A cross-linked nonwoven fibrous mat is disclosed comprising a core layer including a fibrous precursor mat bound with a formaldehyde-free core binder composition and a cross-linker disposed on at least one surface of the core layer, said cross-linker comprising one or more of isocyanate, polyol, and melamine functional groups. The cross-linked nonwoven mat has a hot-wet retention of at least 25%.

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.

The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.

Aqueous binder compositions with reduced rates of salt precipitation are described. The compositions may include a carbohydrate and a sequestrant for sequestering one or more multivalent ions (e.g., Ca.sup.2+, Mg.sup.2+, Ba.sup.2+, Al.sup.3+, Fe.sup.2+, Fe.sup.3+, etc.). The sequestrant reduces a precipitation rate for the multivalent ions from the aqueous binder composition. Methods of reducing salt precipitation from a binder composition are also 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 present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.

The present invention is directed to a method of making at least a portion of a garment that includes at least one three-dimensional contour. The disclosed method includes providing a fiber and solvent mixture that includes fibers and a solvent capable to causing a plurality of covalent bonds to be created between the fibers. In many embodiments, the plurality of covalent bonds form when a catalyst, such as heat, is provided to the fiber and solvent mixture. The process can be performed using, for example, either a 3D printer or mold form. The fibers used can be natural, synthetic, or a blend of natural and/or synthetic fibers. The solvent preferably includes ionic salts in water.

Aqueous binder compositions with reduced rates of salt precipitation are described. The compositions may include a carbohydrate and a sequestrant for sequestering one or more multivalent ions (e.g., Ca.sup.2+, Mg.sup.2+, Ba.sup.2+, Al.sup.3+, Fe.sup.2+, Fe.sup.3+, etc.). The sequestrant reduces a precipitation rate for the multivalent ions from the aqueous binder composition. Methods of reducing salt precipitation from a binder composition are also 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.

Aqueous binder compositions with reduced rates of salt precipitation are described. The compositions may include a carbohydrate and a sequestrant for sequestering one or more multivalent ions (e.g., Ca.sup.2+, Mg.sup.2+, Ba.sup.2+, Al.sup.3+, Fe.sup.2+, Fe.sup.3+, etc.). The sequestrant reduces a precipitation rate for the multivalent ions from the aqueous binder composition. Methods of reducing salt precipitation from a binder composition are also 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.

A cross-linked nonwoven fibrous mat is disclosed comprising a core layer including a fibrous precursor mat bound with a formaldehyde-free core binder composition and a cross-linker disposed on at least one surface of the core layer, said cross-linker comprising one or more of isocyanate, polyol, and melamine functional groups. The cross-linked nonwoven mat has a hot-wet retention of at least 25%.