A fibrous insulation product is provided comprising a nonwoven fiber mat including a plurality of fibers bound together by an aqueous binder composition comprising that includes a thermally degradable polyol; a crosslinking agent; and an acid/aldehyde. The binder composition is free of added formaldehyde.

An insulation product may include a container, a first insulation material forming a first layer inside the container, and a second insulation material forming a second layer inside the container, and the first layer is compressed by the second layer. A structure in a building may include studs, first and second claddings mounted to opposite sides of the studs, and structure spaces defined between the studs and the opposing claddings. A first insulation material may include first layers on and substantially covering a first one of the claddings inside the structure spaces. In addition, a second insulation material may have second layers inside the structure spaces. The first layers are compressed and substantially covered by the second layers, and the second layers substantially cover a second one of the claddings inside the structure spaces.

A method of manufacturing a mineral fibre thermal insulation product comprises the sequential steps of: Forming mineral fibres from a molten mineral mixture; Spraying a substantially formaldehyde free binder solution on to the mineral fibres, the binder solution comprising: a reducing sugar, an acid precursor derivable from an inorganic salt and a source of nitrogen; Collecting the mineral fibres to which the binder solution has been applied to form a batt of mineral fibres; and Curing the batt comprising the mineral fibres and the binder which is in contact with the mineral fibres by passing the batt through a curing oven so as to provide a batt of mineral fibres held together by a substantially water insoluble cured binder.

A method of reducing the formaldehyde emission of a mineral fiber product bonded with a urea-modified phenol-formaldehyde resol resin-type binder comprises adding dextrose to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibers.

Described is a reflective insulating material for use in metal building insulation (MBI) or in post frame building insulation (PFBI) applications, the reflective insulating material comprising: a first outer layer and a second outer layer disposed parallel to one another, the first outer layer made of a reflective radiant barrier material; an insulation layer disposed between the first and second outer layers; and a fabric layer that is a scrim layer or a woven layer disposed between the first and second outer layers. The fabric layer can have various properties. A polymer seal layer can also be provided as part of the material. Processes for manufacturing the reflective insulating material are also provided.

A method of reducing the formaldehyde emission of a mineral fiber product bonded with a urea-modified phenol-formaldehyde resol resin-type binder comprises adding dextrose to the binder composition during and/or after preparation of the binder composition but before curing of the binder composition applied to the mineral fibers.