U.S. patent application number 11/013313 was filed with the patent office on 2006-01-12 for building panel.
Invention is credited to Tom C. Smerchanski, Kenneth M. Yohnke.
Application Number | 20060005492 11/013313 |
Document ID | / |
Family ID | 32660961 |
Filed Date | 2006-01-12 |
United States Patent
Application |
20060005492 |
Kind Code |
A1 |
Yohnke; Kenneth M. ; et
al. |
January 12, 2006 |
Building panel
Abstract
A building panel is provided for affixing to above-grade
exterior building surfaces, the building panel comprising: opposed
front and back sides generally parallel to each other; opposed top
and bottom edges generally parallel to each other; a generally
horizontal groove in the top edge spaced from the front and back
sides; and at least one generally vertical channel extending
downwardly from the generally horizontal groove through the
building panel to the bottom edge at a point on the bottom edge
spaced from the front and back sides. The building panel is
preferably for thermal insulation and for collection and drainage
of moisture from water vapour, and is preferably used in
conjunction with exterior insulated finish systems.
Inventors: |
Yohnke; Kenneth M.;
(Calgary, CA) ; Smerchanski; Tom C.; (Winnipeg,
CA) |
Correspondence
Address: |
ADE & COMPANY
1700-360 MAIN STREET
WINNIPEG
MB
R3C3Z3
CA
|
Family ID: |
32660961 |
Appl. No.: |
11/013313 |
Filed: |
December 16, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10919414 |
Aug 17, 2004 |
|
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|
11013313 |
Dec 16, 2004 |
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Current U.S.
Class: |
52/405.2 ;
52/404.1 |
Current CPC
Class: |
E04B 1/762 20130101 |
Class at
Publication: |
052/405.2 ;
052/404.1 |
International
Class: |
E04B 1/74 20060101
E04B001/74 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 12, 2004 |
CA |
2,455,438 |
Claims
1. An insulated building panel for affixing to exterior building
surfaces in rows of the panels side by side and top to bottom to
form an array of the panels, the building panel comprising: a panel
body formed of an insulating foam material, the panel body having:
opposed inside and outside surfaces generally parallel to each
other; opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies; opposed left and right
vertical sides arranged for butting engagement with other similar
panel bodies; the panel body having therein a plurality of conduits
for transmission of water vapour through the array of panel bodies
including at least one generally horizontal conduit spaced from the
front and back surfaces and a series of transversely spaced
generally vertical conduits spaced from the front and back
surfaces; the number of vertical conduits and the spacing between
the vertical conduits being arranged such that water vapor
migrating from the inside surface toward the outside surface is
collected in the conduits prior to reaching the outside surface;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides such that the conduit is
defined by an open area defined between an adjacent surface of an
adjacent panel on one side and a wall of the groove in the panel on
the other side with the dimensions of the area so formed being
sufficient to allow the passage of water vapor therethrough.
2. The building panel of claim 1 wherein the at least one
horizontal conduit is defined by a groove located at one of the
horizontal sides and which has an open mouth at the side and
converges inwardly toward an apex as it extends into the panel
body.
3. The building panel of claim 1 wherein the groove has a width at
its mouth in the horizontal side of the panel in a direction at
right angles to the inner and outer surfaces at least equal to a
width in the same direction of the vertical conduits.
4. The building panel of claim 1 wherein the groove has a width at
its mouth in the horizontal side of the panel in a direction at
right angles to the inner and outer surfaces greater a width in the
same direction of the vertical conduits.
5. The building panel of claim 1 wherein that side of the groove
which is adjacent the inner surface is substantially coincident
with an adjacent side of the vertical conduits and that side which
is adjacent the outer surface extends closer toward the outer
surface than does the vertical conduit.
6. The building panel of claim 1 wherein one half of the distance
between one of the vertical conduits and the next is less than the
distance between said one of the vertical conduits and the outer
surface such that water vapor tends to migrate to the conduits in
preference to the outer surface.
7. The building panel of claim 1 wherein the groove and the
vertical conduits are closer to the inner surface than the outer
surface.
8. The building panel of claim 1 wherein the groove is V-shaped in
cross section.
9. The building panel of claim 1 wherein the vertical conduits are
rectangular in cross section.
10. The building panel of claim 1 wherein the vertical conduits are
formed by molding such that they are free from a wire cut
connection to an external surface of the panel body.
11. The building panel of claim 1 wherein each of the vertical
sides includes a groove.
12. The building panel of claim 1 wherein at least one of the
vertical and horizontal sides includes a stepped joint.
13. The building panel of claim 1 wherein the stepped joint also
includes a groove.
14. An insulated cladding system affixed to an exterior building
surface comprising: a plurality of insulated building panels
affixed in rows of the panels side by side and top to bottom to
form an array of the panels defining an exterior surface; one or
more exterior coating layers applied over the exterior surfaces of
the panels to form an exterior finish of the building; each
building panel comprising a panel body formed of an insulating foam
material, the panel body having: opposed inside and outside
surfaces generally parallel to each other; opposed top and bottom
horizontal sides arranged for butting engagement with other similar
panel bodies; opposed left and right vertical sides arranged for
butting engagement with other similar panel bodies; the panel body
having therein a plurality of conduits for transmission of water
vapour through the array of panel bodies including at least one
generally horizontal conduit spaced from the front and back
surfaces and a series of transversely spaced generally vertical
conduits spaced from the front and back surfaces; the number of
vertical conduits and the spacing between the vertical conduits
being arranged such that water vapor migrating from the inside
surface toward the outside surface is collected in the conduits
prior to reaching the outside surface; wherein the at least one
horizontal conduit is defined by a groove located at one of the
horizontal sides such that the conduit is defined by an open area
defined between an adjacent surface of an adjacent panel on one
side and a wall of the groove in the panel on the other side with
the dimensions of the area so formed being sufficient to allow the
passage of water vapor therethrough.
15. The cladding system of claim 14 wherein the at least one
horizontal conduit is defined by a groove located at one of the
horizontal sides and which has an open mouth at the side and
converges inwardly toward an apex as it extends into the panel
body.
16. The cladding system of claim 14 wherein the groove has a width
at its mouth in the horizontal side of the panel in a direction at
right angles to the inner and outer surfaces at least equal to a
width in the same direction of the vertical conduits.
17. The cladding system of claim 14 wherein the groove has a width
at its mouth in the horizontal side of the panel in a direction at
right angles to the inner and outer surfaces greater a width in the
same direction of the vertical conduits.
18. The cladding system of claim 14 wherein that side of the groove
which is adjacent the inner surface is substantially coincident
with an adjacent side of the vertical conduits and that side which
is adjacent the outer surface extends closer toward the outer
surface than does the vertical conduit.
19. The cladding system of claim 14 wherein one half of the
distance between one of the vertical conduits and the next is less
than the distance between said one of the vertical conduits and the
outer surface such that water vapor tends to migrate to the
conduits in preference to the outer surface.
20. The cladding system of claim 14 wherein the groove and the
vertical conduits are closer to the inner surface than the outer
surface.
Description
[0001] This application is a continuation in part application of
applications Ser. No. NOT YET KNOWN filed 17 Aug. 2004.
FIELD OF THE INVENTION
[0002] The present invention relates to building panels, and more
particularly to building panels including a conduit system for
transmission of water vapor.
BACKGROUND OF THE INVENTION
[0003] In the context of exterior building panels, the presence of
moisture can lead to undesirable results. Moisture that becomes
trapped within and between panels can generate rot in the substrate
to which the panel is affixed, it can bleed through the panel
finishing coat and discolour it, and it can even cause the panel to
detach from the substrate.
[0004] Prior attempts to address this problem include Canadian
Patent 1,220,041 to Larsson, which teaches a panel having drainage
channels for use with subterranean wall surfaces. The channels
communicate directly with the subterranean wall surface, as the
channels are intended to direct water accumulation on the concrete
surface away from that concrete surface. U.S. Pat. No. 6,318,041 to
Stanley discloses a panel system that also employs drainage
channels or conduits.
[0005] While various attempts have been made to address the problem
of moisture in a variety of building panel contexts, a need has
been felt for an improved means of addressing the problem in the
specific context of Exterior Insulated Finish System (EIFS)
technology. The EIFS system, developed in Europe in the 1950s, uses
multi-layered exterior wall systems for both commercial and
residential buildings, and it typically consists of an interior
insulation board secured to the exterior wall surface, a reinforced
base coat applied to the insulation board, and a finish coat that
is both visually attractive and resistant to environmental impact.
The superior energy efficiency and design flexibility of the EIFS
system have resulted in growing popularity, but the presence of
moisture remains a vexing problem.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention there is
provided an insulated building panel for affixing to exterior
building surfaces in rows of the panels side by side and top to
bottom to form an array of the panels, the building panel
comprising:
[0007] a panel body formed of an insulating foam material, the
panel body having:
[0008] opposed inside and outside surfaces generally parallel to
each other;
[0009] opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies;
[0010] opposed left and right vertical sides arranged for butting
engagement with other similar panel bodies;
[0011] the panel body having therein a plurality of conduits for
transmission of water vapour through the array of panel bodies
including at least one generally horizontal conduit spaced from the
front and back surfaces and a series of transversely spaced
generally vertical conduits spaced from the front and back
surfaces;
[0012] the number of vertical conduits and the spacing between the
vertical conduits being arranged such that water vapor migrating
from the inside surface toward the outside surface is collected in
the conduits prior to reaching the outside surface;
[0013] wherein the at least one horizontal conduit is defined by a
groove located at one of the horizontal sides such that the conduit
is defined by an open area defined between an adjacent surface of
an adjacent panel on one side and a wall of the groove in the panel
on the other side with the dimensions of the area so formed being
sufficient to allow the passage of water vapor therethrough.
[0014] Preferably the at least one horizontal conduit is defined by
a groove located at one of the horizontal sides and which has an
open mouth at the side and converges inwardly toward an apex as it
extends into the panel body. This is preferably the top side but
may be the bottom side.
[0015] Preferably the groove has a width at its mouth in the
horizontal side of the panel in a direction at right angles to the
inner and outer surfaces at least equal to a width in the same
direction of the vertical conduits.
[0016] Preferably the groove has a width at its mouth in the
horizontal side of the panel in a direction at right angles to the
inner and outer surfaces greater a width in the same direction of
the vertical conduits.
[0017] Preferably that side of the groove which is adjacent the
inner surface is substantially coincident with an adjacent side of
the vertical conduits and that side which is adjacent the outer
surface extends closer toward the outer surface than does the
vertical conduit.
[0018] Preferably one half of the distance between one of the
vertical conduits and the next is less than the distance between
said one of the vertical conduits and the outer surface such that
water vapor tends to migrate to the conduits in preference to the
outer surface.
[0019] Preferably the groove and the vertical conduits are closer
to the inner surface than the outer surface.
[0020] Preferably the groove is V-shaped in cross section.
[0021] Preferably the vertical conduits are rectangular in cross
section.
[0022] Preferably the vertical conduits are formed by molding such
that they are free from a wire cut connection to an external
surface of the panel body.
[0023] Preferably each of the vertical sides includes a groove.
[0024] Preferably at least one of the vertical and horizontal sides
includes a stepped joint.
[0025] Preferably the stepped joint also includes a groove.
[0026] According to a second aspect of the invention there is
provided an insulated cladding system affixed to an exterior
building surface comprising:
[0027] a plurality of insulated building panels affixed in rows of
the panels side by side and top to bottom to form an array of the
panels defining an exterior surface;
[0028] one or more exterior coating layers applied over the
exterior surfaces of the panels to form an exterior finish of the
building;
[0029] each building panel comprising a panel body formed of an
insulating foam material, the panel body having:
[0030] opposed inside and outside surfaces generally parallel to
each other;
[0031] opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies;
[0032] opposed left and right vertical sides arranged for butting
engagement with other similar panel bodies;
[0033] the panel body having therein a plurality of conduits for
transmission of water vapour through the array of panel bodies
including at least one generally horizontal conduit spaced from the
front and back surfaces and a series of transversely spaced
generally vertical conduits spaced from the front and back
surfaces;
[0034] the number of vertical conduits and the spacing between the
vertical conduits being arranged such that water vapor migrating
from the inside surface toward the outside surface is collected in
the conduits prior to reaching the outside surface;
[0035] wherein the at least one horizontal conduit is defined by a
groove located at one of the horizontal sides such that the conduit
is defined by an open area defined between an adjacent surface of
an adjacent panel on one side and a wall of the groove in the panel
on the other side with the dimensions of the area so formed being
sufficient to allow the passage of water vapor therethrough.
[0036] In exemplary embodiments of the present invention, the
building panel is for thermal insulation and for collection and
drainage of moisture from water vapour, and the building panel is
made of expanded polystyrene or polyisocyanurate. The generally
horizontal groove is preferably V-shaped in cross section and
configured to facilitate lateral movement of moisture from water
vapour to the at least one generally vertical channel for downward
flow of the moisture through the at least one generally vertical
channel, and the at least one generally vertical channel is
preferably rectangular in cross section. The building panel is
preferably of unitary, shape-moulded construction.
[0037] By providing a building panel that can both insulate and
efficiently direct moisture from water vapour away from the panels
and underlying substrate, while serving the need for an even
surface for application of the base and finish coats, the present
invention is intended to address a pressing need in the
industry.
[0038] A detailed description of an exemplary embodiment of the
present invention is given in the following. It is to be
understood, however, that the invention is not to be construed as
limited to this embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] In the accompanying drawings, which illustrate an exemplary
embodiment of the present invention:
[0040] FIG. 1 is a side cross-section along line I-I in FIG. 2 of
an in situ assembly of building panels according to the present
invention.
[0041] FIG. 2 is a front elevation of the assembly of FIG. 1.
[0042] FIG. 3 is a plan view of a building panel according to the
present invention.
[0043] FIG. 4 is a top plan view on an enlarged scale of one part
of one of the panels of the previous figures.
[0044] FIG. 5 is a cross sectional view transversely through two of
the panels stacked one on top of the next.
[0045] FIG. 6 is a cross sectional view similar to that of FIG. 4
showing a modified arrangement with a ship-lap connection between
the panels.
DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT
[0046] Referring now in detail to the accompanying drawings, and
particularly to FIGS. 1 and 2, there is illustrated an assembly of
building panels according to the present invention, each panel
being referred to generally by the numeral 10. The building panel
10 comprises opposed front and back sides 14, 16 generally parallel
to each other and opposed top and bottom edges 18, 20 generally
parallel to each other. Conduits for transportation of water vapor
are provided in the panel including a generally horizontal V-shaped
groove 22 in the top edge 18 spaced from the front and back sides
14, 16, and generally vertical channels 24 extending downwardly
from the groove 22 though the building panel 10 to the bottom edge
20 at a point on the bottom edge 20 spaced from the front and back
sides 14, 16. Thus the V-shaped groove is located at the surface
and has an open mouth at the surface and converges inwardly and
downwardly into the panel body to an apex. While FIG. 2 shows the
channels 24 only in the centrally positioned building panel 10, the
channels 24 are also in each of the adjacent building panels 10.
The building panel 10 is of a unitary, shape-moulded construction,
an advantage over traditional wire-cut construction since the
vertical channels are free from the necessary wire cut entry slot
from an adjacent surface of the panel.
[0047] As can be seen in FIG. 1, interior surface of the building
panel 10 is includes an air barrier membrane 26 which is applied to
an exterior surface 12 of a building 13 as an air/vapour barrier by
an adhesive 28. In the illustrated embodiment the adhesive 28 is
applied as a layer prior to positioning of the building panel
10.
[0048] Thus the exterior building surface 12 is arranged to be
suitable for application of the building panels 10. Suitable
substrates include but are not limited to exterior grade drywall,
cement board, plywood sheathing, Dens-Glass sheathing, precast
concrete, concrete block, or poured-in-place concrete. The
air/vapour barrier membrane 26 is applied to the exterior building
surface 12. An adhesive 28 is then applied on top of the membrane
26.
[0049] The building panels 10 are then applied over this adhesive
layer 28 and secured in place thereby. For a building of four
stories or greater it is advisable to use mechanical fasteners as
well to secure the panels to the exterior building surface 12.
[0050] The building panels 10 are preferably arranged in the offset
pattern shown in FIG. 2, a pattern well known in the art. The
joints between the building panels 10 should be sealed with a
suitable material (not shown) known to those skilled in the art to
further enhance the insulating properties of the building panels
10.
[0051] Various methods of providing base and finishing coats (not
shown) are then possible, according to the general knowledge of
those skilled in the art of EIFS use.
[0052] With the building panels 10 now in place on the exterior
building surface 12 and finished in a suitable manner, the groove
22 is now configured to facilitate lateral movement of water vapour
to the channels 24 for downward flow of the water vapor through the
channels 24. Water vapor can flow horizontally through a groove 22
and into adjacent grooves 22 as necessary, while the channels 24
then provide vertical conduits for the water vapor flowing through
the grooves 22.
[0053] As is well known in the EIFS system, the exterior cladding
formed by the rows and columns of panels of insulating foam are
covered on the exterior surface by a first layer 30 which is a
flexible mortar layer commonly having embedded therein a
reinforcing fiber layer together with an exterior coating 31 of a
flexible coloured material. These coatings are well known to one
skilled in the art and commonly used. Different types of coating
can be used.
[0054] Each of the blocks or panels forming the system therefore
comprises the block as defined above which has an interior surface
of the foamed insulation material indicated at 32 and an exterior
surface 33. These surfaces are parallel and defined on the exterior
of the insulation material which forms the block and is located
therebetween. The block further includes horizontal sides 34 and 35
at the top and bottom respectively and vertical sides 35 and 36.
These sides are at right angles to the front and rear surfaces so
as to form a rectangular block or panel of the required thickness
with each of the panels being of the same height and the same
width. The panels are then arranged in rows with the top and bottom
surfaces abutting and the sides surfaces also abutting.
[0055] The exterior coating surfaces 30 and 31 are applied directly
onto the outside surface and there are no external sheeting
elements.
[0056] The conduit system defined in the present invention is
arranged to communicate moisture in the form of water vapour
through the system to an exterior location. The system is not
intended to nor required to communicate any form of flowing water
since the amount of moisture which can penetrate is very low. The
required escape of moisture is therefore also very low but, if
prevented from escape, can collect over time which may be many
weeks or many months leading to that moisture penetrating through
the permeable foam to the exterior surfaces 30 and 31 causing
damage thereto.
[0057] Differential pressures across the foam panels can cause
water vapour to transfer or permeate through the structure. The
water vapour tends to migrate to paths of least resistance so that,
provided the conduit system provides sufficient cross sectional
area of the conduits, the water vapour will tend to migrate to
these conduits and pass therethrough in gaseous form in the air
contained within the conduits to any exterior vent.
[0058] As best shown in FIGS. 4 and 5, the vertical conduits 16 are
arranged in a series spaced along the length of the panel. Thus as
shown in FIG. 5, each of the conduits 16 is rectangular in cross
section and has a width W with a spacing between each conduit and
the next of S. The conduits are arranged so that the distance D1
from the inner surface 32 is less than the distance D2 from the
outer surface 33. Also the spacing S between each conduit and the
next is arranged so that moisture tending to migrate from the
inside surface 32 toward the outside surface has a shorter distance
to travel to the conduit 16 than to the exterior surface 33 along
the distance D2. Thus moisture at a point P in the panel tends to
migrate along the distance S/2 to the conduit 16 than over the
distance D2 to the exterior surface. Thus any moisture contained
between the vapour barrier 26 and the panel will tend to migrate to
the conduits and travel along the conduits as water vapour to an
exterior vent.
[0059] In order to provide horizontal transfer of the water vapour,
there are provided the grooves 22. These are preferably provided in
the top surface 34 of the panel 10 but could additionally be
provided in the bottom surface 35 of the panel 10A or could be
provided only in the bottom surface 35 of the panel 10A. However
these grooves are provided at the surface so that the groove has an
open mouth 22A at which is located a portion 35A of the bottom
surface 35 closing the open mouth 22A. Further the conduit is
defined by portions 22B and 22C of the groove converging to an apex
22D. Thus the groove converges inwardly towards the apex as the
groove extends into the body of the panel.
[0060] This arrangement allows the grooves to be formed as common
action in molding the vertical conduits 16. Thus a mold which is
generally rectangular in the form of the shape of the panel also
includes insert elements which define the groove 22 and the
channels or conduits 16. Thus a bar which is triangular in shape
defines the groove 22 and the bar houses a plurality of projecting
rods of rectangular cross section which define the channel 16.
After the injection of the foam and the molding of the foam
material into the required shape, the rods forming the channel 16
and the bar forming the groove 22 are pulled outwardly from the top
face of the block to complete the molding of the hollows within the
block defining the groove 22 and the channel 16. Preferably similar
insert rods are provided at the opposite end forming the bottom 35
of the block 10 so that the rods forming the channel 16 extend only
over one half of the length of the channels allowing them to be
pulled in opposite directions from a junction point half way along
the channels.
[0061] This shape-forming process in which the panels are molded
including the molding of the channels and grooves provides a high
efficiency forming system in which the whole structure is formed in
one molding action without the necessity for cutting elements from
the foam. Wire cutting systems require the necessity for an inlet
and exit slot which are not necessary in the structure of the
present invention.
[0062] The channels 16 are arranged in a common plane and directly
aligned. The channels 16 have an inner surface 16A and an outer
surface 16B. The groove 22 is arranged so that one end of the side
portion 22C terminates at a position coincident with the side 16A
of the channel 16. The groove 22 has a width greater than the width
of the channel between the surfaces 16A and 16B. Thus the apex 22D
is located at a position generally aligned with the surface 16B.
Thus the portion 22B extends from the apex further outwardly of the
surface 16B toward the outer surface 33. In this way, the cross
sectional area of the groove 22 approximates to the cross sectional
area of the rectangular channel 16 to provide approximately a
similar cross sectional area for transmission of water vapour
therethrough. It is clear that the amount of water vapour
transmitted is generally proportional to the cross sectional area
so that sufficient cross sectional area is provided both in the
channel 16 and in the groove 22. Thus the groove 22 has a width at
least equal to the width of the channel 16 and preferably greater
in view of the triangular shape. The location for the groove at the
surface allows water vapor to migrate from one vertical channel in
one panel to one in the next without the necessity to align the
channels in the panel assembling process.
[0063] The groove and the channels are arranged closer to the inner
surface 32 than the outer surface 33 in order to ensure that
moisture preferentially enters the channels rather than reaches the
exterior surface 33 where damage can be caused.
[0064] As shown in FIG. 6, the top and bottom surfaces indicated at
34A and 35A include a ship-lap section generally indicated at 40
wherein there is a surface 41 which extends parallel to the inside
and outside surfaces 32 and 33. Thus the surface 34A is divided
into a first portion 34B and a second portion 34C and similarly the
surface 35A is divided into a first portion 35B and a second
portion 35C. Between these two portions is the surfaces indicated
at 41. The groove indicated at 22X is formed from the portion 34C
of the block 10. A further groove 22Y is formed in the surface 41
between the portions 34C and 34B. The groove 22Y thus further acts
as trap for moisture tending to migrate along the surfaces 34A and
35A. This trap thus acts to collect water vapour and to transmit
that water vapour to discharge. It will be noted that the groove
22X is the same width as the channel 16.
[0065] An additional groove can be provided in the vertical sides
of the block again to act as a trap for any moisture migrating
between the blocks.
[0066] While a particular embodiment of the present invention has
been described in the foregoing, it is to be understood that other
embodiments are possible within the scope of the invention and are
intended to be included herein. Thus, while the embodiment
illustrated in FIGS. 2 and 3 includes fifteen equally-spaced
channels 24 per building panel 10, but it may be preferable to have
nineteen or some other number of channels 24 depending on the
application.
[0067] While particular substrates have been identified in the
foregoing, it is to be understood that the application of the panel
to any substrate is to be considered within the scope of the
invention. Currently it is considered that the invention may not be
especially useful with certain types of substrate, including
oriented strand board and chipboards. It will therefore be clear to
those skilled in the art that modifications of and adjustments to
this invention, not shown, are possible without departing from the
spirit of the invention as demonstrated through the exemplary
embodiment. The invention is therefore to be considered limited
solely by the scope of the appended claims.
* * * * *