NL2033573B1 - Composite Material for Structural Insulation Panels - Google Patents

Abstract

P307583NL 25 Abstract The present invention relates to a composite material for use as insulation and facade and/or roof cladding material, comprising: a first layer comprising a crosslinked polyfuranyl resin and a mineral fibres (1); at least a second insulation layer comprising an insulating core material (2); and a third 5 layer comprising a crosslinked polyfuranyl resin and mineral fibres (3), wherein the second layer (2) is arranged in an intermediate position between the first layer (1) and the third layer (3), and is adhered to the first and third layer.

Description

P307583NL 1

Composite Material for Structural Insulation Panels

The present invention relates to a composite material suitable for use as architectural insulation panels comprising (1} a first layer comprising polyfuranyl resin and glass fibres, {2} a core layer comprising an insulation material, and (3) a third layer comprising a cured polyfuranyl resin and glass fibres. The composite material may comprise one or more additional outer coating and structural layers on one or both sides of the composite material.

BACKGROUND OF THE INVENTION

Composite materials, in particular shaped articles such as panels are used in various applications, for instance as wall insulation in buildings and in structural applications. Such materials usually comprise a shell outer material, and a solid filler material. The shell materials are typically prepared from a woven and/or non-woven fibrous material and a thermoplastic or thermosetting binder system, and form an external layer facing the environment, whereas the filler material usually offers structural integrity, noise protection and/or insulation value.

Specifically for building insulation applications, the composites have to be durably resistant to the different wearing conditions, including physical abrasion, variations in humidity and temperature, exposure to UV and other radiation, exposure to chemicals, or and/or (microbiological growth.

Such composite materials for use in wall insulation have been developed based on fibre- reinforced concrete or gypsum materials. However, these are difficult to shape or affix due to the low mechanical strength of the composites in general. This is usually addressed by adding a tie coat or adhesive layer between the outer shell, and the core material. Furthermore, the thus far employed materials have a high density, which in combination with the low mechanical strength requires comparatively thick walls, which in turn limits their use to applications and constructions that can bear the high weight. A further issue with these materials is the leaching of highly corrosive salts.

In order to reduce weight and/or to improve mechanical performance, composites based on plywood sheet materials and/or wood chips have been developed. Plywood usually consists of sheets of wood that are glued or cemented together, using for instance thermosetting polyurethane or thermosetting unsaturated polyester and styrene binders, or epoxy resin and amino curing agent binders. US-A- 6044604 for instance discloses a composite roofing board having a foam core of polyisocyanurate, polyurethane or mixtures thereof between a gypsum board and a facer layer. US-A- 5718096 discloses using recycled materials and glass fibres in composite panel elements for use in building structures. US-A-6322731 discloses the use of rice husks, wheat husks and sawdust in forming constructions panels.

P307583NL 2

However, while these materials show better mechanical properties as compared to fibre reinforced concrete, they tend to emit organic compounds, such as for example formaldehyde. For environmental reasons, there is a trend to use materials that emit low levels of organic volatiles.

US-A-6158176 discloses a sound absorbing panel comprising a core of mineral wool bounded by flat front and rear surfaces comprising fibre-glass. The sound absorbing panel was disclosed as being prepared by spraying a mineral wool core with an adhesive, then contacting the adhesive layer with fibre-glass sheets, followed by three days of curing. The adhesive used was a styrene-butadiene copolymer in hexane/acetone solvent, the solution having a viscosity of 700 centipoise, and a solids content of 28%. This adhesive was disclosed as having a high volatility and high solids content, so the adhesive did not migrate beyond its initial site of contact and rapidly achieves a tacky state.

US 2020199022 A1 discloses thermal and/or acoustic insulation products based on mineral wool, notably glass wool or rock wool, and a formaldehyde-free organic binder, wherein the binder contains a furan resin and 5-60 wt.% of reducing sugar and/or non-reducing sugar. This document discloses insulation products prepared by sizing of glass fibres directly with the aqueous binder after production of the fibres, and subsequently, insulation products are formed by curing the impregnated non-woven fabrics by aqueous solutions comprising furan resin and sugar, followed by oven-hardening at 220 °C.

While this leads to products with a high tensile strength, the amount of resin binder is significant, since it is used throughout the entire product. Also, by the addition of the sizing binder agent, the insulation efficacy may be reduced since fibres are glued together during the curing stage, and hence comprise less voids, and getting denser.

Accordingly, there remains a need for composite materials that inherently have a higher fire retardancy and a higher resistance to water and/or deterioration, and use less

Applicants have now surprisingly found that environmentally stable, resistant to humidity and/or rot, and highly insulating composite materials can be prepared from a material comprising an insulation core material, such as mineral wool, glass wool or organic polymeric foam materials; and a fibrous exterior material impregnated with an aqueous polyfuranyl binder and curing agent prepreg system. Furthermore, the materials can advantageously be sourced from recycling materials that otherwise has few other uses.

BRIEF SUMMARY OF THE DISCLOSURE

In a first aspect, the present invention relates to a composite material for use as insulation and facade and/or roof cladding material, comprising: a first layer comprising a crosslinked polyfuranyl resin and a mineral fibres (1); at least a second insulation layer comprising an insulating core material (2); and a third layer comprising a crosslinked polyfuranyl resin and

P307583NL 3 mineral fibres (3), wherein the second layer (2) is arranged in an intermediate position between the first layer (1) and the third layer (3), and is adhered to the first and third layer.

In a second aspect, the present invention relates to a cladding assembly comprising the composite material according to claim 1 for a wall or roof of a building, comprising a panel- securing element comprising a first flange, a second flange, and a web securing the first flange with respect to the second flange in a spaced-apart configuration, wherein the first flange is secured to the frame element to attach the panel-securing element to the frame element; a plurality of insulation panels, each of the plurality of insulation panels having opposed faces defining a thickness therebetween and a first edge abutting or facing against the web of the panel- securing element with the second flange of the panel-securing element disposed over a peripheral portion of one of the opposed faces, wherein a spacing between the first and second flanges of the panel-securing element is at least as large as the thickness of the insulation panel; wherein each of the plurality of insulation panels comprises a multi-layer facing material forming at least one of the opposed faces; and wherein the facing material includes an overhanging portion extending beyond a second edge of each of the insulation panels to secure each of the insulation panels adjacent to one another during installation and to form an air, thermal and moisture barrier between each of the adjacent insulation panels. in a third aspect, the present invention relates to a composite material wherein a thermoplastic foam material layer is employed, wherein the foam material is a polyester based material and wherein the polyester is virgin or post-consumer polyethylene terephthalate, or a mixture of the two and wherein the foam material is characterized by elongated cells, which have an aspect ratio larger than 1.5, and by a density according to ISO 845 of lower than 150 kg/m3, preferably lower than 80 kg/m3, and by a thermal conductivity of lower than 0.032 W/mK measured according to ISO 12677.

In a fourth aspect, the present invention relates to a panel element comprising the composite material for a wall or roof of a building, further comprising a vapour-impervious skin and/or a reinforcing layer.

In a fifth aspect, the present invention relates to a panel comprising a core layer formed by the first to third layers, comprising: a. an integrally formed, outwardly-extending attachment flange defined by the entire thickness of the panel and proximal to the outward surface around two around at least two adjacent side edges of the panel, for receiving elongate fastener elements through the entire thickness of the panel and into an underlying support member; b. two spaced- apart elements formed on and extending along respective adjacent sides of the attachment flange remote from the surface and defining a groove therebetween; c. a complementary tongue projecting outwardly from and extending along respective adjacent sides of the panel for being

P307583NL 4 received in a groove of a complementary adjacent structural element; wherein the attachment flange resides intermediate the groove and the surface, for permitting the groove to receive the tongue of the complementary structural element therein.

In a sixth aspect, aspect, the present invention relates to a method for the manufacture of a composite panel, comprising: a. Impregnating a sheet comprising woven of mineral fibres with a liquid polyfuranyl resin composition; to provide an impregnated sheet, b. subjecting the impregnated sheet to conditions inducing gelation of the polyfuranyl resin composition, thereby forming a pre-preg sheet; c. optionally depositing a pre-preg sheet onto a transport medium, preferably a backing sheet and optionally removing the pre-preg sheet on the backing sheet; d. arranging at least a core layer between two pre-preg sheets, such that the first and second prepreg sheets such that the top surface of the second sheet opposes the bottom surface of the first sheet; to form a sandwich structure; and e.subjecting the sandwich structure to conditions that allow the gelled polyfuranyl resin composition to cure essentially fully, preferably including heating the sandwich structure to a temperature and for a time period that results in crosslinking and chain growth of the polyfuranyl resin composition.

In a seventh aspect, the present invention relates to a use of the composite material as a building material, preferably as for use as sound and/or heat insultation building material.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are further described hereinafter with reference to the accompanying drawings.

FIG. 1 is a perspective view of a composite panel according to an embodiment of the invention (1A), and of two conventional comparative panels (1B and 1C). The Figure shows en exploded view, a side elevation and a cross-sectional view of each panel.

FIG. 2 is a side elevation showing attachment of a composite panel through the core adjacent the tongue of a preferred embodiment;

FIG. 3 is a side elevation showing attachment of a composite panel through the core adjacent the groove of a preferred embodiment;

FIG. 4 is a side elevation showing attachment of a composite panel through the core adjacent the groove of a preferred embodiment.

DETAILED DESCRIPTION

Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context

P307583NL otherwise requires, In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be 5 understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The term “binder composition" as used herein means all ingredients applied to the matter to be bound and/or present on the matter to be bound, notably prior to curing, (other than the matter and any moisture contained within the matter) including cellulose hydrolysate sugars, any inorganic ammonium salt crosslinker and any additives, and possibly solvents (including water).

The term “binder” is used herein to designate a thermoset binder resin obtained from the "binder composition".

The term "cured" means that the components of the binder composition have been subjected to conditions that lead to chemical change, such as covalent bonding, hydrogen bonding and chemical crosslinking, which may increase the cured product's durability and solvent resistance, and result in thermoset material.

The term “dry weight of the binder composition” as used herein means the weight of all components of the binder composition other than any water that is present, whether in the form of liquid water or in the form of water of crystallization.

The term “crosslinker” as used herein comprises compounds that are capable of reacting with the carbohydrate components of the cellulose hydrolysate to form ramifications or reticulations of the polyfuranyl compounds.

A first aspect of the present invention relates to a composite material for use as facade comprising: a first layer comprising polyfuranyl resin and a woven or non-woven sheet comprising glass fibres, (1); at least a first core layer comprising an insulation material, (2); and a third layer comprising a polyfuranyl resin and a woven or non-woven sheet comprising mineral fibres, (3), wherein the second layer (2) is arranged in an intermediate position between the first layer {1) and the third layer (3).

P307583NL 6

Applicants have found that the panels of the invention solve the problem of fire retardancy in a lightweight composite construction useful for building application, with a minimum of additional fire retardants or fire protection materials due to the inherent high fire retardancy of the subject materials.

Applicants have found that panels of the invention solve the problem of providing high acoustic insulation properties in a lightweight composite construction useful for building application, in particular as panels for insulation, or as structural building elements .

The composite material comprises a first layer and a third layer comprising a polyfuranyl resin as main binder component. The polyfuranyl resin employed in the present invention may be selected from a variety of different binder materials comprising PolyFurfuryl Alcohol (PFA). The selection will largely depend on the cost and performance targets specified.

The polyfuranyl resin composition may be a biologically derived resin. As such, the biologically derived resin advantageously is not a phenolic resin based on mineral oil as may be found in connection with the manufacturing of conventional fire-rated laminates. The biologically derived resin preferably is a resin that derives some or all of its constituent monomers from biological sources.

Preferably, the biologically derived resin comprises PolyFurfuryl Alcohol (PFA) as the polymeric backbone component. In some embodiments, the biologically derived resin does not comprise fire resistant filler or additive material. Advantageously, such systems can be prepared comprising no Volatile Organic Compounds (VOC) as typically found in phenolic or epoxy resins. As a result, the biologically derived resin may reduce exposure to potential chemical hazards that may otherwise typically occur during manipulation of phenolic or epoxy resin.

Where reference is made to a "biologically derived resin”, it is to be understood that for embodiments of the invention, the biologically derived resin is a furan resin, such as a resin comprising monomer units of furfuryl alcohol. The cured resin may therefore be a poly(furfuryl alcohol). The furanyl resin may be derived from sugar cane, or other sources of sugars, and as such is not only entirely sustainable, but also imparts particularly advantageous properties to the subject assembly. Preferably, the furan resin comprises furfural (furan-2-carbaldehyde) or a derivative of furfural such as furfural alcohol, furan, tetrahydrofuran and tetrahydrofurfuryl alcohol, which are collectively referred to as “furans” herein.

A furan resin may be used in which furfural replaces formaldehyde in a conventional production of a phenolic resin. The furan resin cross links (cures) in the presence of a strong acid catalyst via condensation reactions. Furfural is an aromatic aldehyde, and is derived from pentose (Cs) sugars, and is obtainable from a variety of agricultural by-products. It is typically synthesized by the acid hydrolysis and steam distillation of agricultural by-products such as corn cobs, rice

P307583NL 7 hulls, oat hulls and sugar cane bagasse. Further details relating to furan resins whose use is contemplated in the present invention is set out in "Handbook of Thermoset Plastics”, edited by

Sidney H. Goodman, Edition 2, Published by William Andrew, 1998, ISBN 0815514212, 9780815514213, Chapter 3: Amino and Furan Resins, by Christopher C. tbeh. Furan resins are of particular interest because they are derived from natural, renewable sources, they bond well to glass fibres and they have good flame-retardancy properties.

Preferably, humins may be added to the furfuryl alcohol. In this specification, humins from biomass sources are understood as the often black or dark coloured carbon-based macromolecular substances obtained from om saccharide-based biorefinery processes, in particular those from conversion of 5-hydroxymethylfurfural (HMF). These humins can be in the form of either viscous liquids or solids depending on the process conditions used.

These compounds can be considered as polymers containing moieties from hydroxymethylfurfural, furfural, carbohydrate and levulinic acid. These coloured bodies are produced as by-products in the partial degrading of carbohydrates by heat or other processing conditions, as described in e.g. EP 338151 Al. Humins are believed to be macromolecules containing furfural and hydroxymethylfurfural moieties. Further moieties that may be included in humins are carbohydrate, levulinate and alkoxymethylfurfural groups.

The polyfuranyl resin of the first layer or the third layer, or both layers may also include one or more additional compounds, optionally selected from additional monomers, co-catalysts, diluents, fillers and combinations thereof.

Additional monomers may advantageously be selected from 5-hydroxymethyifurfural (HMF), 2-(2-hydroxyacetyl}furan, 5-alkoxymethylfurfural, formaldehyde, methyl formate, levulinic acid, alkyl levulinates, 2,5-diformyi-furan, carbohydrates and furfural and combinations thereof.

The use of these monomers has the advantage that similar moieties can already be present in the humins so that these additional monomers seamlessly integrate with the polymer of furfuryl alcohol and the humins. The relative amount of these additional monomers may vary within wide ranges. When they are elected from the compounds hereinabove, these compounds have groups that are also present in humins. Therefore they can be added to the humins in very small to extremely large quantities. Generally, economic considerations promote that a small amount of additional monomers is used and a large amount of the by-product humins. Commonly, the amount of additional monomers may vary from 0 to 20 %wt, based on the combined amount of furfuryl alcohol and humins.

Suitable mineral fibres are in particular glass fibres, notably of glass E, C, R or AR (alkali- resistant), or rock fibres, notably of basalt (or wollastonite). These fibres may be fibres containing more than 96 wt % of silica and ceramic fibres based on at least one oxide, nitride or carbide of

P307583NL 8 metal or of metalloid, or a mixture of these compounds, in particular at least one oxide, nitride or carbide of aluminium, of zirconium, of titanium, of boron or of yttrium. More particularly, the mineral fibres according to the invention are aluminosilicate glass fibres, notably aluminosilicate glass fibres comprising aluminium oxide, Al203 , in a fraction by weight of between 14% and 28%.

The composite material further preferably comprises a core layer, preferably a porous matrix layer, for increased thermal or otherwise insulation.

Preferably, when shaped into panels, the edges of the composite panel comprise a higher amount of the composite material to increase mechanic strength. The process may be advantageously be performed in a heated press.

The insulation layer (2) may comprise a polymeric matrix, an inorganic matrix, of combinations thereof. The insulating material may have a nominal thickness in the range 1.5 to 20 cm, preferably in the range 2 to 12 cm; and/or a thermal resistance R value of equal to or below (2) than to 3 m*K/W, preferably wherein R = to 4 m?K/W at a thickness or 200 mm; and/or a thermal resistance R of R 2 to 1.5 m?K/W, preferably R 2 to 2 m?K/W at a thickness or 100 mm; and/or a density in the range of from 5 to 40 kg/m.

Useful materials include mineral wool. The mineral fibres may be glass wool or rock wool; the fibres may have an average diameter between 2 and 9 micrometres; they may have an average length between 8 mm and 80 mm.

Mineral wool herein refers to any fibrous material formed by spinning or drawing molten mineral or rock materials such as slag and ceramics. Applications of mineral wool include thermal insulation and soundproofing. Preferably the mineral wool is selected from glass wool, stone wool and/or ceramic fibre wool, in particular from alkaline earth silicate (AES) wool, alumino silicate (AS) wool, polycrystalline (PC) wool, kaowool or glass wool.

Mineral wool is composed of individual fibres that conduct heat very well. However, in the physical arrangement of fibres within the mineral wool leads to low heat conduction from one fibre to another and when pressed into rolls and sheets, their ability to partition air makes them excellent insulators and sound absorbers. Preferably, the layer comprising mineral wool is a glass wool. Glass wool fir instance is an insulating material made from fibres of glass arranged using a binder into a texture similar to wool. The process traps many small pockets of air between the glass, and these small air pockets result in high thermal insulation properties. Glass wool may be suitably manufactured by the method of US 2133235 A.

Alternatively, the insulation material layer may comprise a foamed polymeric material.

Preferably, the present invention advantageously makes use of a thermoplastic foam material having a low thermal conductivity and preferably comprising a strong cellular orientation with aspect ratio significantly larger than 1.5, ideally even larger than 2.0. The present invention

P307583NL 9 discloses also a shaped composite article obtained from the foam material. In the preferred foam material, additionally polymer blends are present in an amount of not more than 40 wt % and wherein the additional polymer blends are selected from the group of polyatkylene terephthalates, polylactic acid, polycarbonate, polyolefins, polyacrylates, polyamides, thermoplastic elastomers, core-shell polymers, liquid crystal polymers (LCP), or a mixture thereof.

Particularly preferred are polyester-based material, preferably comprising virgin and/or post -consumer polyethylene terephthalate that have a starting IV from 0.56 up to 0.82.

Preferably, these are obtained by a reactive foam extrusion. Herein, the IV of the polymer is increased in a single step to a satisfactory level while at the same time a physical blowing agent is introduced to the mixture, and consequently a sudden pressure drop will result in the physical blowing agent rapidly expanding and foaming the PET. Virgin material is defined as raw material coming from PET producer, and may be supplied in form of powder or granules (pellets). Post- consumer material is typically available in form of flakes or granules, and may contain any products made of PET, such as bottles, food packaging material or blisters, which have been collected, shredded and washed by special recycling companies.

Preferred polyester-based materials comprise preferably virgin and post-consumer polyethylene terephthalate that have a starting IV from 0.56 up to 0.82, and are expanded by means of reactive foam extrusion. Preferably, the IV of the polymer is increased in a single step to a satisfactory level while at the same time a physical blowing agent is introduced to the mixture.

Virgin material is defined as raw material coming from PET producer, and may be supplied in form of powder or granules (pellets). Post-consumer material is typically available in form of flakes or granules, and may contain any products made of PET, such as bottles, food packaging material or blisters, which have been collected, shredded and washed by special recycling companies.

The final shape of the foam extrudate is defined by an extrusion tool and a shaping tool which helps the foam to maintain its shape during solidification and cooling.

A preferred thermoplastic foam material is a polyester based material and wherein the polyester is virgin or post-consumer polyethylene terephthalate, or a mixture of the two and wherein the foam material is characterized by elongated cells, which have an aspect ratio larger than 1.5, and by a density according to ISO 845 of lower than 150 kg/m3, preferably lower than 80 kg/m3, and by a thermal conductivity of lower than 0.032 W/mK measured according to ISO 12677.

Preferably, the composite materials further comprise a wood composite layer, to increase the stability, and to allow for attachment of various fixing or positioning mean in a building structure. Preferably, the wood composite layer is an oriented strand board. The wood composite layer preferably has a thickness of from 10 mm to 35 mm, preferably at least 12-25 mm, yet more

P307583NL 10 preferably 15-20 mm.

Prefearbly, the composite may also comprise further layers, such as wood composite materials suitable for wood composite layer, veneer layers, or decorative layers. Preferred wood materials may be selected from the classes 1 to 4 of OSB materials, e.g. OSB/1, i.e. boards with no load transfer, OSB/2 — board, i.e. with load transfer properties, suitable for applications in dry conditions; OSB/3 boards, i.e. boards with load transfer properties, suitable for usage class according to PN-EN 13986 applications in moderate humidity conditions, or OSB/4 boards, designated as special heavy-duty boards for loadbearing applications, as determined by the DIN

EN 300 standard. The wood composite layers may have a suitable thickness as adequate for loadbearing uses and dimensional stability, whereby a greater thickness will increase the required structural strength.

The present composites may also comprise further functional layers, such as fire resistance layers, or foils or veneer layers for visual effects, or humidity. Such layers may advantageously be applied into the prepreg outer layers, and then integrally formed with the composite material.

The present composite material may also include one or more voids or channels, which are useful to accommodate a variety of different building related elements, such as HVAC equipment and ducts, electricity and telecommunication cables and wiring, plumbing and other important connections; and/or the channels may comprise suitable sound or energy loss insulating materials. Depending on the use and location, these may allow the passage of the cables, wiring, and plumbing along a length. The channels may have also preformed openings in the sides to accommodate the passage of cables, wiring, and plumbing along the panel, or, where desired contain the cables, wiring, and plumbing with standard connectors.

The composite material may further comprise additives, such as pigments, fillers, and other usually applied additives.

The composite material preferably further comprises at least one woven or non-woven sheet layer, to improve the mechanical properties such as tensile strength and surface resilience.

The composite material may further comprise a cover sheet material to create an exterior expression, such as coloured films, preferably also comprising a UV filter, printed films, printed paper or carton box, woven or non-woven fabrics.

The present invention further preferably relates to a shaped article comprising the composite material according to the invention, such as advantageously in the form of a flat, square-shaped panel module for use in assembling building structures. Such panels may also advantageously be employed as replacement for fibre enforced concrete panels in structural applications, such as sound proofing.

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Preferably, where a shaped article comprising the composite material according to the invention is a panel, such panels can be used to insulate flat surfaces such as cavity wall insulation, ceiling tiles, curtain walls, and ducting.

The present composite materials were found to reduce the CO: footprint significantly as compared to other composite materials or to traditional wood or steel skeleton buildings. Also, the components are entirely sustainable, and/or reusable.

A further aspect of the present invention relates to a process for manufacturing a composite material, wherein the process comprises the following steps: providing an insulation layer (2); contacting the insulation layer with a mixture comprising polyfuranyl resin and glass fibre on a first surface of the layer comprising mineral wool to provide a first layer comprising polyfuranyl resin and glass fibres (1); contacting the insulation layer with a mixture comprising polyfuranyl resin and glass fibre on a second surface of the layer comprising mineral wool to provide a third layer comprising polyfuranyl resin and glass fibres (3); heating the composite material comprising the three layers (1-3) under pressure.

Preferably, the insulation layer comprising mineral wool is a glass wool. Glass wool is an insulating material made from fibres of glass arranged using a binder into a texture similar to wool.

The process traps many small pockets of air between the glass, and these small air pockets resuit in high thermal insulation properties. Glass wool may be suitably manufactured by the method of

US 2133235 A.

Preferably, the step of contacting the insulation layer with a resin and glass fibre fabric comprises preparing a pre-gelled polyfuranyl resin and glass fibre fabric prepreg. The use of a prepreg material advantageously allows for a process without a prolonged solvent removal step, such as by heating or at reduced pressures.

The polyfuranyl binder material further has the advantage of being a non-toxic thermoset binder material. The use of such materials allows to avoid toxic or environmentally harmful emissions of volatile compounds, as well as reduced exposure for the applicator to small molecules. Also, the use of thermoset polymers results in a much higher strength obtainable by these components, at elevated temperatures. it was found that the use polyfuranyl resins comprising polyfurfuryl alcohol (PFA) polymers, in particular under acid catalyst, such as paratoluene sulphonic acid, delivered an inherently high flame retarding effect. “Furan” or “polyfuran” resins derived from biomass of vegetable origin are one of the solutions used. Such polyfuranyl resins were initially used in the foundry for ensuring setting of moulding sands in the mould, and are now also used as binders for mineral fibres for making

P307583NL 12 insulation products based on mineral wool, see for example WO 93/25490, WO 94/26676, WO 94/26677, WO 94/26798.

The composite material comprises a first layer and a third layer comprising a polyfuranyl resin as main binder component. The polyfuranyl resin employed in the present invention may be selected from a variety of different binder materials comprising PolyFurfuryl Alcohol (PFA). The selection will largely depend on the cost and performance targets specified.

The polyfuranyl resin composition may be a biologically derived resin. As such, the biologically derived resin advantageously is not a phenolic resin based on mineral oil as may be found in connection with the manufacturing of conventional fire-rated laminates. The biologically derived resin preferably is a resin that derives some or all of its constituent monomers from biological sources.

Preferably, the biologically derived resin comprises PolyFurfuryl Alcohol (PFA) as the polymeric backbone component. In some embodiments, the biologically derived resin does not comprise fire resistant filler or additive material. Advantageously, such systems can be prepared comprising no Volatile Organic Compounds (VOC) as typically found in phenolic or epoxy resins. As a result, the biologically derived resin may reduce exposure to potential chemical hazards that may otherwise typically occur during manipulation of phenolic or epoxy resin.

Where reference is made to a “biologically derived resin”, it is to be understood that for embodiments of the invention, the biologically derived resin is a furan resin, such as a resin comprising monomer units of furfuryl alcohol. The cured resin may therefore be a poly(furfuryl alcohol). The furanyl resin may be derived from sugar cane, or other sources of sugars, and as such is not only entirely sustainable, but also imparts particularly advantageous properties to the subject assembly. Preferably, the furan resin comprises furfural (furan-2-carbaldehyde) or a derivative of furfural such as furfural alcohol, furan, tetrahydrofuran and tetrahydrofurfuryl alcohol, which are collectively referred to as “furans” herein.

Accordingly, useful polyfuranyl resins comprise mixtures of monomers, oligomers and polymers obtained by polycondensation of monomers with a furanyl nucleus and optionally other comonomers such as anhydrides, aldehydes, ketones, urea, phenol etc, in an acid medium. Such polyfuranyl resins usually comprise furfural and/or a derivative of furfural such as furfuryl alcohol.

Polyfuranyl resins are typically prepared by self-polymerisation of furfuryl alcohol and/or furfural.

In a preferred embodiment, the resin may comprise a polyfurfuryl alcohol, a liquid polymer which self-crosslinks in the presence of an acid catalyst. Polyfuranyl resins may be modified by using furfural instead of formaldehyde in a conventional production of a phenolic resin. The furan resin then polymerizes in the presence of a strongly acidic catalyst via various condensation reactions.

Polyfuranyl resins are inherently sustainable, since they are derived from natural, renewable

P307583NL 13 sources, and were found to bond well to mineral fibres, and they have good flame-retardancy properties.

As set out above, the polyfuranyl resin composition preferably comprises an acid catalyst.

The catalyst promotes curing via condensation reactions, thereby releasing water vapour. During the curing step, preferably means to release the formed vapour or steam are provided. The curing step typically takes place in a heated moulding press. Known moulding presses are known for moulding polyurethane-containing products. Such moulding presses are typically operated in a carefully sealed condition, in view of the health and safety issues surrounding the curing of polyurethane.

The binder composition further preferably comprises an acidic polymerization initiator having a pK; at 25 °C of at least 3. Such initiators can be selected from Brgnsted and Lewis acids.

The acidic initiators may be organic or inorganic. Examples of inorganic Lewis acids include aluminium trihalide, e.g. trichloride, boron halide, e.g. trichloride, zinc halide, e.g. dichloride, iron halide, such as ferrous chloride and ferric chloride, chromium halide, such as chromium trichloride, and iodine. Preferably, the acidic initiator is organic and suitably selected from maleic anhydride, phthalic anhydride, formic acid, maleic acid, malic acid, phthalic acid, furoic acid, benzoic acid, furan-dicarboxylic acid, citric acid, levulinic acid and combinations thereof. The acidic initiator is suitably added in an amount that provides for a sufficiently fast and complete polymerization reaction, especially when heated to the desired thermosetting temperature. Preferably, the amount of acidic initiator is in the range of 0.5 to 10% wt, based on combined amount of furfuryl alcohol and, where applicable humins.

In addition, the particulate binder may also contain a prepolymer of furfuryl alcohol. The prepolymer is a resinous product and is available under the trademark Furolite™ (ex TransFurans

Chemicals). The preparation of these prepolymers is known in the art. An example of a known preparation method is described in US 2571994.

The particulate binder may further comprise further additives, such as pigments, fillers, flow improvers, catalysts, wetting agents and other usually applied additives. in a particularly preferred embodiment, the processes comprises the additional step of blending glass fibre and a particulate binder comprising polyfuranyl resin. This step may be performed by any suitable method, including mechanical methods, and/or advantageously the use of cyclone technology, which may equally allow to pre-heat binder and fibrous material, as may be required for a continuous production. In such a line-up, the two materials, together with any additive or other material as required may be advantageously be blended and premixed from e.g. two silos, and then mixed intensively while already pre-heating to allow for an improved flow if a homogenous composite with a thermoset binder is desired. Alternatively, the process may be

P307583NL 14 performed batch-wise. The benefit of such a batch production is the relative ease of heating and shaping, but equally also the fact that a less homogenous material may be obtained, which can be advantageous if porous matrix materials are present as well, whereby a full saturation of cavities in the matrix may be avoided, thereby maintaining high insulation values and low density. In the process according to the invention, the blended material obtained in step (a) is preferably shaped prior to, or during the curing step, to obtain a shaped composite article.

Preferably, the process further comprises adding one or more woven or non-woven sheet or fabric material to at least one side of the composite blend. This may be for simply decorative purposes, as well as UV filtration by using a pigmented or printed foil, or functional such as the use of glass or carbon fibre mats or fabric for increased strength.

By the term “glass fibre fabric” is meant one or more layers of unidirectional rovings that are assembled into a fabric or cloth, i.e. a kind of a textile normally being flexible and bendable.

Glass fibres are typically composed of glass filaments bundled into a roving. The diameter and number of filaments in a roving may vary leading to the variations of the diameter of a roving.

Normally the filaments are coated with a sizing. The glass fibres may be assembled into a fabric by any suitable method, such as by stitching. Useful glass fibre fabrics include those having of one or more layers of fibres, which preferably are multiaxially reinforced. By the term “unidirectional” is meant that the fibres in one layer of fabric are parallel. By the term “multiaxial reinforcements” or simply “multiaxial” is meant fabric made up of multiple plies or layers of parallel fibres. each lying in a different orientation or axis. in a preferred embodiment of the subject invention the glass fibre fabric comprises multiaxial reinforcements, wherein layers of unidirectional fibres are assembled and stitched together, thereby providing strength and stiffness in multiple directions depending on the controlled orientation of the fibres. Useful multiaxial fabrics include unidirectional, biaxial, and triaxial and quadriaxial fabrics, for example those that are tailored to have the reinforcement in four main directions, i.e. O degrees, 90 degrees, +45 and -45 degrees.

However, multiaxial fabrics having other directions between 45 degrees and 90 degrees may be employed.

Useful multiaxial fabrics may further comprise a chopped strand mat (CSM) layer, or different types of surface mats added on one side of the fabric and then it is referred to as combination products. The multiaxial glass fibre fabrics are normally range in weight from 100 g/m? to 2500 g/m?, such as from 200 g/m? to 1200 g/m}.

Useful glass fibre fabrics normally comprise various glass types, including but not limited to E-glass, S-glass, R-glass, H-glass, D-glass and ECR-glass fibres.

P307583NL 15

For hand-lay-up, the fabric is typically into the desired shape and embedded into a polymeric matrix comprising a resin component before the final shape of the product is made, whereas for industrial applications, a pre-reg process as set out herein below is prefearbly used.

The glass fibre fabric material may have different glass fibre dimensions and different thickness as well a being coated with various types of sizing. Normally, the diameter of a glass filament is about 3-25 um. Furthermore various sizes of rovings may be used, where the term roving is used in its conventional meaning, namely a bundle of glass fibre filaments.

Preferably the process further may comprise adding at least one porous polymeric matrix layer, and applying the prepreg material to at least one side of the foamed polymeric matrix layer.

This will result in less dense composites with higher insulation values.

The process according to the invention further comprises heating the composite material such that the polyfuranyl resin is flowing and curing. Preferably, where the polyfuranyl resin is provided as part of a particulate binder, the process according to the invention comprises the step of heating the composite material such that the gelled binder material is flowing and concurrently cures.

Applicants found that surprisingly that the pre-preg materials according to the invention allowed a thorough bond to the core layer, thereby also increasing the strength and cohesion of the core layer significantly, even at a pre-preg thickness in the range of from 0.1 to 0.8 cm.

Without wishing to be bound by any particular theory, it is believed that the polyfuranyl resins are particularly effective in wetting and permeating the surrounding layers before curing, thereby forming an infused composite material with significantly enhanced adhesion.

The materials according to the invention are advantageously prepared using an impregnation and gelation process, also known as a “pre-preg process”, wherein resin-impregnated and gelled fiberglass sheets are used in the formation of pre-preg sheets, which are then employed to form the composite.

In this process, a cloth material, in particular fiberglass cloth, is impregnated with a thermosetting polyfuranyl resin composition, which is then partially cured to induce gelation. The impregnated cloth may then be sheared to form so called prepreg sheets.

In order to enhance the adhesion of the resin to the fiberglass, often a coupling or sizing agent, such as a silane, is coated onto the surface of the fiberglass cloth, or individual fibres prior to impregnation. One of the particularly desirable characteristics of the present resin-impregnated fiberglass sheets is that the resin-impregnation covers the fibres and can be partially cured to a non-tacky state wherein the sheets can be handled for the lamination process, and roll storage.

This is often referred to as a B-stage, a cure state which allows the sheets to be sufficiently self-supporting to be laid up as a laminate, but not advanced enough in the state of cure that they

P307583NL 16 are rigid or non-flowable when heated, and they can be further cured to a final cure with heat and pressure to form a laminate structure as is well known in the art.

Pre-preg materials or sheets, may be directly employed, or removably placed on a polymeric backing sheet, which allows preparing larger coils of prepreg material, whereby each winding is divided by the backing sheet. The thus obtained gelled material may hence be employed directly in line, but usually are coiled, preferably supported by a backing sheet to avoid tacking of the individual layers. As pre-preg sheets retain part of their reactivity, sheets and/or coils are usually stored under controlled and suitable conditions.

For use, the prepreg sheets are then laid up with core materials, and laminated by subjecting them to heat and pressure, to fully cure the laid-up laminate with the core material, thereby forming a hardened surface layer and a bond with the core materials.

As indicated above, the lamination process normally includes the lamination of one or more core layers to provide necessary functionality.

Advantageously, sides and edges may be formed, thereby fully encapsulating the core layer, and giving it various shapes useful for the later use.

Accordingly, the resin-impregnated sheet is formed by providing a coil of the cloth, e.g. fibreglass material, which is unwound from the coil and continuously passed through a tank containing an aqueous solution or dispersion of the polyfuranyl resin, and then the coated or impregnated material is passed through a treater tower wherein heat is applied to drive off part of the water, and to the resin material is partially cured by initiating crosslinking. The cloth may be treated in two or more passes.

The thus obtained gelled material may directly be employed, or it may be coiled, preferably supported by a backing sheet to avoid tacking of the individual layers.

Thereafter, the partially-cured material is uncoiled and may either be applied in line, or cut into sheets of the desired length. Such sheets are also known as prepreg sheets, which may then be employed in the lamination process described above.

In forming laminate structures which include resin impregnated glass fibres and core layers, it was found that the polyfuranyl resins showed a surprisingly high adhesion to the core materials, and good penetration, in particular porous materials, thereby obviating the need for tack or adhesive layers, even when applied a thin layers thicknesses. Also, defects that can occur because of poor adhesion to glass fibre were minimized, while at the same time being extremely low in volatile organic compounds.

According to the present invention, a method and resultant article are provided which showed an optimal adhesion of the fibrous cloth impregnated with a resin to the interior layer

P307583NL 17 materials, in particular optimal adhesion of the impregnated resin layer to the core layers laminated thereto, even at a low layer thickness.

The heating of the uncured laid up composite material may be done by any suitable heating means. According to a continuously operating embodiment of the invention, the blend of mineral wool and polyfuranyl resin (or particulate binder comprising polyfuranyl resin) is pressed and heated from one or both sides, preferably pressed between a heated roll and a transportation belt, or more preferably, between heated rolls. According to another preferred embodiment, the composite to be cured is passed through a heating area, preferably through a furnace, at a temperature of from 100 to 180 °C, preferably of from 110 to 160 °C, yet more preferably of from 120 to 150 °C.

The composite materials may be formed by either a batch process or a continuous process.

According to a further preferred embodiment of the invention, the composite may be heated by radiation, such as microwaves to ensure that the core of the composite material also is heated. Alternatively, and most easily, the process may be performed in a batch-wise operation, wherein the mould with the composite material is heated, advantageously in an oven. Preheating of the polyfuranyl resin, the binder material or the blended material comprising polyfuranyl resin and mineral prior to introduction into the mould may also be performed, provided that in case of a thermoset binder, the heat supply should be limited to not allow the material to cure completely.

This allows adapting the curing cycle to the particulate binder material in the case of thermoplastic binders.

Preferably, the increased temperature refers to a temperature in the range of from 100 to 250 °C, preferably 120 to 200 °C, yet more preferably 130 to 150°C. The pressure may be any pressure that is suitably applied, and may range from ambient pressure or slightly above that, such as the pressure exerted by a vacuum bag, to a pressure of several tons per square meter, as suitably applied by e.g. a hydraulic press. Preferably the pressure ranges of from 0.1 MPa to 10

MPa, preferably from 1 to 7 Mpa, again more preferably from 2 to 6.5 Mpa. The unit pressure applied to the moulding material in a mould. The area is calculated from the projected area taken at right angles to the direction of applied force and includes all areas under pressure during the complete closing of the mould. The unit pressure, expressed in kg per square centimetre, is calculated by dividing the total force applied by this projected area. This is particularly suitable as a high-volume, high-pressure process suitable for a semi-continuous or continuous mode of operation. The time required to achieve a suitable strength and appearance depends largely on the kind of particulate binder used, but may range from several seconds, e. g. at high pressure and temperature, to several hours. Preferably, the time wherein the increased temperature and

P307583NL 18 pressure are applied ranges of from 1 s to 10 hours, more preferably from 5 s to 5 h, yet more preferably from 30 s to 3 h, again more preferably from 1 min to 1 h. Furthermore, the material may be pre-heated, and/or post-cured as required.

The present invention further relates to the use of the optionally shaped composite article as building or insulation sheet material, as decorative and/or functional wall panels, e.g. as noise suppression or as panels for wall insulation. The optionally shaped composite article may also be advantageously used for filling stud cavities in wall of roof insulation assemblies.

The composite material is resistant to attack by microbes and insects and thus does not require expensive chemical treatments. Also, the material is resistant to degradation from exposure to ultraviolet light as well as damp and/or freezing conditions.

In a third aspect, the invention relates to a composite material for use as a facade produced by the processes of the invention as described above.

In a fourth aspect, the invention relates to the use of a composite material as a building material, preferably as for use as sound and/or heat insultation building material.

Referring now specifically to the drawings, a composite panel according to the present invention as well as two conventional facade panels are illustrated in FIG. 1. This figure shows an exploded view, followed by a view sowing the layers, and a profile view of the panels.

The panel of Figure 1A represents a preferred embodiment of the present invention, as compared to conventional facade panels 1B and 1C. IN Figure 1A, and shows generally at reference numeral 10. The composite panel 10 includes surface layers 11 of a cladding material, and may further comprise a decorative and/or functional layers, such fire resistance layers, humidity and weather resistant layers, and may have aspects of as stone, glass, ceramic, wood, textiles paper or polymer foils or a combination of these materials. Any cladding material which can be bonded to a core can be used as the cladding surface. The preferred composite panel 10 of

Figure 1a includes a core layer 13 to which the surface layer 11 of cladding material is bonded via a pre-preg sheet 11A. The core layer 13 is preferably formed of a material which may define a tongue 13B which cooperates with a groove 13 in a groove member defined between spaced- apart extensions 13A and 13C. The core layer may advantageously comprise different layers, e.g.

OSB panels or similar structural materials, and various different coating layers.

Two conventional panels are also shown in Figure 1 B and 1C for comparison. These typically comprise gypsum board, two glass wool panels with a timber frame and intermittent OSB panels, an air-filled cavity with a mounting system, and solid outward facing panel (1B); or a concrete sheet, a PIR HR insulation foam layer, an air cavity and a brick work layer (1C).

As shown in FIG. 2, an attaching portion 14 of the core layer may project outwardly beyond one side edge of the surface layer 11. This attaching portion 14 provides an exposed, solid

P307583NL 19 structure through which fasteners (not sbown) such as nails, screws or bolts can be extended into a supporting structure . Advantageously, the length of the attaching portion 14 matches the length of an overhang portion of the surface layer 11 over the opposite side of the core layer 12. Hereby, opposite longitudinally-extending side edges of the composite panels 10 may complement each other, so that a plurality of composite panels 10 can be placed side-by-side in a complementary, interlocking array. Fasteners may advantageously be placed into the attaching portion 14 at any point and with any spacing necessary to achieve a required degree of attachment.

The use of fasteners with flat heads or countersinking is desirable to achieve a flat, regular surface on which the adjacent surface layer 11 will be supported, and reddening adhesives or support members unnecessary. Holes for fasteners such as screws or bolts are advantageously preformed during manufacture, thereby preventing leakage of water, or cold bridges.

By reference back to FIG. 2, it can be seen that the attaching portion 14 may extend around onto the end edge of the core layer 13, for combination with a recess (15). Thus, opposite laterally-extending side edges of the composite panel 10 complement each other, so that a plurality of composite panels 10 can be placed end-to-end in a complementary, interlocking array.

Referring now to FIG. 3, a composite panel 10 is shown having a similar structure, but wherein the surface layer 11 of cladding material and the core layer 13 are oriented such that the surface layer 14 may project outwardly. An attaching portion 15 of the core layer 13 may comprise part of a groove 15 defined by spaced-apart extensions 11 and 12. Fasteners 16 are extended through the attaching portion 24, which resides between the edge of the cladding layer 21 and the innermost portion of the groove 25 in the manner shown in FIG. 3.

Referring now to FIG. 4, an alternative construction is shown wherein a composite panel 10 includes a surface layer 11 of cladding material supported on first and second spaced-apart core layer segments 13. The first core layer segments each include a groove 15, for receiving a fastening element 15. The core layer segment 13 carrying the groove 14 can be positioned as shown in FIG. 4 to receive fasteners, if desired.

A composite panel is described above. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation--the invention being defined by the claims.

EXAMPLES

The following examples are provided to exemplify the invention.

Example 1-Pre-preg: A pre-preg material was prepared as follows: A liquid polyfuranyl resin composition comprising a furan resin dispersion in water, further comprising an acidic curing

P307583NL 20 agent, was applied using a resin bath and scraper blade to a glass fibre fabric exhibiting cross lapping, having a weight of 250 g/m!. The impregnated mat was then dried for 150 seconds at 110°C in a series of calenders, to reduce the water content of the resin, and to pre-cure the resin to form a pre-preg sheet. The pre-preg sheet was then placed onto a non-stick polypropylene backing sheet, and rolled onto a storage roll.

Example 2 — Facade panel : Then suitably sized sheets were cut from pre-preg material.

Then the following sandwich structure was prepared: an interior decorative surface film; a pre- preg sheet as obtained from example 1, without a backing sheet; a core layer of recycled PET foam; and a third pre-preg as obtained from example 1, without a backing sheet. Each glassfibre resin prepreg sheet had a nominal layer thickness of 2.5 mm and a density of 1950 kg/m?; the foamed PET core with a layer thickness of 145 mm and a core density of 50 kg/m3. The resultant sandwich construction was then placed in a moulding press, which was operated to press and heat the sandwich, and under vacuum. The moulding press was controlled in order to provide a steam vent step at different times during the curing process. After the preparation and curing of the sandwich, the resultant sheet was coated at an exterior surface with an UHS coating layer with a total layer thickness of 200 um and a consumption of 200 g/m?. The final product has a total thickness of 155 mm. The resultant rectangular panel is further referred to as facade panel herein.

Example 3 - Fire Test: A facade panel prepared according to Example 2 was provided and its reaction to fire evaluated by the B 51 DO standard. The results showed that the composite facade panel according to the invention was surprisingly resilient to fire penetration, produced remarkably little smoke and no flaming droplets. These properties in combination allow the material to provide superior resistance to fire and are ideally suited for architectural uses in housing and office space provision.

Surprisingly, the composite material according to the invention was found to achieve a flame retardancy rating of B S1 DO according to NEN-EN 13501-2018 SBi. This renders this material particularly suitable for use in articles of sustainable and recyclable fire-resistant furniture, a building exterior or interior panel, or an exterior or interior finishing material.

Example 4 — CO,/kg calculation: The facade panel according to example 2, however including an OSB board as outlined in Figure 1A was compared with representative insulation facade panels of known art. The facade according to example 1 was compared to an insulated HSB facade (as in Fig 1B) consisting of the following sequential layers: {1) 13 mm thick gypsum board, (2) 40 mm thick glass wool isolation with timber frame, (3) 18 mm thick orientated strand board, (4) 170 mm thick glass wool isolation with timber frame, (5) 18 mm thick orientated strand board, (6) 40 mm thick air-cavity with mounting system and (7) 12 mm thick solid surface face panel.

P307583NL 21

As can be seen from FIG. 1, the facade according to the present invention is advantageously (1) lighter, (2) thinner) and requires less CO, emissions/kg to produce than conventional insulted HSB facades.

The facade panel according to example 2 was also compared to an insulated concrete facade consisting of the following sequential layers: (1) 130 mm thick concrete layer, (2) 145 mm thick PIR HR insulation foam, (3) 40 mm thick air cavity and (4) 90 mm thick brick work layer. The facade panel according to example 2 was significantly thinner, lighter per surface area covered, while providing at least the same, if not better insulation effect, at least the same flame resistance.

Claims (17)

22 NL 2 033 573 Conclusions 1. Composite material for use as insulation material and as cladding material for facades and/or roofs, comprising: a. a first layer comprising a cross-linked polyfuranyl resin and mineral fibres (1); b. a second insulating layer comprising an insulating core material (2); and c. a third layer comprising a cross-linked polyfuranyl resin and mineral fibres (3); d. wherein the second layer (2) is provided in an intermediate position between the first layer (1) and the third layer (3), and is bonded to the first layer and to the third layer. 2. Composite material according to claim 1, wherein the insulating core material comprises a mineral wool composition and/or a thermoplastic foam composition. 3. Composite material according to claim 2, wherein the mineral wool is selected from glass wool, rock wool, and/or ceramic fibre wool. 4. Composite material according to claim 2, wherein the foamed polymer composition is selected from a foamed polyurethane, from a foamed polystyrene, and/or from a foamed polyester. 5. The composite material of claim 4, wherein the foamed polymer composition comprises polyethylene terephthalate. 6. Composite material according to claim 5, wherein a layer of a thermoplastic foam material is used, wherein the foam material is a material based on polyester, and wherein the polyester is virgin or recycled polyethylene terephthalate or a mixture of the two foregoing, and wherein the foam material is characterised by elongated cells having an aspect ratio greater than 1.5, and by a density in accordance with ISO 845 of less than 150 kg/m?, and preferably less than 80 kg/m?®, and by a thermal conductivity of less than 0.032 W/mK, measured in accordance with ISO 12677. 7. The composite material of claim 5, wherein additional polymer blends are present in the layer formed from the thermoplastic foam material in an amount of not more than 40% by weight, and wherein the additional polymer blends are selected from the group consisting of polyalkylene terephthalates, polylactic acid, polycarbonate, polyolefins, polyacrylates, polyamides, thermoplastic elastomers, core-shell polymers, liquid crystal polymers (LCP), or a mixture of the foregoing. 23 NL 2 033 573 8. Composite material according to any one of claims 1 to 6, further comprising a structural layer or a structural sheet. 9. Panel element comprising a composite material according to any one of claims 1 to 8, for a wall or a roof of a building, further comprising a vapour-impermeable skin and/or a reinforcing or reinforcement layer. 10. A panel element as claimed in claim 9 for forming part of a facade or of a roof, the panel comprising an overhanging portion extending beyond a second of each of the panels to secure each of the adjacent panels to another panel during installation and to form an air, thermal and moisture barrier between each of the adjacent insulation panels. 11. A panel as claimed in claim 9 or claim 10, comprising a core layer formed by the first through third layers comprising: a. an integrally formed and outwardly extending connecting flange defined through the full thickness of the panel, and proximal to the outer surface around at least two adjacent side edges of the panel, for receiving elongated fasteners through the full thickness of the panel and into the underlying support member; b. two spaced apart elements formed on and extending along the respective adjacent sides of the connecting flange, spaced from the surface and defining a groove between them; c. a complementary tongue projecting outwardly from and extending along respective adjacent sides of the panel for receipt in a groove of a complementary adjacent structural member; the connecting flange being provided between the groove and the surface so as to enable the groove to receive therein the tongue of the complementary structural member. 12. A panel as claimed in claim 11 further comprising means for connecting the panel to an underlying support using fasteners through the connecting flange. 13. A panel as claimed in claim 11 or claim 12, wherein the first and second alternately interlocking tongues and alternately interlocking grooves comprise dovetail elements. 24 NL 2033573 14. A panel as claimed in any one of claims 11 to 13, wherein the panel is substantially rectangular or square in shape. 15. A method for manufacturing a composite panel according to any one of claims 1 to 14, comprising: a. impregnating a sheet comprising woven mineral fibres with a liquid polyfuranyl resin composition to provide an impregnated sheet, b. subjecting the impregnated sheet to conditions which induce gelling of the polyfuranyl resin composition, thereby forming a pre-preg sheet; c. optionally applying a pre-preg sheet to a transport medium, preferably a backing sheet, and optionally removing the pre-preg sheet from the backing sheet; d. providing at least one core layer between two pre-preg sheets, in such a manner that the upper surface of the second sheet is opposite the lower surface of the first sheet, thereby forming a sandwich structure; and e. subjecting the sandwich structure to conditions which allow the gelled polyfuranyl resin composition to substantially completely cure, preferably comprising heating the sandwich structure to a specified temperature and for a specified period of time which results in cross-linking and growth of the chains in the polyfuranyl resin composition. 16. A method according to claim 10, further comprising adding an additional layer consisting of a solid material, preferably a plywood composite material next to a pre-preg composite layer, prior to step (e), in order to obtain a reinforced or reinforced composite material. 17. Use of a composite material according to any one of claims 1 to 9, as a building material, preferably for use as a sound and/or thermally insulating building material.