Interlocking Shiplap Foam Insulation Boards
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Solution Overview
Problem
Conventional foam insulation board installations in permafrost regions require two layers to mitigate thermal breaks, leading to increased material, labor, and time costs due to the need for additional boards to cover edge gaps.
Innovation Solution
Rigid foam insulation boards with interlocking shiplap edges, allowing adjacent boards to overlap and form a flush joint, reducing the need for multiple layers by preventing thermal breaks and minimizing the requirement for additional fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional foam boards are installed with simple edges, then installation is simple and quick, but thermal breaks occur at the edges requiring additional layers of boards
Solution Approach 1:
The edge of the foam board is segmented into distinct geometric features (recess and protrusion) that create an interlocking shiplap joint. This segmentation allows the edge to serve multiple functions: maintaining thermal integrity through the recess-protrusion interface and enabling quick installation through the predetermined geometry that guides alignment.
Solution Approach 2:
The shiplap features (recess and protrusion) are pre-formed on the foam boards during manufacturing. This preliminary action eliminates the need for field preparation or additional fastening steps, allowing workers to simply place the boards together and achieve both thermal integrity and installation efficiency.
2Reliability
If two layers of foam boards are used to prevent thermal breaks, then thermal integrity is improved, but material cost and installation time increase
Solution Approach 1:
The solution moves from a vertical stacking approach (two layers) to a horizontal interlocking approach (single layer with shiplap edges). By developing the joint geometry in the horizontal plane rather than requiring vertical layering, the patent achieves thermal integrity without increasing material quantity.
Solution Approach 2:
The patent merges the functions of thermal insulation and edge sealing into a single layer of foam board with integrated shiplap features. This consolidation eliminates the need for separate layers dedicated to preventing thermal breaks, reducing overall material quantity while maintaining thermal integrity.
3Productivity
If foam boards are installed without interlocking edges, then installation is faster, but board displacement occurs requiring additional fasteners
Solution Approach 1:
The shiplap features enable the foam boards to self-align and self-lock during installation. The protrusion fits into the recess, automatically positioning adjacent boards correctly and preventing displacement without requiring external fasteners. This self-service mechanism maintains board stability while preserving installation speed.
Solution Approach 2:
The recess-protrusion interface acts as an intermediary mechanical element between adjacent foam boards. This intermediate feature facilitates the connection by providing a predetermined path for alignment and a positive locking mechanism, eliminating the need for additional fasteners while ensuring board stability.
Data Source
AI summary
Foam insulation boards having an improved shiplap edge for interfacing with one another are disclosed.