Cross laminated material and method for producing material, and use

Abstract

The application relates to a material and a method for producing the material. The material comprises at least a structural component and a filler component, and the material is cyclic loading resistant material. The method comprises forming individual components and assembling the components to form the material. Further, the application relates to a use of the material.

Description

[0001] CROSS LAMINATED MATERIAL AND METHOD FOR PRODUCING MATERIAL, AND USE

[0002] FIELD

[0003] The application relates to a material , which is cyclic loading resistant , defined in claim 1 and a method defined in claim 9 for producing the material , and a use of the material defined in claim 13 .

[0004] BACKGROUND

[0005] Manufacturing of bio-based solid foams by the liquid foam route is showing up as a promising method to obtain new lightweight materials . Presently, foams produced through the known methods demonstrate no or very little resistivity to cyclic loading in their structure , a characteristic attributed to their biobased and biodegradeable nature . In various applications , there is a growing need for a lightweight composite material with properties similar to polyurethane that exhibits resilience against cyclic loading . Significantly, there is a need for natural foam like materials that outperform their counterparts with isotropic structures in terms of resistance to cyclic loading .

[0006] One way to produce biodegradeble materials enduring cycl ic loading i s to use bioplastics . These materials have four drawbacks : a) they are too soft and al l the air from the material is squeezed out ; b) they are too hard and the movement is very small i . e . Young' s modulus is large ; c) they are not really biodegradeable and take years to biodegrade in industrial composting; d) high price and dif ficulty to produce in large quantities . All the known single component materials commonly produced for industrial and engineering purposes have one or more of these limitations .

[0007] Biodegradeable materials with resistance to cyclic loading are not man-made . Oak, cork or similar floor panels are used as it feels soft under the foot compared to stone flooring . Here , the deformation of the floor tile is small . An example of a larger deformation with resistivity repeated cyclic motion is a bow that shoots arrows . The wooden part is long allowing large motion in the total scale of the bow-item while the wood-material itself deforms only small amounts , comparable to the example of wood tile flooring .

[0008] Laminated structures and reinforced structures contain two different materials e . g . steel reinforced concrete , carbon fiber reinforced polyurethane . These materials utili ze the best aspects of each other . For example , one material provides the elasticity and the other the softness or structural strength . These materials are very hard to recycle and do not biodegrade . The principles are not directly transferrable to biomaterials .

[0009] The biggest drawback of the biomaterials is the lack of soft materials with large breaking threshold . In other words , there are no biomaterials that feel soft when squeezed with repeated moderate loading ( 3- 65 kPa) but do not break under large forces ( 65-330 kPa ) . Nonbiobased materials like polyurethane have these properties .

[0010] OBJECTIVE

[0011] The obj ective is to solve the above problems . Further, the obj ective is to disclose a new-type material which is cyclic loading resistant . Further, the obj ective is to produce the material which is resistant for mechanical degradation and simultaneously biodegradeable . Further, the obj ective is to disclose a method for producing a cyclic loading resistant material . SUMMARY

[0012] The material , method and use are characteri zed by what are presented in the claims .

[0013] The material comprises at least a structural component and a filler component .

[0014] The method for producing the material comprises forming individual components , and assembling the components to form the material , and the individual components comprises at least a structural component and a filler component .

[0015] The material may be used in packaging, cushioning, shock absorbing, construction, heat insulation, sound insulation, manufacture of shoe , insole or slipper, or the like , or any combination thereof .

[0016] BRIEF DESCRIPTION OF THE DRAWING

[0017] The accompanying drawings , which are included to provide a further understanding of the invention and constitute a part of this specification, illustrate some embodiments of the invention and together with the description help to explain the principles of the invention . In the drawings :

[0018] Fig . 1 shows one material comprising a structural component , filler component , binding component and base component according to the invention,

[0019] Fig . 2 shows some examples of structures of the material ,

[0020] Fig . 3 shows an example of a FEM simulation of the structural component , and

[0021] Fig . 4 shows a performance of the material according to one embodiment .

[0022] DETAILED DESCRIPTION

[0023] The material comprises at least a structural component and a filler component , and the material is cyclic loading resistant material . Preferably, the structural component protects the filler component and / or the filler component protects the structural component. Further, preferably, the filler component provides memory and lateral rigidity. In one embodiment, the material is a foam, foam-based or foam composite product. In one embodiment, the material is formed from bio-based starting materials.

[0024] Preferably, the material comprises at least a bio-based structural component and a bio-based filler component, and the material is cyclic loading resistant material. The structural component is formed from thin sheets, having thickness of 0.01 - 1 mm, which are cross laminated, and the sheets are mold-ed, bent, formed and / or machined to make an inverted double wave shape.

[0025] In this context, cyclic loading refers to the process, in which stress or strain is applied to a material repeatedly over time, causing stress in-tensities to locations on the material. The cyclic loading may mean any cyclic loading, repeated stress, cyclic load or the like. In this context, cyclic loading resistance means any resistance to the cyclic loading or to mechanical degradation caused by repeated stress or strain. Then mechanical properties, such as resilience, yield stress, yield strain, Young's modulus or elastic deformation region, do not degrade under cyclically repeated stress or strain.

[0026] In this context, the material means any material, sheet, structure, layered product, foam product or the like, which comprises at least structural component and filler component. Preferably, the material is resistive to mechanical degradation under cyclic loading. The material may consist of 2-4 components, such as structural component, filler component, binding component and base component, and the material comprises at least the structural component and the filler component. The material comprises at least the structural component and the filler component, and additionally the material may comprise the binding component, the base component or both. In one embodiment, the material is formed from the bio-based starting materials. The structural component, filler component, binding component and / or base component may comprise one or more components. Further, the material can comprise also other materials or material components, e.g. one or more additives. In one embodiment, the material has a two- dimensional or three-dimensional structure. The material may comprise a desired shape. In one embodiment, the material may be any material, structure, article, product, or the like or any combination thereof. In one material comprises layers of the components. In one embodiment, the material comprises at least two material layers, and preferably more than two material layers. The material can comprise the material layers one on top of the other.

[0027] In one embodiment, the material is a foam composite material. In one embodiment, the material is a solid foam or a solid foam containing material / product . In one embodiment, the material comprises at least one solid foam component, e.g. structural component and / or filler component.

[0028] In one embodiment, the structural component is selected from the group consisting of polyethylene, carbon fiber, wood, leaf, paper, cardboard, foamwood, similar material, and any combination thereof. In one embodiment, the structural component is bio-based material. In one embodiment, the structural component is selected from a group consisting of wood, leaf, paper, cardboard, foamwood or any combination thereof. The structural component may comprise one or more components or agents. In one embodiment, the structural component can be same material than the filler component or turn into the filler component gradually in time and / or space. Without the filler component the material will break as local stresses increase over the breaking limit. Preferably, in one embodiment, the structural component provides the instant elastic response to external mechanical loading and acts like a spring component. Preferably, the purpose of the structural component is to protect the filler component from an extreme deformation by carrying part of the load. In addition, the structural component may store deformation work to potential energy enabling, partial, recovery of the deformation. The structural component can be compressed and / or thermoformed fully, partially or left uncompressed during the fabrication process.

[0029] In one embodiment, the structural component can be described as a sparse open cell foam. In one alternative embodiment, the structural component can be a structure of beams, plates, rods, spheres, ellipsoids and / or rectangles. The structure of the structural component can vary based on the observation length scale and manufacturing process, e.g. an engineered structure or porous material.

[0030] In one embodiment, the structural component alone has high air content compared to amount of solids, e.g. 70 - 99.9 vol-% of the pure structural component material is empty or air. Due to the high air content the structural component can collapse in a controlled manner providing large movement and large deformations in an item scale. While in the collapsed form, the structural component also creates full solid blocks 0.1 - 30 % of the original volume, that endure high loads.

[0031] In one embodiment, the structural component comprises thin sheets, e.g. below 3 mm, of natural fibre materials. In one embodiment, thickness of the sheets is 0.01 - 1.0. mm. In one embodiment, the sheets are stacked and joined together with a binding component. In one embodiment, grains of the sheets are oriented at angle less than 90 degrees, e.g. 30 - 80 degrees. In one embodiment, the sheets are molded, bent, formed and / or machined to form a desired shape, e.g. wave shape. In one embodiment, the structural component comprises a laminated material where thin sheets of wood, leaf, paper, cardboard or foamwood are cross laminated to make the structure. In one embodiment, 1 - 10 thin sheets, preferably 2 - 10 thin sheets, are used in the cross lamination. In one embodiment, the thin sheets have thickness of 0.01 - 1 mm. In one embodiment, the sheets are cross laminated, and grains of the sheets are oriented at angle 30 - 80 degrees. In one embodiment, the structural component is formed from sheets of thin layers, e.g. <3mm, which are molded, bent, formed and / or machined to make an inverted double wave shape. In this context, the inverted double wave shape refers to a shape where two waves are on top of each other aligned in a way that the lower wave crest is in contact with the upper wave's trough. According to an example, the shape can comprise sine waves where the subsequent waves have 0.5 wave length phase shift. However, the shape is not limited to sine waves. In one embodiment, two or more wave layers with space between them are bridged laterally with the same supporting structural component resulting in a meshed structure, with empty spaces inbetween them. For example, two parallel wave structures, e.g. layers, next to each other may be connected with a similar wave structure, e.g. layer, which is rotated 90 degrees. In one embodiment, the empty spaces between the layers are filled with the filler component, which preferably is bio-based / natural biodegradable foam and thus will form a bio-based biodegradable composite material.

[0032] In this context, grains of the sheets mean the longitudinal orientation of particles constituting the sheet. For example, in the sheet material, e.g. veneer, paper, cardboard or foamwood, the grains of sheet refer to direct ion / orientation of f ibers in the sheet of the structural material . The degree of orientation for the grains of the sheets refers to a direction relative to the grains of the sheet in the previous layer . For example , in the cros s laminating, an angle i s defined as angle measured between the grains of subsequent layers of sheets . According to an example , the angle between the grains of subsequent cross laminated sheets is less than 90 degrees , preferably 30 - 80 degrees .

[0033] In one embodiment , the filler component can consist of liquids , chemicals , fibers or other particles or any combinations thereof . In one embodiment , the filler component is selected from the group consisting of styrofoam, polyurethane ( PU) , foamwood, similar material , and any combination thereof . In one embodiment , the filler component is foamwood . Preferably, the filler component is bio-based material . The filler component may comprise one or more components or agents . In one embodiment , the filler component is a foam l ike porous material with open or closed cells . In one embodiemt , the fi ller component can be inserted as l iquid suspension or as solidified form . In one embodiment , the filler component can be same material as the structural component or turns into the structural component gradually in time and / or space . Preferably, in one embodiment , the filler component provides the delayed elastic response and tactile response of softness . Preferably, the purpose of the filler component is to hide the structural component and provide pleasant mechanical touch and feel , while for example the base component provides the texture feel . The filler component can also provide so called memory effect as the filler component does not recover if the local deformation exceeds 30 % . Further, the filler component can also bring stability to the spring like behaviour . Lateral movement perpendicular to loading direction is slowed down and reduced . Also , the filler component enables the alignment of structural components when the sheets of the material are assembled to a stack with or without the binding component . In one embodiment , the filler component acts as a 3D shock absorber . The filler component can protect the structural component by redistributing the load to a larger area progressively as the loading increases .

[0034] In one embodiment , the material further comprises a binding component and / or a base component .

[0035] In one embodiment , the binding component is selected from the group consisting of glue , silicon, epoxy, latex glue , similar material , and any combination thereof . In one embodiment , the binding component comes from natural sources and is biodegradable . In one embodiment , the binding component is bio-based material . The binding component may comprise one or more components or agents . Preferably, the binding component can act as a glue that binds all , some or none of the components together . The glue can bind also two or more components of similar type together, e . g . two structural components can be bound together .

[0036] In one embodiment , the base component is selected from the group consisting of fabric, fiber cloth, cork, wood, hemp, foamwood, polyurethane , similar material , and any combination thereof . In one embodiment , the base component is bio-based material . The base component may comprise one or more components or agents . Preferably, the base component protects the other components from ambient hazards such as but not restricted to : water, moisture , bacteria, heat and fire entirely, partially or for a finite time dependent on the use . The combination of protection against hazards can include al l , some or none depending on the use . In one embodiment , the base component is arranged on a top surface and / or a bottom surface of the material to protect the other component or components . In one embodiment , the base component is arranged at least on the top surface of the material. In one embodiment, the base component is arranged at least on the bottom surface of the material .

[0037] In one embodiment, the material comprises foam component or foam-like component, such as the structural component, filler component, binding component and / or base component. In one embodiment, at least one of the components is the foam component or foam-like component. In one embodiment, the structural component, filler component, binding component and / or base component comprises foam material or foam-like material. In one embodiment, the structural component, filler component, binding component and / or base component comprises foamwood or is formed from foamwood. In this context, foamwood may be any foam material or foamed material, e.g. a solid foam, which comprises at least bio-based material, e.g. biomass, bio-based residue material, wood, wood-based material, forest-based material, cellulose, treated bio-based material, untreated bio-based material or any combination thereof, and in one embodiment wood, wood-based material, forest-based material and / or cellulose. In one embodiment, the foamwood is produced according to patent application WO 2022 / 074289. In one embodiment, the solid foam is an anisotropic solid foam. In one embodiment, the bubbles of the anisotropic solid foam have been shrunk and deformed in off-length directions to form the shaped bubbles, e.g. elongated bubbles, in the foam.

[0038] In one embodiment, the material comprises four components, such as the structural component, filler component, binding component and base component. In one embodiment, any, some, all or none of the four components can be foam or foam-like component or formed from the foam-like material, e.g. foamwood. In one embodiment, the foam-like component is formed according to the method described in patent application WO 2022 / 074289. In one embodiment, any, some or all of the four components can be the foam-like component or formed from the foam-like material, e.g. foamwood, as described in patent application WO 2022 / 074289, with one or more additive added during the foam making. In one embodiment, the said additive is natural rubber latex, rubber, or xanthan gum. In one embodiment, the said additive is hemp, cotton, linen, or wool. In one embodiment, different additives are used in different components of the material .

[0039] In one embodiment, an additive can be added to the material or at least one of the components, such as the structural component, filler component, binding component and / or base component. In one embodiment, the additive is selected from the group consisting of natural rubber latex, rubber, and / or xanthan gum. In one embodiment, the additive is added before the foaming. In one embodiment, an amount of the additive is 10 - 30 % by weight in the foam material.

[0040] In one embodiment, the filler component is foamwood, where the elastic properties is improved with the additive.

[0041] In the method for producing the material, individual components are formed, and the components are assembled to form the material, which is cyclic loading resistant material, and the individual components comprises at least a structural component and a filler component. In one embodiment, the method comprises forming the individual components, at least the structural component and filler component and optionally also binding component and / or base component, and assembling the components to form the material.

[0042] Preferably, the method for producing the material comprises forming individual components, and assembling the components to form the material, which is cyclic loading resistant material. The individual components comprise at least a bio-based structural component and a bio-based filler component. The structural component is formed from thin sheets, having thickness of 0.01 - 1 mm, which are cross laminated, and the sheets are molded, bent, formed and / or machined to make an inverted double wave shape.

[0043] In one embodiment, the structural component is formed from thin sheets, and the sheets are stacked and joined together with a binding component. In one embodiment, grains of the sheets are oriented at angle less than 90 degrees. In one embodiment, the sheets are molded, bent, formed and / or machined to form a desired shape, e.g. wave shape.

[0044] In one embodiment, the material is formed from layers of the components, e.g. at least from the structural components and filler components. In one embodiment, the method comprises assembling the material layer by layer. In one embodiment, the method comprises assembling the first component layer by the second component layer, and repeating the assembly of the layers. In one embodiment, the filler component layers are wet during the assembly. In one embodiment, the filler component layers are dry during the assembly.

[0045] In one embodiment, two or more material layers are arranged one on top of the other to form the material, e.g. material structure. In one embodiment, the material layer is formed from at least one component or the components, such as the structural component, filler component, binding component and / or base component. Any suitable method can be used to form the material layer.

[0046] In one embodiment, the method comprises shaping the structural component and depositing the filler component between the structural component layers. In one embodiment, the method comprises depositing the filler component between the structural component layers. In one embodiment, the method comprises fabricating the structural component structure and casting the filler component inside the structural component, e.g. the structural component voids.

[0047] In one embodiment, the method comprises assembling the material in a continuous process, roll-to- roll process, or reel-to-reel process.

[0048] The material can be manufactured using any combination of the method described in this description. The method can be used to produce any material. The material can be manufactured using the formulated mixtures .

[0049] In one embodiment, the material achieves elastic behaviour with bounce-back characteristics, where the structural component, i.e. the structural component structure, provides the mechanical support and the filler component, e.g. foam filler, acts as a shock absorber thus complementing each other properties. In one embodiment, the material is arranged to withstand at least 100,000 cycles of at least 240 kPa loads without losing its elastic properties.

[0050] In one embodiment, the material is used for packaging, cushioning, shock absorbing, construction, heat insulation, sound insulation, manufacture of shoe, insole or slipper, or the like, or any combination thereof .

[0051] The material and the method allow, unlike the previous solutions, the production of cyclic resistive biomaterial in continuous fashion. The potential uses are in packaging, textile, footwear and construction industry. In one embodiment, the material is used to form a shoe, shoe insole, shoe sole or slippers. In one embodiment, an inner or / and outer sole of the shoe is one specific use, which is suitable for this type of material and production process. In one embodiment, the shoe insole is formed of the material, where a top-layer is covered with soft material , such as a fibre cloth, leather, or wood-foam, for making the material breathable and comfortable , and a bottom-layer is covered with a sti ff material , such as hemp, thin veneer sheets , or hardened foam, for making the material stable . In one embodiment , the material is used as an alternative to polyurethane or polyethylene foams in different uses or applications . For example , replacing the polyurethane foams currently used with the same feel ing at the same price to the foot requires in-depth understanding of the materials and production techniques , and thus it is highly non-trivial solution as there are no similar compostable materials .

[0052] Thanks to the invention, the material with cyclic loading resistant can be produced from desired starting materials , such as biobased materials and / or compostable materials . The material is resistant for mechanical degradation under cyclic loading . Preferably, the material is biodegradeable material . Further, foam-based material or foam material , which is cyclic loading resistant , can be achieved easily .

[0053] The method offers a possibility to produce the material easily, and energy- and cost-effectively . The present invention provides an industrially applicable , simple and affordable way to produce the different materials . The method is easy and simple to reali ze in connection with different production processes .

[0054] EXAMPLES

[0055] The examples below, accompanied by the figures , aim to provide some exemplary insights into the invention ' s construction, production and utili zation . It should be noted that while specific examples are provided, they do not represent the sole forms in which the invention may be implemented . Equivalent functions and structures can be achieved through various alternative examples .

[0056] The material , which is a cycl ic loading resistant , is formed from at least the structural component and filler component . Further, the material can comprise the binding component and / or base component . The material can be formed from suitable starting materials , e . g . bio-based material components , for achieving the cyclic loading resistant material , which is biodegradeable . According to the example , the material i s a foam composite material comprising at least one foam composite material .

[0057] According to one example , the structural component comprises thin sheets , e . g . below 3 mm, of natural fibre materials , and the sheets are stacked and j oined together with the binding component , which comes from natural sources and is biodegradable . The grains of the sheets are oriented at angle less than 90 degrees , and are molded, bent , formed, machined to make an inverted double wave shape . The layers with space between them are bridged laterally resulting in a meshed structure with empty spaces , and the empty spaces between the layers are filled with the filler component which is bio-based / natural biodegradable foam . This will form a bio-based biodegradable composite material .

[0058] The method for producing the material comprises forming the individual components , at least the structural component and filler component and optionally also binding component and / or base component , and assembling the components to form the material . In one example , the structural component is shaped, and the filler component is deposited between the structural component layers . In one example , the structural component structure is produced, and the filler component is casted inside the structural component voids . Fig . 1 - 4 present some embodiments of the materials and the components and some embodiments of performances of the material .

[0059] Example 1

[0060] Fig . 1 presents the material comprising four components , i . e . structural , filler, binding and base components . A cyclic loading tests was performed using a compression, and the cyclic loading was performed with a weight . Typically, the filler material would be destroyed by crushing by the weight , but now the filler component was protected by the structural component . The base component at the top surface , and also at the bottom surface , protected the filler component from moisture . It was observed that the local stress would break the structural component without the load redistribution of the filler component . The structural component delivers elastic response , while the filler component undergoes compression in high load areas and remains protected in low load zones . This seamless transition of the fil ler component from compressed to intact redistributes the load, preventing the structural component failure under the weight . Notably, either component alone would fail under similar stress .

[0061] Example 2

[0062] Fig . 2 presents some examples of ideali zed structural foam and structures , which can be compressed to shape layer by layer . In Fig . 2 the structural components are shown depicting them as large-scale structures with centimeter-si zed unit cells . While they are shown on this scale , structures as small as 1 mm or even 1 pm are feasible . For example , a hot roll press facilitates the creation of single layers of these structures . Example 3

[0063] Fig . 3 presents a Finite Element Method ( FEM) simulation of the structural component . Arrows show typical places where the component breaks without the filler component . In Fig . 3 , the FEM simulation visuali zes one ideali zed structural component . The striped sine wave structure delineates the voids and pathways for filler penetration . The arrows highlight areas of maximum stress and strain, typically indicating potential breakage points . The role of the f iller component is paramount in mitigating locali zed stress and strain within the structural component .

[0064] Example 4

[0065] Fig . 4 presents the performance of the material , which comprises the structural , filler, binding and base components , under cyclic loading in comparison to the filler component alone . The cyclic loading is repeatedly changed between zero and maximum loading . In picture a) the two upper curves show the performance of the protected foam compared to the unprotected reference case without any optimi zation of the material structure . Both cases , unloaded zero load and loaded maximum load cases are in much higher level throughout the cyclic loading . The loading lasts thousands of cycles and is indicated in the units of a typical sample lifetime . Pictures b) and c ) show the unloaded and loaded thickness after loading cycles compared to the initial thickness for the material and the reference material respectively . The increased soft region is evident from the comparison of the pictures . The substantial enhancement of the elastic region (displacement ) underscores the material ' s suitability for textile applications .

[0066] The manufacturing devices and techniques of the process used in the examples are known per se in the art , and therefore they are not described in any more detail in this context .

[0067] The material is suitable in different embodiments for using in different uses and applications . The method is suitable in different embodiments for producing desired materials from different starting materials .

[0068] The invention is not limited merely to the examples referred to above ; instead many variations are possible within the scope of the inventive idea defined by the claims .

Claims

CLAIMS1. A material, c h a r a c t e r i z e d in that the material comprises at least a bio-based structural component and a bio-based filler component, and the material is cyclic loading resistant material, and that the structural component is formed from thin sheets, having thickness of 0.01 - 1 mm, which are cross laminated, and the sheets are molded, bent, formed and / or machined to make an inverted double wave shape.

2. The material according to claim 1, c h a r a c t e r i z e d in that the material further comprises a binding component and / or a base component.

3. The material according to claim 1 or 2, c h a r a c t e r i z e d in that the structural component is selected from the group consisting of wood, leaf, paper, cardboard, foamwood, and any combination thereof.

4. The material according to any one of claims l to 3, c h a r a c t e r i z e d in that the filler component is selected from foamwood.

5. The material according to any one of claims 1 to 4, c h a r a c t e r i z e d in that the binding component is selected from the group consisting of glue, silicon, epoxy, latex glue, and any combination thereof.

6. The material according to any one of claims 1 to 5, c h a r a c t e r i z e d in that the base component is selected from the group consisting of fabric, fiber cloth, cork, wood, hemp, foamwood, polyurethane, and any combination thereof.

7. The material according to any one of claims 1 to 6, c h a r a c t e r i z e d in that the structural component comprises thin sheets of natural fibre materials, and the sheets are stacked and joined together with a binding component.

8. The material according to any one of claims 1 to 7, c h a r a c t e r i z e d in that the structural component is formed from thin sheets, having thicknessof 0.01 - 1 mm, which are cross laminated, and 2 - 10 thin sheets are cross laminated and grains of the sheets are oriented at angle 30 - 80 degrees, and the sheets are molded, bent, formed and / or machined to make an inverted double wave shape.

9. A method for producing the material, c h a r a c t e r i z e d in that the method comprises forming individual components, and assembling the components to form the material, which is cyclic loading resistant material, and the individual components comprises at least a bio-based structural component and a bio-based filler component, and the structural component is formed from thin sheets, having thickness of 0.01 - 1 mm, which are cross laminated, and the sheets are molded, bent, formed and / or machined to make an inverted double wave shape.

10. The method according to claim 9, c h a r a c t e r i z e d in that the material is formed at least from the structural component and filler component, and optionally also from binding component and / or base component .

11. The method according to claim 9 or 10, c h a r a c t e r i z e d in that the method comprises depositing the filler component between the structural component layers.

12. The method according to any one of claims 9 to 11, c h a r a c t e r i z e d in that the method comprises fabricating the structural component structure and casting the filler component inside the structural component voids.

13. A use of the material according to any one of claims 1 to 8, c h a r a c t e r i z e d in that the material is used for packaging, cushioning, shock absorbing, construction, heat insulation, sound insulation, manufacture of shoe, insole or slipper, or any combination thereof.

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