Rigid Insulating Panel With S-Shaped Tongue and Groove
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Solution Overview
Problem
Rigid insulating panels commonly used in building structures are not well-suited for uneven surfaces, often leading to connector breakage and breaches in insulation, particularly when used over materials like gravel or crushed stone.
Innovation Solution
A rigid insulating panel design featuring a core with a tongue and groove assembly and a polymeric-based membrane, where the tongue and groove assembly includes an S-shaped median wall for flexible interlocking and enhanced structural integrity, and the membrane provides additional resilience and resistance to breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid insulating panels are used on uneven surfaces, then insulation coverage is achieved, but connectors and panel cores break or spread open causing breaches in isolation
Solution Approach 1:
The patent incorporates a compressible resilient material between the connector and the panel core that deforms under compression to absorb excess force before it can break the connector or panel. This cushioning element is positioned in advance to prevent damage when panels are installed on uneven surfaces, directly addressing the reliability-strength contradiction by protecting structural integrity while maintaining insulation coverage.
2Strength
If connectors are made more rigid to prevent breakage, then connector strength increases, but flexibility to accommodate uneven surfaces decreases
Solution Approach 1:
The connector is constructed as a composite structure combining a rigid outer shell providing structural strength with an inner core of compressible resilient material that provides flexibility. This composite design allows the connector to maintain its shape and resist breaking while the resilient core deforms to accommodate uneven surfaces, simultaneously achieving both strength and adaptability.
Solution Approach 2:
The connector incorporates a resilient material that dynamically deforms under compression forces encountered during installation on uneven surfaces, then returns to its original shape. This dynamic behavior allows the connector to adapt to surface variations while maintaining structural integrity, resolving the contradiction between rigidity and flexibility.
3Adaptability or versatility
If panels are made more flexible to accommodate uneven surfaces, then adaptability improves, but structural integrity and resistance to breakage decrease
Solution Approach 1:
The patent incorporates a flexible membrane that spans across the panel surface and is anchored to the panel edges. This membrane provides flexibility to accommodate uneven surfaces while the panel core maintains its structural integrity. The membrane acts as a flexible skin that can deform without compromising the overall panel strength, resolving the adaptability-strength contradiction.
Data Source
AI summary
A rigid insulating panel comprising an insulating material core with an R-value of at least 2.5 (hr·ft2·° F.)/BTU·in. The insulating material core has opposed first and second surfaces, a pair of spaced-apart longitudinal edges, and a pair of spaced-apart lateral edges extending between the pair of longitudinal edges. At least one of the pair of longitudinal edges and the pair of lateral edges comprises connecting members including a tongue and groove assembly with an inner groove and an outer tongue separated by a substantially S-shaped median wall. The tongue and groove assembly is engageable with the tongue and groove assembly of an adjacent insulating panel to provide a flexible interconnection therebetween. The rigid insulating panel also comprises at least one membrane covering one of the first surface and the second surface. An assembly method for insulating a concrete surface of a building using an assembly of insulating panels is also provided.