A non-woven fibrous mat is provided that includes a mixture of a thermoset resin and a thermoplastic resin. It has been found that the physical properties (e.g., flexibility, tensile strength) of a non-woven mat may be improved by formulating a binder composition comprising variable ratios of the thermoset material and the thermoplastic material. In this way, a bonded nonwoven mat may be achieved having a desirable combination of strength and flexibility, while maintaining good heat and water resistance.

A non-woven fibrous mat is provided that includes a mixture of a thermoset resin and a thermoplastic resin. It has been found that the physical properties (e.g., flexibility, tensile strength) of a non-woven mat may be improved by formulating a binder composition comprising variable ratios of the thermoset material and the thermoplastic material. In this way, a bonded nonwoven mat may be achieved having a desirable combination of strength and flexibility, while maintaining good heat and water resistance.

The invention relates to an apparatus for manufacturing mineral wool. The apparatus includes means (1) for producing molten mineral material, at least one fiberizing device (3) for forming fibres, into which fiberizing device the molten mineral material is fed (2) and by which fibres (12) are formed. The fiberizing device (3) comprises, rotationally arranged around a vertical axis (15), at least one fiberizing plate (13) having a vertical peripheral edge, into which are formed numerous small-sized holes (14), through which the molten material is led by centrifugal force to form fibres (12). Into the fiberizing device (3) are arranged elements to produce a vertical flow of blowing medium (16) to be led around the fiberizing plate (13), the flow causing the fibres (12) to turn downwards and, at the same time, to thin. Downstream the fiberizing device (3) is arranged a collection device (6), into which the formed fibres (12) are led and collected into a mat-like material. In connection with said at least one fiberizing plate (13) is arranged a substantially horizontal, relatively narrow channel (5), through which the fibres (12) are brought into the chamber space (7) of the collection device (6). The invention further relates to a method for manufacturing mineral wool and a mineral wool product manufactured by the method.

A fiberglass reinforced aerogel composite may include coarse glass fibers, glass microfibers, aerogel particles, and a binder. The coarse glass fibers may have an average fiber diameter between about 8 μm and about 20 μm. The glass microfibers may have an average fiber diameter between about 0.5 μm and about 3 μm. The glass microfibers may be homogenously dispersed within the coarse glass fibers. The aerogel particles may be homogenously dispersed within the coarse glass fibers and the glass microfibers. The fiberglass reinforced aerogel composite may include between about 50 wt. % and about 75 wt. % of the aerogel particles. The binder bonds the coarse glass fibers, the glass microfibers, and the aerogel particles together.

The invention relates to the field of materials based on mineral fibers, in particular mineral wool such as glass wool or rock wool. More specifically, the present invention relates to a method and a device for recycling the water recovered in a fiberizing and shaping method when using a specific acid binder based on monomeric polycarboxylic acid, or a salt of such an acid.

Provided are a heat-insulating and sound-absorbing material improved in construction workability, and a partition wall in which degradation in sound insulation performance is suppressed. The heat-insulating and sound-absorbing material 1 is comprised of an agglomerate of inorganic fibers, wherein the agglomerate has a density of 10 to 20 kg/m.sup.3 and the inorganic fibers of the agglomerate have a length-weighted average fiber diameter of 2.0 to 8.7 μm, and wherein the agglomerate contains: 20 to 66% of inorganic fibers having a length-weighted average fiber diameter of less than 4.0 μm; and 13 to 58% of inorganic fibers having a length-weighted average fiber diameter of 7.0 μm or more. The partition wall comprises a hollow wall portion, and the above heat-insulating and sound-absorbing material installed in the hollow wall portion.

Fiber-containing composites are described that include woven or non-woven fibers, and a binder that holds the fibers together. The binder may include the reaction product of a starch and a polycarboxylic acid. The starch has a weight average molecular weight that ranges from 1×10.sup.6 Daltons to 10×10.sup.6 Daltons. The fiber-containing composite has an unaged tensile strength of greater than 4.0 and an aged tensile strength greater than 3.0. Also described are methods of making the fiber-containing composites. The methods may include applying a binder composition to fibers to form coated fibers, measuring a moisture content of the coated fibers, and curing the coated fibers in a curing oven to form the fiber-containing composite. The binder composition may include a starch having a weight average molecular weight that ranges from 1×10.sup.6 Daltons to 10×10.sup.6 Daltons, and a polycarboxylic acid.

Fiber-containing composites are described that include woven or non-woven fibers, and a binder that holds the fibers together. The binder may include the reaction product of a starch and a polycarboxylic acid. The starch has a weight average molecular weight that ranges from 1×10.sup.6 Daltons to 10×10.sup.6 Daltons. The fiber-containing composite has an unaged tensile strength of greater than 4.0 and an aged tensile strength greater than 3.0. Also described are methods of making the fiber-containing composites. The methods may include applying a binder composition to fibers to form coated fibers, measuring a moisture content of the coated fibers, and curing the coated fibers in a curing oven to form the fiber-containing composite. The binder composition may include a starch having a weight average molecular weight that ranges from 1×10.sup.6 Daltons to 10×10.sup.6 Daltons, and a polycarboxylic acid.

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.

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.