INSULATING PANEL WITH ALIGNMENT ASSEMBLY AND INSULATING PANEL ASSEMBLY INCLUDING SAME

Abstract

A rigid insulating panel has a plurality of surface elements and four edges. At least two of the four edges have a connecting member including a tongue and groove assembly engageable with the tongue and groove assembly of an adjacent insulating panel to maintain the panels in engagement. The connecting members of the at least two of the four edges further include an alignment assembly wherein at least one of the connecting members includes at least one alignment projection protruding in its groove and at least another one of the connecting members includes at least one alignment recess defined in its tongue. The at least one alignment projection is insertable in the at least one alignment recess to laterally align engaged ones of the adjacent insulating panels. A rigid insulating panel assembly includes at least two rigid insulating panels with the above characteristics.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. §119(e) of U.S. provisional patent application No. 62/086,935 which was filed on Dec. 3, 2014. The entirety of the aforementioned application is herein incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to the field of insulating panels. More particularly, it relates to insulating panels including surface elements and connecting members with an alignment assembly and the insulating panel assemblies comprising such panels.

BACKGROUND

Insulating panels with surface elements are known in the art, for example, to provide insulation of the underside of a radiant floor, such as a hydronic radiant floor. Hydronic radiant floors are radiant floors where a pipe system carrying a heat transfer fluid (such as water, ethylene glycol, or the like) is laid within a structure, such as a concrete slab, to heat the structure by heat conduction.

In the construction of such floors, it is common to use insulation panels with surface elements projecting upwardly therefrom, for the pipes to be arranged and maintained between the surface elements prior and simultaneously to the casting of the concrete slab with the pipe system laid therein. In such cases, multiple panels are often required to cover the entire undersurface of the radiant floor. Therefore, the insulating panels must be connectable to one another in order to define an insulating panel assembly spanning over the whole underside of the floor. In addition to being connectable, the panels must also be aligned with one another, such that the surface elements of adjacent insulating panels of the insulating panel assembly are aligned with one another and allow the creation of a regular pipe pattern throughout the insulating panel assembly.

It will be understood that other types of insulating panels with surface elements, different than those used for maintaining pipes of a radiant floor can also require such alignment of surface elements between adjacent panels of an insulating panel assembly. For example and without being limitative, in an embodiment, the insulating panels can be provided with surface elements creating depressions in the surface of the insulation panels, for example and without being limitative for draining fluids, such as water or the like rather than projecting from the insulating panels.

Known to the applicant are insulating panels and insulating panel assemblies with surface elements, where a combination of spaced-apart connecting tabs extending from the panels and corresponding spaced-apart recesses defined in the panels are used for aligning adjacent panels. Such panels however tend to suffer from several drawbacks. Firstly, the combination of connecting tabs and corresponding recess only allows alignment of the panels, without firmly maintaining the corresponding edges of the panels interlocked. Therefore, in order to maintain the engagement between the adjacent panels, additional connecting methods, such as taping of the joint between the adjacent panels often is required.

Applicant is also aware of panels including engagement assemblies for maintaining the corresponding edges of panels interlocked, for example using complementary U-shaped engagement members along the corresponding edges thereof. Such systems however do not offer a solution for the alignment of adjacent panels, the engagement assemblies being limited to maintaining the edges of the panels in engagement.

In view of the above, there is a need for an improved insulating panel and insulating panel assembly, which, would be able to overcome or at least minimize some of the above-discussed prior art concerns.

SUMMARY OF THE INVENTION

According to a first general aspect, there is provided a rigid insulating panel engageable with an adjacent rigid insulating panel. The rigid insulating panel comprises an insulating material core having an upper surface, a lower surface, a plurality of surface elements on at least one of the upper surface and the lower surface and four edges. At least two of the four edges comprise a connecting member including a tongue and groove assembly with an inner groove and an outer tongue engageable with the tongue and groove assembly of an adjacent rigid insulating panel to maintain the rigid insulating panels in engagement. The connecting members of the at least two of the four edges further comprise an alignment assembly wherein at least one of the connecting members comprises at least one alignment projection protruding in the corresponding inner groove and at least another one of the connecting members comprises at least one alignment recess defined in the corresponding outer tongue. The at least one alignment projection is insertable in the at least one alignment recess to laterally align engaged ones of the adjacent rigid insulating panels.

In an embodiment, the surface elements protrude from the upper surface.

In an embodiment, each one of the surface elements comprises scalloped side walls and bevelled corners.

In an embodiment, each one of the surface elements is substantially square shaped.

In an embodiment, each one of the surface elements comprises side walls extending substantially perpendicular to the upper surface of the insulating material core, along an entire height thereof.

In an embodiment, the at least two of the four edges comprising a connecting member are opposed edges.

In an embodiment, the four edges of the insulating material core each comprise one of the connecting members. A first one of the edges and a second one of the edges each comprise a plurality of alignment projections, and a third one of the edges and a fourth one of the edges each comprise a plurality of alignment recesses.

In an embodiment, the inner groove and the outer tongue of each one of the connecting members are separated by a substantially S-shaped median wall defining consecutive convex and concave sections in the inner groove and the outer tongue.

In an embodiment, the at least one alignment projection and the at least one alignment recesses are substantially trapezoidally shaped.

In an embodiment, the at least one alignment projection extends from the outer tongue and into the inner groove of each corresponding one of the connecting members.

In an embodiment, a notch is defined in the outer tongue of each one of the connecting members including the at least one alignment projection extending from the outer tongue, on each side of the at least one alignment projection.

In an embodiment, the outer tongue and the inner groove extend substantially perpendicular to the upper surface and the lower surface of the insulating material core.

In an embodiment, each one of the insulating material core and the surface elements is formed of one of expanded polystyrene, extruded polystyrene, polyurethane, polyisocyanurate and phenolic foam.

In an embodiment, the insulating material core has an R-value of at least 2.5 (hr.ft².° F.)/BTU.in.

According to another general aspect, there is also provided a rigid insulating panel assembly. The rigid insulating panel assembly comprises at least two rigid insulating panels engaged to one another. Each one of the rigid insulating panels comprises an insulating material core having an upper surface, a lower surface, a plurality of surface elements and four edges spaced apart from one another; a connecting member defined in at least two of the four edges and an alignment assembly defined in the connecting member of the at least two of the four edges. Each connecting member includes a tongue and groove assembly with an inner groove and an outer tongue engageable with the tongue and groove assembly of an adjacent one of the at least two rigid insulating panels to maintain the rigid insulating panels in engagement. The alignment assembly comprises at least one alignment projection protruding in the inner groove of at least one of the connecting members defined in the at least two of the four edges and at least one alignment recess defined in the outer tongue of at least another one of the connecting member defined in the at least two of the four edges. The at least one alignment projection is insertable in the at least one alignment recess to laterally align the engaged adjacent rigid insulating panels.

In an embodiment, the surface elements protrude from the upper surface of each one of the at least two rigid insulating panels.

In an embodiment, each one of the surface elements comprises scalloped side walls and bevelled corners.

In an embodiment, each one of the surface elements is substantially square shaped.

In an embodiment, each one of the surface elements comprises side walls extending substantially perpendicular to the upper surface of the insulating material core, along an entire height thereof.

In an embodiment, the at least two of the four edges of each one of the at least two rigid insulating panels are opposed edges.

In an embodiment, the four edges of the insulating material core each comprise one of the connecting members. A first one of the edges and a second one of the edges each comprise a plurality of alignment projections, and a third one of the edges and a fourth one of the edges each comprise a plurality of alignment recesses.

In an embodiment, the inner groove and the outer tongue of each one of the connecting members are separated by a substantially S-shaped median wall defining consecutive convex and concave sections in the inner groove and the outer tongue.

In an embodiment, the at least one alignment projection and the at least one alignment recesses are substantially trapezoidally shaped.

In an embodiment, the at least one alignment projection extends from the outer tongue and into the inner groove of each corresponding one of the connecting members.

In an embodiment, a notch is defined in the outer tongue of each one of the connecting members including the at least one alignment projection extending from the outer tongue, on each side of the at least one alignment projection.

In an embodiment, the outer tongue and the inner groove extend substantially perpendicular to the upper surface and the lower surface of the insulating material core of each one of the at least two rigid insulating panels.

In an embodiment, each one of the insulating material core and the surface elements of each one of the at least two rigid insulating panels is formed of one of expanded polystyrene, extruded polystyrene, polyurethane, polyisocyanurate and phenolic foam.

In an embodiment, the insulating material core of each one of the at least two rigid insulating panels has an R-value of at least 2.5 (hr.ft².° F.)/BTU.in.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, advantages and features will become more apparent upon reading the following non-restrictive description of embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings in which:

FIG. 1 is a top perspective view of an insulating panel, according to an embodiment.

FIG. 1A is an enlarged view of a section of an inner groove and an outer tongue of a connecting member of the insulating panel of FIG. 1, wherein an alignment projection is shown.

FIG. 2 is a cross sectional side view of the insulating panel of FIG. 1, taken along lines 2-2 of FIG. 1.

FIG. 3 is a bottom perspective view of the insulating panel of FIG. 1.

FIG. 3A is an enlarged view of a section of the inner groove and the outer tongue of another connecting member of the insulating panel of FIG. 1, wherein an alignment recess is shown.

FIG. 4 is a top plan view of a panel assembly including four insulating panels of FIG. 1, engaged together.

FIG. 5 is a cross sectional side view of the panel assembly of FIG. 4, taken along lines 5-5 of FIG. 4.

FIG. 6 is a cross sectional side view of the panel assembly of FIG. 4, taken along lines 6-6 of FIG. 4.

DETAILED DESCRIPTION

In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures or described in the present description are embodiments only, given solely for exemplification purposes.

Moreover, although the embodiments of the insulating panel and insulating panel assembly and corresponding parts thereof consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, can be used for the insulating panel and insulating panel assembly, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art. Moreover, it will be appreciated that positional descriptions such as “upper”, “lower”, “above”, “below”, “left”, “right” and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

In reference to FIGS. 1 to 3A, there is shown an insulating panel 10 in accordance with an embodiment. The insulating panel 10 has a rigid or semi rigid insulating material core 11 with a first edge 20, a second edge 22, a third edge 24 and a fourth edge 26. The first edge 20 is located opposite to the third edge 24 and the second edge 22 is located opposite to the fourth edge 26 to substantially form a polygon having an upper surface 30 and a lower surface 32. A plurality of surface elements 28 extend upwardly from the upper surface 30 of the insulating material core 11. In an embodiment, the surface elements 28 are sized, shaped, and configured to receive therebetween pipes (not shown) for a hydronic radiant floor (not shown).

In an embodiment, the insulating material core 11 of the panel 10 is made of molded expanded polystyrene (EPS), which results in a rigid panel having insulation and resiliency properties. One skilled in the art will understand that, in alternative embodiments, other substantially rigid materials having similar thermal insulation properties, such as extruded polystyrene, polyurethane, polyisocyanurate, phenolic foam, or the like, can also be used. In an embodiment, the insulating material core 11 is substantially made of rigid plastic foam and, more particularly, of rigid insulation foam suitable for building thermal insulation applications.

In an embodiment, the insulating material core 11 of the thermal insulating panel 10 has an R-value ranging between 2.5 and 30 (hr.ft².° F.)/BTU. In another embodiment, the insulating material core 11 of the insulating panel 10 has an R-value of at least 2.5 (hr.ft².° F.)/BTU. In an embodiment, the thermal insulating panel has a thickness of at least 0.75 inch (without the surface elements 28). More precisely, in an embodiment, the rigid insulating panel has a thickness ranging between about 0.75 inch and 6 inches (without the surface elements 28). In an embodiment, the insulating material core 11 of the insulating panel 10 has a density between about 0.8 lb/ft³ and about 2.3 lb/ft³. Moreover, in an embodiment, the insulating material core 11 has a compressive strength ranging between about 8 psi and about 40 psi. More precisely, in an embodiment, the insulating material core 11 has a compressive strength ranging between about 15 psi and about 30 psi.

In an embodiment, the surface elements 28 are integral to the insulating material core 11 of the panel 10, i.e. the panel 10 is molded with the surface elements 28 extending from the upper surface 30 of the insulating material core 11. One skilled in the art will understand that, in alternative embodiments, the insulating material core 11 of the panel 10 can also be made using methods of manufacture different from molding. For example and without being limitative, in an embodiment, the insulating material core 11 of the insulating panel 10 can be manufactured by machining, thermoforming or the like.

In the embodiment shown, each one of the surface elements 28 is a substantially square shaped protrusion and includes scalloped side walls 28a and beveled corners 28b. The scalloped side walls 28a and beveled corners 28b of the surface elements 28 contribute to the effective maintaining of the pipes (not shown) inserted between the surface elements 28, through minimization of the contact between an outer surface of the surface elements 28 and the pipes (not shown), which results in minimal damage of the surface elements 28 during insertion of the pipes (not shown) therebetween.

In the embodiment shown, each side wall 28a extends substantially perpendicular to the upper surface 30 of the insulating material core 11, along an entire height thereof (i.e. the side wall 28a do not present a concave or convex section but rather extend substantially upwardly straight from the upper surface 30 of the insulating material core 11). The configuration and positioning of the surface elements 28 allow the insulating panel 10 to receive and maintain pipes (not shown) extending substantially straight between the surface elements 28 or zigzagging between the surface elements 28, for instance defining “S” shaped patterns.

In a non-limitative embodiment, in order to conform to common standards, the surface elements 28 are spaced apart from one another of a distance of about six inches, taken from the center of the surface elements 28. One skilled in the art will however understand that, in alternative embodiments, the surface elements 28 can be spaced apart from one another of a greater or smaller distance, such as, for example and without being limitative, between about three inches and about 12 inches, taken from the center of the surface elements 28.

In the embodiment shown, each one of the surface elements 28 also includes a substantially circular base 28c. Each one of the bases 28c has a surface area slightly greater than the substantially square shaped main portion thereof and projects slightly upwardly from the upper surface 30 of the insulating material core 11. In an embodiment, each base 28c projects upwardly from the upper surface 30 of the insulating material core 11 of a distance of between about ⅛ inch and about 5/16 inch. The circular base 28c of each one of the surface elements 28 contributes to maintain pipes (not shown) inserted between surface elements 28, spaced apart from the upper surface 30 of the insulating panel 10, which favors the encasement of the pipes (not shown) in the concrete of the concrete slab (not shown) and therefore results in better heat diffusion in the concrete slab (not shown).

In the embodiment shown, spacing bars 27 are defined between diagonally adjacent surface elements 28. Each one of the spacing bars 27 projects slightly upwardly from the upper surface 30 of the insulating material core 11 and connects the bases 28c of diagonally adjacent surface elements 28. In the embodiment shown, none of the spacing bars 27 intersects with another one of the spacing bars 27. In the embodiment shown, a height of the spacing bars 27 substantially correspond to a height of the bases 28c. In an embodiment, each spacing bar 27 projects upwardly from the upper surface 30 of the insulating material core 11 of a distance of between about ⅛ inch and about 5/16 inch. The spacing bars 27 also contribute to maintain pipes (not shown) inserted between surface elements 28, spaced apart from the upper surface 30 of the insulating panel 10.

One skilled in the art will understand that, in alternative embodiments (not shown), the surface elements 28 can have a configuration different than the above described configuration of the embodiment shown in the accompanying figures. One skilled in the art will also understand that, in an alternative embodiment (not shown), the surface elements 28 can be depressions defined in the upper surface 30 of the insulating material core 11, for example and without being limitative, in order to define a fluid evacuation path, rather than protrusions projecting upwardly from the upper surface 30 of the insulating material core 11.

As better seen in FIGS. 2 and 3A, in the embodiment shown, the lower surface 32 of the insulating material core 11 also includes a plurality of surface elements embodied by main depressions 29a, each corresponding with one of the plurality of surface elements 28 projecting upwardly from the upper surface 30 of the insulating material core 11. Each one of the main depressions 29a is sized and shaped to at least partially receive therein the surface element 28 of an insulating panel 10 positioned directly underneath, when a plurality of insulating panels 10 are stacked, for example during storage and/or transportation. In other words, each one of the main depressions 29a allows insulating panels 10 to be stacked by inserting each one of the plurality of surface elements 28 projecting upwardly from the upper surface 30 of the insulating material core 11 of a first panel 10 in a corresponding main depression 29a defined in the lower surface 32 of a second panel 10 positioned directly above in the stack, such as to reduce the overall height of the stack, which is advantageous for storage and/or shipping purposes. In the embodiment shown, each one of the main depressions 29a is substantially squircle shaped, i.e. a rounded square, and sized to receive therein a respective one of the surface elements 28.

In the embodiment shown, the lower surface 32 of the insulating material core 11 also includes longitudinal depressions 29b extending between diagonally adjacent ones of the main depressions 29a. Each one of the longitudinal depressions 29b is aligned with one of the plurality of spacing bars 27 projecting upwardly from the upper surface 30 of the insulating material core 11 when two superposed panels 10 are engaged together by inserting a respective one of the surface elements 28 in a respective one of the main depressions 29a. Thus, each one of the longitudinal depressions 29b is designed and configured to at least partially receive therein the spacing bars 27 of an insulating panel 10 positioned directly underneath, when a plurality of insulating panels 10 are stacked.

One skilled in the art will understand that, in an alternative embodiment (not shown), depressions having a configuration different than that of the embodiment shown can be provided. Moreover, in another alternative embodiment (not shown), no depressions can be provided, i.e. the lower surface 32 of the insulating material core 11 can be substantially flat.

Again referring to FIGS. 1 to 3A, in the embodiment shown the insulation panel 10 further includes, a first connecting member 40 provided along the first edge 20, a second connecting member 42 provided along the second edge 22, a third connecting member 44 provided along the third edge 24, and a fourth connecting member 46 provided along the fourth edge 26. The first connecting member 40 comprises a first inner groove 40a and a successive first outer tongue 40b, thereby defining a tongue and groove assembly (or male and female member assembly). Similarly, the second connecting member 42 comprises a second inner groove 42a and a successive second outer tongue 42b, the third connecting member 44 comprises a third inner groove 44a and a successive third outer tongue 44b and the fourth connecting member 46 comprises a fourth inner groove 46a and a successive fourth outer tongue 46b, thereby each also defining a tongue and groove assembly. One skilled in the art will understand that, in an alternative embodiment (not shown), the insulating panel 10 can be provided with connecting members such as the one described above, along only two of the edges 20, 22, 24, 26, rather than along each one of the edges 20, 22, 24, 26.

In an embodiment, each one of the inner grooves 40a, 42a, 44a, 46a and the outer tongues 40b, 42b, 44b, 46b extend substantially perpendicularly to the upper surface 30 and the lower surface 32 of the insulating material core 11 of the rigid insulating panel 10. The inner grooves 40a, 42a, 44a, 46a are elongated recesses defined either in the upper surface 30 or in the lower surface 32 respectively while the outer tongues 40b, 42b, 44b, 46b are elongated protrusions extending upwardly from the upper surface 30 or the lower surface 32 respectively.

The term “substantially perpendicularly” is used herein to indicate that the inner grooves 40a, 42a, 44a, 46a and the outer tongues 40b, 42b, 44b, 46b are generally perpendicular to the upper and lower surfaces 30, 32 of the insulating material core 11 of the insulating panel 10, but do not need to be perfectly perpendicular with them. In other words, interlock of two adjacent rigid insulating panels 10 occurs by displacing at least one of the adjacent panels in a direction substantially perpendicular to its upper and/or lower surfaces 30, 32 rather than by displacing the adjacent panels laterally towards one another, i.e. along an axis substantially parallel to their upper and lower surfaces 30, 32.

In the embodiment shown, the tongue and groove assembly of the first connecting member 40, located along the first longitudinal edge 20, extends upwardly with respect to the upper surface 30 of the insulating material core 11, i.e. the first inner groove 40a is open on the upper surface 30. To be engageable with the first connecting member 40 of an adjacent panel 10, the tongue and groove assembly of the third connecting member 44, located along the third longitudinal edge 24, extends downwardly with respect to the upper surface 30 of the rigid insulating panel 10, i.e. the inner groove 44a is open on the lower surface 32. Similarly, to be engageable together when adjacent rigid insulating panels 10 are interlocked, the tongue and groove assemblies of the second connecting member 42 and the fourth connecting member 46 extend in opposed directions. In the embodiment shown, the tongue and groove assembly of the second connecting member 42, located along the second edge 22, extends upwardly with respect to the upper surface 30 of the insulating material core 11 of the rigid insulating panel 10. On the opposite, the tongue and groove assembly of the fourth connecting member 46, located along the fourth edge 26 extends downwardly with respect to the upper surface 30 of the insulating material core 11 of the rigid insulating panel 10. Thus, the second and fourth inner grooves 42a, 46a are respectively open on the upper surface 30 and the lower surface 32.

Referring to FIG. 2, in an embodiment, a median wall 42c, 46c separates the consecutive inner grooves 42a, 46a and outer tongues 42b, 46b and defines substantially complementary shapes of the consecutive inner grooves 42a, 46a and outer tongues 42b, 46b. One skilled in the art will understand that while FIG. 2 shows only the second connecting member 42 and the fourth connecting member 46, the present teachings regarding the configuration of each median wall 42c, 46c also apply to the first connecting member 40 and the third connecting member 44.

In the embodiment shown, each median wall 42c, 46c is substantially S-shaped and defines a convex section 42b′, 46b′ and a consecutive concave section 42b″, 46b″ for each outer tongue 42b, 46b. As will be easily understood, the corresponding inner grooves 42a, 46a consequently present complementary convex and concave sections, inverted with respect to the convex sections 42b′, 46b′ and the concave sections 42b″, 46b″ of the outer tongues 42b, 46b.

In an embodiment, the shape and size of the first inner groove 40a, first outer tongue 40b, second inner groove 42a and second outer tongue 42b is complementary to the shape and size of the third inner groove 44a, third outer tongue 44b, fourth inner groove 46a and fourth outer tongue 46b. This configuration allows the first connecting member 40 of a panel 10 to be interlocked with the third connecting member 44 of an adjacent panel (not shown) and the second connecting member 42 of the panel 10 to be interlocked with the fourth connecting member 46 of another adjacent panel (not shown).

It is appreciated that, in an alternative embodiment, the shape of the complementary tongue and groove of each one of the connecting members 40, 42, 44, 46 can vary from the embodiment shown. For instance and without being limitative, the tongues can have a substantially rectangular profile, with or without rounded edges, with the grooves having a complementary profile. In an embodiment, the median walls separating the tongues from the grooves can be substantially planar.

Again referring to FIGS. 1 to 3a, the connecting members 40, 42, 44, 46 further include an alignment assembly 47 (see FIG. 6) allowing adjacent ones of the insulating panels 10 to be laterally aligned, when corresponding connecting members 40, 42, 44, 46 of adjacent insulating panels 10 are interlocked.

In the embodiment shown, the alignment assembly 47 (see FIG. 6) includes a combination of alignment projections 50 and alignment recesses 52. In more details, in the embodiment shown, the first connecting member 40 and the second connecting member 42 include a plurality of spaced-apart alignment projections 50, each projecting respectively from the first outer tongue 40b and the second outer tongue 42b, into the corresponding one of the first inner groove 40a and the second inner groove 42a. The third connecting member 44 and the fourth connecting member 46 include a plurality of corresponding spaced-apart alignment recesses 52 defined in the third outer tongue 44b and the fourth outer tongue 46b.

One skilled in the art will understand that, in an alternative embodiment, the alignment projections 50 and alignment recesses 52 can respectively be associated to a different combination of connecting members 40, 42, 44, 46 than the combination of the embodiment shown. For example and without being limitative, in an embodiment (not shown), the first connecting member 40 and the second connecting member 42 can include the alignment recesses 52, while the third connecting member 44 and the fourth connecting member 46 include the projections 50. Once again, one skilled in the art will understand that, in an alternative embodiment (not shown), the insulating panel 10 can also be provided with alignment projections 50 and alignment recesses 52 in only two corresponding ones of the connecting members 40, 42, 44, 46.

Moreover, in an embodiment, each one of the connecting members 40, 42, 44, 46 can comprise only one alignment projection 50 or the corresponding alignment recess 52. Hence, it is appreciated that the number and the spacing between consecutive ones of the alignment projections 50 or the alignment recesses 52 can vary from the embodiment shown. Furthermore, the shape and configuration of the alignment projections 50 and the alignment recesses 52 can also vary from the embodiment shown.

Each one of the alignment recesses 52 is sized and shaped to receive therein a corresponding one of the alignment projections 50, when the insulating panel 10 is engaged to an adjacent insulating panel 10. Moreover, the position of each alignment recess 52 corresponds to the position of the corresponding alignment projections 50 (i.e. the distance between consecutive ones of the alignment recesses 52 corresponds to the distance between consecutive ones of the alignment projections 50), to allow such engagement therebetween.

The combination of the complementary alignment projections 50 and corresponding alignment recesses 52, of the first connecting member 40, second connecting member 42, third connecting member 44, and fourth connecting member 46 results in adjacent insulating panels 10 being maintained in engagement (i.e. results in the corresponding edges 20, 22, 24, 26 being coupled to one another) and laterally aligned, when the connecting members 40, 42, 44, 46 of adjacent panels are engaged to one another. In other words, adjacent insulating panels 10 are maintained in engagement, as well as laterally aligned, when the first connecting member 40 of a panel 10 is interlocked with the third connecting member 44 of an adjacent panel 10 and/or when the second connecting member 42 of the panel 10 is interlocked with the fourth connecting member 46 of an adjacent panel 10.

In the course of the present description, the terms in “alignment”, “aligned”, “laterally aligned” or the like refer to features, such as the surface elements 28, being substantially aligned throughout adjacent panels (i.e. the features of a first panel 10 are substantially aligned with the features of a second adjacent panel 10 and so on) to produce a uniform pattern for a panel assembly 80 (see FIG. 4) including at least two panels 10.

One skilled in the art will understand that, in an alternative embodiment (not shown), an alignment assembly different than the one of the embodiment shown can be provided to provide the lateral alignment of adjacent panels 10, when the corresponding connecting members 40, 42, 44, 46 of adjacent insulating panels 10 are interlocked. For instance, the shape, size and/or configuration of the complementary alignment projections 50 and alignment recesses 52 can vary from the embodiment shown. Furthermore, each one of the connecting members 40, 42, 44, 46 can include both alignment projections 50 and alignment recesses 52, respectively engageable in complementary alignment projections 50 and alignment recesses 52 of a corresponding one of the connecting members 40, 42, 44, 46 of an adjacent panel 10.

In the embodiment shown, each one of the alignment projections 50 extends along the entire thickness of the connecting members 40, 42 (along the entire thickness of the inner groove 40a, 42a and outer tongue 40b, 42b). However, in alternative embodiments (not shown), the alignment projections 50 can extend only along a section of the thickness of the connecting members 40, 42, including a portion of the width of the inner grooves 40a, 42a, such as to protrude therein.

In the embodiment shown, the first connecting member 40 and the second connecting member 42 include one alignment projection 50 substantially aligned with each one of the surface elements 28 closest to the respective one of the edges 20, 22. The distribution of the alignment projections 50 is regular, i.e. the distance between each one of the the alignment projection 50 is substantially the same. The third connecting member 44 and fourth connecting member 46 include one alignment recess 52 substantially aligned with each one of the surface elements 28, closest to the respective one of the edges 24, 26. Once again, the distribution of the alignment recesses 52 is regular, i.e. the distance between each one of the the alignment recesses 52 is substantially the same. One skilled in the art will understand that, in an alternative embodiment (not shown), each one of the connecting members 40, 42, 44, 46 can include more or less alignment projections 50 and/or alignment recesses 52 than the embodiment shown. For instance and without being limitative, one alignment projection 50 or one alignment recess 52 can be provided at each two or more surface elements 28. The alignment projections 50 and the alignment recesses 52 can be aligned with the surface elements 28 or be located between consecutive ones of the surface elements 28.

In the embodiment shown, the alignment projections 50 and the alignment recesses 52 have beveled lateral edges 50a, 52a, i.e. the lateral edges 50a, 52a are not perpendicular to the upper surface 30 and lower surface 32 of the insulating panel 10 or a bottom of the inner grooves 40a, 42a, 44a, 46a. In an embodiment, from a side elevation view, the alignment projections 50 and the alignment recesses 52 have a complementary substantially trapezoidal shape, with the alignment projections 50 being larger closer to a center of the insulating material core 11 and narrower closer to the respective one of the upper surface 30 and lower surface 32 and the alignment recesses being narrower closer to a center of the insulating material core 11 and larger closer to the respective one of the upper surface 30 and lower surface 32. The trapezoidal shape facilitates insertion of the alignment projections 50 in the alignment recesses 52. It is appreciated that, in alternative embodiments (not shown), the shape of the alignment projections 50 and the alignment recesses 52 can vary from the embodiment shown.

In the embodiment shown, when the connecting members 40, 42, 44, 46 of a rigid insulating panel 10 engages a connecting member 40, 42, 44, 46 of an adjacent rigid insulating panel 10, the resiliency of the material causes the outer tongues 40b, 42b, 44b, 46b to deform momentarily during the engagement therebetween (as a result of the convex sections and the concave sections of the outer tongues 40b, 42b, 44b, 46b), and subsequently return to their original shape when the interlock of the adjacent panels 10 is achieved. This momentary deformation of the shape of the outer tongues 40b, 42b, 44b, 46b during the engagement, results in a sturdier interlock between the connecting members 40, 42, 44, 46.

In order to allow the above described momentary deformation and increase the flexibility of the insulating panel 10, in an embodiment, notches 48 are defined in the outer tongues 40b, 42b of the first and second connecting members 40, 42 on each side of the alignment projections 50. Each one of the notches 48 extends over the entire thickness of the outer tongues 40b, 42b. In the embodiment shown, a bottom of each one of the notches 48 is substantially aligned with a bottom of the corresponding adjacent inner grooves 40a, 42a. The notches 48 allow the normal deformation of the outer tongues 40b, 42b of the first and second connecting members 40, 42, even in the presence of the alignment projections 50. One skilled in the art will understand that, in an alternative embodiment, the outer tongues 40b, 42b of the first connecting and second members 40, 42 can however be free of such notches 48, i.e. the outer tongues 40b, 42b of the first connecting and second members 40 can extend continuously along the edges 20, 22 of the insulating panel 10. In an embodiment (not shown), a notch can be provided in the alignment projection 50, substantially parallel to the corresponding edge 20, 22 to allow the desired normal momentary deformation of the outer tongues 40b, 42b during the interlock.

With reference to FIGS. 1 to 6, in an embodiment, in order to cast a concrete slab, at least two rigid insulating panels 10 such as the one described above are provided. The rigid insulating panels 10 are engageable with one another through the substantially complementary connecting members 40, 42, 44, 46, which include the alignment assembly 47 as described above. In order to form an insulating panel assembly 80 (see FIG. 4), the connecting members 40, 42, 44, 46 of adjacent rigid insulating panels 10 are engaged with one another to interlock the adjacent rigid insulating panels 10. The engagement is performed by pressing the corresponding connecting members 40, 42, 44, 46 together substantially perpendicularly to the upper surface 30 of the rigid insulating panels 10, for the connecting members 40, 42, 44, 46 to interlock (see FIG. 5).

In an embodiment, interlock of the corresponding connecting members 40, 42, 44, 46 causes each one of the alignment projections 50 to be inserted into a corresponding one of the alignment recesses 52 (see FIG. 6). Such insertion of the alignment projections 50 into corresponding alignment recesses 52 causes adjacent insulating panels 10 of the panel assembly 80 to be maintained in alignment such that the surface elements 28 of adjacent insulating panels 10 of the panel assembly 80 create a regular pattern. In the embodiment shown where the surface elements 28 projects from the upper surface 30 of the insulating panels 10 to act as guide for corresponding pipes (not shown), the surface elements 28 can therefore define regular paths for the pipes to be inserted therebetween. Hence, the pipes can be inserted in the paths defined between the surface elements 28 of each insulating panel 10 of the panel assembly 80 and concrete can subsequently be poured over (i.e. on top of) the rigid insulating panel assembly 80 with the pipes engaged thereto.

One skilled in the art will understand that, in an embodiment (not shown), the panel 10 of the panel assembly 80 can be arranged in an offset arrangement, i.e. an arrangement where the edges 20, 22, 24, 26 of adjacent panels 10 are not aligned, in order to define a panel assembly with a greater structural strength. It will be understood that, even in such an offset arrangement, the surface elements 28 of adjacent panels 10 of the panel assembly 80 are substantially aligned to define a substantially uniform pattern on the upper surface 30 thereof.

Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person skilled in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person skilled in the art would further appreciate that any of the embodiments could be provided in any combination with the other embodiments disclosed herein. It is understood that the invention can be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the scope of the invention as defined in the appended claims.

Claims

1. A rigid insulating panel engageable with an adjacent rigid insulating panel, the rigid insulating panel comprising:

an insulating material core comprising: an upper surface and a lower surface; a plurality of surface elements on at least one of the upper surface and the lower surface; and four edges with at least two of the four edges comprising a connecting member including a tongue and groove assembly with an inner groove and an outer tongue engageable with the tongue and groove assembly of the adjacent rigid insulating panel to maintain the rigid insulating panels in engagement, the connecting members of the at least two of the four edges further comprising: an alignment assembly wherein at least one of the connecting members comprises at least one alignment projection protruding in a corresponding inner groove and at least another one of the connecting members comprises at least one alignment recess defined in a corresponding outer tongue, the at least one alignment projection being insertable in the at least one alignment recess to laterally align the adjacent insulating rigid insulating panels when engaged to one another.

2. The rigid insulating panel of claim 1, wherein each one of the surface elements projects from the upper surface of the insulating material core of the rigid insulating panel.

3. The rigid insulating panel of claim 2, wherein each one of the surface elements comprises scalloped side walls and bevelled corners.

4. The rigid insulating panel of claim 3, wherein each one of the surface elements is substantially square shaped.

5. The rigid insulating panel of claim 2, wherein each one of the surface elements comprises side walls extending substantially perpendicular to the upper surface of the insulating material core, along an entire height thereof.

6. The rigid insulating panel of claim 1, wherein the at least two of the four edges comprising a connecting member are opposed edges.

7. The rigid insulating panel of claim 1, wherein the four edges of the insulating material core each comprise one of the connecting members, a first one of the edges and a second one of the edges each comprising a plurality of alignment projections, and a third one of the edges and a fourth one of the edges each comprising a plurality of alignment recesses.

8. The rigid insulating panel of claim 1, wherein the inner groove and the outer tongue of each one of the connecting members are separated by a substantially S-shaped median wall defining consecutive convex and concave sections in the inner groove and the outer tongue.

9. The rigid insulating panel of claim 1, wherein the at least one alignment projection and the at least one alignment recesses are substantially trapezoidally shaped.

10. The rigid insulating panel of claim 1, wherein the at least one alignment projection extends from the outer tongue into the inner groove of each corresponding one of the connecting members.

11. The rigid insulating panel of claim 10, wherein a notch is defined in the outer tongue of each one of the connecting members including the at least one alignment projection extending from the outer tongue, on each side of the at least one alignment projection.

12. The rigid insulating panel of claim 1, wherein the outer tongue and the inner groove extend substantially perpendicular to the upper surface and the lower surface of the insulating material core.

13. The rigid insulating panel of claim 1, wherein each one of the insulating material core and the surface elements is formed of one of expanded polystyrene, extruded polystyrene, polyurethane, polyisocyanurate and phenolic foam.

14. The rigid insulating panel of claim 1, wherein the insulating material core has an R-value of at least 2,5 (hr.ft2.° F.)/BTU.in.

15. A rigid insulating panel assembly comprising:

at least two rigid insulating panels engaged to one another, each one of the rigid insulating panels comprising: an insulating material core having an upper surface, a lower surface, a plurality of surface elements and four edges spaced apart from one another; a connecting member defined in at least two of the four edges; each connecting member including a tongue and groove assembly with an inner groove and an outer tongue engageable with the tongue and groove assembly of an adjacent one of the at least two rigid insulating panels to maintain the rigid insulating panels in engagement; and an alignment assembly defined in the connecting member of the at least two of the four edges, the alignment assembly comprising at least one alignment projection protruding in the inner groove of at least one of the connecting members defined in the at least two of the four edges and at least one alignment recess defined in the outer tongue of at least another one of the connecting member defined in the at least two of the four edges, the at least one alignment projection being insertable in the at least one alignment recess to laterally align the engaged adjacent rigid insulating panels.

16. The rigid insulating panel assembly of claim 15, wherein the surface elements protrude from the upper surface of each one of the at least two rigid insulating panels.

17. The rigid insulating panel assembly of claim 16, wherein each one of the surface elements comprises scalloped side walls and bevelled corners.

18. The rigid insulating panel assembly of claim 16, wherein each one of the surface elements comprises side walls extending substantially perpendicular to the upper surface of the insulating material core, along an entire height thereof.

19. The rigid insulating panel assembly of claim 15, wherein the four edges of the insulating material core each comprise one of the connecting members, a first one of the edges and a second one of the edges each comprising a plurality of alignment projections, and a third one of the edges and a fourth one of the edges each comprising a plurality of alignment recesses.

20. The rigid insulating panel assembly of claim 15, wherein the inner groove and the outer tongue of each one of the connecting members are separated by a substantially S-shaped median wall defining consecutive convex and concave sections in the inner groove and the outer tongue.

21. The rigid insulating panel assembly of claim 15, wherein the at least one alignment projection and the at least one alignment recesses are substantially trapezoidally shaped.

22. The rigid insulating panel assembly of claim 15, wherein the at least one alignment projection extends from the outer tongue and into the inner groove of each corresponding one of the connecting members.

23. The rigid insulating panel assembly of claim 22, wherein a notch is defined in the outer tongue of each one of the connecting members including the at least one alignment projection extending from the outer tongue, on each side of the at least one alignment projection.

24. The rigid insulating panel assembly of claim 15, wherein the outer tongue and the inner groove extend substantially perpendicular to the upper surface and the lower surface of the insulating material core of each one of the at least two rigid insulating panels.

25. The rigid insulating panel assembly of claim 15, wherein each one of the insulating material core and the surface elements of each one of the at least two rigid insulating panels is formed of one of shaped expanded polystyrene, extruded polystyrene, polyurethane, polyisocyanurate and phenolic foam.

26. The rigid insulating panel assembly of claim 15, wherein the insulating material core of each one of the at least two rigid insulating panels has an R-value of at least 2.5 (hr.ft2.° F.)/BTU.in.