U.S. patent application number 09/813191 was filed with the patent office on 2001-09-27 for insulation board.
Invention is credited to Gattis, Christopher G., McLaughlin, Richard L., Snider, Timothy E., Szymanski, David E..
Application Number | 20010023565 09/813191 |
Document ID | / |
Family ID | 27392831 |
Filed Date | 2001-09-27 |
United States Patent
Application |
20010023565 |
Kind Code |
A1 |
Snider, Timothy E. ; et
al. |
September 27, 2001 |
Insulation board
Abstract
An insulation board includes an array of elements such as domes,
pyramids, or frustrums coupled to a top surface of a body. These
elements are arranged to lie in rows and columns to define fluid
flow passageways to promote fluid drainage away from a building
containing the insulation board.
Inventors: |
Snider, Timothy E.;
(Franklin, OH) ; Szymanski, David E.; (Franklin,
OH) ; McLaughlin, Richard L.; (Lebanon, OH) ;
Gattis, Christopher G.; (Centerville, OH) |
Correspondence
Address: |
BARNES & THORNBURG
11 South Meridian Street
Indianapolis
IN
46204
US
|
Family ID: |
27392831 |
Appl. No.: |
09/813191 |
Filed: |
March 20, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60190980 |
Mar 21, 2000 |
|
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|
60266547 |
Feb 5, 2001 |
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Current U.S.
Class: |
52/408 ;
52/302.1; 52/302.3; 52/413; 52/96; 52/97 |
Current CPC
Class: |
E02D 31/06 20130101 |
Class at
Publication: |
52/408 ; 52/97;
52/96; 52/413; 52/302.1; 52/302.3 |
International
Class: |
E04D 003/40; E04B
007/00; E04D 013/00; E04D 015/00; E04B 001/70 |
Claims
1. An insulation board for use in construction and provided for
fluid drainage away from a building, the insulation board
comprising: a body having a top surface and a bottom surface,
frustums coupled to the top surface of the body, each frustum
having a base portion coupled to the top surface of the body and a
tip portion spaced apart from the top surface of the body, and
fluid flow passageways positioned to lie between the frustums.
2. The insulation board of claim 1, wherein the base portion and
tip portion of each frustum includes four sides and each frustum
further includes four angled side walls positioned to extend from
the base to the tip.
3. The insulation board of claim 2, wherein the frustums are
arranged in rows and columns and the base portion of each frustum
is positioned to lie adjacent another base portion to cause the
passageways to be "V-shaped" and defined by the angled walls of the
frustums.
4. The insulation board of claim 2, wherein the body and the
frustums are made from expanded polystyrene.
5. The insulation board of claim 1, wherein the base and tip of
each frustum is generally circular.
6. The insulation board of claim 2, wherein the base portion
includes a width, W1, and the peak portion includes a width, W2,
and wherein W1 is greater than W2.
7. The insulation board of claim 6, wherein W1 is twice the value
of W2.
8. The insulation board of claim 6, wherein W1 is one inch and W2
is one-half inch.
9. The insulation board of claim 1, wherein the insulation board
further includes a ship-lap edge coupled to the body, the ship-edge
being adapted to abut a ship-lap edge of another insulation
board.
10. The insulation board of claim 1, wherein the body of the
insulation board has a thickness, t, and each frustum has a height,
h, and wherein t is greater than h.
11. The insulation board of claim 10, wherein h is at least 1/4 of
an inch.
12. The insulation board of claim 10, wherein an overall thickness,
T, of the insulation board is equal to t plus h and wherein T is 2
inches and h is at least 1/4 of an inch.
13. The insulation board of claim 1, wherein the tip of each
frustum is adapted to abut the building to position the body of the
insulation board in spaced-apart relation to the building.
14. An insulation board for above-grade use is provided for the
drainage of fluids away from a building, the insulation board
comprising: a body having front surface and a back surface, an
array of domes coupled to the front surface of the body and adapted
to face toward the building, and flow passageways defined between
each dome.
15. The insulation board of claim 14, wherein the domes are
positioned to lie in alternating rows.
16. The insulation board of claim 14, wherein the each dome
includes a base coupled to the front surface of the body and an
apex adapted to lie adjacent to and in contact with a portion of
the building.
17. An insulation board provided for fluid drainage away from an
exterior portion of a building, the insulation board comprising: a
body having a top surface and a bottom surface, and protrusions
coupled to the top surface of the body to form flow passageways
therebetween, each protrusion having a base portion coupled to the
top surface, a tip portion spaced-apart from the base portion, and
a side wall coupled to the base portion and the tip portion and
formed to converge inwardly from the base portion to the tip
portion.
18. The insulation board of claim 17, wherein the protrusions are
frustums positioned to lie in rows and columns.
19. The insulation board of claim 18, wherein the frustums and the
body of the insulation board are made of expanded polystyrene.
20. The insulation board of claim 18, wherein the base portion and
the tip portion of each frustum are square-shaped and wherein each
frustum includes four angled side walls coupled to the base portion
and the tip portion.
21. The insulation board of claim 18, wherein the base portion of
each frustum is round in shape.
22. The insulation board of claim 17, wherein the base portion of
each protrusion is round and each side wall is dome-shaped.
23. An insulation board for use with a building to provide
water-drainage, the insulation board comprising: a body including a
front surface an da back surface, and protrusions coupled to the
front surface of the body to form flow passageways between each
protrusion, the protrusions each including a base portion coupled
to the front surface of the body and a tip portion spaced-apart
from the body, a cross-section of each tip portion taken through a
plane parallel to the top surface of the body having a smaller
surface area than a surface area of a cross-section of each base
portion taken through a plane parallel to the top surface of the
body.
24. An insulation board is provided for draining fluids away from a
building, the insulation board comprising: a body having top
surface and a bottom surface, and an array of right cylinders
coupled to the top surface of the body, the right cylinders being
positioned in spaced-apart relation from one another to define flow
passageways therebetween.
25. An insulation board is provided for draining fluids away from a
building, the insulation board comprising: a body having top
surface and a bottom surface, and an array of alternating pyramids
and blocks coupled to the top surface of the body and positioned in
spaced-apart relation to one another to define flow passageways
therebetween.
Description
[0001] This application claims priority under 35 U.S.C. 119(e) to
U.S. Provisional Application Serial No. 60/190,980, filed Mar. 21,
2000 and to U.S. Provisional Application Serial No. 60/266,547,
filed Feb. 5, 2001, both of which are expressly incorporated by
reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to water-drainage and
insulation systems for buildings, and particularly to an insulation
board for use in such systems. More particularly, the present
invention relates to a polystyrene building insulation board.
[0003] According to the present invention, an insulation board for
use in construction is provided for fluid drainage away from a
building. The insulation board includes a body having a top surface
and a bottom surface. The insulation board further includes
frustums coupled to the top surface of the body and arranged to lie
in rows and columns. Each frustum includes a base portion coupled
to the top surface of the body and a tip portion spaced apart from
the top surface of the body. The insulation board further includes
fluid flow passageways positioned to lie between the frustums.
[0004] In other embodiments, the insulation board includes an array
of domes coupled to the body. The fluid flow passageways are
positioned to lie between the domes. Similar to the frustums, each
dome includes a base portion coupled to the top surface of the body
and a tip portion spaced-apart from the top surface of the body.
Further each dome includes a side wall coupled to the base portion
and the tip portion and formed to converge inwardly from the base
portion to the tip portion. In further embodiments, the insulation
board includes an array of right cylinders coupled to the top
surface of the body to provide fluid flow passageways therebetween.
In still other embodiments, the insulation board includes an array
of alternating pyramids and blocks coupled to the top surface of
the body to define flow passageways therebetween.
[0005] Features of the present invention will become apparent to
those skilled in the art upon consideration of the following
detailed description of preferred embodiments exemplifying the best
mode of carrying out the invention as presently perceived.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The detailed description particularly refers to the
accompanying figures in which:
[0007] FIG. 1 is a perspective view of a polystyrene insulation
board of the present invention showing the insulation board having
a body including four sides, an array of pyramid frustums coupled
to the body, and a flat edge or ship-lap edge coupled to two of the
four sides of the body;
[0008] FIG. 2 is a perspective view of an alternate insulation
board of the present invention similar to the insulation board of
FIG. 1 showing the alternate board including the body and the array
of pyramid frustums coupled to the body, one ship-lap edge coupled
to each side of the body, and further showing the array of pyramid
frustums positioned to lie at a 45 degree angle with respect to the
sides of the body to form a "diagonal" pattern on the body;
[0009] FIG. 3 is a perspective view of a portion of the insulation
board of FIG. 1 showing one ship-lap edge and the array of pyramid
frustums comprising columns and rows of multiple adjacent pyramid
frustums each including four angled side walls and a flat top;
[0010] FIG. 4 is a top view of a portion of the insulation board of
FIGS. 1 and 3 showing a "V-shaped" water-drainage channel of the
insulation board formed between each column and row of pyramid
frustums at a point where the angled walls of adjacent pyramid
frustums meet;
[0011] FIG. 5 is a sectional view taken along line 5-5 of FIG. 4
showing the point at which the angled walls of adjacent pyramid
frustums meet to form the V-shaped water-drainage channel
between;
[0012] FIG. 6 is a sectional view showing a first above-ground use
of the insulation board used in an Exterior Insulation and Finish
System (EIFS) attached to an outside surface of a frame of a
building shown to include cement blocks, a sill plate, a stud, and
a substrate material covering the stud, for example, the insulation
board being shown to rest upon a foundation of the building in an
inward position so that the array of pyramid frustums is positioned
to face the frame, and further showing two exterior finish boards
coupled to a bottom surface of the insulation board, and finally
showing a weep hole or space formed between the bottom of the
insulation board and a flashing positioned to lie adjacent to the
foundation for drainage of water and moisture which may collect
between the frame and the insulation board;
[0013] FIG. 7 is a sectional view, similar to FIG. 6, showing the
insulation board in a second, below-grade use as a "foundation
board" adjacent a concrete foundation where the insulation board is
shown in an outward position so that the array of pyramid frustums
is positioned to face away from the frame, and a porous fabric
material or "geo-membrane" is coupled the array of pyramid frustums
to prevent the dirt from clogging the water-drainage channels of
the insulation board and to drain any water and moisture away from
the frame without the use of a weep hole;
[0014] FIG. 8 is view similar to FIG. 7 showing the insulation
board again used as a foundation board and shown in the inward
position;
[0015] FIG. 9 is a side view of an alternate insulation board
showing the insulation board including a body similar to the
insulation board shown in FIGS. 1-8 and an array of domes coupled
to the body to provide multiple water drainage channels or
paths;
[0016] FIG. 10 is a top view of the insulation board of FIG. 9
showing the water drainage channels or paths formed by the array of
domes;
[0017] FIG. 11 is a side view of the insulation board of FIGS. 9
and 10 showing the insulation board coupled to the substrate
material with a mechanical fastener so that an apex of each dome is
adjacent to and in contact with the substrate material thus
providing a space or separation between the body of the board and
the substrate material which defines the water drainage channels or
paths;
[0018] FIG. 12 is a side view of yet another insulation board
showing the insulation board including an array of square blocks
coupled to the body of the board;
[0019] FIG. 13 is a top view of the insulation board of FIG. 12
showing the water drainage channels or paths formed by the square
blocks;
[0020] FIG. 14 is a side view of yet another insulation board
showing the insulation board including right cylinders coupled to
the body of the board;
[0021] FIG. 15 is a top view of the insulation board of FIG.
14;
[0022] FIG. 16 is a side view of yet another insulation board
showing the board including a combination array of alternating rows
of square pyramids and square blocks each spaced apart from one
another; and
[0023] FIG. 17 is a top view of the insulation board of FIG.
16.
DETAILED DESCRIPTION OF THE DRAWINGS
[0024] An insulation board 10 is provided for use in construction
to drain water and moisture, which may collect, away from a
building (not shown) being constructed, for example. Insulation
board 10 is made from expanded polystyrene (EPS) and is formed to
include a body 12 and an array of pyramid frustums 14 coupled to
body 10. Body 10 includes a top surface 16, a bottom surface 18,
and four sides 20, 22, 24, and 26, as shown in FIG. 1. Array 14 is
coupled to top surface 16 of body 10. In a preferred embodiment,
the dimensions of insulation board 10 are 2'.times.4'.times.2"
where sides 20 and 24 are two feet, sides 22 and 26 are four feet,
and an overall thickness, T, of each side 20, 22, 24, 26 is two
inches. This size is representative of the industry standard. It is
within the scope of this disclosure, however, to include an
insulation board having different dimensions than those provided
above.
[0025] Array 14 is made up of multiple, individual pyramid frustums
30, as shown in FIGS. 3 and 4. A frustum is herein defined as the
part of a pyramid formed by cutting off the top by a plane parallel
to the base. It is also within the scope of this disclosure to
include a frustum formed from the base part of a solid cone.
Pyramid frustums 30 of the present invention are arranged in rows
and columns to form a grid. Each pyramid frustum 30 includes four
angled walls 32 and a "square-shaped" flat top 34. Each pyramid
frustum 30 further includes a base portion 36 and a tip portion 38,
as shown in FIG. 5. Angled walls 32 are coupled to the base portion
36 and tip portion 38 and are formed to converge inwardly toward
each other from the base portion 36 to the tip portion 38 so that
base portion 36 has a wider width 40 than a width 42 of peak
portion 38, as shown in FIG. 4. Therefore, base portion 36 has a
surface area, S1, greater than a surface area, S2, of tip portion
38.
[0026] In a preferred embodiment, the dimensions of width 40 and
width 42 are one inch and 1/2 inch, respectively. Further, it is
preferred that a height, h, of each frustum 30, as shown in FIG. 5
be no less than 1/4 inch. It is within the scope of this
disclosure, however, to include pyramid frustums 30 having
different specifications than the ones provided above. It is also
within the scope of this disclosure to include an insulation board
having an array or grid of components of various shapes and sizes
other than pyramid frustums 30, as provided. The one inch width 40
of each frustum 30 is a preferred base dimension for all geometric
profiles disclosed herein; however, it is within the scope of this
disclosure to include any width 40 for any geometric profile. The
overall thickness, T, of insulation board 10, including body 12 and
any geometric profile coupled to body 12 which creates a separation
from top surface 16 to facilitate flow of a liquid on a sloped or
vertical plane, is preferred to be, but not limited to, 2 inches,
as shown in FIG. 3. As further shown in FIG. 3, overall thickness,
T, is equal to a thickness, t, of body 12 of insulation board 10
plus height, h, of frustums 30.
[0027] Insulation board 10 further includes one or more ship-lap
edges 28 coupled to side 20 and side 24. Ship-lap edges 28 are
provided so that each insulation board 10 is able to couple with
another insulation board 10 at each ship-lap edge 28. The
overlapping effect of ship-lap edges 28 also offers extra
protection from wind and water infiltration. Each ship-lap edge 28
includes a lip 31 extending out from one of the four sides 22, 24,
26, 28 of board 10 and having a top face 33. As shown in FIG. 3,
lip 31 is positioned to lie adjacent to bottom surface 18 of board
10. Side 22 of FIG. 1, however, shows ship-lap edge 28 extending
from top surface 16 of board 10. Top face 33 of each lip 31 is
adapted to lie adjacent to a corresponding top face 33 of ship-lap
edge 28 of another board 10 when boards 10 are stacked vertically
on top of each other so that side 20 of one board 10 and side 24 of
another board 10 lie adjacent to each other and next to each other
so that side 26 of one board 10 and side 22 of another board 10 lie
adjacent to each other. Although the insulation board 10 of the
present invention includes ship-lap edges 28, it is preferred for
insulation board 10 to include flat or straight edges, as shown in
FIG. 3 by side 26, for example. It is within the scope of this
disclosure to manufacture an insulation board having either flat or
straight edges, ship-lap edges, or a mixture of both.
[0028] Insulation board 10 further includes multiple "V-shaped"
flow passageways or water-drainage channels 50 formed between the
rows and columns of pyramid frustums 30, as shown in FIGS. 4 and 5.
Each water-drainage channel 50 is defined by angled walls 32 of
pyramid frustums 30. Water-drainage channels 50 running between the
rows and columns are formed to provide multiple paths through which
the water or moisture that collects may flow. In the preferred
embodiment shown in FIG. 1, pyramid frustums 30 are positioned so
that water-drainage channels 50 between the columns of pyramid
frustums 30 are generally parallel to sides 22, 26 of body 12. In
an alternate insulation board 110, shown in FIG. 2, pyramid
frustums 30 are positioned so that water-drainage channels 50 run
generally diagonally or at a 45 degree angle to sides 20, 22, 24,
26. Alternate insulation board 110 is further shown to include four
ship-lap edges 28 coupled to each side 20, 22, 24, 26. Other
features of board 110 are similar to the features of board 10
described above.
[0029] In a first use, insulation board 10 may be used with an
Exterior Insulation Finish System (EIFS), as shown in FIG. 6. In
such a system, insulation board 10 is positioned to lie
above-grade, or above a top surface 70 of the ground or dirt 72 and
adjacent to a frame 60 of a building (not shown). Frame 60 may
include cement blocks 62, a sill plate 64, a stud 66, and a
substrate material 67 supported by stud 66, for example, as shown
in FIG. 6. Commonly used substrate materials include plywood
sheets, oriented strand board (OSB) and fiberboard, for example.
Insulation board 10 is positioned to rest upon a foundation 68 in
an inward position so that array of pyramid frustums 14 is
positioned to face toward and abut frame 60. When insulation board
10 is in this inwardly facing position, array 14 causes body 12 of
insulation board 10 to be spaced-apart from frame 60. In order to
compensate for uneven surfaces on the exterior of the building or
frame 60 it may be necessary to rasp or sand insulation board
10.
[0030] As shown in FIG. 6, foundation 68 is positioned to lie below
grade or below a top surface 70 of the ground or dirt 72. Two
exterior finish boards 74 are coupled to bottom surface 18 of
insulation board 10. Finally, a weep hole 76 is provided between a
bottom portion of insulation board 10 and a flashing 77. Flashing
77 is positioned to lie between cement blocks 62 and insulation
board 10. Flashing 77 rests upon foundation 68 and is provided to
allow the water and moisture (not shown) which may collect between
frame 60 and insulation board 10 to drain away from frame 60 and
onto dirt 72. Weep hole 76 is also positioned to lie between
exterior finish boards 74 and flashing 77. When insulation board 10
is adjacent to frame 60, water-drainage channels 50 of insulation
board 10 are positioned to lie in a generally vertical direction to
allow water and moisture collected to run down water-drainage
channels 50 and out weep hole 76 onto dirt 72 in order to
collectively drain water and moisture away from frame 60.
[0031] A second application of insulation board 10 is shown in
FIGS. 7 and 8. In FIGS. 7 and 8, insulation board 10 is used as a
"foundation board" and is positioned to lie adjacent concrete
foundation 68. FIG. 7 shows insulation board 10 in an outward
position so that array of pyramid frustums 14 faces outwardly and
bottom surface 18 of insulation board 10 abuts foundation 68.
Further, in this alternate application, insulation board 10 is
positioned to lie below grade or below top surface 70 of dirt 72. A
"geo-membrane" or fabric material 78 is provided and is coupled to
array 14 in order to prevent dirt 72 from accumulating within
water-drainage channels 50. In FIG. 7, insulation board 10 is also
provided to drain water and moisture away from frame 60. The water
and moisture is collected in water-drainage channels 50 and
conducted through water-drainage channels 50 to drain into the dirt
72. Weep hole 76 is not provided or necessary because of the porous
quality of fabric material 78 which allows the water and moisture
that is collected to pass through fabric material 78 into the dirt
72.
[0032] A final application of insulation board 10 is provided in
FIG. 8. Insulation board 10 is used as a foundation board, similar
to FIG. 7, however, insulation board 10 is positioned to lie in the
inward position so that array of pyramid frustums 14 faces and lies
adjacent to frame 60. Insulation board 10 is situated to lie below
grade or top surface 70 of dirt 72 to rest upon foundation 68.
Although insulation board 10 is below grade, fabric membrane 78 is
not needed because array 14 is faced toward frame 60 so that dirt
72 is not able to clog water-drainage channels 50. Weep hole 78 is
not necessary for the drainage of water and moisture collected in
water-drainage channels 50. The water and moisture collected runs
down through water-drainage channels 50 into the dirt 72 below
insulation board 10.
[0033] Additional insulation boards having alternate drainage
patterns are provided in FIGS. 9-18. Each insulation board shown in
FIGS. 9-18 is identical in structure and function to insulation
board 10 with the exception that an alternate array is coupled to
top surface 16 of each additional insulation board. Further, each
additional insulation board is formed to cooperate with each of the
systems shown in FIGS. 6-8 and described above.
[0034] As shown in FIGS. 9-11, for example, an alternate insulation
board 111 includes body 12 and an array of domes 114 coupled to the
top surface 16 of body 12. As shown in FIG. 10, array 114 includes
multiple domes 130 positioned to lie in alternating rows to form
water drainage channels or paths 150. It is within the scope of
this disclosure, however, to include array 114 having domes 130
arranged to lie in aligned rows, rather than alternating rows.
[0035] Further, each dome 130 includes an apex 135 which lies
adjacent to and in contact with substrate material 67, as shown in
FIG. 11 to provide a space between body 12 of board 111 and
substrate material 67 in order to form water drainage channels 150
when insulation board 111 is used in such a system as shown in FIG.
6. Each dome 130 also includes a base portion 136 coupled to top
surface 16 and a tip portion 138 spaced-apart from top surface 16.
Each dome 130 further includes a side wall 132 coupled to the base
portion 136 and the tip portion 138 and formed to converge inwardly
from the base portion 136 to the tip portion 138, as shown in FIGS.
9 and 11. Insulation board 111 is coupled to substrate material 67
by a mechanical fastener 113. Mechanical fastener 113 may also
extend through substrate material 67 to couple insulation board 111
to stud 66, for example.
[0036] Another insulation board 210 is shown in FIGS. 12 and 13
which includes an array of square blocks 214 coupled to top surface
16 of body 12. Array 214 includes multiple square blocks 230 spaced
apart to provide water drainage channels 250 between each block
230, as shown in FIG. 13. Yet another insulation board 310 is shown
in FIGS. 14 and 15. Board 310 includes an array of right cylinders
314 coupled to top surface 16 of body 12. As shown in FIG. 15,
array 314 is made up of multiple individual right cylinders 330
spaced apart and positioned to lie in alternating rows to form
water drainage channels 350 therebetween. It is within the scope of
this disclosure, however, to provide array 314 including cylinders
330 positioned to lie in aligned rows, rather than alternating
rows, as well.
[0037] Still another insulation board 410 is provided in FIGS. 16
and 17. Insulation board 410 includes a combination array 414 of
alternating rows of pyramids 430 and blocks 431. Array 414 forms
water drainage channels or paths 450, as shown in FIG. 16. It is
within the scope of this disclosure to include an insulation board
having any type of combination array including any number of shapes
or protrusions described herein. It is further within the scope of
this disclosure for each of the arrays 14, 114, 214, 314, 414 to
include components of any suitable shape and size which will
provide a space or separation between the body 12 of each
insulation board and the obstructions which each insulation board
is place up against, such as substrate material 67, foundation 68,
cement blocks 62, or fabric material 78, for example, in order to
facilitate the flow of liquid through the formed water-drainage
channels or paths when the insulation board is facing inwardly
toward the building in a vertical or sloped position.
[0038] In a preferred embodiment each of the insulation boards 10,
110, 111, 210, 310, and 410 described above are formed using a
shape-mold process. In the shape-mold process, a first and a second
metal mold is provided. When each of the first and second metal
molds are coupled to each other an enclosed cavity is formed. This
cavity forms the same shape as any one of the insulation boards 10,
110, 111, 210, 310, or 410 depending upon the shape of each of the
first and second metal molds. Once the first and second metal molds
are in a closed position, steam injected EPS beads are inserted
into the cavity to fill the cavity. After the cavity is filled and
the EPS beads have conformed to the shape of the cavity, the first
and second metal molds are moved to an open position spaced-apart
from each other to provide the shape-molded insulation board. The
shape-molding method can save manufacturing time and provide
greater uniformity in each piece. Although, it is preferred for the
insulation board of the present invention to be shape-molded, it is
within this disclosure to include any method of manufacturing an
insulation board including wire-cutting, for example.
[0039] Although this invention has been described in detail with
reference to certain embodiments, variations and modifications
exist within the scope and spirit of the invention as described and
defined in the following claims.
* * * * *