A method of manufacturing a mineral fibre thermal insulation product comprises the sequential steps of: Forming mineral fibres from a molten mineral mixture; Spraying a substantially formaldehyde free binder solution on to the mineral fibres, the binder solution comprising: a reducing sugar, an acid precursor derivable from an inorganic salt and a source of nitrogen; Collecting the mineral fibres to which the binder solution has been applied to form a batt of mineral fibres; and Curing the batt comprising the mineral fibres and the binder which is in contact with the mineral fibres by passing the batt through a curing oven so as to provide a batt of mineral fibres held together by a substantially water insoluble cured binder.

A method of manufacturing a mineral fibre thermal insulation product comprises the sequential steps of: Forming mineral fibres from a molten mineral mixture; Spraying a substantially formaldehyde free binder solution on to the mineral fibres, the binder solution comprising: a reducing sugar, an acid precursor derivable from an inorganic salt and a source of nitrogen; Collecting the mineral fibres to which the binder solution has been applied to form a batt of mineral fibres; and Curing the batt comprising the mineral fibres and the binder which is in contact with the mineral fibres by passing the batt through a curing oven so as to provide a batt of mineral fibres held together by a substantially water insoluble cured binder.

A high density mineral fibre board having a formaldehyde free binder has acceptable strength and good dimensional stability.

A high density mineral fibre board having a formaldehyde free binder has acceptable strength and good dimensional stability.

A method of manufacturing a mineral fiber insulating board comprising i) spraying a formaldehyde-free aqueous binder solution onto a plurality of mineral fibers to provide uncured binder disposed on the plurality of mineral fibers, ii) passing the plurality of mineral fibers having uncured binder disposed thereon through a curing oven to cure the uncured binder and provide the mineral fiber insulating board with a cured binder disposed on the plurality of mineral fibers in about 0.5%-15% by weight as determined by loss on ignition, wherein the binder is based on reducing sugar(s) and the cured binder includes at least one reaction product of the reducing sugar(s) and an amine reactant.

A method of manufacturing a mineral fiber insulating board comprising i) spraying a formaldehyde-free aqueous binder solution onto a plurality of mineral fibers to provide uncured binder disposed on the plurality of mineral fibers, ii) passing the plurality of mineral fibers having uncured binder disposed thereon through a curing oven to cure the uncured binder and provide the mineral fiber insulating board with a cured binder disposed on the plurality of mineral fibers in about 0.5%-15% by weight as determined by loss on ignition, wherein the binder is based on reducing sugar(s) and the cured binder includes at least one reaction product of the reducing sugar(s) and an amine reactant.

The present invention concerns a method for manufacturing an insulating product based on organic or mineral fibers, which comprises—applying an aqueous binder composition to organic or mineral fibers, preferably mineral wool fibers; —heating the fibers bonded with the aqueous binder composition so as to evaporate the volatile phase of the aqueous binder composition and to bring about the thermal curing of the non-volatile residue, or packaging the organic or mineral fibers bonded with the aqueous binder composition for the purpose of storage and/or transport, the aqueous binder composition having a pH of between 1.0 and 6.5, preferably between 1.5 and 5.0, and comprising: a) at least one carbohydrate selected from hydrogenated sugars, reducing sugars, non-reducing sugars and mixtures thereof, (b) at least one polycarboxylic acid or an anhydride of such an acid, (c) from 1 to 35% by weight, relative to the total weight of components (a), (b) and (c), of a water-soluble, amine-containing phenolic resin consisting essentially of phenol-formaldehyde condensates and phenol-formaldehyde-amine condensates.

The present invention concerns a method for manufacturing an insulating product based on organic or mineral fibers, which comprises—applying an aqueous binder composition to organic or mineral fibers, preferably mineral wool fibers; —heating the fibers bonded with the aqueous binder composition so as to evaporate the volatile phase of the aqueous binder composition and to bring about the thermal curing of the non-volatile residue, or packaging the organic or mineral fibers bonded with the aqueous binder composition for the purpose of storage and/or transport, the aqueous binder composition having a pH of between 1.0 and 6.5, preferably between 1.5 and 5.0, and comprising: a) at least one carbohydrate selected from hydrogenated sugars, reducing sugars, non-reducing sugars and mixtures thereof, (b) at least one polycarboxylic acid or an anhydride of such an acid, (c) from 1 to 35% by weight, relative to the total weight of components (a), (b) and (c), of a water-soluble, amine-containing phenolic resin consisting essentially of phenol-formaldehyde condensates and phenol-formaldehyde-amine condensates.

Fiber-containing composites are described that contain woven or non-woven fibers, and a cured binder formed from a binder composition that includes (1) a reducing sugar and (2) a crosslinking agent that includes a reaction product of a urea compound and a polycarbonyl compound. Exemplary reaction products for the crosslinking agent may include the reaction product of urea and an α,β-bicarbonyl compound or an α,γ-bicarbonyl compound. Exemplary fiber-containing composites may include fiberglass insulation.

Fiber-containing composites are described that contain woven or non-woven fibers, and a cured binder formed from a binder composition that includes (1) a reducing sugar and (2) a crosslinking agent that includes a reaction product of a urea compound and a polycarbonyl compound. Exemplary reaction products for the crosslinking agent may include the reaction product of urea and an α,β-bicarbonyl compound or an α,γ-bicarbonyl compound. Exemplary fiber-containing composites may include fiberglass insulation.