Edge cut to increase effective width of insulation sheet and method of forming the same

A method for insulating wall, floor, ceiling or roof cavities having widths defined by opposed, parallel surfaces of spaced apart framing members with insulation sheets formed on an on-line process comprising:

• providing a continuous, flexible, compressible and resilient insulation sheet;
• the insulation sheet having a density;
• the insulation sheet having a width defined by lateral edges which extend the length of the insulation sheet, and a thickness defined by first and second major surfaces of the insulation sheet;
• feeding the insulation sheet through a cutting station which has a series of spaced apart cutting means evenly spaced across the width of the insulation sheet and located between the lateral edges of the insulation sheet for cutting through the thickness of the insulation sheet to form a plurality of secondary insulation sheets of lesser widths than the insulation sheet;
• cutting the insulation sheet with the cutting means of the cutting station to form sized insulation sheets having lateral edges with contours along the lengths of the lateral edges, which with the flexibility, compressibility and resilience of the sized insulation sheets, increase the effective widths of the sized insulation sheets, relative to a conventional insulation sheet of the same length, width, thickness and density with straight lateral edges extending perpendicular between major surfaces of the conventional insulation sheet, with no or substantially no increase in the amount of insulation material forming each of the sized insulation sheets relative to the insulation material used in the conventional insulation sheet so that when the sized insulation sheets are placed in cavities having widths less than the effective widths of the sized insulation sheets the forces exerted on the lateral contoured edges of the sized insulation sheets by the opposed surfaces of the framing members are increased to better retain the sized insulation sheets within the cavities;
• and
• placing the sized insulation sheets in cavities having widths less than the effective widths of the sized insulation sheets with the forces exerted on the lateral contoured edges of the sized insulation sheets by the opposed surfaces of the framing members retaining the sized insulation sheets within the cavities.