Abstract: A method for the manufacture of mineral wool products 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. The prereact is contacted with a second amount of urea. The resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives is applied to the surface of mineral fibers. The binder is cured on the surface of the mineral fibers. A mineral wool product with reduced emissions of formaldehyde is also disclosed.

Abstract: A method for the manufacture of mineral wool products 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. The prereact is contacted with a second amount of urea. The resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives is applied to the surface of mineral fibers. The binder is cured on the surface of the mineral fibers. A mineral wool product with reduced emissions of formaldehyde is also disclosed.

Abstract: Embodiments of a curable formaldehyde-free resin, and a method for the manufacture of the curable formaldehyde-free resin are provided herein. The curable formaldehyde-free resin is provided in the form of an aqueous dispersion. The curable formalde-hyde-free resin comprises component a) a reducing sugar, component b) a polycarboxylic acid, component c) one or more polyols having a molecular weight of less than 1000 g/mol, and component d) epoxysilane. The total amount of component c) in the curable formaldehyde-free resin is between 0.5 and 10% wt. with respect to the sum of components a) and b). The amount of component d) is from 0.1% wt. to less than or equal to 2% wt. with respect to the sum of components a) and b). Further, a method for the manufacture of the curable formaldehyde-free resin according to one of the embodiments of the present disclosure is provided.

Abstract: 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.

Abstract: A method for the manufacture of mineral wool products 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. The prereact is contacted with a second amount of urea. The resulting mixture of prereact and second amount of urea, as part of a binder, optionally with additives is applied to the surface of mineral fibers. The binder is cured on the surface of the mineral fibers. A mineral wool product with reduced emissions of formaldehyde is also disclosed.

Abstract: 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.

Abstract: The present invention relates to a new formaldehyde-free binder composition for mineral wool products, wherein the binder composition is an aqueous composition containing starch, wherein an amount of 95 weight % or more of the starch is water-insoluble native starch, and an acrylic component. The present invention also relates to the use of this formaldehyde-free binder composition in the manufacturing of mineral wool insulation products. Finally, the present invention relates to a process for manufacturing the formaldehyde-free binder composition wherein a dispersion of starch, wherein an amount of 95 weight % or more of the starch is water-insoluble native starch, is brought in contact with the acrylic component at a temperature of not higher than 40° C.

Abstract: The present invention relates to a new formaldehyde-free binder composition for mineral wool products, wherein the binder composition is an aqueous composition containing starch, wherein an amount of 95 weight % or more of the starch is water-insoluble native starch, and an acrylic component. The present invention also relates to the use of this formaldehyde-free binder composition in the manufacturing of mineral wool insulation products. Finally, the present invention relates to a process for manufacturing the formaldehyde-free binder composition wherein a dispersion of starch, wherein an amount of 95 weight % or more of the starch is water-insoluble native starch, is brought in contact with the acrylic component at a temperature of not higher than 40° C.