The present invention relates to a method of producing a coherent growth substrate product formed of man-made vitreous fibres (MMVF), comprising the steps of (vi) providing MMVF; (vii) providing an uncured binder composition; (viii) providing a superabsorbent polymer; (ix) forming a mixture of the MMVF, the uncured binder composition and the superabsorbent polymer; (x) curing the uncured binder composition in the mixture to form the coherent growth substrate product; wherein the uncured binder composition comprises at least one hydrocolloid.

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 first carbon moiety selected from an aldehyde, a ketone, a nitrile, and a nitro group, wherein an α-carbon atom having at least one acidic hydrogen is directly bonded to the first carbon moiety. Exemplary reducing sugars include dextrose and exemplary crosslinking agents include glyoxal. Exemplary fiber-containing composites may include fiberglass insulation.

A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. Generally, two processing steps for forming materials are involved. In a first step, dense pellets or granules are formed from starch and a plasticizing agent, such as a plasticizing polymer, for example, polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water as the expansion agent in which the dwell time in the extruder is short. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.

Biodegradable pellet compositions comprising: a starch at about 30% to about 80% by weight of the composition, a plasticizer at about 2% to about 30% by weight of the composition; a flexibility agent at about 10% to about 40% by weight; a binder at about 3% to about 13% by weight of the composition; a hydrophobic agent at about 0.1% to about 5% by weight of the composition; and an emulsifier at about 0.1% to about 5% by weight of the composition. The compositions further comprise a defoaming agent where a biodegradable foam pellet is the end product. The compositions may optionally include a plant fiber.

A composite material, comprising a first component and a second component, the first component forming a three-dimensional mesh-type structure and the second component forming a matrix at least regionally filling the interstices between the first component, wherein the second component at least partially comprises an expanded material.

A binder has at least one isocyanate and at least one biopolymer mixed with water. The biopolymer may be a biopolymer nanoparticle or cooked and chemically modified starch. Optionally, the binder may also include urea. The biopolymer and water are mixed, and the isocyanate is added to the mixture. The binder may have a viscosity that is suitable for being sprayed on a substrate to make a composite material, for example a viscosity of 700 cP or less or 500 cP or less at 40 C. The substrate may be wood, another lignocellulosic material, or synthetic or natural fibers. In particular examples, the binder is used to make no added formaldehyde wood composites including particle board and fiberboard. Alternatively, the binder may have a higher viscosity and be used to make plywood.

A binder comprising isocyanate droplets in water, wherein the isocyanate droplets have an average droplet size of 500 microns or less, and the isocyanate droplets have shells comprising a biopolymer or a reaction product of a biopolymer and isocyanate. The biopolymer may be a biopolymer nanoparticle or cooked and chemically modified starch. Optionally, the binder may also include urea. The substrate for the binder may be wood, another lignocellulosic material, or synthetic or natural fibers. In particular examples, the binder is used to make no added formaldehyde wood composites including particle board and MDF.

The present invention relates to a thermosetting binder composition containing water and a water-soluble oligomeric ester of at least one saccharide chosen from reducing sugars, non-reducing sugars and hydrogenated sugars, the hydrogenated sugars being chosen from the group consisting of erythritol, arabitol, xylitol, sorbitol, mannitol, iditol, maltitol, isomaltitol, lactitol, cellobitol, palatinitol, maltotritol and hydrogenation products of hydrolyzates of starch or of lignocellulose materials, and of at least one polycarboxylic acid, the binder composition having a dry matter content of between 50% and 80% by weight, the water-soluble oligomeric ester representing at least 80% by weight, preferably at least 90% by weight, of the cry matter content of the thermosetting binder composition, and the thermosetting binder composition containing less than 10% by weight, preferably less than 5% by weight, with respect to its dry matter content, of free sorbitol.

It also relates to the use of such a binder composition for the manufacture of a product based on mineral or organic fibers which are bonded by an insoluble organic binder.

A processing system for producing starch based expanded products useful as packing material for shipping, packaging and insulating applications. Generally, two processing steps for forming materials are involved. In a first step, dense pellets or granules are formed from starch and a plasticizing agent, such as a plasticizing polymer, for example, polyvinyl alcohol. The starch in the pellets is generally formed, for example with an extruder, into a thermoplastic or thermosetting form for further processing. The pellets generally have an individual density of at least about 70 lbs./cubic foot and a small size for convenient delivery for the second processing step. The second process step is based on the expanding of the material from an extruder with water as the expansion agent in which the dwell time in the extruder is short. The process is designed such that a less expensive single screw extruder is suitable for extruding the expanded material. The starch based pellets are convenient for shipping closer to the end use location.

A formaldehyde-free binder composition for mineral fibers which comprises at least one phenol containing compound and at least one protein.