Method for manufacturing a mineral fibre-containing element and element produced by that method

A method for manufacturing a mineral fibre-containing element, said method comprising the steps of:

• providing mineral fibres in an amount of from 70 to less than 89 wt % of the total weight of starting materials in the form of a collected web,
• providing a thermally curable binder in an amount of greater than 11 up to 30 wt % of the total weight of starting materials,
• subjecting the collected web of fibres to a disentanglement process, suspending the fibres in a primary air flow,
• mixing the thermally curable binder with the mineral fibres before, during or after the disentanglement process to form a mixture of mineral fibres and thermally curable binder,
• collecting the mixture of mineral fibres and thermally curable binder and pressing and curing the mixture to provide a consolidated composite with a density of from 120 kg/m3 to 1000 kg/m3,
• wherein the mineral fibres and thermally curable binder, when suspended in the primary air flow, are subjected to a further air flow in a different direction to the primary air flow, and
• wherein the primary air flow is generally lateral and the further air flow is generally upwards, and
• wherein the mineral fibres and thermally curable binder together make up at least 96% of the total weight of starting materials.