Insulation boards with interlocking shiplap edges

Abstract

Foam insulation boards having an improved shiplap edge for interfacing with one another are disclosed.

It is claimed: 
     
         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 1 ;   wherein the second shiplap has a width a 2 ;   wherein the first shiplap has a thickness b 1 ;   wherein the second shiplap has a thickness b 2 ;   wherein the first insulation board has a thickness e 1 ;   wherein the second insulation board has a thickness e 2 ;   wherein the a 1 =a 2 ;   wherein b 1 =b 2 ;   wherein b 1 <e 1 ;   wherein b 2 <e 2 ;   wherein e 1 =e 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 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 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 1  of the first shiplap is in the range of 25% to 75% of the thickness e 1 ; and
 wherein the thickness b 2  of the second shiplap is in the range of 25% to 75% of the thickness e 2 .   
     
     
         5 . The insulation system of  claim 1 , wherein the thickness e 1  of the first insulation board is in the range of 1 inch to 12 inches; and
 wherein the thickness e 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 1  of the first insulation board is in the range of 1 inches to 6 inches; and
 wherein the thickness e 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 1 ;   wherein the second leg portion has a width c 2 ;   wherein the first end portion has a width d 1 ;   wherein the second end portion has a width d 2 ;   wherein the first insulation board has a thickness e 1 ;   wherein the second insulation board has a thickness e 2 ;   wherein the first leg portion has a thickness g 1 ;   wherein the second leg portion has a thickness g 2 ;   wherein the first end portion has a thickness i 1 ;   wherein the second end portion has a thickness i 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 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 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 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 2 ;   wherein g 1 <i 1 <e 1 ;   wherein g 2 <i 2 <e 2 ;   wherein e 1 −g 1 =f 1 ;   wherein e 2 −g 2 =f 2 ;   wherein e 1 −i 1 =h 1 ;   wherein e 2 −i 2 =h 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 1 =d 1 ; and
 wherein c 2 =d 2 .   
     
     
         12 . The insulation system of  claim 10 , wherein c 1 <d 1 ; and
 wherein c 2 <d 2 .   
     
     
         13 . The insulation system of  claim 10 , wherein c 1 >d 1 ; and
 wherein c 2 >d 2 .   
     
     
         14 . The insulation system of  claim 10 , wherein f 1 =i 1 ; and
 wherein f 2 =i 2 .   
     
     
         15 . The insulation system of  claim 10 , wherein f 1 >i 1 ; and
 wherein f 2 >i 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 1  of the first insulation board is in the range of 1 inch to 12 inches; and
 wherein the thickness e 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.