Note: Descriptions are shown in the official language in which they were submitted.
CA 02209184 2004-07-16
1
INSULATION PRODUCT AND METHOD FOR PRODUCING THE SAME
The invention relates to an insulation
product comprising a base material of cellulosic pulp
wool. and additionally a bonding agent bonded with an
adhesive to the cellulosic pulp wool.
The invention also relates to a method for
producing an insulation product, in which the base
material for the insulation product is formed from
cellulosic pulp wool, and a bonding agent to which the
cellulosic pulp wool is bonded with an adhesive that is
also applied in the method is employed to produce the
insulation.
The known insulation product employing
cellulosic pulp wool and the method for producing it are
of a kind in which water is sprayed into the cellulosic
pulp wool when a building element, such as a wall ele-
ment, is produced. A significant problem is presented by
the fact that the insulation will settle with time, and
hence the insulation product will not show sufficient
insulation performance. The insulation will settle during
storage and transport, and also at the actual instal-
lation site. A further disadvantage is that the known
approach requires a long time for drying on account of
the use of water, which again necessitates large drying
halls or other spaces. The building element with inner
insulation must be removed from the production line to
another location for drying for the time water dries off.
Also insulation produced at a construction site requires
time for drying on account of the use of water.
It is obvious that the known method involves
difficulties in production and thereby considerable
economic losses. US Patent Nos. 5,085,898 and 5,155964
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and published International application No. WO 93j04239
published on March 4, 1993 disclose cellulose-based
insulation elements, but in the applicant's observation,
their materials, properties and methods for their
production are not sufficiently effective and
practicable, since the heat and moisture transfer
capacity of the bonding agent and of the adhesive are not
the same as with the base material. In the prior art
solutions, the insulation material will not be
sufficiently uniformly distributed. In addition to
cellulosic pulp wool insulation products, mineral wool
and glass wool insulation products are known, which may
also be attended by bacterial problems.
The present invention provides a novel
insulation product and a method for producing the same,
avoiding the problems related with the prior art
solutions.
Accordingly, the present invention provides an
insulation product comprising a base material of
cellulosic pulp wool and additionally a bonding agent
bonded with an adhesive to the cellulosic pulp wool,
characterized in that the bonding agent is viscose fibre,
and that also the adhesive is of a cellulose-based
material.
In a further aspect, the present invention
provides a method for producing an insulation product, in
which a base material for the insulation product is
formed from cellulosic pulp wool, and a bonding agent to
which the cellulosic pulp wool is bonded with an
adhesive, characterized in that viscose fibre is employed
as a bonding agent in manufacturing the insulation
product, and that a cellulose-based adhesive material is
employed as an adhesive.
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The insulation product and the method for pro-
ducing the same in accordance with the invention are
based on the idea that the structure of cellulosic pulp
wool is stiffened with a bonding agent adhered to the
cellulosic pulp wool with an adhesive. Thus the bonding
agent and the adhesive form a kind of a woven supporting
structure in the insulation product, and thus the insula-
tion product will not settle. A further basic idea is
that all materials employed are ecological, natural
materials, for example in such a way that together with a
base material of cellulosic pulp wool, viscose fibre
which is a cellulose-based material is employed as a
bonding agent, and a cellulose-based adhesive, for
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instance viscose glue, is used as an adhesive. It is not
necessary to employ a separate bonding agent and adhes--
ive, but the bonding agent and adhesive may also be in
combination when a viscose glue that is fiberized, i.e.
forms fibres that serve as a bonding agent or supporting
structure, is employed.
The insulation product and the method for pro-
ducing the same in accordance with the invention afford
several advantages. The insulation product and the
method provide a novel, natural, ecological, wood-based,
i.e. in practice cellulose-based, solution wherewith a
wide variety of insulations can be implemented. On
account of the bonding, i.e. supporting, structure
formed therein, the insulation product of the invention
is drip-free, and it is unnecessary to apply water
thereto, except for diluting the adhesive. Thus no bac-
terial growth can occur in the insulation product. The
insulation product of the invention is implemented in
such a way and with such materials that besides t;he cel-
lulosic pulp wool also the bonding agent and the adhes-
ive are based on the same material, i.e. cellulose,
since in that case the bonding agent and the adhesive
have the same heat and moisture transfer capacity as the
base material, which will improve the properties of the
insulation product. The invention is particularly suit-
able for implementing a flat insulating board and for
realizing an insulation to be furnished within a build-
ing element, such as a wall element, but also fo=~ imple-
menting an insulation to be produced at a construction
site. The insulation material will also be uniformly
distributed.
In the following the invention will be e~!:plained
in greater detail with reference to the accompanying
drawings, in which
Figure 1 is a schematic representation of an
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apparatus for producing insulating boards by the method ,
of the invention,
Figure 2 is a schematic representation of an ,
apparatus wherewith building elements are insulated by
the method of the invention,
Figure 3 shows the construction of a planar
insulation product,
Figure 4 shows the treatment of the ends of a
planar insulation product,
Figure 5 shows the insulating of a building ele-
ment in a top view,
Figure 6 shows the insulating of a building ele-
ment in the direction of arrow A of Figure 5,
Figure 7 shows the construction of the end of an
actuator of Figure 5.
In Figure 1, reference 1 denotes a blower
through which a distributed cellulosic pulp wool-viscose
fibre insulation material 2 a.s fed into a funnel 3. The
bottom of the funnel 3, is made up by a wire 4 that
rotates between rolls 5. Slabs defining the width of the
insulating boards are provided on the wire 4 in the
longitudinal direction thereof. A distributing conveyor
7 rotating at the speed of the screen conveyor 6 is
located at the lower portion of the funnel 3 to rest on
rollers 8. Pushers 9 of the distributing conveyor 7 are
abutted against the surface of the wire 4 in their
lowermost position. Adhesive is sprayed into the insula-
tion mass through adhesive spraying nozzles 10. A lower
viscose gauze 11 is supplied from roller 12 onto the
wire 4. The cellulosic pulp wool-viscose fibre insula-
tion 2 is sucked with blowers 13 and 14 into a smooth
mat on top of the viscose gauze 11 onto which it is
glued. The negative pressures produced by the blowers 13
and 14 are equalized with suction boxes 15 and 16
provided below the wire 4. The arrows show the direction
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of flow. A rotary brush 17 flattens out the thickness
of
the insulation layer 18. An upper viscose gauze 19 is
supplied onto the insulation layer 18 from ro:Ller 20
with a screen conveyor 21. Wire 22 presses the viscose
5 gauze 19 onto of the insulation layer 18, and the: fabric
is glued with adhesive sprayed from the spraying nozzle
10. The adhesive is a cellulose-based adhesive. The wire
22 is located between rolls 23. Air is circulated with
a blower 24 through the insulation layer 18, thus
effecting drying. The arrows show the flows in supply
box 25 and suction box 26. In the flow direction, a
condenser unit 28 wherewith water is separated from the
air flow and a heater unit 29 heating the drying air are
located in circulation conduit 27. The completed insula-
ting board 30 is supplied to rollers 31 for paclkaging.
Figure 2 shows the insulation of an element with
a cellulosic pulp wool insulation and the apparatus em-
ployed for the work, which has the same operating prin-
ciple as the preceding embodiment. Reference 32 denotes
a blower through which the cellulosic pulp wool-viscose
fibre insulation 33 is fed into a feed funnel 39:. Frame
35 for the element is assembled on table 36, wh.erefrom
the frame 35 is transferred onto a pivoted wire. member
37 beneath the feed funnel 34. The wire is denoted by
reference 38 and the suction box beneath it by reference
numeral 39. A negative pressure is sucked with a blower
40 beneath the wire 38, and the insulation layer for the
element will be smoothed. A rotary valve 42 and. a low-
pressure chamber 43 are provided in conduit 41, by means
of which a pulsating negative pressure is generated in
the suction box 39. With the pulsating negative pres-
sure, compacting of the cellulosic pulp wool insulation
can be enhanced . A rotary brush 44 moves reciprocally
upon the frame 35 of the element and evens out the
insulation layer. Extra insulation is sucked affray with
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blower 45 along conduit 46 and is returned through ,
blower 32 into conduit 47 for reuse. Once the insulation
has been effected, the feed funnel 34 is lifted away and
a lid is nailed or otherwise attached onto the frame of
the element. Thereafter the frame 35 of the element is
turned onto table 49 with the wire member 37 supported
by pivot 48 for attachment of a bottom sheet, whereafter
the insulation of the element is complete.
The insulation method of the invention operates
as follows. An insulation based on cellulosic pulp wool
with which viscose fibres or equivalent are admixed is
distributed onto a wire with compressed air. With a
negative pressure provided beneath the wire, the insula
tion layer is sucked into a smooth, homogeneous and
resilient layer. By adapting the negative pressure to be
pulsating, the compacting can be enhanced. The thickness
of the insulation is evened out with a rotary brush, and
extra insulation is removed. With the apparatus shown in
Figure 1, insulating board 30 is produced in a continu-
ous process. Cellulosic pulp wool-viscose fibre insula-
tion 2 is blown onto a viscose gauze 11 laid on top of
wire 4. Adhesive is sprayed through nozzles 10 into the
insulation layer 18, and thus the insulation material
adheres to the gauze 11. The insulation layer is cut on
distribution conveyor 7 with pushers 9. The insulation
layer 18 is evened out with a rotary brush 17, adhesive
is sprayed onto the insulation layer with nozzles 10,
and an upper viscose gauze 19 is glued on top. The wet
insulating board 30 is dried with hot, dried air blown
through the board 30. Air is circulated into condenser "
units 28 provided in conduit 27 and through heater unit
29 with blower 24. A heat pump may also be used for the '
task. The completed insulating board 30 is removed on
rollers 31 for packaging.
In a second embodiment shown in Figure 2,
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insulation of a building element operates in pr~Lnciple
as a batch process, one element at a time. The f~:ame
- of the element is assembled on table 36 and is trans-
ferred for insulation onto a wire member 37. Funnel 34
5 is lowered on top of the wire member 37. The ne=gative
pressure provided in the suction box 39 beneath the wire
38 will even out the insulation layer (cellulos~~c pulp
wool and viscose) into all locations, also the corners.
A vibration effect is produced in the insulation layer
10 by a pulsating negative pressure, produced by rotary
valve 42 provided in duct 41. Low-pressure chamber 43
intensifies the effect of the pressure impact. The pul-
sating negative pressure reduces the power requ_Lrement
for blower 40. The insulation layer is evened out with
15 a vertically adjustable, reciprocally moving rotary
brush 44. Extra insulation is sucked away with blower
45. Feed funnel 34 is lifted into its uppermost: posi-
tion; conduits 46 and 47 are resilient for lifi:ing. A
lid is nailed on top of the insulated frame 35; adhesive
20 can be applied to the lid, or adhesive can be sprayed
on
top of the insulation. The frame 35 is turned on table
49 with the pivotable wire member, and the same: oper-
ation is repeated for the bottom.
It is obvious to one skilled in the art that the
25 insulation method of the invention can be impleme=nted
in
a wide variety of applications. The amount of adhesive
and bonding fibres may be varied. Also the locat=ion and
number of the adhesive spray nozzles 10 may var~. Dif-
ferent conveyor and transfer solutions are naturally
30 also possible. The surface materials of the insulating
board may vary, or they may be entirely omitted. Also
the brushes 17 and 44 may be of a type other than the
rotary brushes disclosed in the present applicat:ion.
Next, the structure of a planar insulation
35 product 430 will be set forth with reference to :Figures
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3-4. Figure 3 shows an insulating board 430. The insu-
lating board includes two wide side planes 431 and 432
and four smaller end planes 433-436. The insulating ,
board 430 comprises a base material 437, 438 of cel-
lulosic pulp wool in two layers. The insulation product
430 further comprises a bonding agent 439, 440, 441,
bonded with an adhesive 442, 440 and 443 to the
cellulosic pulp wool 437, 438. Thus the reference 440
denoting the middlemost bonding agent and the middle
adhesive layer has two meanings, as the bonding agent
and the adhesive may be in combination for example in
such a way that viscose glue or other cellulose glue
that is fiberized upon drying and thus forms a bonding
structure, i.e. a supporting structure, is employed as
the adhesive. However, viscose mesh 439 and 441 consti
tutes the actual bonding agent, i.e. bonding structures
that are attached to the cellulosic pulp wool, i.e. cel
lulosic chips 437 and 438, through adhesive 442 and 443.
The cellulosic pulp wool is cotton wood-like, wool-like
wood fibre pulp.
In the invention, besides the cellulosic pulp
wool also the bonding agent and the adhesive are of a
cellulose-based material, since a.n such a case all
materials of the insulation are based on the same mater-
ial, and hence the heat and moisture transfer capacity
of the bonding agent and of the adhesive are the same as
with the base material, i.e. cellulosic pulp wool, thus
improving the properties of the insulation. Viscose
fibre is employed as a bonding agent, since it is a cel-
lulose-based material and since it has a good insulating '
capacity. The viscose fibre employed as a bonding agent
in the insulation product is viscose yarn, viscose mesh
439, 441, or viscose fibre dried of viscose glue, spe-
cifically 440, employed as an adhesive. In the embodi-
ment of Figure 3, the uppermost bonding agent 439 and
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the lowermost bonding agent 441 are of viscose mesh,
because this provides a good bonding structure, i.e.
supporting structure, which supports the cellulosj:c pulp
wool 437, 438 and also enables cutting of the insulation
product 430 . Viscose meshes 439 , 441 also give a neat
outer surface that withstands handling.
The adhesive 442, 440, 443 employed in the
manufacture of the insulation product is a cell.ulose-
based adhesive, preferably viscose glue, cmc glue or
equivalent. Specifically between the layers of cellu-
losic pulp wool 437, 438, the adhesive 440, i.e. bonding
agent 440, made of viscose glue serves two purposes.
Also the upper adhesive 443 and lower adhesive 942 can
be contemplated to have two purposes, that is, they form
viscose fibre upon drying and hence contribute to making
up the bonding structure, i . e. supporting structure,
and
on the other hand adhere the fibres thereof and also the
fibres of the viscose meshes 439, 441 to the cel7_ulosic
pulp wool 437, 438.
At its simplest, the insulation material between
the side planes 431, 432 could comprise cellulos_LC pulp
wool into which viscose glue has been sprayed or other-
wise introduced, as in that case fibre and also adhesive
wherewith the fibre and the cellulosic pulp wool are
adhered to one another are simultaneously introduced
into the insulation.
The insulation shown in Figures 3-4 is thus a
planar insulating board 430, comprising two wide side
planes 431, 432 and four smaller end planes 433-436. As
a bonding agent 439, 441 the insulating board comprises
at least two viscose meshes 439, 441 between i:he end
planes in the direction of the side planes. Cel:lulosic
pulp wool 437, 438 is provided in the area between said
at least two viscose meshes 439, 441 in the insulation
product. Adhesive 442 is provided between viscoae mesh
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439 and cellulosic pulp wool 437. Likewise, adhesive 443
is provided between viscose mesh 441 and cellulosic pulp
wool 438.
In a preferred embodiment, viscose fibre a.s also
5 provided between the viscose meshes 439, 441 among the
cellulosic pulp wool. This can be achieved for example
with layer 440. Said structure can also be produced in
such a way that for instance viscose yarn is introduced
into the cellulosic pulp wool 437, 438 as a continuous
10 yarn or as shorter pieces of yarn. The viscose yarn or
other fibre in the cellulosic pulp wool layer 437 and
438 is denoted by reference 450. By adjusting the amount
of viscose fibres 450 to be laid a.n the area between the
side planes 431, 432, i.e. in the area between the
viscose meshes 439, 441, and by adjusting the amount of
adhesive to be employed in connection with the viscose
fibres, insulation products of varying grades of
hardness can be produced.
In an embodiment of the invention, a planar
insulating board 430 is produced. A viscose mesh made of
viscose fibres is employed as a bonding agent 439, 441.
Also adhesive layers 442, 440 and 443 serve as a bonding
agent for their part, if they are viscose adhesive or
other, preferably cellulose-based adhesive that becomes
fiberized upon drying.
Referring now to Figures 3-4, manufacture of a
planar insulation product, i.e. the first embodiment of
the invention, is set forth. Implementing the apparatus
of Figure 1, the insulating board of Figure 3 has been
produced in such a way that in the method adhesive 442,
preferably viscose glue or other cellulose glue, is
applied to a first viscose mesh 439, i.e. bonding agent
439. The next step is to form a cellulosic pulp wool
layer 437, i.e. a cellulosic pulp chip layer, on top of
the adhesive 442. In that connection, viscose yarn 450
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- can be admixed with the cellulosic pulp layer 4;37 with
adhesive to serve as a reinforcement, as stated in the
~ foregoing. This is achieved in such a way that viscose
fibre 450 treated with adhesive is admixed with the
cellulosic pulp wool 437 and/or 438 that will be :Located
between the viscose meshes 439, 441. As a next: step,
adhesive 440, which will thus also serve as a bonding
agent between the layers of cellulosic pulp wool 437,
438, is applied to the cellulosic pulp wool 437. The
next step is the forming of a cellulosic pulp wool layer
438, i.e. cellulosic pulp chip layer, upon the adhesive
440. As a next step, a second viscose mesh 441 :is laid
on top of the adhesive layer 443 as a bonding agent 441.
The next step is cutting to size of the continuous
insulation band with an actuator, into an insulating
board 430 having a given length.
Figure 4 shows a step in which the ends .433-436
of the insulation product are coated by means of an
actuator 460. In a preferred embodiment, the insulation
product thus comprises ends 433-436 coated with adhes-
ive, preferably a cellulose-based adhesive, such as vis-
cose glue, and hence the insulation will withstand
handling and have better properties . The coating is pre-
ferably performed after the cutting, to enable coating
of the ends of the insulation product 430 transverse to
the production line simultaneously with the lateral ends
of the insulation that have the direction of the
production line.
Figures 5-7 illustrate another embodiment of the
invention. Figures 5-7 show a building element 100, such
as a wall element 100. The building element comprises
posts 101 of a frame structure, providing the frame of
the building element. The building element further
comprises boards 102, 103, closing the building .element
and forming therewithin a partitioned encased structure
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104-107 into which the insulation, now reference numeral ,
130, can be blown or wherein the insulation can be
formed otherwise. The insulation is denoted by reference ,
130. In Figures 5-6, the building element comprises five
frame posts 101, and thus the element comprises four
compartments 104-107, the two leftmost compartments 104
and 105 being already blown full of insulation material
in Figures 5-6. The third compartment 106 is presently
being filled, and the fourth compartment 107 is still
empty. In Figure 5, the element is not shown entirely
but is shown with the upper edge cut away.
In the second embodiment of the invention, the
insulation 130 is an insulation formed within the
encased building element 100.
In the second embodiment of the invention in
Figures 5-7, the apparatus comprises a production line
201 upon which the insulation is built into the element.
The production line comprises for instance conveyor
belts 202 rotating between rolls 203 and producing a
leftward movement in the direction of arrow C i Figure
6. The apparatus further comprises an actuator 210
wherewith the materials employed in the production of
the insulation 130 can be blown in or otherwise
introduced into the element 100. The actuator 210 com-
prises a transfer element 211 wherewith the actuator 210
can be transferred both in the longitudinal and in the
transverse direction relative to the element 100 and the
production line, in order for the insulation 130 to fill
the inner space of the element 100 as well as possible,
also the possible dead spaces. In Figure 5, the
apparatus also comprises a compacting member 700 where-
with the insulation material blown into the building
element can be compacted still further. The apparatus
also comprises a feeding device 800 through which the
materials can be fed into the actuator 210.
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Both the first and the second embodiment 9.nvolve
a method for manufacturing an insulation product 430 or
, 130. The base material of the insulation product 430,
130 is thus constituted by cellulosic pulp wool. In the
method, a bonding agent, such as viscose fibre directly
in the form of fibres and/or in the form of visco:ae glue
is employed in the manufacture of the insulation prod-
uct. The cellulosic pulp wool is bonded to the 1;>onding
agent with adhesive employed in the method, which in
ZO fact may be the same bonding agent/adhesive that: forms
fibres upon drying.
In a preferred embodiment, viscose fibre or
other cellulose-based bonding agent is employed as a
bonding agent in the manufacture of the insulation prod-
uct, such as 430, 130. Likewise, a cellulose-based adhes-
ive, such as viscose glue, cmc glue or equivalent:, that
becomes fiberized upon drying is employed as an adhes-
ive, and thus in simple versions of the invention no
separate bonding agent, such as viscose yarn, need be
employed, though the advantages of the invention are en-
hanced with the use of viscose yarn or other solid
viscose fibre or an equivalent cellulosic fibre.
In Figures 5-7, the base material, i.e. the cel
lulosic pulp wool or cellulosic pulp chips, is denoted
by reference 237, the bonding agent, such as viscose
yarn, is denoted by reference 239, and the adhesive,
such as viscose glue or other cellulose glue, is denoted
by reference 240.
In Figure 7, the actuator 210 is such that it
comprises a feeding device 212, such as a screw conveyor
212, for feeding cellulosic pulp wool 237, a second
feeding device 213 for feeding bonding agent 239, such
as viscose fibre 239, and a third feeding device :?14 for
feeding adhesive 240, such as viscose glue 240. The
actuator 210 incorporates a rotary nozzle 210a centrally
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at the end of screw 212, through which nozzle the
bonding agent 239 and adhesive 240 are fed, simultane-
ously rotating the nozzle 210a. Herein the method is ,
preferably such that the bonding agent 239 and adhesive
240 are fed into the centre of the cellulosic pulp wool
flow 237 in such a way that the flow of bonding agent
239, i.e. fibre flow 239, and the flow of adhesive 240
are rotated, which makes the materials to become
scattered/distributed effectively.
lp The second embodiment of the invention in Fig-
ures 5-7 thus relates to the fact that in the method an
insulation 130 is produced within the building element
100. The base material for the insulation 130 a.s formed
from cellulosic pulp wool 237 . A bonding agent 239 , such
as viscose fibre 239 in the form of a long or shorter
yarn, to which the cellulosic pulp wool is bonded by
adhesive 240 also applied in the method, is employed to
produce the insulation. At its simplest, the method is
such that the bonding agent 239, such as viscose yarn
239, is treated with adhesive 240 prior to its being
blown into the cellulosic pulp wool 237. The fibre 239
is cut at the nozzle 210a.
The actuator 210, 210a is moved relative to the
element 100 or vice versa, and thus the actuator 210,
210a weaves the bonding agent 239, utilizing adhesive
240, into the cellulosic pulp wool 237.
In Figures 5-7, initially adhesive 240 is
applied to the interior of the building element 100,
whereafter cellulosic pulp wool 237, bonding agent 239
and adhesive 240 are blown substantially simultaneously
into the building element 100 with the actuator 210,
210a.
The initial application of adhesive to the empty
element has the result that the insulation 130 comprises
bonding sites 400 between the building element 100 and
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th.e insulation 130, which will prevent settling of the
insulation 130 even better than heretofore.
. Since compressed air is used for blowing the
materials into the element 100, the overpressure, i.e.
5 circulated air, must be removed using the same flow path
and evacuation means 500. Cellulosic pulp wool dust can
be collected from the circulated air and reused when
necessary.
Also the embodiment of Figures 5-7 can .utilize
10 the arrangement of Figure 2, in which an air-pervious
wire and negative pressure suction are used. 7Cn that
case, the procedure is such that the boards 102, 103 or
equivalent closing means are fastened to the element
only as a last step, that is, after the insulation has
15 been spread.
Even though the invention has been described in
the foregoing with reference to examples in accordance
with the accompanying drawings, it is obvious that the
invention is not restricted to them, but it can be mod-
ified in a variety of ways within the scope of the
inventive idea disclosed in the attached claims..
