U.S. patent application number 17/215049 was filed with the patent office on 2021-11-11 for insulation boards with interlocking shiplap edges.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to Jason E. Bollinger, John F. Budinscak, JR., David Caputo, Nigel W. Ravenscroft.
Application Number | 20210348388 17/215049 |
Document ID | / |
Family ID | 1000005538590 |
Filed Date | 2021-11-11 |
United States Patent
Application |
20210348388 |
Kind Code |
A1 |
Budinscak, JR.; John F. ; et
al. |
November 11, 2021 |
INSULATION BOARDS WITH INTERLOCKING SHIPLAP EDGES
Abstract
Foam insulation boards having an improved shiplap edge for
interfacing with one another are disclosed.
Inventors: |
Budinscak, JR.; John F.;
(Wadsworth, OH) ; Bollinger; Jason E.; (Sylvania,
OH) ; Ravenscroft; Nigel W.; (Hudson, OH) ;
Caputo; David; (Sylvania, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Family ID: |
1000005538590 |
Appl. No.: |
17/215049 |
Filed: |
March 29, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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63020463 |
May 5, 2020 |
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/80 20130101; E04C
2/205 20130101; E04C 2002/004 20130101 |
International
Class: |
E04C 2/20 20060101
E04C002/20; E04B 1/80 20060101 E04B001/80 |
Claims
1. An insulation system comprising: a first insulation board having
four edges, wherein a first shiplap is formed on at least one of
the edges of the first insulation board; and a second insulation
board having four edges, wherein a second shiplap is formed on at
least one of the edges of the second insulation board; wherein the
first shiplap has a width a.sub.1; wherein the second shiplap has a
width a.sub.2; wherein the first shiplap has a thickness b.sub.1;
wherein the second shiplap has a thickness b.sub.2; wherein the
first insulation board has a thickness e.sub.1; wherein the second
insulation board has a thickness e.sub.2; wherein the
a.sub.1=a.sub.2; wherein b.sub.1=b.sub.2; wherein
b.sub.1<e.sub.1; wherein b.sub.2<e.sub.2; wherein
e.sub.1=e.sub.2; and wherein the first shiplap is operable to
interface with the second shiplap to form an insulated joint
between the first insulation board and the second insulation
board.
2. The insulation system of claim 1, wherein the first shiplap is
formed on each of the four edges of the first insulation board; and
wherein the second shiplap is formed on each of the four edges of
the second insulation board.
3. The insulation system of claim 1, wherein the thickness b.sub.1
of the first shiplap is uniform along the entire length of the at
least one edge of the first insulation board; and wherein the
thickness b.sub.2 of the second shiplap is uniform along the entire
length of the at least one edge of the second insulation board.
4. The insulation system of claim 1, wherein the thickness b.sub.1
of the first shiplap is in the range of 25% to 75% of the thickness
e.sub.1; and wherein the thickness b.sub.2 of the second shiplap is
in the range of 25% to 75% of the thickness e.sub.2.
5. The insulation system of claim 1, wherein the thickness e.sub.1
of the first insulation board is in the range of 1 inch to 12
inches; and wherein the thickness e.sub.2 of the second insulation
board is in the range of 1 inch to 12 inches.
6. The insulation system of claim 1, wherein the thickness e.sub.1
of the first insulation board is in the range of 1 inches to 6
inches; and wherein the thickness e.sub.2 of the second insulation
board is in the range of 1 inches to 6 inches.
7. The insulation system of claim 1, further comprising fastening
means for securing the first insulation board to the second
insulation board at the insulated joint.
8. The insulation system of claim 1, wherein the first insulation
board is made of a first foam; and wherein the second insulation
board is made of a second foam.
9. The insulation system of claim 8, wherein the first foam is one
of an extruded polystyrene foam, an expanded polystyrene foam, a
polyisocyanurate foam, a polyethylene terephthalate foam; and a
phenolic foam; and wherein the second foam is one of an extruded
polystyrene foam, an expanded polystyrene foam, a polyisocyanurate
foam, a polyethylene terephthalate foam; and a phenolic foam.
10. An insulation system comprising: a first insulation board
having four edges, wherein a first shiplap is formed on at least
one of the edges of the first insulation board; and a second
insulation board having four edges, wherein a second shiplap is
formed on at least one of the edges of the second insulation board;
wherein the first shiplap includes a first leg portion and a first
end portion; wherein the second shiplap includes a second leg
portion and a second end portion; wherein the first leg portion has
a width e.sub.1; wherein the second leg portion has a width
c.sub.2; wherein the first end portion has a width d.sub.1; wherein
the second end portion has a width d.sub.2; wherein the first
insulation board has a thickness e.sub.1; wherein the second
insulation board has a thickness e.sub.2; wherein the first leg
portion has a thickness g.sub.1; wherein the second leg portion has
a thickness g.sub.2; wherein the first end portion has a thickness
i.sub.1; wherein the second end portion has a thickness i.sub.2;
wherein a space between an upper surface of the first leg portion
and an upper surface of the first insulation board has a thickness
f.sub.1; wherein a space between an upper surface of the second leg
portion and an upper surface of the second insulation board has a
thickness f.sub.2; wherein a space between an upper surface of the
first end portion and an upper surface of the first insulation
board has a thickness h.sub.1; wherein a space between an upper
surface of the second end portion and an upper surface of the
second insulation board has a thickness h.sub.2; wherein
g.sub.1<i.sub.1<e.sub.1; wherein
g.sub.2<i.sub.2<e.sub.2; wherein e.sub.1-g.sub.1=f.sub.1;
wherein e.sub.2-g.sub.2=f.sub.2; wherein e.sub.1-i.sub.1=h.sub.1;
wherein e.sub.2-i.sub.2=h.sub.2; and wherein the first shiplap is
operable to interface with the second shiplap to form an insulated
joint between the first insulation board and the second insulation
board.
11. The insulation system of claim 10, wherein c.sub.1=d.sub.1; and
wherein c.sub.2=d.sub.2.
12. The insulation system of claim 10, wherein c.sub.1<d.sub.1;
and wherein c.sub.2<d.sub.2.
13. The insulation system of claim 10, wherein c.sub.1>d.sub.1;
and wherein c.sub.2>d.sub.2.
14. The insulation system of claim 10, wherein f.sub.1=i.sub.1; and
wherein f.sub.2=i.sub.2.
15. The insulation system of claim 10, wherein f.sub.1>i.sub.1;
and wherein f.sub.2>i.sub.2.
16. The insulation system of claim 10, wherein the first shiplap is
formed on each of the four edges of the first insulation board; and
wherein the second shiplap is formed on each of the four edges of
the second insulation board.
17. The insulation system of claim 10, wherein the thickness
e.sub.1 of the first insulation board is in the range of 1 inch to
12 inches; and wherein the thickness e.sub.2 of the second
insulation board is in the range of 1 inch to 12 inches.
18. The insulation system of claim 10, wherein the first insulation
board is made of a foam selected from the group consisting of an
extruded polystyrene foam, an expanded polystyrene foam, a
polyisocyanurate foam, a polyethylene terephthalate foam; and a
phenolic foam; and wherein the second insulation board is made of a
foam selected from the group consisting of an extruded polystyrene
foam, an expanded polystyrene foam, a polyisocyanurate foam, a
polyethylene terephthalate foam; and a phenolic foam.
19. An insulation board having four edges, wherein a shiplap is
formed on at least one of the edges of the insulation board;
wherein the shiplap includes a leg portion and an end portion;
wherein the leg portion has a width c; wherein the end portion has
a width d; wherein the insulation board has a thickness e; wherein
the leg portion has a thickness g; wherein the end portion has a
thickness i; wherein a space between an upper surface of the leg
portion and an upper surface of the insulation board has a
thickness f; wherein a space between an upper surface of the end
portion and an upper surface of the insulation board has a
thickness h; wherein g<i<e; wherein e-g=f; wherein e-i=h; and
wherein the first shiplap is operable to interface with the second
shiplap to form an insulated joint between the first insulation
board and the second insulation board.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority to and any benefit of U.S.
Provisional Application No. 63/020,463, filed May 5, 2020, the
content of which is incorporated herein by reference in its
entirety.
FIELD
[0002] The general inventive concepts relate to foam insulation
boards and, more particularly, to foam insulation boards with
interlocking shiplap edges.
BACKGROUND
[0003] Rigid foam insulation boards (e.g., extruded polystyrene
(XPS) boards) are well known. There are many applications for such
boards. For example, it is known to use foam boards in the
construction of insulated roadways, such as in permafrost regions.
Given their dimensions (e.g., 4 feet.times.8 feet), many such
boards are needed to form a roadway. In a conventional installation
100, as shown in FIGS. 1A and 1B, foam boards 102 having a defined
thickness (e.g., 1.5 inches) are laid down next to each other to
cover the width and length of the intended roadway. The edges of
adjacent boards 102 can be fastened together (e.g., using tape,
staples) to prevent displacement of the boards. However, because
the edges where adjacent boards meet represent a potential "thermal
break" (i.e., locations where the insulative properties of the
system of boards 102 may be compromised), additional foam boards
102 having a defined thickness (e.g., 1.5 inches) are laid on top
of the existing arrangement of foam boards 102, resulting in two
distinct layers of the foam boards 102 having a combined total
thickness (e.g., 3 inches). Of note, the upper layer of foam boards
102 are positioned in an offset manner relative to the lower layer
of foam boards 102, such that the edges of adjacent foam boards 102
in the lower layer are covered by the foam boards 102 in the upper
layer, and vice versa, as shown in FIG. 1B. Using two layers of
foam board to resolve the "thermal break" issue represents a
significant cost in terms of material, labor, and time to
install.
[0004] Because the placement of two separate layers of foam boards
is time (and, thus, cost) intensive, there is an unmet need for an
improved foam insulation board that facilitates quicker, easier,
and/or cheaper installation thereof.
SUMMARY
[0005] The general inventive concepts relate to a rigid insulation
board having at least one interlocking shiplap edge. As used
herein, the term "shiplap" is intended to encompass any shaping
imparted to the edges of the insulation boards that allows the
edges of adjacent boards to overlap with one another to form a
substantially flush joint. The shaping can occur during formation
of the boards of after formation thereof. To illustrate various
aspects of the general inventive concepts, several exemplary
embodiments of a rigid insulation board are disclosed.
[0006] In one exemplary embodiment, an insulation system comprises:
a first insulation board having four edges, wherein a first shiplap
is formed on at least one of the edges of the first insulation
board; and a second insulation board having four edges, wherein a
second shiplap is formed on at least one of the edges of the second
insulation board; wherein the first shiplap has a width a.sub.1;
wherein the second shiplap has a width a.sub.2; wherein the first
shiplap has a thickness b.sub.1; wherein the second shiplap has a
thickness b.sub.2; wherein the first insulation board has a
thickness e.sub.1; wherein the second insulation board has a
thickness e.sub.2; wherein the a.sub.1=a.sub.2; wherein
b.sub.1=b.sub.2; wherein b.sub.1<e.sub.1; wherein
b.sub.2<e.sub.2; wherein e.sub.1=e.sub.2; and wherein the first
shiplap is operable to interface with the second shiplap to form an
insulated joint between the first insulation board and the second
insulation board.
[0007] In some exemplary embodiments, the first shiplap is formed
on each of the four edges of the first insulation board; and the
second shiplap is formed on each of the four edges of the second
insulation board.
[0008] In some exemplary embodiments, the first shiplap is formed
on two opposite edges of the first insulation board; and the second
shiplap is formed on two opposite edges of the second insulation
board.
[0009] In some exemplary embodiments, the first shiplap is formed
on two adjacent edges of the first insulation board; and the second
shiplap is formed on two adjacent edges of the second insulation
board.
[0010] In some exemplary embodiments, the thickness b.sub.1 of the
first shiplap is uniform along the entire length of the at least
one edge of the first insulation board; and the thickness b.sub.2
of the second shiplap is uniform along the entire length of the at
least one edge of the second insulation board.
[0011] In some exemplary embodiments, the thickness b.sub.1 of the
first shiplap is in the range of 25% to 75% of the thickness
e.sub.1; and the thickness b.sub.2 of the second shiplap is in the
range of 25% to 75% of the thickness e.sub.2. In some exemplary
embodiments, the thickness b.sub.1 of the first shiplap is in the
range of 45% to 55% of the thickness e.sub.1; and the thickness
b.sub.2 of the second shiplap is in the range of 45% to 55% of the
thickness e.sub.2.
[0012] In some exemplary embodiments, the thickness e.sub.1 of the
first insulation board is in the range of 1 inch to 12 inches; and
the thickness e.sub.2 of the second insulation board is in the
range of 1 inch to 12 inches. In some exemplary embodiments, the
thickness e.sub.1 of the first insulation board is in the range of
1 inches to 6 inches; and the thickness e.sub.2 of the second
insulation board is in the range of 1 inches to 6 inches.
[0013] In some exemplary embodiments, the insulation system further
comprises fastening means for securing the first insulation board
to the second insulation board at the insulated joint. In some
exemplary embodiments, the fastening means is a tape. In some
exemplary embodiments, the fastening means is an adhesive. In some
exemplary embodiments, the fastening means is a staple.
[0014] In some exemplary embodiments, the first insulation board is
made of a first foam; and the second insulation board is made of a
second foam.
[0015] In some exemplary embodiments, the first foam is an extruded
polystyrene foam. In some exemplary embodiments, the first foam is
an expanded polystyrene foam. In some exemplary embodiments, the
first foam is a polyisocyanurate foam. In some exemplary
embodiments, the first foam is a polyethylene terephthalate (PET)
foam. In some exemplary embodiments, the first foam is a phenolic
foam.
[0016] In some exemplary embodiments, the second foam is an
extruded polystyrene foam. In some exemplary embodiments, the
second foam is an expanded polystyrene foam. In some exemplary
embodiments, the second foam is a polyisocyanurate foam. In some
exemplary embodiments, the second foam is a polyethylene
terephthalate (PET) foam. In some exemplary embodiments, the second
foam is a phenolic foam.
[0017] In some exemplary embodiments, the first foam and the second
foam are different.
[0018] In one exemplary embodiment, an insulation system comprises:
a first insulation board having four edges, wherein a first shiplap
is formed on at least one of the edges of the first insulation
board; and a second insulation board having four edges, wherein a
second shiplap is formed on at least one of the edges of the second
insulation board; wherein the first shiplap includes a first leg
portion and a first end portion; wherein the second shiplap
includes a second leg portion and a second end portion; wherein the
first leg portion has a width c.sub.1; wherein the second leg
portion has a width c.sub.2; wherein the first end portion has a
width d.sub.1; wherein the second end portion has a width d.sub.2;
wherein the first insulation board has a thickness e.sub.1; wherein
the second insulation board has a thickness e.sub.2; wherein the
first leg portion has a thickness g.sub.1; wherein the second leg
portion has a thickness g.sub.2; wherein the first end portion has
a thickness i.sub.1; wherein the second end portion has a thickness
i.sub.2; wherein a space between an upper surface of the first leg
portion and an upper surface of the first insulation board has a
thickness f.sub.1; wherein a space between an upper surface of the
second leg portion and an upper surface of the second insulation
board has a thickness f.sub.2; wherein a space between an upper
surface of the first end portion and an upper surface of the first
insulation board has a thickness h.sub.1; wherein a space between
an upper surface of the second end portion and an upper surface of
the second insulation board has a thickness h.sub.2; wherein
g.sub.1<i.sub.1<e.sub.1; wherein
g.sub.2<i.sub.2<e.sub.2; wherein e.sub.1-g.sub.1=f.sub.1;
wherein e.sub.2-g.sub.2=f.sub.2; wherein e.sub.1-i.sub.1=h.sub.1;
wherein e.sub.2-i.sub.2=h.sub.2; and wherein the first shiplap is
operable to interface with the second shiplap to form an insulated
joint between the first insulation board and the second insulation
board.
[0019] In some exemplary embodiments, c.sub.1=d.sub.1; and
c.sub.2=d.sub.2.
[0020] In some exemplary embodiments, c.sub.1<d.sub.1; and
c.sub.2<d.sub.2.
[0021] In some exemplary embodiments, c.sub.1>d.sub.1; and
c.sub.2>d.sub.2.
[0022] In some exemplary embodiments, f.sub.1=i.sub.1; and
f.sub.2=i.sub.2.
[0023] In some exemplary embodiments, f.sub.1>i.sub.1; and
f.sub.2>i.sub.2.
[0024] In some exemplary embodiments, the first shiplap is formed
on each of the four edges of the first insulation board; and the
second shiplap is formed on each of the four edges of the second
insulation board.
[0025] In some exemplary embodiments, the first shiplap is formed
on two opposite edges of the first insulation board; and the second
shiplap is formed on two opposite edges of the second insulation
board.
[0026] In some exemplary embodiments, the first shiplap is formed
on two adjacent edges of the first insulation board; and the second
shiplap is formed on two adjacent edges of the second insulation
board.
[0027] In some exemplary embodiments, the thickness e.sub.1 of the
first insulation board is in the range of 1 inch to 12 inches; and
the thickness e.sub.2 of the second insulation board is in the
range of 1 inch to 12 inches. In some exemplary embodiments, the
thickness e.sub.1 of the first insulation board is in the range of
1 inches to 6 inches; and the thickness e.sub.2 of the second
insulation board is in the range of 1 inches to 6 inches.
[0028] In some exemplary embodiments, the first insulation board is
made of a first foam; and the second insulation board is made of a
second foam.
[0029] In some exemplary embodiments, the first foam is an extruded
polystyrene foam. In some exemplary embodiments, the first foam is
an expanded polystyrene foam. In some exemplary embodiments, the
first foam is a polyisocyanurate foam. In some exemplary
embodiments, the first foam is a polyethylene terephthalate (PET)
foam. In some exemplary embodiments, the first foam is a phenolic
foam.
[0030] In some exemplary embodiments, the second foam is an
extruded polystyrene foam. In some exemplary embodiments, the
second foam is an expanded polystyrene foam. In some exemplary
embodiments, the second foam is a polyisocyanurate foam. In some
exemplary embodiments, the second foam is a polyethylene
terephthalate (PET) foam. In some exemplary embodiments, the second
foam is a phenolic foam.
[0031] In some exemplary embodiments, the first foam and the second
foam are different.
[0032] In some exemplary embodiments, c.sub.1=d.sub.1;
c.sub.2=d.sub.2; f.sub.1=i.sub.1; and f.sub.2=i.sub.2.
[0033] In some exemplary embodiments, c.sub.1=d.sub.1;
c.sub.2=d.sub.2; f.sub.1>i.sub.1; and f.sub.2>i.sub.2.
[0034] In some exemplary embodiments, c.sub.1<d.sub.1;
c.sub.2<d.sub.2; f.sub.1=i.sub.1; and f.sub.2=i.sub.2.
[0035] In some exemplary embodiments, c.sub.1<d.sub.1;
c.sub.2<d.sub.2; f.sub.1>i.sub.1; and f.sub.2>i.sub.2.
[0036] In some exemplary embodiments, c.sub.1>d.sub.1;
c.sub.2>d.sub.2; f.sub.1=i.sub.1; and f.sub.2=i.sub.2.
[0037] In some exemplary embodiments, c.sub.1>d.sub.1;
c.sub.2>d.sub.2; f.sub.1>i.sub.1; and f.sub.2>i.sub.2.
[0038] In one exemplary embodiment, an insulation board has four
edges, wherein a shiplap is formed on at least one of the edges of
the insulation board; wherein the shiplap includes a leg portion
and an end portion; wherein the leg portion has a width c; wherein
the end portion has a width d; wherein the insulation board has a
thickness e; wherein the leg portion has a thickness g; wherein the
end portion has a thickness i; wherein a space between an upper
surface of the leg portion and an upper surface of the insulation
board has a thickness f; wherein a space between an upper surface
of the end portion and an upper surface of the insulation board has
a thickness h; wherein g<i<e; wherein e-g=f; wherein e-i=h;
and wherein the first shiplap is operable to interface with the
second shiplap to form an insulated joint between the first
insulation board and the second insulation board.
[0039] Other aspects and features of the general inventive concepts
will become more readily apparent to those of ordinary skill in the
art upon review of the following description of various exemplary
embodiments in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The general inventive concepts, as well as embodiments and
advantages thereof, are described below in greater detail, by way
of example, with reference to the drawings in which:
[0041] FIGS. 1A and 1B illustrate conventional foam insulation
boards being interfaced with one another. FIG. 1A is a side
elevational view of the boards. FIG. 1B is a top plan view of the
boards.
[0042] FIGS. 2A, 2B, and 2C illustrate foam insulation boards with
shiplap edges, according to one exemplary embodiment. FIG. 2A is a
side elevational view of the boards. FIG. 2B is a side elevational
view of the boards interfaced with one another. FIG. 2C is a top
plan view of the boards interfaced with one another.
[0043] FIGS. 3A, 3B, and 3C illustrate foam insulation boards with
shiplap edges, according to another exemplary embodiment. FIG. 3A
is a side elevational view of one edge of a portion of the foam
insulation board. FIG. 3B is a side elevational view of the edge of
the portion of the foam insulation board. FIG. 3C is a side
elevational view of the edge of the portion of the foam insulation
board.
[0044] FIG. 4 is a side elevational view showing the foam
insulation boards of FIG. 3A interfaced with one another.
[0045] FIG. 5 illustrates a side elevational view of a shiplap edge
of a foam insulation board, according to another exemplary
embodiment.
[0046] FIG. 6 illustrates a side elevational view of a shiplap edge
of a foam insulation board, according to another exemplary
embodiment.
[0047] FIG. 7 illustrates a side elevational view of a shiplap edge
of a foam insulation board, according to another exemplary
embodiment.
DETAILED DESCRIPTION
[0048] Several illustrative embodiments will be described in detail
with the understanding that the present disclosure merely
exemplifies the general inventive concepts. Embodiments
encompassing the general inventive concepts may take various forms
and the general inventive concepts are not intended to be limited
to the specific embodiments described herein.
[0049] The general inventive concepts are based, at least in part,
on the discovery that forming an insulation board with an
interlocking shiplap on at least one edge of the board facilitates
quicker, easier, and/or cheaper installation thereof.
[0050] The general inventive concepts relate to a rigid insulation
board having at least one interlocking shiplap edge.
[0051] As noted above, because the placement of two separate layers
of foam boards is time (and, thus, cost) intensive, it is proposed
(in one exemplary embodiment of an installation 200) to use a
modified foam board 202 having a defined thickness (e.g., 3
inches). The board 202 allows for a single layer of the boards to
be used to effectively insulate a roadway. The foam board 202 has a
shiplap edge formed around all four sides thereof, as shown in
FIGS. 2A and 2B. In some exemplary embodiments, a length of the
shiplap edge is the same as a length of the side. In some exemplary
embodiments, a length of the shiplap edge is less than a length of
the side. The shiplap edge has a width a (e.g., 3 inches) and a
depth b (e.g., 1.5 inches). Typically, any width a can be used for
the shiplap edge, so long as the width a is suitable to resist
movement of the boards 202 relative to one another and to prevent
formation of a thermal break at the interface of adjacent boards.
Typically, the depth b will be 1/2 of the total board thickness. In
some exemplary embodiments, the depth b is in the range of 25% of
the total board thickness to 75% of the total board thickness.
[0052] The foam boards 202 are laid down next to each other to
cover the width and length of the intended roadway. More
specifically, the foam boards 202 are arranged so that the shiplap
edges of adjacent boards 202 interface with one another in a
complementary manner, as shown in FIG. 2B. Because the mated
shiplap edges avoid any thermal break at the interface between
adjacent boards, only a single layer of the foam boards 202 need be
placed for the roadway, as shown in FIG. 2C, which results in a
significant installation time savings. Furthermore, the mated
shiplap edges are more likely to prevent movement of the boards
202, such that there is less of a need for fasteners, which also
results in a significant installation time savings.
[0053] Nonetheless, movement of the boards 202 may still occur.
Thus, in another exemplary embodiment of an installation 300, it is
proposed to use a modified foam board 302 having a defined
thickness (e.g., 3 inches). The board 302 allows for a single layer
of the boards to be used to effectively insulate a roadway.
However, as shown in FIGS. 3A-3C, the board 302 had a modified
shiplap 304 formed on at least one edge thereof. In some exemplary
embodiments, the modified shiplap 304 extends along the entire
edge. In some exemplary embodiments, the modified shiplap 304
extends along a portion of the edge.
[0054] In some exemplary embodiments, the modified shiplap 304 is
formed on all sides of the foam board 302. In some exemplary
embodiments, the modified shiplap 304 is formed on two sides of the
foam board 302, wherein the two sides are opposite one another. In
some exemplary embodiments, the modified shiplap 304 is formed on
two sides of the foam board 302, wherein the two sides are adjacent
to one another.
[0055] More specifically, the shiplap 304 is formed, such as by
removing material from the board 302, with specific dimensions that
form a leg portion 306 and an end portion 308. The general
inventive concepts are not limited to a particular approach to
forming the shiplap 304. For example, while the shiplap 304 could
be formed mechanically (e.g., by milling, computer numerical
control (CNC) routing with abrasive or hot wire, sawing, etc.), the
shiplap 304 could also be pre-formed in the edge during manufacture
of the foam board 302.
[0056] Each of the leg portion 306 and the end portion 308 has a
thickness that is less than a thickness of the board 302.
Furthermore, in general, the thickness of the leg portion 306 is
less than the thickness of the end portion 308.
[0057] As shown in FIG. 3B, a width of the leg portion 306 of the
shiplap 304 is denoted by the letter c, while a width of the end
portion 308 of the shiplap 304 is denoted by the letter d.
[0058] As shown in FIG. 3C, the thickness of the board 302 is
denoted by the letter e, the thickness of the leg portion 306 is
denoted by the letter g (which is equal to e-f), and the thickness
of the end portion 308 is denoted by the letter i (which is equal
to e-h).
[0059] In some exemplary embodiments, the thickness e is in the
range of 1 inch to 12 inches. In some exemplary embodiments, the
thickness e is in the range of 1 inches to 6 inches.
[0060] The shiplap 304 is sized and shaped so that it can interface
with similar shiplaps on other boards, as shown in the installation
400 of FIG. 4. In particular, the shiplap 304 allows adjacent
boards 302 to effectively be "locked" together at a joint 402. In
other words, once positioned together, the boards 302 with the
shiplaps 304 are less likely to move relative to one another than
boards without shiplaps or boards with conventional shiplaps. In
this manner, the installation 400 can generally be performed more
quickly and reliably. By interlocking the adjacent foam boards 302,
the field or array of boards react as one homogeneous layer instead
of individually, which increases the resistance of the installation
400 to wind uplift and displacement. Furthermore, the interfaced
shiplaps 304 avoid or otherwise mitigate against a thermal break at
the joint 402. In some instances, the interfaced shiplaps 304 may
be sufficient to lock the boards together without requiring any
additional fasteners (e.g., tape, staples).
[0061] According to the general inventive concepts, the actual
dimensions of the shiplap 304 can be selected or otherwise adjusted
based on the thickness e of the board 302, the desired properties
(e.g., strength) of the edge with the shiplap 304, the behavior of
the interface between interlocked boards 302, etc.
[0062] For example, in one exemplary embodiment, the shiplap 304 is
designed to provide a loose fitting joint between interlocked
boards 302. It is contemplated that during installation of the
boards 302 in road sections, the alignment of the boards 302 will
not always be uniform. Consequently, fabricating the shiplap 304 so
that the interlocking joint formed between adjacent boards 302 has
matching dimensions (e.g., c=d or f=i may prove problematic during
installation. This is particularly true if the boards are not
perfectly square or cut to the same length. Thus, in this
embodiment, the shiplap 304 is formed such that c>d and/or
f>i, which results in a joint 402 that provides space to allow
the adjacent boards to better accommodate any misalignment.
[0063] In another exemplary embodiment, the shiplap 304 is designed
to provide a tight fitting joint between interlocked boards 302. It
is contemplated that having a tight fitting joint will better
prevent the boards 302 from moving relative to one another after
installation. This embodiment is particularly suited to foam boards
that have a degree of compressibility, such as with XPS foam
boards. In this case, the shiplap 304 is formed such that d>c.
By slightly oversizing dimension d, relative to dimension c, it
forces compression of dimension d to fit into dimension c. This
compression creates a friction fit that "locks" the adjacent boards
together and keeps them from inadvertently separating.
[0064] In accordance with the general inventive concepts, the
particular dimensions of the shiplap structure can be structured to
provide flexibility of the interlocking joint to suit a particular
application. In some exemplary embodiments, c=d. In some exemplary
embodiments, c>d. In some exemplary embodiments, c<d. In some
exemplary embodiments, f=i. In some exemplary embodiments, f>i.
In some exemplary embodiments, h=g. In some exemplary embodiments,
h>g. In some exemplary embodiments, (i-g)=h. The general
inventive concepts encompass the various permutations/combinations
of these dimensional relationships (e.g., c:d, f:i, etc.), for
example, c>d and f>i.
[0065] While the shiplap 304 edges (and resulting joint 402)
described above involve flat faces (e.g., leg portions and end
portions) that meet at 90-degree angles, the general inventive
concepts contemplate embodiments wherein the shiplap 304 assumes a
different geometry, such as a shiplap 500 with a V-shape (see FIG.
5), a shiplap 600 with a curved/arched-shape (see FIG. 6), a
shiplap 700 with an angled shape (see FIG. 7), or a shiplap with
any other shape that enhances the strength of the joint 402.
[0066] While various exemplary embodiments are described herein in
the context of foam boards, any suitably rigid insulating member
(e.g., board, panel) may be used. In the case of foam boards, any
suitable foaming mechanism (e.g., an extruded polystyrene (XPS)
foam, an expanded polystyrene (EPS) foam, a polyisocyanurate foam,
a polyethylene terephthalate (PET) foam, a phenolic foam, etc.) may
be used.
[0067] Furthermore, while various exemplary embodiments are
described herein in the context of insulating a roadway, it should
be understood that the general inventive concepts contemplate many
other potential applications in which the interlocking shiplap edge
could provide meaningful advantages, such as commercial roofing,
below slab insulation, radon barrier systems, precast or site cast
concrete sandwich panels, etc.
[0068] In general, in some embodiments, it may be possible to
utilize the various inventive concepts in combination with one
another. Additionally, any particular element recited as relating
to a particularly disclosed embodiment should be interpreted as
available for use with all disclosed embodiments, unless
incorporation of the particular element would be contradictory to
the express terms of the embodiment. The scope of the general
inventive concepts presented herein are not intended to be limited
to the particular exemplary embodiments shown and described herein.
From the disclosure given, those skilled in the art will not only
understand the general inventive concepts and their attendant
advantages, but will also find apparent various changes and
modifications thereto. For example, as noted above, the inventive
foam boards disclosed and suggested herein can be used at least in
any application for which foam boards are known to be suitable. It
is sought, therefore, to cover all such changes and modifications
as fall within the spirit and scope of the general inventive
concepts, as described and/or claimed herein, and any equivalents
thereof
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