A method for the manufacture of mineral wool, is disclosed. In one example, the method comprises reacting an aqueous phenol-formaldehyde resole with free formaldehyde with a first amount of urea, thereby preparing a prereact; contacting the prereact with a second amount of urea; applying the resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives, to the surface of mineral fibers; and curing the binder on the surface of the mineral fibers. The total amount of urea used ranges 10-40 wt. % relative to the sum of the dry weight of the phenol-formaldehyde resole and the total amount of urea, and the second amount of urea used is at least 40 wt.-% of the total amount of urea. The invention also relates to a mineral wool product with reduced emissions of formaldehyde obtained by the method.

A method for the manufacture of mineral wool, is disclosed. In one example, the method comprises reacting an aqueous phenol-formaldehyde resole with free formaldehyde with a first amount of urea, thereby preparing a prereact; contacting the prereact with a second amount of urea; applying the resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives, to the surface of mineral fibers; and curing the binder on the surface of the mineral fibers. The total amount of urea used ranges 10-40 wt. % relative to the sum of the dry weight of the phenol-formaldehyde resole and the total amount of urea, and the second amount of urea used is at least 40 wt.-% of the total amount of urea. The invention also relates to a mineral wool product with reduced emissions of formaldehyde obtained by the method.

Hydrophobic mineral insulation materials and method of making the same are disclosed. The mineral insulants may include at least one amino-functional organosilicon compound. The amino-functional organosilicon compounds may have an amine number in the range of 0.05 to 0.40. The method of hydrophobicizing may include providing an aqueous emulsion having at least one amino-functional organosilicon compound which may have an amine in the range of 0.05 to 0.40.

Hydrophobic mineral insulation materials and method of making the same are disclosed. The mineral insulants may include at least one amino-functional organosilicon compound. The amino-functional organosilicon compounds may have an amine number in the range of 0.05 to 0.40. The method of hydrophobicizing may include providing an aqueous emulsion having at least one amino-functional organosilicon compound which may have an amine in the range of 0.05 to 0.40.

A fiber and a fiber manufacturing method are provided, in which IGCC slag constitute a component of raw materials of the fiber. The fiber can be fabricated stably from the melt of the raw materials by the method in which the raw materials are preheated up to 1300° C. or higher; the raw materials are maintained at the same temperature for certain period of time; subsequently, the temperature of the raw materials are raised further to cause the melted materials are spun into fiber.

The present invention relates to a method for the manufacturing of a coated panel, in particular a wall, ceiling or flooring panel for applications in outdoor areas, as well as such a panel. The method comprises the following steps: providing a carrier plate of mineral wool and/or glass wool, comprising a front side and a rear side, applying a primer onto the front side of the carrier plate, thereafter applying a liquid first oligomer in an amount of 30 to 150 g/m.sup.2 onto the front side of the carrier plate; thereafter applying a liquid second oligomer, which differs from the first oligomer, in an amount of 30 to 180 g/m.sup.2 onto the wet surface of the before applied layer of the first oligomer.

The present invention relates to a method for the manufacturing of a coated panel, in particular a wall, ceiling or flooring panel for applications in outdoor areas, as well as such a panel. The method comprises the following steps: providing a carrier plate of mineral wool and/or glass wool, comprising a front side and a rear side, applying a primer onto the front side of the carrier plate, thereafter applying a liquid first oligomer in an amount of 30 to 150 g/m.sup.2 onto the front side of the carrier plate; thereafter applying a liquid second oligomer, which differs from the first oligomer, in an amount of 30 to 180 g/m.sup.2 onto the wet surface of the before applied layer of the first oligomer.

A process for the manufacture of inorganic fibres comprises: (a) selecting a composition and proportion of: (i) silica sand; (ii) lime comprising at least 0.10 wt % magnesia; and (iii) optional additives comprising a source of oxides or non-oxides of one or more of the lanthanides series of elements, or combinations thereof; (b) mixing the silica sand; lime; and optional additives to form a mixture; (c) melting the mixture in a furnace; and (d) shaping the molten mixture into inorganic fibres. The raw materials selection comprises composition selection and proportion selection of the raw materials to obtain an inorganic fibre composition comprising a range of from 61.0 wt % and 70.8 wt % silica; less than 2.0 wt % magnesia; less than 2.0% incidental impurities; and no more than 2.0 wt % of metal oxides and/or metal non-oxides derived from said optional additives; with calcia providing the balance up to 100 wt %; and wherein the inorganic fibre composition comprises no more than 0.80 wt % Al.sub.2O.sub.3 derived from the incidental impurities and/or the optional additives.

A process for the manufacture of inorganic fibres comprises: (a) selecting a composition and proportion of: (i) silica sand; (ii) lime comprising at least 0.10 wt % magnesia; and (iii) optional additives comprising a source of oxides or non-oxides of one or more of the lanthanides series of elements, or combinations thereof; (b) mixing the silica sand; lime; and optional additives to form a mixture; (c) melting the mixture in a furnace; and (d) shaping the molten mixture into inorganic fibres. The raw materials selection comprises composition selection and proportion selection of the raw materials to obtain an inorganic fibre composition comprising a range of from 61.0 wt % and 70.8 wt % silica; less than 2.0 wt % magnesia; less than 2.0% incidental impurities; and no more than 2.0 wt % of metal oxides and/or metal non-oxides derived from said optional additives; with calcia providing the balance up to 100 wt %; and wherein the inorganic fibre composition comprises no more than 0.80 wt % Al.sub.2O.sub.3 derived from the incidental impurities and/or the optional additives.

The invention relates to a method for manufacturing water treated man-made vitreous fibres (MMVF) comprising:

a. providing a mineral melt,

b. providing a fiberizing apparatus,

c. fiberizing the mineral melt to form man-made vitreous fibres (MMVF),

d. collecting the MMVF, and thereafter

e. applying about 0.1 wt % to about 1 wt % water, based on the weight of the MMVF, to the MMVF to form water treated MMVF.