A process for manufacturing a mat of mineral fibers, wherein fibers are formed and a binding compound resulting from the mixture of a binder composition with dilution water is applied on the fibers, the fibers impregnated with the binding compound are collected on a perforated receiving device equipped with a fiber-receiving surface and, below the surface, at least one suction duct, and the mat is heat treated. The process includes determining an optimal amount of dilution water as a function of the humidity of the air in the fiberizing station, of the humidity of the intake air and of the intake air flow rate in the at least one suction duct, and of the desired amount of water in the mat at the outlet of the receiving chamber, and adjusting the amount of dilution water as a function of the optimal amount thus determined.

Methods of reducing salt precipitation from a binder composition are described. The methods may include the steps of providing an aqueous binder solution having one or more carbohydrates. They may also include adding a sequestrant for one or more multivalent ions to the aqueous binder solution. The sequestrant reduces a precipitation rate for the multivalent ions from the binder composition. The binder composition may include a polymerization catalyst. Exemplary sequestrants may include polycarboxylic acids or anhydrides. Exemplary sequestrant concentrations may range from about 2 wt. % or less of the aqueous binder solution.

A method of producing a sandwich panel core of mineral wool fibres from a cured mineral fibre product includes the steps of providing a cured mineral fibre product with a dual density having a top layer with mineral fibres with a first density and a base layer having mineral fibres with a second density, the second density is at least two times lower than said first density. The top layer and the base layer have different fibre orientations. Further steps including cutting the mineral fibre product into a plurality of lamellae, rotating the lamellae 90 degrees, and re-joining the lamellae so that the top layers with the first density are vertically oriented.

A method of producing a sandwich panel core of mineral wool fibres from a cured mineral fibre product includes the steps of providing a cured mineral fibre product with a dual density having a top layer with mineral fibres with a first density and a base layer having mineral fibres with a second density, the second density is at least two times lower than said first density. The top layer and the base layer have different fibre orientations. Further steps including cutting the mineral fibre product into a plurality of lamellae, rotating the lamellae 90 degrees, and re-joining the lamellae so that the top layers with the first density are vertically oriented.

A method for ventilating an oven configured to cure a binder bonding mineral fibers placed on a conveyor, the oven including, in series on the path of the conveyor, an inlet, a plurality of heating chambers and an outlet, the method including a procedure in which a predictive model for estimating an amount of pollutants is used.

A thermal insulation product based on mineral wool, characterized in that the fibers have a micronaire of less than 10 1/min, preferably less than 7 1/min and especially between 3 and 6 1/min, and in that the material has a thermal conductivity of less than 31 mW/m.K, especially less than 30 mW/m.K. The parameters for obtaining this product are in particular the pressure of the burner, the rotation speed of the fiberizing spinner and the daily fiber output per spinner orifice.

A thermal insulation product based on mineral wool, characterized in that the fibers have a micronaire of less than 10 1/min, preferably less than 7 1/min and especially between 3 and 6 1/min, and in that the material has a thermal conductivity of less than 31 mW/m.K, especially less than 30 mW/m.K. The parameters for obtaining this product are in particular the pressure of the burner, the rotation speed of the fiberizing spinner and the daily fiber output per spinner orifice.

Systems, devices and methods are provided for producing fibrous materials and products, such as filters. A system comprises a first device for generating one or more fiber stream(s), and a second device for isolating nanoparticles within a gaseous medium. The second device forms the nanoparticles into a stream and feeds this stream into the fiber streams to form the fibrous material. This distributes the nanoparticles more uniformly throughout the fibrous material. In addition, the nanoparticles increase the overall surface area within the material, which, in certain applications, increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop through the filter. Filters produced with these systems and methods are capable of withstanding rigorous conditioning, which allows the filter to achieve substantially the same level of filtration performance throughout the lifetime of the filter.

Systems, devices and methods are provided for producing fibrous materials and products, such as filters. A system comprises a first device for generating one or more fiber stream(s), and a second device for isolating nanoparticles within a gaseous medium. The second device forms the nanoparticles into a stream and feeds this stream into the fiber streams to form the fibrous material. This distributes the nanoparticles more uniformly throughout the fibrous material. In addition, the nanoparticles increase the overall surface area within the material, which, in certain applications, increases its filtration efficiency and allows for the capture of submicron contaminants without significantly compromising other factors, such as pressure drop through the filter. Filters produced with these systems and methods are capable of withstanding rigorous conditioning, which allows the filter to achieve substantially the same level of filtration performance throughout the lifetime of the filter.

An oven for heating a fibrous mat includes a first conveyor for conveying the mat in a forward direction, and a measurement system inside the mat, including a sensor mounted on the first conveyor and adapted to move, in a transverse direction of the mat, between a first retracted position inside the conveyor and a measurement position inside the mat under the effect of an activation system, the measurement system being such that the sensor is connected by a mechanical transmission system to a finger projecting on a lateral side of the first conveyor, and the activation system includes at least one contact surface located facing the lateral side of the conveyor and adapted to engage with the finger, when it moves in the forward direction in order to move the sensor from its retracted position to its measurement position by the mechanical transmission system.