Composite insulation materials, compositions and manufacturing thereof

Abstract

The present invention relates to a composition comprising an expanded insulation material, and a curable binder precursor; wherein the curable binder precursor comprises one or more epoxidized vegetable oils and one or more organic acids. The invention further relates to a composite insulation material comprising an expanded insulation material and a cured product of the curable binder precursor as provided herein, manufacturing processes of the composite insulation material, and articles comprising at least one of such composite insulation materials.

Description

[0001] COMPOSITE INSULATION MATERIALS, COMPOSITIONS AND MANUFACTURING THEREOF

[0002] FIELD OF THE INVENTION

[0003] The present invention is broadly situated within the field of insulation materials. In particular, the invention is directed to compositions, comprising an expanded insulation material and a curable binder precursor, and manufacturing methods thereof. The invention further relates to composite insulation materials, obtained by curing the aforementioned compositions, and articles made therefrom.

[0004] BACKGROUND OF THE INVENTION

[0005] Insulation materials are critical components in building construction, industrial applications, and various other fields where thermal management is essential. Traditional insulation materials, such as fiberglass, mineral wool, expanded polystyrene (EPS), extruded polystyrene (XPS), and polyurethane foams, are widely used due to their thermal resistance and cost-effectiveness. These materials typically rely on various binders to maintain structural integrity and performance.

[0006] Curable binder precursors play a crucial role in the manufacture of insulation materials by binding the insulating fibers or particles together upon curing to form a cohesive and stable structure. Conventional binder formulations include formaldehyde-based resins, phenolic resins, and polyvinyl acetate. However, these binders often present several limitations, including potential health hazards, environmental concerns, and suboptimal performance under certain conditions.

[0007] Formaldehyde-based resins, for instance, are known to emit volatile organic compounds (VOCs) that can pose health risks to process operators and users. Phenolic resins, while offering good fire resistance, may suffer from brittleness and reduced mechanical strength. Polyvinyl acetate binders, on the other hand, can degrade under high temperatures and prolonged exposure to moisture, compromising the long-term performance of the insulation materials.

[0008] For instance, US 2016 / 053065 Al describes polystyrene-phenolic foam composites and precursor compositions.

[0009] More recently, there has been a growing demand for more environmentally friendly and high- performance curable binder precursors that can overcome the drawbacks of traditional binder systems. Epoxy resins have emerged as a promising alternative due to their exceptional adhesive properties, chemical resistance, and versatility. Epoxy-based binders can provide superior bonding strength, durability, and thermal stability, making them ideal for use in advanced insulation materials.

[0010] Despite the advantages of epoxy resins, their application in insulation materials has been limited due to challenges in formulation, processing, and sustainability. In particular, more environmentally friendly curable binder precursors typically lack reactivity, which needs to be compensated by using excessively high temperatures and / or by using additional (toxic) catalysts and / or activators.

[0011] In view of the above, there exists a need for compositions that are suitable for preparing insulation materials that addresses one or more of the aforementioned problems of the art without reducing, and advantageously even improving, their cohesive strength and / or chemical resistance.

[0012] SUMMARY OF THE INVENTION

[0013] The present inventor has discovered that some or all of the foregoing challenges can be addressed, either individually or in any combination, by providing a composition comprising an expanded insulation material and a curable binder precursor as defined herein. In particular, the present invention is based, at least in part, on the finding that a curable binder precursor comprising one or more epoxidized vegetable oils and one or more organic acids advantageously provides a (curing) composition that is environmentally friendly, can efficiently bind an expanded insulation material, and displays good reactivity.

[0014] Another advantage is that the composition described herein can be used to manufacture various insulation materials with improved ductility, chemical resistance, and / or water resistance.

[0015] Another advantage is that the curable binder precursor can be made substantially water-free, which may decrease the time needed to dry the cured composite insulation material. Especially for applications requiring thicker layers of curable binder precursor to adhere the expanded insulation material it is particularly advantageous to avoid the presence of water, which may remain trapped in the core of the composite insulation material for months.

[0016] Accordingly, a first aspect of the present invention relates to a composition comprising an expanded insulation material and a curable binder precursor; and wherein the curable binder precursor comprises one or more epoxidized vegetable oils and one or more organic acids.

[0017] In particular embodiments of the composition as disclosed herein, the epoxidized vegetable oil is selected from the group consisting of epoxidized linseed oil, epoxidized soybean oil, epoxidized castor oil, epoxidized canola oil, epoxidized grapeseed oil, epoxidized coconut oil, epoxidized corn oil, epoxidized cottonseed oil, epoxidized olive oil, epoxidized palm oil, epoxidized peanut oil, epoxidized safflower oil, epoxidized sesame oil, epoxidized sunflower oil, epoxidized tung oil, and mixtures thereof.

[0018] In particular embodiments of the composition as disclosed herein, the organic acid has a total number of carbon atoms of from 1 to 30, and preferably comprises at least two carboxylic acid functional groups or at least one carboxylic acid functional group and one anhydride functional group or at least one carboxylic acid functional group and one amine functional group.

[0019] Experimentation has revealed that the aforementioned epoxidized vegetable oil(s) and organic acid(s) are particularly advantageous for providing a curable binder precursor with good reactivity and which allows to reduce or eliminate the emission of VOCs and other harmful substances when binding expanded insulation materials. In addition, the curable binder precursor as disclosed herein provides good cohesion between the expanded insulation material.

[0020] In particular embodiments of the composition as disclosed herein, the curable binder precursor may further comprise one or more diluents.

[0021] In particular embodiments of the composition as disclosed herein, the one or more organic acids and the one or more diluents comprised in the curable binder precursor form an eutectic mixture.

[0022] A second aspect of the present invention relates to a curable binder precursor comprising one or more epoxidized vegetable oils and one or more organic acids.

[0023] It should be noted that (preferred) embodiments and associated advantages of the first aspect of the invention are also (preferred) embodiments of the second aspect of the invention and vice versa.

[0024] According to a third aspect, the present invention relates to a process for manufacturing a composite insulation material, the process comprising the steps of: a) mixing an expanded insulation material and a curable binder precursor, thereby obtaining a composition as disclosed herein; and b) curing the composition to obtain the composite insulation material.

[0025] It should be noted that (preferred) embodiments and associated advantages of the first or second aspect of the invention are also (preferred) embodiments of the third aspect of the invention and vice versa.

[0026] In particular embodiments of the process as disclosed herein, the expanded insulation material and the curable binder precursor are mixed in a volume ratio of between 20:1 and 140:1, preferably between 50:1 and 120:1. This has the advantage that less curable binder precursor is needed to prepare the composite insulation material as disclosed herein, which can save overall production and energy costs.

[0027] A fourth aspect of the present invention relates to a composite insulation material comprising an expanded insulation material and a cured product of a curable binder precursor comprising one or more epoxidized vegetable oils and one or more organic acids.

[0028] It should be noted that (preferred) embodiments and associated advantages of the first, second, or third aspect of the invention are also (preferred) embodiments of the fourth aspect of the invention and vice versa.

[0029] A fifth aspect of the present invention relates to an article comprising at least one composite insulation material as disclosed herein, wherein the article is a panel, sandwich panel, layer, foam, tile, laminate, board, or foil.

[0030] It should be noted that (preferred) embodiments and associated advantages of the first, second, third, or fourth aspect of the invention are also (preferred) embodiments of the fifth aspect of the invention and vice versa.

[0031] The above and other characteristics, features and advantages of the present invention will become apparent from the following detailed description, which illustrate, by way of example, the principles of the invention.

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] Unless otherwise defined, all terms used in disclosing the invention, including technical and scientific terms, have the meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. By means of further guidance, term definitions are included to better appreciate the teaching of the present invention.

[0034] The discussion of the background to the invention herein is included to explain the context of the invention. This is not to be taken as an admission that any of the material referred to was published, known, or part of the common general knowledge in any country as of the priority date of any of the claims. Throughout this disclosure, various publications, patents, and published patent specifications may be referenced by an identifying citation. All documents cited in the present specification are hereby incorporated by reference in their entirety. In particular, the teachings or sections of such documents herein specifically referred to are incorporated by reference. As used herein, the singular forms "a" , "an", and "the" include both singular and plural referents unless the context clearly dictates otherwise. By way of example, "a step" means one step or more than one step.

[0035] The terms "comprising", "comprises" and "comprised of" as used herein are synonymous with "including", "includes" or "containing", "contains", and are inclusive or open-ended and do not exclude additional, non-recited members, elements, or method steps. The terms also encompass "consisting of" and "consisting essentially of", which enjoy well-established meanings in patent terminology.

[0036] Whereas the terms "one or more" or "at least one", such as one or more members or at least one member of a group of members, is clear per se, by means of further exemplification, the term encompasses inter alia a reference to any one of said members, or to any two or more of said members, such as, e.g., any >3, >4, >5, >6 or >7 etc. of said members, and up to all said members. In another example, "one or more" or "at least one" may refer to 1, 2, 3, 4, 5, 6, 7 or more.

[0037] As used herein, the term "and / or" when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a list is described as comprising group A, B, and / or C, the list can comprise A alone, B alone, C alone, A and B in combination, A and C in combination, B and C in combination, or A, B, and C in combination.

[0038] Reference throughout this specification to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" or "in a particular embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to a person skilled in the art from this disclosure, in one or more embodiments. Furthermore, while certain embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art.

[0039] The recitation of numerical ranges by endpoints includes all integer numbers and, where appropriate, fractions subsumed within that range (e.g. 1 to 5 can include 1, 2, 3, 4 when referring to, for example, a number of elements, and can also include 1.5, 2, 2.75 and 3.80, when referring to, for example, measurements). The recitation of endpoints also includes the end point values themselves (e.g. from 1.0 to 5.0 includes both 1.0 and 5.0). Any numerical range recited herein is intended to include all subranges subsumed therein. This applies to numerical ranges irrespective of whether they are introduced by the expression "from... to..." or the expression "between... and..." or another expression.

[0040] As used herein, the terms "about" or "approximately" are used to provide flexibility to a numerical value or range endpoint by providing that a given value may be "a little above" or "a little below" said value or endpoint, depending on the specific context. Hence, the terms "about" or "approximately" as used herein when referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, are meant to encompass variations of and from the specified value or endpoint, such as variations of + / -10% or less, preferably + / - % or less, more preferably + / -1% or less, and still more preferably + / -0.1% or less of and from the specified value, insofar such variations are appropriate to perform in the disclosed invention.

[0041] Unless otherwise stated, use of the terms "about" or "approximately" in accordance with a specific number or numerical range should also be understood to provide support for such numerical terms or range without the term "about". For example, the recitation of "about 30" should be construed as not only providing support for values a little above and a little below 30, but also for the actual numerical value of 30 as well.

[0042] As used herein, the term "substantially" refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is "substantially" enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of "substantially" is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result.

[0043] The terms "wt.%," "vol%", or "mol%" refers to a weight percentage of a component, a volume percentage of a component, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component.

[0044] The term "alkyl" as a group or part of a group, refers to a hydrocarbyl group of formula CnHjn+i wherein n is a number greater than or equal to 1, with no site of unsaturation. Alkyl groups may be linear or branched and may be substituted as indicated herein. Generally, alkyl groups can comprise from 1 to 30 carbon atoms, preferably from 1 to 20 carbon atoms. When a subscript is used herein following a carbon atom, the subscript refers to the number of carbon atoms that the named group may contain. For example, the term "Ci.galkyl", as a group or part of a group, refers to a hydrocarbyl group of formula CnF n+i wherein n is a number ranging from 1 to 6. Thus, for example, "Ci-galkyl" includes all linear or branched alkyl groups with between 1 and 6 carbon atoms, and thus includes methyl, ethyl, n-propyl, / -propyl, butyl, and its isomers (e.g., n-butyl, / -butyl, and t-butyl); pentyl and its isomers, hexyl, and its isomers, etc. For example, Ci.4alkyl includes all linear or branched alkyl groups having 1 to 4 carbon atoms, and thus includes for example methyl, ethyl, n-propyl, / -propyl, 2-methyl-ethyl, butyl, and its isomers (e.g., n-butyl, / -butyl, and t-butyl), and the like. In particular embodiments, the term alkyl refers to Ci-izalkyl (C1-12 hydrocarbons), yet more in particular to Cuoalkyl (C1-10 hydrocarbons), yet more in particular to Ci_9a I ky I (C1.9 hydrocarbons), yet more in particular to Ci.galkyl (Ci-6 hydrocarbons) as further defined herein above. Non-limiting examples of alkyl include methyl, ethyl, 1-propyl (n-propyl), 2-propyl ( / Pr), 1-butyl, 2-methyl-l-propyl(i-Bu), 2-butyl (s-Bu), 2-dimethyl- 2-propyl (t-Bu), 1-pentyl (n-pentyl), 2-pentyl, 3-pentyl, 2-methyl-2-butyl, 3-methyl-2-butyl, 3-methyl-

[0045] 1-butyl, 2-methyl-l-butyl, 1-hexyl, 2-hexyl, 3-hexyl, 2-methyl-2-pentyl, 3-methyl-2-pentyl, 4-methyl-

[0046] 2-pentyl, 3-methyl-3-pentyl, 2-methyl-3-pentyl, 2,3-dimethyl-2-butyl, 3,3-dimethyl-2-butyl, n-heptyl, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, n-tridecyl, n-tetradecyl, n-pentadecyl, n-hexadecyl, n- heptadecyl, n-octadecyl, n-nonadecyl, and n-icosyl.

[0047] In the following passages, different aspects or embodiments of the invention are defined in more detail. Each aspect or embodiment so defined may be combined with any other aspect(s) or embodiment(s) unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.

[0048] As corroborated by the experimental section, which illustrates certain representative embodiments of the present invention, the present inventors have demonstrated that a curable binder precursor, which comprises one or more epoxidized vegetable oils and one or more organic acids, is more sustainable compared to curable binder precursors comprised in the art and can efficiently bind expanded insulation material.

[0049] Accordingly, a first aspect of the present invention relates to a composition comprising an expanded insulation material and a curable binder precursor; and wherein the curable binder precursor comprises one or more epoxidized vegetable oils and one or more organic acids. Advantageously, the present composition can be used to prepare a composite insulation material that meets industrial demands. Furthermore, the compositions described herein can be obtained in an economically advantageous manner. It is a further advantage that the components of the present composition are compatible with conventional additives that may be present in the expanded insulation material.

[0050] The term "expanded insulation material" as used herein generally refers to a type of insulation material that has been processed to create a (rigid) cellular structure. Preferably, the expanded insulation material has a low density and high thermal resistance. Expansion of insulation material may be obtained by methods that are known in the art. For instance, incorporating gas or air bubbles into the material, either through chemical reactions, physical foaming, or mechanical methods may provide an expanded insulation material as defined herein.

[0051] In particular embodiments, the expanded insulation material comprises expanded polystyrene (EPS) beads, extruded polystyrene (XPS), polyethylene terephthalate (PET) beads, silica aerogel particles, pectin aerogel particles, foam glass, cellulose particles, rubber granulates such as ethylene propylene diene monomer (EPDM) rubber, synthetic foam particles, and / or naturally derived insulation materials. Preferably, the expanded insulation material comprises expanded polystyrene (EPS) beads, polyethylene terephthalate (PET) beads, silica aerogel particles, pectin aerogel particles, foam glass, and / or cellulose particles. The listed materials may be prepared by methods known in the art.

[0052] In particular embodiments, the expanded insulation material comprises particles, and is preferably prepared from polystyrene, polyethylene terephthalate, polypropylene, polyurethane, polyisocyanurate, silica, glass, cellulose, wood fiber, pectin, copolymers thereof and / or mixtures thereof.

[0053] In particular embodiments, the expanded insulation material comprises spherical particles, and preferably wherein the spherical particles have an average diameter of at least 300 pm, or at least 350 pm, or at least 400 pm, or at least 450 pm, preferably at least 500 pm, or at least 550 pm, or at least 600 pm, or at least 650 pm, or at least 700 pm, or at least 750 pm, or at least 800 pm, or at least 850 pm, or at least 900 pm, or at least 950 pm, more preferably at least 1 mm as determined according to EN 933-1.

[0054] In some embodiments, the expanded insulation material, preferably expanded polystyrene (EPS) beads, has a density of between 15.0 and 40.0 kg / m3, or between 17.5 and 40.0 kg / m3, or between 17.5 and 37.5 kg / m3, or between 18.0 and 37.5 kg / m3, or between 18.0 and 35.0 kg / m3, determined according to ASTM C303-21. In some embodiments, the expanded insulation material, preferably silica aerogel particles, has a density of between 200.0 and 1000.0 kg / m3, or between 300.0 and 1000.0 kg / m3, or between 300.0 and 900.0 kg / m3, or between 300.0 and 800.0 kg / m3, or between 350.0 and 800.0 kg / m3, determined according to EN1097-6.

[0055] In some embodiments, the expanded insulation material has a substantially closed pore structure and / or has a textured surface.

[0056] In particular embodiments, the volume ratio of the expanded insulation material to the curable binder precursor in the composition as described herein is between 20:1 and 140:1, or between 25:1 and 140:1, or between 25:1 and 135:1, or between 30:1 and 135:1; or between 35:1 and 135:1, or between 35:1 and 130:1, or between 40:1 and 130:1, or between 45:1 and 130:1, or between 45:1 and 125:1, or between 50:1 and 125:1, preferably between 50:1 and 120:1. Advantageously, it has been found that the expanded insulation material can be bonded using less binder material. The reduced amount of curable binder precursor may facilitate faster curing times and simplify the application process, leading to increased production efficiency and reduced labour costs.

[0057] The terms "curable binder precursor" or "binder precursor" as used herein as synonyms refers to a mixture of chemical compounds that, upon application of appropriate conditions, can undergo a chemical reaction resulting in a hardened or solidified polymer network. In the context of insulation materials, the curable binder precursor is designed to encapsulate and bind the expanded insulation material as disclosed herein into a cohesive and stable structure.

[0058] In particular embodiments, the curable binder precursor can be made substantially water-free, for instance the curable binder precursor has a water content of less than 1.0 %, or less than 0.9%, or less than 0.8%, or less than 0.7%, or less than 0.6%, or no more than 0.5%.

[0059] In particular embodiments, the weight ratio of the organic acid to the epoxidized vegetable oil comprised in the curable binder precursor is at least 1:3, or at least 1:4, or at least 1:5, or at least 1:6.

[0060] Epoxidized vegetable oils as described herein are derived from vegetable oils comprising vegetable oil fatty acids and corresponding triglycerides thereof. Preferred vegetable oils include, but are not limited to, soybean oil, linseed oil, sunflower oil, castor oil, corn oil, canola oil, chia seed oil, rapeseed oil, palm kernel oil, cottonseed oil, peanut oil, coconut oil, palm oil, tung oil, safflower oil and derivatives, conjugated derivatives, genetically-modified derivatives and mixtures thereof. As used herein, a reference to a vegetable oil includes all its derivatives as outlined above. For instance, the use of the term "linseed oil" includes all derivatives including conjugated linseed oil. In particular embodiments, the epoxidized vegetable oil is selected from the group consisting of epoxidized linseed oil, epoxidized soybean oil, epoxidized castor oil, epoxidized canola oil, epoxidized chia seed oil, epoxidized grapeseed oil, epoxidized coconut oil, epoxidized corn oil, epoxidized cottonseed oil, epoxidized olive oil, epoxidized palm oil, epoxidized peanut oil, epoxidized safflower oil, epoxidized sesame oil, epoxidized sunflower oil, epoxidized tung oil, and mixtures thereof.

[0061] Fatty acids and corresponding triglycerides thereof derived from vegetable oils include fatty acids comprising carbon chains of about 2 to about 24 carbons. More preferably, the carbon chain contains about 12 to about 24 carbons. Most preferably, the number of carbons is about 16 to about 18. Preferably, at least one fatty acid is unsaturated. The sites of unsaturation (i.e., olefin groups) can be epoxidized by methods that are known in the art. For instance, the olefin groups can be epoxidized with peracids, such as perbenzoic acid, peracetic acid and the like, and / or with hydrogen peroxide. Suitable non-limiting procedures for preparing epoxidized vegetable oils are described in "Advanced organic Chemistry", 2nd Ed. by J. March, McGraw-Hill Book Company, 1977, p.750, in U.S. Pat. No. 3,488,404, and in the J. of org. Chem, 1983, Vol. 48, pp. 3831-3833 by C. Venturello, et al.

[0062] In the present invention, the fatty acid chains of the epoxidized vegetable oil can have one or more oxirane rings. Thus, a fatty acid that has multiple sites of unsaturation can be epoxidized to a greater extent. However, the present invention also encompasses fatty acid chains that are partially epoxidized (i.e., not all olefin groups are epoxidized).

[0063] In some embodiments, the epoxidized vegetable oil may have an epoxide equivalent weight of between about 100 and about 400. The "epoxy equivalent weight" is defined herein as the epoxidized oil molecular weight (g / mole) per epoxy group. For example, an epoxidized oil having a molecular weight of 200 g / mole and having 2 epoxy groups in the molecule has an "epoxy equivalent weight" value of 100.

[0064] In particular embodiments, the curable binder precursor has an oxirane oxygen value of at least 4%, or at least 5%, or at least 6%, or at least 7%, or at least 8%, or at least 9%, or at least 10% as determined according to ASTM D1652.

[0065] In the context of the present invention, the oxirane rings comprised in the epoxidized vegetable oil can be cured through nucleophilic ring-opening of the oxirane group with a carboxyl group, resulting in the formation of an ester bond. In particular embodiments, the organic acid as disclosed herein comprises at least two carboxyl functional groups; or at least one carboxyl functional group and one anhydride functional group; or at least one carboxyl functional group and one amine functional group.

[0066] As used herein, any reference to an "organic acid" also includes isomers such as stereoisomers and tautomers, salt derivatives thereof such as metal salts, hydrates, and solvates, unless expressly indicated otherwise. For instance, when referring to "citric acid", the present invention also encompasses sodium salts thereof, e.g. monosodium citrate, disodium citrate, or trisodium citrate.

[0067] In particular embodiments, the organic acid is a polyvalent or polyprotic acid comprising at least two carboxyl functional groups, such as two, three, four, five, or six carboxyl functional groups.

[0068] In particular embodiments, the organic acid may have a total number of carbon atoms of from 1 to 120, or from 1 to 75, or from 1 to 60, preferably from 1 to 30.

[0069] In particular embodiments, the organic acid is selected from the group consisting of citric acid, oxalic acid, malonic acid, maleic acid, fumaric acid, succinic acid, malic acid, tartaric acid, glutaric acid, itaconic acid, adipic acid, 2,5-furan dicarboxylic acid, glucaric acid, gluconic acid, pimelic acid, phthalic acid, terephthalic acid, cork acid, isocitric acid, aconitic acid, propane-1, 2, 3-tricarboxylic acid, agaric acid, azelaic acid, aspartic acid, diaminopimelic acid, sebacic acid, brassylic acid, dimer acid (e.g., a dimerized fatty acid), trimer acid (e.g., a trimerized fatty acid), hemimellitic acid, suberic acid, 1,4- cyclohexanedicarboxylic acid, undecanedioic acid, dodecanedioic acid, thapsic acid, japanic acid, phellogenic acid, equisetollic acid, tartronic acid, mesoxalic acid, malic acid, tartaric acid, oxaloacetic acid, dioxosuccinic acid, a-hydroxyglutaric acid, arabinaric acid, acetonedicarboxylic acid, a- ketoglutaric acid, saccharic acid, trimellitic acid, trimellitic acid anhydride, and mixtures thereof.

[0070] In some embodiments, the dimer acid or trimer acid as described herein may have a total number of carbon atoms of at least 10, such as at least 20.

[0071] Advantageously, and in some embodiments, the organic acid can be extracted from biological (e.g. vegetable or animal) sources or produced through fermentation processes starting from a biological source. In contrast to conventional petrochemically derived reagents, which pose several environmental and health challenges, biologically derived organic acids are often less toxic and produce fewer VOC emissions, enhancing worker safety and improving indoor air quality.

[0072] Another advantage of the organic acids as disclosed herein is that they can impart unique properties to cured materials, such as enhanced flexibility, improved thermal stability, and better adhesion, which can be difficult to achieve with synthetic reagents disclosed in the prior art. In particular embodiments, the curable binder precursor further comprises one or more diluents.

[0073] The term "diluent" as used herein generally refers to a compound or a mixture of compounds that may be added to the curable binder precursor to advantageously adjust the viscosity, and / or improve processability and handling. The diluent may be reactive or non-reactive. Reactive diluents can participate in the curing process, becoming an integral part of the solidified polymer network. Non- reactive diluents typically do not participate in the curing reaction but can be used to modify the physical properties of the curable binder precursor.

[0074] In particular embodiments, the one or more organic acids and the one or more diluents may form a eutectic mixture. The term "eutectic mixture" as used herein refers to a substantially homogeneous mixture of two or more compounds that can melt at a temperature, which is lower than the melting points of the individual compounds. This specific composition, known in the art as the eutectic point, results in the lowest possible melting temperature for the combination of compounds.

[0075] In preferred embodiments, the eutectic mixture has a viscosity of at most 150000 mPa.s, or at most 125 000 mPa.s, or at most 100000 mPa.s at 20 °C. Suitable equipment for determining the viscosity of the eutectic mixture include a Brookfield viscometer, preferably equipped with a spindle operating between 1 and 100 rpm.

[0076] In particular embodiments, the organic acid is an hydrogen bond donor and the diluent is a hydrogen bond acceptor. Without wishing to be bound by theory, it has been found that the diluent may disturb intermolecular organic acid-organic acid hydrogen bonding to obtain a mixture with a reduced melting point. This has the advantage that the overall viscosity of the curable binder precursor may be reduced. Another advantage is that the components comprised in the curable binder precursor may form a more homogeneous mixture.

[0077] In particular embodiments, the molar ratio of diluent:organic acid in the curable binder precursor is between 2:1 and 1:6, or between 1:1 and 1:6, or between 1:1 and 1:5, or between 1:1 and 1:4, preferably between 1:1 and 1:3.

[0078] In particular embodiments, the diluent is an ester or a halide salt.

[0079] In particular embodiments, the ester is a Ci.8alkyl ester of an organic acid; optionally an organic acid as described herein above.

[0080] In some embodiments, the ester is a Ci-galkyl ester of an organic acid, wherein the organic acid has a total number of carbon atoms of from 1 to 30 and at least one carboxyl functional group. It should be understood that the term "Ci.8alkyl ester of an organic acid" encompasses compounds derived from an organic acid, wherein one or more of the carboxyl groups are substituted with a Ci. galkyl ester.

[0081] In some embodiments, the ester is a Ci_8alkyl ester of an organic acid selected from the group consisting of lactic acid, citric acid, acetic acid, propionic acid, benzoic acid, adipic acid, and mixtures thereof.

[0082] In some embodiments, the ester is a Ci_8alkyl ester of acetic acid and is selected from the group consisting of ethyl lactate, methyl lactate, butyl lactate, propyl lactate, isopropyl lactate, isobutyl lactate, ethyl hexyl lactate, and mixtures thereof.

[0083] In some embodiments, the ester is a Ci_8alkyl ester of citric acid and is selected from the group consisting of acetyl triethyl citrate, acetyl tributyl citrate, acetyl trihexyl citrate, triethyl citrate, tributyl citrate, trihexyl citrate, tripropyl citrate, trimethyl citrate, triisopropyl citrate, triethyl citrate monolaurate, triethyl citrate monostearate, triethyl citrate monopalmitate, triethyl citrate monolinoleate, triethyl citrate monooctanoate, triethyl citrate monooleate, triethyl citrate monopalmitoleate, triethyl citrate monomyristate, triethyl citrate monocaprylate, triethyl citrate monocaprate, triethyl citrate monoundecanoate, triethyl citrate monodecanoate, triethyl citrate monononanoate, triethyl citrate monoisononanoate, triethyl citrate monocaprate, triethyl citrate monomyristoleate, triethyl citrate monostearyl citrate, triethyl citrate monooleyl citrate, triethyl citrate monolinolenate, triethyl citrate monocaprylic / capric triglycerides, triethyl citrate monoisostearyl citrate, glyceryl citrate, ethyl cellulose citrate, butyl cellulose citrate, and mixtures thereof.

[0084] In some embodiments, the ester is a Ci-8alkyl ester of lactic acid and is selected from the group consisting of ethyl acetate, methyl acetate, vinyl acetate, isopropyl acetate, butyl acetate, propyl acetate, allyl acetate, ethyl hexyl acetate, pentyl acetate, isobutyl acetate, sec-butyl acetate, tert-butyl acetate, n-butyl acetate, methyl ethyl ketone acetate, propylene glycol monomethyl ether acetate (PGMEA), ethyl glycol acetate, and mixtures thereof.

[0085] In some embodiments, the ester is a Ci-8alkyl ester of propionic acid and is selected from the group consisting of methyl propionate, ethyl propionate, propyl propionate, isopropyl propionate, butyl propionate, isobutyl propionate, and mixtures thereof. In some embodiments, the ester is a Ci_8alkyl ester of benzoic acid and is selected from the group consisting of methyl benzoate, ethyl benzoate, propyl benzoate, isopropyl benzoate, butyl benzoate, isobutyl benzoate, and mixtures thereof.

[0086] In some embodiments, the ester is a Ci_8alkyl ester of adipic acid and is selected from the group consisting of dimethyl adipate, diethyl adipate, dipropyl adipate, dibutyl adipate, diisopropyl adipate, dihexyl adipate, dioctyl adipate, diisononyl adipate, and mixtures thereof.

[0087] In particular embodiments, the halide salt comprises a quaternary ammonium cation or metal cation. Exemplary quaternary ammonium cations are choline, tetramethylammonium, tetraethylammonium, tetrapropylammonium, tetrabutylammonium, tetrahexylammonium, tetraoctylammonium, tetradodecylammonium, or combinations thereof. Exemplary metal cations are sodium, potassium, lithium, zinc, or combinations thereof.

[0088] In exemplary embodiments, the composition according to a first aspect of the present invention comprises an expanded insulation material and a curable binder precursor; and wherein the curable binder precursor comprises one or more epoxidized vegetable oils, one or more organic acids, and one or more diluents, preferably wherein the one or more diluents are a Ci_8al kyl ester of lactic acid.

[0089] In some embodiments, the curable binder precursor does not comprise a catalyst and / or activator.

[0090] In some embodiments, the curable binder precursor further comprises a catalyst. Any suitable catalyst may be used that is known within the art to promote nucleophilic ring-opening of the oxirane group with carboxylic acids.

[0091] In some embodiments, the catalyst may be selected from the group consisting of a tertiary amine and / or a corresponding quaternary ammonium salt, a phosphonium compound, 4-N,N- dimethylaminopyridine, 2-methylimidazole, and mixtures thereof.

[0092] In some embodiments, the curable binder precursor may comprise from about 0.1 wt.% to about 5.0 wt.%, or from about 0.25 wt.% to about 5.0 wt.%, or from about 0.25 wt.% to about 4.0 wt.%, or from about 0.25 wt.% to about 3.0 wt.%, or from about 0.25 wt.% to about 2.0 wt.% of catalyst; with wt.% relative to the total weight of the curable binder precursor.

[0093] In some embodiments, the composition according to a first aspect of the invention further comprises one or more additives or fillers. Preferably, the one or more additives or fillers are biobased. In some embodiments, the one or more additives or fillers are derived from (nano)cellulose, lignocellulose, hemicellulose, lignin, pectin, chitin, chitosan, polysaccharides, polypeptides, polynucleotides, and / or combinations thereof.

[0094] In some embodiments, the one or more additives or fillers are selected from the group consisting of lignocellulose nanofibers, hopped or milled glass fibres, chopped or milled carbon fibres, and combinations thereof.

[0095] As described above, the present invention provides a curable binder precursor that can overcome some or all of the drawbacks of the prior art.

[0096] Accordingly, the present invention relates in a second aspect to a curable binder precursor comprising one or more epoxidized vegetable oils and one or more organic acids.

[0097] It should be noted that (preferred) embodiments and associated advantages of the first aspect of the invention are also (preferred) embodiments of the second aspect of the invention and vice versa.

[0098] It has been found that the curable binder precursor may be particularly suitable to adhere cellulose, wood, cardboard, paper, textile, polystyrene (expanded and / or extruded), ethylene propylene diene terpolymer (EPDM), polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), polyurethane (PU), polyisocyanurate (PIR), polyamide (PA), polyimide (PI), acrylonitrile butadiene styrene (ABS), rubber, cork, latex, cementitious compositions, gypsum, plaster ceramics, glass, composite material, metals, and / or combinations thereof.

[0099] In certain exemplary embodiments, the curable binder precursor may be used in the manufacturing of insulation foams, insulation boards, non-woven mats, carbon fiber products, and / or for use in binding organic fibers such as cellulose and wood-based fibers.

[0100] According to a third aspect, the present invention relates to a process for manufacturing a composite insulation material, the process comprising the steps of: a) mixing an expanded insulation material and a curable binder precursor, thereby obtaining a composition as disclosed herein; and b) curing the composition to obtain the composite insulation material.

[0101] It should be noted that (preferred) embodiments and associated advantages of the first or second aspect of the invention are also (preferred) embodiments of the third aspect of the invention and vice versa. In particular embodiments of the process as disclosed herein, the expanded insulation material and the curable binder precursor are mixed in a volume ratio of between 20:1 and 140:1, or between 25:1 and 140:1, or between 25:1 and 135:1, or between 30:1 and 135:1; or between 35:1 and 135:1, or between 35:1 and 130:1, or between 40:1 and 130:1, or between 45:1 and 130:1, or between 45:1 and 125:1, or between 50:1 and 125:1, preferably between 50:1 and 120:1.

[0102] Mixing of the expanded insulation material and curable binder precursor in step a) of the process as disclosed herein may comprise any suitable means known in the prior art for said purpose. For instance, the curable binder precursor may be sprayed onto the expanded insulation material using suitable spraying means.

[0103] In some embodiments, the curable binder precursor is a two-component curing system. In particular, at least the majority of the epoxidized vegetable oils may be kept separated from the organic acids to avoid premature curing (i.e., cross-linking). The two separated parts may then be combined upon mixing the curable binder precursor and the expanded insulation material to initiate the polymerization or curing process.

[0104] In some embodiments, the one or more epoxidized vegetable oils and the one or more organic acids comprised in the curable binder precursor may be pre-mixed prior to application to the expanded insulation material. Suitable equipment for pre-mixing of the epoxidized vegetable oils and organic acids may comprise any suitable feeding means, such as a hydraulic proportioning unit.

[0105] In some embodiments, between about 50 vol.% to about 90 vol.% epoxidized vegetable oil and between about 10 vol.% to about 50 vol.% of organic acid may be pre-mixed prior to application to the expanded insulation material.

[0106] In some embodiments, the one or more epoxidized vegetable oils and the one or more organic acids comprised in the curable binder precursor may be stored in separate containers, preferably preheated containers.

[0107] In some embodiments, the pre-mixed components are applied to the expanded insulation material by a suitable application means, preferably a spray gun. Non-limiting examples of spray guns include an air purge gun or a mechanical spray gun.

[0108] Curing of the composition in step b) of the process as disclosed herein may, in some embodiments, comprise heating, preferably to a temperature of at most 100 °C, or at most 90 °C, or at most 80 °C, or at most 70 °C, or at most 60 °C, or at most 50 °C. In some embodiments, curing may be performed at about 20 °C.

[0109] In some embodiments, the amount of curable binder precursor applied to the expanded insulation material is between about 50 g and about 350 g per square meter of expanded insulation material.

[0110] The present invention further encompasses the composite insulation material obtained or obtainable by means of the process as disclosed herein or cured with the curable binder precursor as disclosed herein.

[0111] A fourth aspect of the present invention relates to a composite insulation material comprising an expanded insulation material and a cured product of a curable binder precursor comprising one or more epoxidized vegetable oils and one or more organic acids.

[0112] In particular embodiments, the composite insulation material is characterized by: a thermal conductivity of less than 0.035 W / m.K, preferably of less than 0.030 W / m.K, and most preferably of less than 0.025 W / m.K as determined according to ASTM C518-17; and / or a compressive strength higher than 70 kPa, higher than 90 kPa, higher than 110 kPa, preferably higher than 130 kPa, and most preferably higher than 150 kPa as determined according to ASTM 0165-07(2017).

[0113] It should be noted that (preferred) embodiments and associated advantages of the first, second, or third aspect of the invention are also (preferred) embodiments of the fourth aspect of the invention and vice versa.

[0114] A fifth aspect of the present invention relates to an article comprising at least one composite insulation material as disclosed herein, wherein the article is a panel, sandwich panel, layer, foam, tile, laminate, board, or foil.

[0115] An advantage of the present invention is thus that it provides an article comprising a composite insulation material having improved sustainability, without reducing and preferably even improving the mechanical performance of the article.

[0116] Suitable panels include, but are not limited to, metal panels, wooden panels, cardboard panels, polystyrene panels, polyurethane panels, and combinations thereof.

[0117] In some embodiments, wherein the article according to an aspect of the present invention is a panel, and wherein the panel has a compressive strength of at least 2 N / mm2, or at least 3 N / mm2, or at least 4 N / mm2, as measured according to NBN EN 789:2004. In some embodiments, wherein the article according to an aspect of the present invention is a panel, and wherein the panel has a bending tensile strength of at least 5 N / mm2, or at least 6 N / mm2, or at least 7 N / mm2, or at least 8 N / mm2, or at least 9 N / mm2, as measured according to NBN EN 12467:2012.

[0118] In some embodiments, wherein the article according to an aspect of the present invention is a panel, and wherein the panel has an E-modulus of at least 1000 N / mm2, or at least 1100 N / mm2, or at least 1200 N / mm2, or at least 1300 N / mm2, as measured according to NBN EN 12467:2012.

[0119] Any commonly known sandwich panel may be used in the context of the present disclosure. Sandwich panels as described herein may be easily identified by those skilled in the art in the light of the present disclosure.

[0120] Suitable sandwich panels include, but are not limited to, those comprising a core material selected from the group consisting of honeycomb structures (such as e.g. metal - aluminium, steel; Nomex - aramid fibre dipped in resin (epoxy, phenolic or polyamide) honeycomb structures), open and closed- cell-structured foams (such as e.g. polyvinylchloride, polyurethane, polyethylene, polystyrene or metal foams), expanded or extruded foams (such as e.g. polymer - polyurethane, epoxy, metal - aluminium foams), syntactic foams, solid cores (such as e.g. wood - balsa; polymer - epoxy cores), and any combinations thereof.

[0121] In particular embodiments, the articles as described herein may be used as a thermally insulating layer and / or an acoustic insulating layer.

[0122] Advantageously, the articles as disclosed herein can be particularly suitable in the building industry for floor insulation, wall insulation, cavity wall insulation, and insulation of roofs and attics.

[0123] It should be noted that (preferred) embodiments and associated advantages of the first, second, third, or fourth aspect of the invention are also (preferred) embodiments of the fifth aspect of the invention and vice versa.

[0124] The invention is illustrated but not limited by the following examples.

[0125] EXAMPLES

[0126] Example 1

[0127] In a first example, an organic acid was mixed with a diluent to prepare a eutectic mixture having a desirable melting point for further handling. Citric acid particles (>99.5% purity, anhydrous (max. 0.5% water content), granule sizes of 0.2-1.25 mm) were slowly added to a vessel containing ethyl lactate (>98% (w / w) purity) under stirring in a molar ratio of ethyl lactate to carboxyl groups of 1:6. The mixture was heated to 160°C while stirring at 1000 rpm. A faint yellow and transparent viscous liquid, eutectic mixture 1, was obtained after which the heating and stirring was stopped. During cooling down, the viscosity of the eutectic mixture increased from about 1300 mPa.s to about 3000 mPa.s at 60°C and to about 60000 mPa.s at 20 °C. The eutectic mixture had a density of 1.4 g / cm3at 20°C.

[0128] Example 2

[0129] In a second example, different eutectic mixtures were prepared to demonstrate the versatility of the present invention.

[0130] The same procedure was repeated as described for Example 1, with the exception that part of the citric acid was replaced by tartaric acid such that a tartaric acid:citric acid mixture having a weight ratio of 1:3 was added to the vessel containing the ethyl lactate, thereby producing eutectic mixture 2.

[0131] Example 3

[0132] In a third example, a curable binder precursor composition was prepared, applied to an expanded insulation material, expanded polystyrene (EPS) spherical particles, and the resulting composition was subsequently cured to obtain a composite insulation material according to the invention.

[0133] Epoxidized linseed oil having an oxirane oxygen value of 9% (determined according to ASTM D1652) was heated to 60 °C before being mixed with eutectic mixture 1 preheated to 70 °C. The resulting composition had a molar ratio of carboxyl groups to epoxide groups of 0.9. Next, the composition was stirred for 15-20 seconds until a opaque cream-like homogeneous mixture was obtained. 12 kg of this curing mixture was then added to and mixed with 1 m3grey EPS spherical particles having a density of 22-25 kg / m3and spherical particle size of 3-5 mm in diameter in a volume ratio of EPS:eutectic mixture 1 of 90:1, until most spherical particles were wetted / coated.

[0134] The coated EPS spherical particles were then poured on a concrete floor and spread evenly to a thickness of 200 mm. After 18 hours, the resulting layer of glued EPS spherical particles (composite 1) had been cured to such extent a person could walk on said layer without any substantial sinking into the layer. A layer of screed was then applied on composite 1. The thermal conductivity of composite 1 was close to the thermal conductivity of the pure EPS spherical particles. An acoustic insulation comprising a reduction of 30 dB was measured according to ISO 12999-1. The same procedure was repeated for eutectic mixture 2, resulting in composite 2. The thermal conductivity and acoustic insulation were practically identical to those of composite 1, however, composite 2 was more rigid and cured after 12 hours compared to 18 hours for composite 1.

[0135] Example 4

[0136] In a fourth example, a curable binder precursor composition was prepared, applied to a panel made of an expanded insulation material, and the resulting composition was subsequently cured to obtain a composite insulation material according to the invention.

[0137] A thin layer of the composition of Example 3 comprising epoxidized linseed oil and eutectic mixture 1 was spread over a concrete surface of 1 m2for which 350 g of said composition was used. Immediately after applying the composition, an insulation panel made of extruded polystyrene (XPS) was pressed against said composition. After 24 hours, the panel was firmly attached to the concrete surface.

[0138] The same procedure was repeated, except that the composition was not evenly spread but poured in a zig-zag pattern, using only about 200 g.

[0139] The same procedure was repeated, except that a sheet of EPDM was used.

[0140] Example 5

[0141] In a fifth example, a curable binder precursor composition was prepared, applied to an expanded insulation material, and the resulting composition was subsequently cured to obtain a composite insulation material according to the invention.

[0142] In particular, expanded glass particles having a grain size of 0.25-2 mm and a particle density of 400- 700 kg / m3(determined according to EN1097-6) were bound with eutectic mixture 1 to produce a panel, panel 1, having the following size dimensions 300 mm x 300 mm x 10 mm. To that end, first, 60 g of eutectic mixture 1 was added to 383 grams of powder while stirring. Subsequently, the obtained mixture was pressed for 40 minutes in a dedicated mold using a hydraulic hot-press operating at a temperature of 130 °C and a pressure of 20 kg / cm2. The resulting panel had a density of 610 kg / m3, a compressive strength of 7 N / mm2(measured according to NBN EN 789:2004), a bending tensile strength of 12.6 N / mm2(measured according to NBN EN 12467:2012) and an E-modulus of 1600 N / mm2(measured according to NBN EN 12467:2012).

[0143] Comparative Example 1 In a comparative example, a conventional epoxy binder was applied to an expanded insulation material, and the resulting composition was subsequently cured to obtain a comparative composite insulation material.

[0144] The same procedure was repeated as described for Example 5, with the exception that the eutectic mixture 1 was replaced by a conventional epoxy binder, thereby producing comparative panel 1. The resulting comparative panel 1 had a compressive strength of 7 N / mm2(NBN EN 789:2004), a bending tensile strength of 8 N / mm2(NBN EN 12467:2012) and an E-modulus of 1800 N / mm2(measured according to NBN EN 12467:2012).

[0145] The comparative data demonstrate that the composite insulation material according to the invention has comparable or even improved mechanical properties compared to materials of the art.

Claims

CLAIMS1. A composition comprising: i) an expanded insulation material; ii) a curable binder precursor; wherein the curable binder precursor comprises one or more epoxidized vegetable oils and one or more organic acids.

2. The composition according to claim 1, wherein the epoxidized vegetable oil is selected from the group consisting of epoxidized linseed oil, epoxidized soybean oil, epoxidized castor oil, epoxidized canola oil, epoxidized grapeseed oil, epoxidized chia seed oil, epoxidized coconut oil, epoxidized corn oil, epoxidized cottonseed oil, epoxidized olive oil, epoxidized palm oil, epoxidized peanut oil, epoxidized safflower oil, epoxidized sesame oil, epoxidized sunflower oil, epoxidized tung oil, and mixtures thereof.

3. The composition according to claim 1 or 2, wherein the organic acid has a total number of carbon atoms of from 1 to 30, and preferably comprises at least two carboxyl functional groups or at least one carboxyl functional group and one anhydride functional group or at least one carboxyl functional group and one amine functional group.

4. The composition according to any one of the preceding claims, wherein the organic acid is selected from the group consisting of citric acid, oxalic acid, malonic acid, maleic acid, fumaric acid, succinic acid, malic acid, tartaric acid, glutaric acid, itaconic acid, adipic acid, 2,5-furan dicarboxylic acid, glucaric acid, gluconic acid, pimelic acid, phthalic acid, terephthalic acid, cork acid, isocitric acid, aconitic acid, propane-1, 2, 3-tricarboxylic acid, agaric acid, azelaic acid, aspartic acid, diaminopimelic acid, sebacic acid, brassylic acid, dimer acids, trimer acids, hemimellitic acid, suberic acid, 1,4-cyclohexanedicarboxylic acid, undecanedioic acid, dodecanedioic acid, thapsic acid, japanic acid, phellogenic acid, equisetollic acid, tartronic acid, mesoxalic acid, malic acid, tartaric acid, oxaloacetic acid, dioxosuccinic acid, a- hydroxyglutaric acid, arabinaric acid, acetonedicarboxylic acid, a-ketoglutaric acid, saccharic acid, trimellitic acid, trimellitic acid anhydride, and mixtures thereof.

5. The composition according to any one of the preceding claims, wherein the expanded insulation material comprises spherical particles, and preferably wherein the spherical particles have an average diameter of at least 300 pm; as determined according to EN 933-1.

6. The composition according to any one of the preceding claims, wherein the curable binder precursor has an oxirane oxygen value of at least 4%.

7. The composition according to any one of the preceding claims, wherein the volume ratio of the expanded insulation material to the curable binder precursor is between 20:1 and 140:

1. preferably between 50:1 and 120:1.

8. The composition according to any one of the preceding claims, wherein the curable binder precursor further comprises one or more diluents.

9. The composition according to claim 8, wherein the one or more organic acids and the one or more diluents comprised in the curable binder precursor form an eutectic mixture; and preferably wherein the molar ratio of diluent:organic acid in the curable binder precursor is between 2:1 and 1:6.

10. The composition according to claim 8 or 9, wherein the diluent is a hydrogen bond acceptor.

11. The composition according to any one of claims 8 to 10, wherein the diluent is an ester or a halide salt; preferably wherein the ester is a Ci_8alkyl ester of an organic acid, wherein the organic acid has a total number of carbon atoms of from 1 to 30 and at least one carboxyl functional group; and preferably wherein the halide salt comprises a quaternary ammonium cation or metal cation.

12. A process for manufacturing a composite insulation material, the process comprising the steps of: a) mixing an expanded insulation material and a curable binder precursor, wherein the curable binder precursor comprises one or more epoxidized vegetable oils and one or more organic acids, thereby obtaining a composition according to any one of claims 1 to 11; and b) curing the composition to obtain the composite insulation material.

13. The process according to claim 12, wherein the expanded insulation material and the curable binder precursor are mixed in a volume ratio of between 20:1 and 140:1, preferably between 50:1 and 120:1.

14. A composite insulation material comprising an expanded insulation material and a cured product of a curable binder precursor comprising one or more epoxidized vegetable oils and one or more organic acids, and preferably wherein the expanded insulation material and the curable binder precursor are as defined in any one of claims 1 to 11.

15. An article comprising at least one composite insulation material according to claim 14, wherein the article is a panel, sandwich panel, layer, foam, tile, laminate, board, or foil.