises a catalyst.

15. A method according to claims 14 or 15, wherein the drying is performed in 40-90 RH% at 30-55 °C for 20-30 hours followed by 80-110 °C for 1-3 hours, preferably 30-55 °C for 24 hours, followed by 100 °C for 2 hours.

16. A method according to claims 14-15, wherein the drying is performed in 40-90 RH% at 80-110 °C for 3-4 hours, preferably 100 °C for 3,5 hours.

17. Use of a material according to claims 1-12 or produced by the method of claims 13-16, for molding or extruding the material in form of sheets, panels, laminates and/or granulating the material to lightweight granules as pumpable insulation material.