Fibres fuse the web

Rigid boards, flexible designs

Discover how Beaulieu’s thermal bonding fibres transform loose materials into high-performance insulation boards, without the use of chemical binders, water, or VOCs. Ideal for thermal and acoustic insulation, as well as flexible and semi-rigid boards, this solution offers a truly sustainable and adaptable approach to material bonding.

Thermal bonding

Beaulieu’s thermoplastic bonding fibres can be efficiently blended with loose substrates to form stable mats and boards. During thermal consolidation, the fibres fuse the web to deliver the required strength without the need for separate chemical binders. This inherently VOC-free route avoids hazardous chemicals such as formaldehyde and can reduce or eliminate production-related air-scrubbing costs associated with traditional binders. Lower activation temperatures cut line energy, and the water-free process adds further economic and sustainability gains.

Solutions

Our portfolio spans mono and bi-component grades, both of which are available in shortcut (3mm - 24mm) and staple fibre configurations (40mm - 60mm). These fibres are especially suited as a binder for flexible insulation mats and semi-rigid boards, commonly produced via airlay or airlaid processes. The fibres disperse reliably in wood, cellulose, shredded textiles, and other recycled materials, supporting consistent quality and targeted performance in insulation products and other binder-free nonwovens.

If you’re developing new products or seeking higher bonding strength, our team can specify and tailor a dedicated solution to match your substrate and process.