# US 2022/0034082 A1 · Insulation board comprising enhanced strength > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0034082 A1 - Document ID: US20220034082A1 - Status: Published application - Kind: A1 - Application number: 17/378,907 - Filed: 2021-07-19 - Published: 2022-02-03 - Earliest claimed: 2020-07-30 - Inventors: Gustavo Velazquez - Web page: https://patentgrep.com/patent/US20220034082A1 ## CPC - E04B 1/80: slab-shaped - F16L 59/028: {Compositions for or methods of fixing a thermally insulating material} - E04B 2001/742: {Use of special materials; Materials having special structures or shape} - E04B: GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS (border constructions of opening in walls, floors or ceilings E06B1/00; {electromagnetic shielding H05K9/0001}) - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL ## Abstract The presently disclosed subject matter is directed to an insulation board for use in a wide variety of applications, such as construction of new structures. The disclosed insulation board comprises an interior foam core and an exterior support layer. The interior foam layer provides insulative characteristics to the disclosed board. In addition, the exterior support layer provides an added layer of durability, preventing or reducing the incidence of cracks, bending, and the like. The disclosed board is angled at a top edge to allow for a seamless fit during installation. The insulation board further includes a groove on the rear face that allows for the board to be easily installed during use. ## Claims ### Claim 1 An insulation board comprising: an interior foam core; and an exterior support layer surrounding the interior foam core; a front face and an opposed rear face, a top edge and an opposed bottom edge, and a pair of opposed side edges; wherein the front face comprises an angled top edge; and wherein the rear face comprises a groove defined therein. ### Claim 2 (depends on 1) The insulation board of claim 1, wherein the interior foam core comprises polystyrene foam, graphite polystyrene foam, polyurethane foam, polyisocyanurate foam, polyethylene foam, polypropylene foam, polyimide foam, polyvinyl chloride foam, polyacrylic foam, epoxide foam, polyester foam, polytetrafluoroethylene foam, or combinations thereof. ### Claim 3 (depends on 1) The insulation board of claim 1, wherein the foam core comprises one or more rigid foam materials. ### Claim 4 (depends on 1) The insulation board of claim 1, wherein the foam core comprises one or more additives selected from the group comprising inorganic fillers, pigments, antioxidants, acid scavengers, ultraviolet absorbers, flame retardants, processing aids, stabilizers, extrusion aids, or nucleating agents. ### Claim 5 (depends on 1) The insulation board of claim 1, wherein the foam core has a density of about 0.8-5 pounds/ft3. ### Claim 6 (depends on 1) The insulation board of claim 1, wherein the foam core has a compressive resistance at yield of 10% deformation in psi (min) of about 5-30 in accordance with ASTM D 1621. ### Claim 7 (depends on 1) The insulation board of claim 1, wherein the foam core has a flexural strength of about 20-55 psi in accordance with ASTM D790. ### Claim 8 (depends on 1) The insulation board of claim 1, wherein the angled top edge is about 5-85 degrees. ### Claim 9 (depends on 8) The insulation board of claim 8, wherein the angled top edge is about 45 degrees. ### Claim 10 (depends on 1) The insulation board of claim 1, wherein the groove contacts one edge of the rear face of the board. ### Claim 11 (depends on 1) The insulation board of claim 1, wherein the rear face comprises more than one groove. ### Claim 12 (depends on 1) The insulation board of claim 1, wherein the groove has a thickness of about 5-95 percent of a total thickness of the insulation board. ### Claim 13 (depends on 1) The insulation board of claim 1, wherein the support layer comprises cement, acrylic, or combinations thereof. ### Claim 14 (depends on 1) The insulation board of claim 1, wherein the support layer comprises about 25 weight percent cement and about 75 weight percent acrylic, based on the total weight of the support layer. ### Claim 15 (depends on 13) The insulation board of claim 13, wherein the cement is Portland cement. ### Claim 16 (depends on 1) The insulation board of claim 1, wherein the support layer has a thickness of about 0.1-2 inches. ### Claim 17 (depends on 1) The insulation board of claim 1, comprising a yield tensile strength of at least about 5,000-10,000 psi in accordance with ASTM C1583. ### Claim 18 (depends on 1) A method of constructing the insulation board of claim 1, the method comprising: forming the interior foam core through extrusion or expansion; forming an angled top edge in the foam core; forming a groove in the foam core; applying the exterior support layer such that it surrounds the interior foam core; and allowing the exterior support layer to dry. ### Claim 19 (depends on 18) The method of claim 18 wherein the groove, angled top edge, or both are formed through thermosetting, casting, molding cutting, impressing, or embossing. ### Claim 20 (depends on 18) The method of claim 18, wherein the exterior support layer is applied by spray coating, dip coating, roller coating, brush coating, casting, the use of a mold, or combinations thereof.