A binder composition for use in the manufacture of a nonwoven mat including a low-density fiber, and nonwoven mats made with the binder, are disclosed. The low-density fiber is able to reduce the acoustic openness of the nonwoven mats made therefrom while also capable of being delivered with existing binder technology and equipment.

The present invention provides: a binder for inorganic fibers, the binder being characterized by containing (B) an ammonia-modified maleic anhydride-containing copolymer at a quantity of 3 parts by mass or more relative to 100 parts by mass of (A) a cellulose ether having a viscosity at 20° C. of 500 mPa.Math.s or less when in the form of a 2 mass % aqueous solution: and an inorganic fiber mat comprising inorganic fibers treated with the binder for inorganic fibers. By using this binder for inorganic fibers, it is possible to produce an inorganic fiber mat having a high recoverability similar to that of a phenol resin, and the amount of volatile organic compounds released from the inorganic fiber mat is extremely low.

The invention relates to a process for producing non-woven fabric-like composite materials, novel non-woven fabric-like composite materials, articles made therefrom and their use. In particular the fabric-like composite materials are derived from shredded polymer-glued or polymer-coated paper products and coffee grounds as raw material.

Binder compositions are described that contain (1) a reducing sugar and (2) a reaction product of a urea compound and an aldehyde-containing compound. A specific example of the binder compositions include dextrose and an imidazolidine compound such as 4,5-dihydroxyimidazolidin-2-one. The binder compositions may be applied to collections of fibers and cured to form a fiber-containing composite, such as fiberglass insulation.

Binder compositions are described that contain (1) a reducing sugar and (2) a reaction product of a urea compound and an aldehyde-containing compound. A specific example of the binder compositions include dextrose and an imidazolidine compound such as 4,5-dihydroxyimidazolidin-2-one. The binder compositions may be applied to collections of fibers and cured to form a fiber-containing composite, such as fiberglass insulation.

The invention relates to a nonwoven fabric material having sufficient strength to be used in a pre-moistened state but also having dispersibility properties which allow the product to be flushed. The material comprises at least two nonwoven webs, at least one of which is hydroentangled. Each of the individual webs comprise 50%-95% wood pulp and 5%-50% of short cut man-made fibers and/or natural fibers and has a basis weight of 20-100 gsm. After forming the webs, the two nonwoven webs are dried and then joined together by particle binders through size press or spraying. The particle binder joined webs separate into individual webs after flushing due to the breakage of particle binder-nonwoven hydrogen bond which makes the material highly dispersible.

The invention relates to a nonwoven fabric material having sufficient strength to be used in a pre-moistened state but also having dispersibility properties which allow the product to be flushed. The material comprises at least two nonwoven webs, at least one of which is hydroentangled. Each of the individual webs comprise 50%-95% wood pulp and 5%-50% of short cut man-made fibers and/or natural fibers and has a basis weight of 20-100 gsm. After forming the webs, the two nonwoven webs are dried and then joined together by particle binders through size press or spraying. The particle binder joined webs separate into individual webs after flushing due to the breakage of particle binder-nonwoven hydrogen bond which makes the material highly dispersible.

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 water-dispersible composite structure, which comprises one or more layers, and a method of producing the same. At least a part of the layers is formed by a fibrous web or sheet containing 50-90 parts by weight of wood fibers and 10-90 parts by weight of annual or perennial plant fibers and/or 10-50 parts by weight of synthetic short-cut fibers, and 0.1-20% by weight of a binder, calculated from the weight of the fibers, and at least a part of the binder being a water-soluble polymer and another part a water dispersible binder, and the fibrous sheet or web being produced by wet forming. By means of the invention, the fibers of the composite structure can be recovered and recycled by equipment conventionally used in the paper and paperboard industry.