Method for manufacturing a blocking product based on mineral wool

Abstract

A method for producing an insulating product based on mineral wool bound by an organic binder is provided. [Solution] A method for producing an insulation product based on mineral wool bound by an organic binder, comprising the following series of steps: (a) providing mineral wool at room temperature; (b) applying an aqueous thermosetting binder composition to the mineral wool; (c) drying the mineral wool impregnated with the aqueous thermosetting binder composition to obtain thermosetting mineral wool; (d) shaping the thermosetting mineral wool; and (e) heating the shaped thermosetting mineral wool at a temperature and for a length of time sufficient to allow the binder components to condense and form an insoluble binder.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a barrier product based on mineral wool bonded by an organic binder, comprising preparing a dried non-sticky thermosetting mineral wool, and thermosetting the mineral wool after optionally blending it with virgin mineral wool and / or recycled mineral wool, or with natural organic fibers.

Embodiments of the Invention

[0002] Generally, the manufacture of mineral wool-based barrier products involves producing glass fibers or rock fibers by centrifuging molten glass or molten rock (fiberization). The newly formed fibers are conveyed by a stream of hot air onto a conveyor belt, which collects (forms) the fibers and transports them through a curing furnace. In the path between the centrifuge device (fiberization) and the fiber collection belt, an aqueous thermosetting binder composition is sprayed onto the fibers, which then undergoes a thermosetting reaction at a temperature of about 200°C in the curing furnace.

[0003] The aqueous binder composition is a dilute aqueous solution of low-viscosity monomeric reagents, oligomers, and / or polymeric resins. They are sprayed onto the newly formed, still hot mineral fibers near the centrifuge device, downstream of the centrifuge device, by a spray ring.

[0004] When the fibers are collected as a mat (or loft) on the collection belt, they are sticky, and the binder composition film surrounding the mineral fibers still contains water.

[0005] Evaporation of the water is completed and the condensation reaction of the binder reagent begins only when the sized mineral wool mat enters the temperature-controlled curing furnace.

[0006] Operating as described above (spraying the binder composition onto the still-hot fibers, partial evaporation of water, formation of a mat of sticky fibers, curing of the mat of sticky fibers in the furnace), an apparatus for manufacturing a thermal insulation product based on mineral wool bound by an organic binder necessarily includes a system for cleaning the apparatus, in particular, a system for cleaning the forming chamber and the collecting belt. In fact, the high tack of the still-wet sized fibers is carried in the hot air stream between the fiberizing device and the conveyor belt, causing contamination of the walls of the forming chamber, the conveyor belt, and the suction device located downstream thereof.

[0007] The cleaning water is recycled, filtered, neutralized, and reused in a closed circuit for the production of the binder solution and for cleaning the production equipment. The system for cleaning the production apparatus and recycling the cleaning water in a closed circuit represents a significant portion of the investment and operating costs of the production apparatus for thermal insulation products based on bound mineral wool.

[0008] The present invention aims to propose a method for manufacturing a thermal insulation product based on mineral wool bound by an organic binder, the method not including the step in which the mineral fibers sized with a partially dried and sticky binder composition are carried by an air stream between a fiberizing device and a region for forming a mat.

[0009] In the method for manufacturing the thermal insulation product of the present invention, the binder composition is not applied to the still-hot, newly formed mineral fibers, but is applied to mineral fibers at room temperature (i.e., in thermal equilibrium with the surrounding environment). The sized mineral fibers are then dried at a temperature high enough to completely or almost completely evaporate the water and eliminate the sticky properties of the fibers. However, the drying temperature is lower than the crosslinking start temperature of the binder reagent.

[0010] In this way, at the end of the drying process carried out at a temperature lower than the crosslinking temperature of the binder, mineral fibers surrounded by a layer of dried binder are obtained. The dried binder is no longer sticky. However, it is thermosetting, i.e., it contains binder reagents and can polymerize and / or crosslink and form an insoluble binder. The terms "thermosetting mineral wool" and "bonding fiber" are used interchangeably hereinafter to refer to these mineral fibers that are sized with an organic binder, dried, not sticky, and retain the ability to cure by crosslinking when heated to a sufficiently high temperature.

[0011] The present invention is based on the discovery that a layer of non-sticky dried binder still enables mineral fibers to bind to each other when a set of fibers is heated to a temperature high enough to cause condensation of the binder reagents.

[0012] In the method for producing mineral wool of the present invention, the thermosetting mineral wool is then optionally blended with non-thermosetting mineral wool and then formed and subjected to a curing process. During this curing process, the dried binder first softens and then melts, thereby promoting the adhesion of the fibers to each other, and then the binder reagents polymerize and crosslink to form an insoluble molten organic binder.

[0013] In the method of the present invention, the mineral wool newly sized with an aqueous binder composition is not carried by a hot air stream. Therefore, it hardly adheres significantly to the device for forming the mineral wool mat, and the method can be operated without a cleaning water system operating in a closed circuit. In the method of the present invention, the mineral wool sized with an aqueous binder composition is first dried before being carried, optionally blended with other fibers, formed, and cured in a furnace.

[0014] Accordingly, the present invention relates to a method for manufacturing a barrier product based on mineral wool bound by an organic binder, comprising the following series of steps: (a) providing mineral wool at room temperature, (b) applying an aqueous thermosetting binder composition to the mineral wool, (c) drying the mineral wool impregnated with the aqueous thermosetting binder composition to obtain a thermosetting mineral wool, (d) shaping the thermosetting mineral wool, and (e) heating the shaped thermosetting mineral wool at a temperature and for a length of time sufficient to allow the components of the binder to condense and form an insoluble binder.

[0015] Accordingly, the first step of the method consists of providing mineral wool at room temperature. The term "at room temperature" does not specify a particular temperature or temperature range, but means that the mineral fibers are in thermal equilibrium with their immediate environment. Thus, the mineral fibers are not mineral fibers in the process of cooling, having emerged from the process of being fiberized by centrifugation of molten glass or molten rock. "Room temperature" is typically from 15°C to 30°C, in particular from 18°C to 25°C.

[0016] The mineral wool provided in step (a) may be unused mineral wool. In the present case, the term "unused mineral wool" refers to mineral wool obtained by internal or external centrifugation, in particular glass wool or rock wool, the fibers of which are not bound to each other by an organic binder. Such unused mineral wool is typically used as wool blown for attic insulation. The fibers of the unused mineral wool can be coated with a thin layer of sizing or lubricant.

[0017] The mineral wool provided in step (a) may be recycled mineral wool. In the present disclosure, the term "recycled mineral wool" refers to mineral wool composed of mineral fibers having an insoluble, non-molten organic binder that has already been crosslinked on its surface.

[0018] Of course, the mineral wool provided in step (a) may be a blend of unused mineral wool and recycled mineral wool in any respective ratio.

[0019] The following step of the method of the present invention consists of applying an aqueous binder composition to unused mineral wool and / or recycled mineral wool. This is advantageously an aqueous solution of the components of the binder, which can form an insoluble, non-molten crosslinked polymer network by reacting with each other.

[0020] The application of the binder composition can be carried out by any suitable means known per se, for example, spraying, roller coating, or dipping the mineral fibers into the aqueous binder composition.

[0021] Therefore, the aqueous binder composition advantageously has a low enough viscosity to be applicable to the mineral fibers by spraying or to enable the impregnation of the mineral wool by dipping into the aqueous binder composition.

[0022] As described above, during the step of applying the aqueous binder composition (step (b)), the mineral wool is preferably at room temperature. The same applies to the aqueous binder composition.

[0023] The aqueous binder composition advantageously has a solids content of 1 to 10% by mass, preferably 1.5 to 8% by mass, particularly 2 to 7% by mass.

[0024] After applying the aqueous binder composition, the sized mineral wool undergoes a drying step (step (c)) aimed at sufficiently evaporating water so as to make the sized fibers substantially non-sticky.

[0025] This drying step can be carried out, for example, by heating in a temperature-controlled ventilation furnace or by irradiating with infrared or microwave radiation. It is important to ensure that the drying does not heat the mineral wool fibers to an excessive temperature, as excessive heating can lead to softening of the dried binder or the initiation of crosslinking of the binder components. Usually, a heating temperature close to the boiling point of water is sufficient.

[0026] Therefore, the drying (step (c)) of the mineral wool impregnated with the aqueous binder composition is preferably carried out by heating to a temperature of 60 - 110 °C, particularly 70 - 100 °C. The fibers of the mineral wool obtained at the end of the drying step are surrounded by a sheath of the dried organic binder. If the wettability of the unused wool / recycled wool by the aqueous binder composition is not too high, the sheath of the organic binder may be uneven and droplets of the dried binder may be observable under a microscope.

[0027] The mineral wool obtained after drying (step (c)) is referred to herein as "thermosetting mineral wool". Therefore, this term refers to mineral wool formed by mineral fibers having a water-soluble dried solid binder on the surface, and this binder contains a reagent that can polymerize and / or crosslink when heated to a temperature higher than a given value (crosslinking start temperature) and can form an insoluble binder. The fibers constituting this thermosetting mineral wool are also called "bonding fibers".

[0028] The thermosetting mineral wool contains, by dry mass, usually 3 to 20%, preferably 4 to 18%, and in particular 5 to 15% of a thermosetting binder. It should be noted that if the mineral wool provided in step (a) is recycled mineral wool that already contains a certain proportion of cross-linked organic binder, the above percentages do not include the amount of cross-linked organic binder present on the fibers before applying the binder composition. Therefore, the loss on ignition (LOI) of the thermosetting mineral wool may be greater than the content of the thermosetting dry organic binder.

[0029] In a preferred embodiment, the method of the present invention further includes a step of blending the thermosetting mineral wool (bonding fibers) with unused mineral wool and / or recycled mineral wool and / or natural organic fibers (unbonded fibers) between the drying step (c) and the forming step (d).

[0030] The natural organic fibers are non-thermoplastic fibers derived from plants or animals. The plant fibers are preferably selected from the group consisting of lignocellulosic fibers and cotton fibers. The lignocellulosic fibers are preferably selected from the group consisting of wood fibers, hemp fibers, flax fibers, sisal fibers, cotton fibers, jute fibers, coconut fibers, raffia fibers, abaca fibers, cereal straws or rice straws. The animal fibers are preferably selected from the group consisting of animal wools such as wool.

[0031] This blend can in principle be carried out by any suitable mechanical means and / or pneumatic means. The inventors have found that the mechanical properties of the final cut-off product are better the more the blending method preserves the length of the blended mineral fibers. In fact, if the size of the fibers is significantly reduced by the blending step, the entanglement of the mineral fibers decreases and the tensile strength of the final product decreases. In a preferred embodiment of the method of the present invention, the blend of the bonding fibers and the unbonded fibers is carried out by a stream of compressed air passing through a vortex chamber. Such a device makes it possible to obtain a highly regular blend without unduly shortening the length of the fibers.

[0032] When using pneumatic means for blending two types of fibers, it is important to ensure that the flow of compressed air is at a temperature low enough to prevent the softening of any possible organic binder.

[0033] In fact, in a preferred embodiment of the method of the present invention, the dry organic binder that forms an organic sheath surrounding the fibers of the thermosetting mineral wool exhibits thermoplastic behavior, i.e., when it is heated to a certain temperature (hereinafter referred to as the "softening temperature" or "glass transition temperature", determined by differential scanning calorimetry (DSC)), it becomes soft or liquefies. This softening temperature is higher than the drying temperature but lower than the crosslinking start temperature of the binder. This softening advantageously gives the fibers a certain tack, thereby enabling them to adhere to each other and, optionally, also to any unbonded mineral fibers (unused mineral wool / recycled mineral wool) or unbonded natural organic fibers that may be present. The inventors have observed that when the dry organic binder becomes sufficiently fluid at high temperatures, it migrates from the fibers of the thermosetting mineral wool, even from the fibers of unused mineral wool / recycled mineral wool or natural organic fibers. When examining a barrier product obtained by blending 50% by mass of thermosetting mineral wool and 50% by mass of unused mineral wool under an optical microscope, the inventors found the presence of the organic binder not only on half of them but on all the fibers.

[0034] The respective ratios of the thermosetting mineral fibers (bonding fibers) to the unused mineral fibers / recycled mineral fibers or natural organic fibers can be varied within a fairly wide range. These ranges depend, inter alia, on the uniformity of the fiber blend and the content of the thermosetting binder in the bonding fibers. The higher the uniformity of the blend and the higher the content of the thermosetting binder in the bonding fibers, the higher the proportion of unbonded unused fibers / recycled fibers or natural organic fibers may be.

[0035] Typically, 100 parts by mass of thermosetting mineral wool is blended with 10 to 400 parts by mass, preferably 20 to 300 parts by mass, and in particular 30 to 200 parts by mass of unused mineral wool and / or recycled mineral wool (unbonded mineral wool), or natural organic fibers.

[0036] Accordingly, in a particularly advantageous embodiment, a method for manufacturing a barrier product based on mineral wool bonded by an organic binder comprises the following series of seven steps: - Providing mineral wool at room temperature, - Applying an aqueous thermosetting binder composition to the mineral wool, - Drying the mineral wool impregnated with the aqueous thermosetting binder composition to obtain thermosetting mineral wool, - Blending the thermosetting mineral wool with unused mineral wool and / or recycled mineral wool, or with natural organic fibers, - Shaping the blend of the thermosetting mineral wool with unused mineral wool and / or recycled mineral wool, or with natural organic fibers, and - Heating the shaped blend at a temperature and for a length sufficient to allow the components of the binder to crosslink and form an insoluble binder.

[0037] The step of shaping the thermosetting mineral wool (or a blend of thermosetting mineral wool with unused mineral wool and / or recycled mineral wool and / or natural organic fibers) is preferably carried out by molding and / or compression. The mold used for shaping the product needs to be manufactured from a material that can withstand the temperature of the thermosetting process. Further, it needs to have a structure that enables the hot air from the hardening furnace to easily penetrate the shaped product. The mold may consist of, for example, a box-shaped metal screen. The metal screen box is preferably filled with a large amount of bulk-packed thermosetting mineral wool that is greater than its capacity and then closed by a metal screen cover. Thus, the thermosetting mineral wool is compressed more or less depending on the excess filling amount. This excess filling amount of the box with thermosetting mineral wool is, for example, 10% - 150%, preferably 15 - 100%, particularly 20 - 80%.

[0038] When the method of the present invention is a continuous method, the shaping of the thermosetting mineral wool can be carried out, for example, by compression with rollers at the entrance of the hardening furnace on a conveyor.

[0039] The step of curing the shaped thermosetting mineral wool by heating it at a temperature and for a length sufficient to allow the constituents of the binder to condense (polymerize / crosslink) and form an insoluble binder is carried out under conditions well known to those skilled in the art. When the method is a continuous method, the hardening furnace is advantageously the same as the furnace in a line for manufacturing prior art cutoff products, where very high-temperature compressed air passes through the mat of mineral wool.

[0040] The heating temperature in step (e) is advantageously 130°C - 240°C, preferably 180°C - 230°C, particularly 190°C - 220°C. The heating time is advantageously 30 seconds - 15 minutes, preferably 1 minute - 10 minutes, particularly 2 - 8 minutes.

[0041] By changing the compression ratio of the thermosetting mineral wool during the hardening process, it is easy to adjust the density and thickness of the insulation product based on the mineral wool obtained by the method of the present invention. The density of the insulation product is usually 4 to 150 kg / m 3 , preferably 5 to 60 kg / m 3 , in particular, 6 to 40 kg / m 3 . Its thickness is usually 20 mm to 500 mm, preferably 40 mm to 300 mm, preferably 50 mm to 200 mm, in particular, 60 mm to 150 mm.

[0042] The method for manufacturing the insulation product based on mineral wool disclosed above can, in principle, be carried out using any thermosetting organic binder currently used in the field of mineral wool.

[0043] Examples of such binders include the following. - Resole resin (phenol-formaldehyde), preferably based on a resole resin modified with urea, - Based on Maillard reagents (reducing sugars and amines), - Based on an acrylic polymer and a crosslinking agent such as a polyhydroxylated reagent and a polyaminated reagent, - Based on a non-reducing sugar and / or a hydrogenated sugar and a polycarboxylated reagent such as citric acid, - Based on an aminoamide obtained by the reaction of a carboxylic acid anhydride and an alkanolamine.

[0044] The binder preferably does not contain formaldehyde and advantageously contains bio-derived reagents that can be regenerated in a short period. In one advantageous embodiment, the aqueous binder composition contains more than 50% by dry mass of bio-derived reagents.

[0045] These bio-derived reagents are selected, for example, from saccharides and saccharide hydrogenation products. The aqueous binder composition additionally contains a crosslinking agent, which is typically a polycarboxylic acid, preferably citric acid. The reaction between the saccharide and saccharide hydrogenation product and the polycarboxylic acid is preferably catalyzed by a catalyst, in particular sodium hypophosphite (HPS).

[0046] A system of thermosetting binders for mineral wool based on reducing sugars, non-reducing sugars and / or hydrogenated sugars and polycarboxylic acids is disclosed in detail in the name of the applicant in international applications WO2009 / 080938, WO2010 / 029266, WO2013 / 014399, WO2013 / 021112 and WO2015 / 132518.

[0047] As far as the applicant is aware, the intermediate product obtained at the end of step (c) of the method of the present invention, i.e., the thermosetting mineral wool formed from mineral fibers surrounded by a dried thermosetting organic layer in thermal equilibrium with the surrounding environment, has not been previously disclosed in the prior art.

[0048] As a result, the present case further relates to a bulk-filled thermosetting mineral wool containing bound mineral fibers surrounded by a dried layer of thermosetting organic binder and optionally unbound fibers. This mineral wool is bulk-filled, i.e., it consists of individual fibers that can be intertwined but are not adhered to each other to form a mat of fibers.

[0049] The organic binder layer on the surface of the fibers does not contain water and is therefore not an aqueous viscous composition of the organic binder, so this thermosetting mineral wool is not sticky.

[0050] Furthermore, this thermosetting mineral wool is in thermal equilibrium with its environment, i.e., it is not in the process of cooling (e.g., after fiberization) or heating (e.g., in a furnace).

[0051] The thermosetting mineral wool of the present invention is a stable intermediate product that can be stored, transported, and processed under environmental conditions of temperature and relative humidity.

[0052] It can consist exclusively of bound fibers (mineral fibers surrounded by layers of thermosetting organic binders), but can also contain both bound fibers and unbound fibers. In the latter case, as defined and disclosed above, preferably, the unbound fibers are selected from fibers of unused mineral wool and / or recycled mineral wool and / or natural organic fibers.

[0053] When the bulk-packed thermosetting mineral wool of the present invention is a blend of bound fibers and unbound fibers, it usually contains 10 to 400 parts by mass, preferably 20 to 300 parts by mass, particularly 30 to 200 parts by mass, of unused mineral wool and / or recycled mineral wool (unbound mineral wool) or natural organic fibers per 100 parts by mass of the thermosetting mineral wool. The present disclosure also includes the following. [Aspect 1] A method for manufacturing a blocking product based on mineral wool bound by an organic binder, the method comprising the following series of steps: (a) providing mineral wool at room temperature, (b) applying an aqueous thermosetting binder composition to the mineral wool, (c) drying the mineral wool impregnated with the aqueous thermosetting binder composition to obtain thermosetting mineral wool, (d) shaping the thermosetting mineral wool, and (e) heating the shaped thermosetting mineral wool at a temperature and for a length sufficient to allow the components of the binder to condense and form an insoluble binder A method comprising. [Aspect 2] The method according to aspect 1 above, characterized in that the mineral wool provided in step (a) is virgin mineral wool or recycled mineral wool, or a blend of virgin mineral wool and recycled mineral wool. [Aspect 3] The method according to aspect 1 or 2 above, characterized in that the mineral wool is at room temperature during the step of applying the aqueous binder composition. [Aspect 4] The method according to any one of aspects 1 to 3 above, further comprising a step of blending the thermosetting mineral wool with virgin mineral wool and / or recycled mineral wool and / or natural organic fibers between step (c) and step (d). [Aspect 5] The method according to aspect 4 above, characterized in that the natural organic fibers are plant fibers, preferably selected from the group consisting of lignocellulosic fibers and cotton, or the natural organic fibers are animal fibers, preferably selected from the group consisting of animal wool. [Aspect 6] The method according to aspect 4 or 5 above, characterized in that 100 parts by mass of the thermosetting mineral wool is blended with 10 to 400 parts by mass, preferably 20 to 300 parts by mass, particularly 30 to 200 parts by mass of the virgin mineral wool and / or the recycled mineral wool and / or the natural organic fibers. [Aspect 7] The method according to any one of aspects 1 to 6 above, characterized in that the drying of the mineral wool impregnated with the aqueous binder composition (step (c)) is carried out by heating to a temperature of 60 to 110 °C, preferably 70 to 100 °C. [Aspect 8] The method according to any one of the above aspects 1 to 7, characterized in that the thermosetting mineral wool contains 3 to 20%, preferably 4 to 18%, particularly 5 to 15% of a thermosetting binder by dry mass. [Aspect 9] The density of the barrier product obtained in the step (e) is 4 to 150 kg / m 3 , preferably 5 to 60 kg / m 3 , particularly 6 to 40 kg / m 3 , and the method according to any one of the above aspects 1 to 8 is characterized thereby. [Aspect 10] The method according to any one of the above aspects 1 to 9, characterized in that the thickness of the barrier product obtained in the step (e) is 20 mm to 500 mm, preferably 50 mm to 200 mm, particularly 60 mm to 150 mm. [Aspect 11] The method according to any one of the above aspects 1 to 10, characterized in that the aqueous binder composition contains more than 50% of a bio-derived reagent by dry mass. [Aspect 12] The method according to any one of the above aspects 1 to 11, characterized in that the bio-derived reagent is selected from saccharides and saccharide hydrogenation products. [Aspect 13] The method according to any one of the above aspects 1 to 12, characterized in that the step (d) of shaping the thermosetting mineral wool is carried out by shaping and / or compressing the thermosetting mineral wool. [Aspect 14] The method according to any one of the above aspects 1 to 13, characterized in that the heating temperature in the step (e) is 130°C to 240°C, preferably 180°C to 230°C. [Aspect 15] Loose-filled thermosetting mineral wool containing bonded mineral fibers surrounded by a dried layer of a thermosetting organic binder and optionally unbonded fibers. [Aspect 16] The loose-filled thermosetting mineral wool according to the above aspect 15, wherein the unbonded fibers are selected from fibers of unused mineral wool and / or recycled mineral wool and / or natural organic fibers.

Claims

1. A method for manufacturing a blocking product based on mineral wool bound by an organic binder, the method comprising the following series of steps: (a) providing mineral wool at room temperature, (b) applying an aqueous thermosetting binder composition to the mineral wool, (c) drying the mineral wool impregnated with the aqueous thermosetting binder composition to obtain thermosetting mineral wool, (d) shaping the thermosetting mineral wool, and (e) heating the shaped thermosetting mineral wool at a temperature and for a length sufficient to allow the components of the aqueous thermosetting binder composition to condense and form an insoluble binder. A method comprising the above.

2. The method according to claim 1, characterized in that the mineral wool provided in step (a) is virgin mineral wool or recycled mineral wool, or a blend of virgin mineral wool and recycled mineral wool.

3. The method according to claim 1 or 2, characterized in that the mineral wool is at room temperature during the step of applying the aqueous thermosetting binder composition.

4. The method according to any one of claims 1 to 3, further comprising, between step (c) and step (d), a step of blending the thermosetting mineral wool with virgin mineral wool and / or recycled mineral wool and / or natural organic fibers.

5. The method according to claim 4, characterized in that the natural organic fibers are plant fibers, preferably selected from the group consisting of lignocellulosic fibers and cotton, or the natural organic fibers are animal fibers, preferably selected from the group consisting of animal wool.

6. The method according to claim 4 or 5, characterized in that 100 parts by mass of the thermosetting mineral wool is blended with 10 to 400 parts by mass, preferably 20 to 300 parts by mass, particularly 30 to 200 parts by mass of the virgin mineral wool and / or the recycled mineral wool and / or the natural organic fibers.

7. The method according to any one of claims 1 to 6, characterized in that the drying of the mineral wool impregnated with the aqueous thermosetting binder composition (step (c)) is carried out by heating to a temperature of 60 to 110 °C, preferably 70 to 100 °C.

8. The method according to any one of claims 1 to 7, characterized in that the thermosetting mineral wool contains 3 to 20%, preferably 4 to 18%, particularly 5 to 15% of a thermosetting binder by dry mass.

9. The density of the blocking product obtained in the step (e) is 4 to 150 kg / m ３ , preferably 5 to 60 kg / m ３ , particularly 6 to 40 kg / m ３ , and the method according to any one of claims 1 to 8, characterized in that.

10. The method according to any one of claims 1 to 9, characterized in that the thickness of the barrier product obtained in the step (e) is 20 mm to 500 mm, preferably 50 mm to 200 mm, particularly 60 mm to 150 mm.

11. The method according to any one of claims 1 to 10, characterized in that the aqueous thermosetting binder composition contains more than 50% of a bio-derived reagent by dry mass.

12. The method according to claim 11, characterized in that the bio-derived reagent is selected from saccharides and saccharide hydrogenation products.

13. The method according to any one of claims 1 to 12, characterized in that the step (d) of shaping the thermosetting mineral wool is carried out by molding and / or compressing the thermosetting mineral wool.

14. The method according to any one of claims 1 to 13, characterized in that the heating temperature in the step (e) is 130 °C to 240 °C, preferably 180 °C to 230 °C.

15. Loose-packed thermosetting mineral wool containing bonded mineral fibers surrounded by a dried layer of a thermosetting organic binder and optionally unbonded fibers.

16. The loose-packed thermosetting mineral wool according to claim 15, characterized in that the unbonded fibers are selected from fibers of unused mineral wool and / or fibers of recycled mineral wool and / or natural organic fibers.