Patent ID: 8142584

Claim:
A method of manufacturing an insulation product comprising the following steps: forming an insulation sheet containing randomly oriented fibers bonded together by a binder, said sheet having first and second major surfaces and a pair of side portions; and after forming said insulation sheet forming a nonwoven facing layer on at least one of said first and second major surfaces, the step of forming the nonwoven facing layer comprising the steps of: conveying the formed insulation sheet to a bicomponent fiber deposition apparatus for applying a layer of bicomponent fibers onto the at least one major surface of the insulation sheet; applying the layer of bicomponent fibers to the at least one of said major surfaces, each of said bicomponent fibers including first component and second component portions; and meltbonding a portion of said layer to said at least one of said major surfaces, wherein the bicomponent fiber deposition apparatus comprises a chamber for depositing said bicomponent fibers onto said insulation sheet, said chamber having a side wall, a top wall, and an opening at a bottom thereof disposed over the insulation sheet, the method further comprising the step of blowing the bicomponent fibers into said chamber in an air stream direct at an upward orientation toward a top wall of said bicomponent fiber deposition chamber.