US20050257477A1 - Roofing system and roofing tile - Google Patents
Roofing system and roofing tile Download PDFInfo
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- US20050257477A1 US20050257477A1 US11/134,086 US13408605A US2005257477A1 US 20050257477 A1 US20050257477 A1 US 20050257477A1 US 13408605 A US13408605 A US 13408605A US 2005257477 A1 US2005257477 A1 US 2005257477A1
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- tile
- roofing
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/12—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
- E04D1/16—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of ceramics, glass or concrete, with or without reinforcement
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/29—Means for connecting or fastening adjacent roofing elements
- E04D1/2907—Means for connecting or fastening adjacent roofing elements by interfitted sections
- E04D1/2914—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements
- E04D1/2916—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements the fastening means taking hold directly on adjacent elements of the same row
Definitions
- This invention relates in general to roofing, and particularly relates to the use of lightweight yet structurally sound clay material roofing tiles that simulate wood shake roofing.
- wood shakes In the field of roofing, it is well known to use wood shakes as roofing elements. Typically, the wood shakes are installed in an overlapping manner to divert water. However, wood shakes have disadvantages, including their flammability and their tendency to leak after sufficient weathering. Nevertheless, consumers have shown a preference towards wood shakes due to their desirable appearance.
- roofing elements that simulate wood shakes and are comprised of nonflammable materials, such as concrete, metal, or clay (sometimes called “terracotta”), have become known.
- roofing elements made to date with these alternative materials present additional disadvantages.
- roofing tiles made of concrete or clay tend to be heavy, weighing between 8 and 11 pounds per square foot, making them unsuitable for remodeling or re-roofing roofs that previously used lighter roofing elements, such as wood shakes or asphalt roofing tiles.
- previous attempts to reduce the weight of the concrete or clay tiles significantly have resulted in a reduction in the flexural strength of the tiles.
- known concrete and clay roofing tiles are categorized as a lower grade of building material because of their inability to provide adequate protection for severe climate weathering.
- known tiles are typically characterized as having a Grade 1 Weathering Index of less than 500 (see ASTM C1167-96, Table 1).
- metal pressed roofing tiles tend to be limited to shapes with identical contours on both the top and bottom surfaces. Further, tiles made with alternate materials, such as concrete and metal, have a tendency to rub against one another during shipping, causing unwanted scratching and chipping on the surfaces of the tiles.
- the present invention overcomes deficiencies of the prior art by providing an improved roofing system and roofing tile that simulate the appearance of a wood shake roof and have improved weathering capabilities, an improved strength to weight ratio, and improved packing, or shipping, characteristics.
- One embodiment of the roofing tile system includes tiles having one or two unique profiles, an “A” profile and a “B” profile, that are alternately or randomly installed adjacent each other to simulate the appearance of wood shakes.
- Each tile having an “A” profile has a uniform cross-section throughout the body of the tile, and each tile having a “B” profile has a depressed center portion and two raised side portions throughout at least a portion of the body of the tile, wherein the two raised side portions have substantially the same cross-section as the tiles having an “A” profile.
- each tile includes a plurality of ribs that extend from a lower face of the tile.
- the width of each rib may also be varied along the length of the rib to provide additional strength to portions of the tile that have reduced flexural strength.
- each tile includes upper touch points that prevent the tiles from moving relative to each other when vertically stacked together and lower touch points that provide a headlap alignment guide for the next-laid course in a roofing installation.
- the upper and lower touch points extend from the lower face of the tile and seat adjacent to upper and lower touch surfaces, respectively, on a tile positioned vertically adjacent to the tile.
- FIG. 1 is a perspective view of unique tile configurations 20 A according to one embodiment of the invention.
- FIG. 2 is a top view of the upper face of tile configuration 20 A of FIG. 1 ;
- FIG. 3 is a perspective view of a lower face of tile configuration 20 A of FIG. 1 ;
- FIG. 4 is a top view of the lower face of tile configuration 20 A of FIG. 1 ;
- FIG. 5 is an front view of tile configuration 20 A of FIG. 1 ;
- FIG. 6 is a end view of tile configuration 20 A of FIG. 1 ;
- FIG. 7 is a side view of the left side of tile configuration 20 A of FIG. 1 ;
- FIG. 8 is a side view of the right side of tile configuration 20 A of FIG. 1 ;
- FIG. 9 is a perspective view of unique tile configuration 20 B according to one embodiment of the invention.
- FIG. 10 is a top view of the upper face of tile configuration 20 B of FIG. 9 ;
- FIG. 11 is a perspective view of a lower face of tile configuration 20 B of FIG. 9 ;
- FIG. 12 is a top view of the lower face of tile configuration 20 B of FIG. 9 ;
- FIG. 13 is an front view of tile configuration 20 B of FIG. 9 ;
- FIG. 14 is a end view of tile configuration 20 B of FIG. 9 ;
- FIG. 15 is a side view of the left side of tile configuration 20 B of FIG. 9 ;
- FIG. 16 is a side view of the right side of tile configuration 20 B of FIG. 9 ;
- FIG. 17 is a perspective view of an exemplary rotating mold 10 that includes multiple tile-shaped cavities 11 A, 11 B for receiving clay;
- FIG. 18 is an end view of the mold 10 of FIG. 17 , viewed along its axis of rotation and illustrating its interaction with a reciprocating top mold member 14 ;
- FIG. 19 is a side view illustrating an exemplary installation of tiles atop a support surface 43 ;
- FIG. 20 is a plan view illustrating an exemplary installation of tiles atop a support surface.
- FIG. 21 is a perspective view of an exemplary installation of tiles atop a support surface.
- the present invention addresses the above needs and achieves other advantages by providing a roofing system that includes roofing tiles that have one of at least two profiles.
- a portion of the tiles has an “A” profile
- a portion of the tiles has a “B” profile.
- the tiles having an “A” profile are installed alternately or in a random fashion with tiles having a “B” profile, the tiles simulate the appearance of a wood shake roof, as shown in FIG. 21 .
- the structures of each of the profiles according to one embodiment are described below in the section “Tile Structure,” and exemplary methods of manufacturing the tiles and installing the tiles are described below in the sections “Method of Manufacturing the Tiles” and “Method of Installing the Tiles,” respectively.
- FIGS. 1 through 8 illustrate an embodiment of a singe roofing tile having an “A” profile.
- the “A” profile tile 20 A includes an upper face, a lower face, a “head” end 32 A, a “nose” end 33 A, and a body 36 A extending between the head end 32 A and nose end 33 A.
- the upper face of the tile 20 A is substantially flat, with the exception of the simulated wood grain design on the body 36 A and the nose end 33 A.
- the simulated wood grain design gives each tile 20 A the appearance of a conventional wood shake member with natural variances.
- FIG. 5 the gaps and shadows that are expected in a wood shake roof are maintained at the nose end 33 A of the tile 20 A, such that two overlapping tiles have irregular clearance.
- the body 36 A includes a left portion 23 A, a right portion 24 A, and a center portion 22 A that extends between the left portion 23 A and the right portion 24 A, as illustrated in FIG. 1 .
- the center portion 22 A has substantially the same elevation as the left and right portions 23 A, 24 A, resulting in a substantially uniform cross section through the body 36 A and extending towards the nose end 33 A. Further, the upper face of the nose end 33 A is level and has a slightly higher elevation than the head end 32 A of the tile 20 A, which is shown in FIGS. 7 and 8 .
- the head end 32 A includes two transverse ridges 250 A, 251 A that extend across the upper face of the tile 20 A.
- the ridges 250 A, 251 A lie along a substantially common transverse axis C.
- the lower ridge 251 A is substantially straight so as to provide a “straight edge” and stable support for tiles that are placed atop the lower ridge 251 A in the next-laid course.
- the portion of the tile 20 A between the lower ridge 251 A and the body 36 A defines a lower touch surface 312 A for receiving a lower touch point 307 A, 307 B located on the rear side of an above-stacked tile, which is discussed in more detail below in relation to FIGS. 3 and 11 .
- the upper ridge 250 A jogs back and forth, defining upper touch surfaces 310 A for receiving upper touch points 311 A, 311 B located on the rear side of an above-stacked tile, which is discussed in more detail below in relation to FIGS. 3 and 11 .
- the upper ridge 250 A provides a water barrier for preventing water from backing up behind the tile 20 A or from reaching behind the tile 20 A in the case of wind driven rain.
- the upper 250 A and lower ridge 251 A further define an intermediate channel 255 A that provides a water channel for wind driven rain.
- the intermediate channel 255 A diverts the rain to the edges of the left side of the tile 20 A and into channel 26 A of engagement member 25 A or to the right side of the tile 20 A and off of downwardly directed ledge 30 A of engagement member 29 A.
- Channels 26 A, ledge 30 A, and engagement members 25 A, 29 A are discussed below in relation to FIGS. 1, 4 , 7 , and 8 .
- apertures 260 A, 261 A for receiving fasteners are provided in the upper 250 A and lower ridges 251 A, respectively. Fasteners are engaged through the apertures 260 A, 261 A to secure the tile 20 A to the roof. As shown in FIG. 2 , aperture 260 A is located in a portion of the upper ridge 250 A and aperture 261 A is located in a portion of the lower ridge 251 A. The additional cross sectional area of each ridge 250 A, 251 A provides more strength for the tile 20 A, reducing its tendency to split. Additionally, the ridges 250 A, 251 A provide a raised surface against which a nail or other suitable fastener can be driven.
- the lower face of the tile 20 A includes a plurality of strategically placed structural ribs 300 A to provide lightweight yet structurally sound support for the tile 20 A.
- the ribs 300 A which extend normally from the lower face of the body 36 A, include two edge ribs 301 A, one center rib 303 A, and three secondary ribs 305 A that extend along the length of the tile 20 A.
- the two edge ribs 301 A extend the length of the tile 20 A from the head end 32 A to the nose end 33 A to provide support for the edges of the tile 20 A
- the center rib 303 A extends the length of the tile 20 A from the head end 32 A to the nose end 33 A to provide support for the center portion 22 A.
- the three secondary ribs 305 A which are shorter than the edge ribs 301 A and the center rib 303 A, extend lengthwise and adjacent the body 36 A of tile 20 A. Further, the three secondary ribs 305 A are interspaced between the edge ribs 301 A and the center rib 303 A to provide intermediate support to the portions of the tile 20 A between the left 23 A and right portions 24 A and the center portion 22 A. Thus, by having a reduced length and being positioned between the edge ribs 301 A and the center rib 303 A, the secondary ribs 305 A provide additional strength for the tile 20 A between the edge 301 A and the center portions 301 A without adding unnecessary weight.
- the ribs 301 A, 303 A, 305 A are substantially evenly spaced, providing superior strength when the tile 20 A is subjected to flexural strength testing or actual field conditions, such as exposing the tiles to foot traffic.
- the secondary ribs 305 A and the center structural rib 303 A vary in width such that the width of each rib 305 A, 303 A increases adjacent portions of the tile 20 A that have a reduced flexural strength.
- the width of each rib 303 A, 305 A increases as the rib approaches the center of the body 36 A and decreases as the rib 305 A, 305 A approaches the head end 32 A and the nose end 33 A.
- each rib 303 A, 305 A may be increased if the rib 303 A, 305 A is adjacent an area of the tile that has a reduced cross-section. Varying the thickness of the ribs 303 A, 305 A further reduces the amount of material needed for structural support, which reduces the weight of the tile without compromising the flexural strength of the tile.
- the embodiment of the tile 20 A described above can support the same load as most standard tiles, but has an installed weight of less than 6 pounds per square foot, which is about 40% lighter than most standard tiles.
- the number and structure of the ribs may vary depending on the size, aesthetic design, and intended use of the tile. Accordingly, the concepts of varying the width and length of the ribs and strategically positioning the ribs to support the tile where the flexural strength may be compromised are within the scope of this invention.
- the secondary ribs 305 A further improve certain manufacturing characteristics. As may be understood, when the tiles 20 A are initially produced, they are not completely solidified, and can sag in certain instances, especially in locations that include unsupported spans. The secondary ribs 305 A, if they are supported, can provide support to prevent such sagging. Therefore, the secondary ribs 305 A provide support for an otherwise unsupported horizontal portion.
- the lower face of the tile 20 A further includes touch points 307 A, 311 A.
- Touch points 307 A, 311 A are protrusions that extend from the lower face of the tile 20 A.
- upper touch points 311 A are adjacent to the head end 32 A, and one of the upper touch points 311 A is part of the ribs 300 A and one of the upper touch points 311 A is separate from the ribs 300 A.
- the upper touch points 311 A of upper tile 20 A seat within the upper touch surfaces 310 A of lower tile 20 A.
- the upper touch points 311 A and upper touch surfaces 310 A reduce the height of vertical stack of tiles, which allows more tiles to be included in a shipment. Furthermore, the upper touch points 311 A are not visible once the tile 20 A is installed, thus maintaining the simulated appearance of wood shakes.
- Lower touch point 307 A is positioned transverse across the nose end 33 A. When a tile 20 A is positioned in the next-laid horizontal course above a lower tile 20 A during installation, the lower touch point 307 A seats upon the lower touch surface 312 A of the lower tile 20 A. The lower touch point 307 A and the lower touch surface 312 A provide a headlap alignment guide for the roofing installers.
- all of the upper touch points 311 A can be part of the ribs 300 A, all of the upper touch points 311 A can be separate from the ribs 300 A, the lower touch point 307 A can comprise a plurality of protrusions that seat against the lower touch surface 312 A, or the tile 20 A can include one or more upper touch points 311 A.
- the tile 20 A also includes an upwardly facing, sidewardly extending engagement member 25 A and a downwardly facing, sidewardly extending engagement member 29 A, as shown in FIGS. 1, 4 , 7 , and 8 .
- Engagement member 25 A extends to the left of the left portion 23 A, defines a channel 26 A, and includes an upwardly directed ledge portion 27 A.
- Engagement member 29 A extends to the right of the right portion 24 A, defines a channel 31 A, and includes a downwardly directed ledge portion 30 A.
- Engagement member 25 A of a first tile mates with the engagement member 29 A of a second tile placed horizontally to the left of the first tile.
- the downwardly directed ledge portion 30 A of the second tile is received by the channel 26 A of the first tile. Additionally, the channel 26 A serves to divert water from the first and second tiles to the tile below the first and second tiles. Similarly, engagement member 29 A of the first tile mates with the engagement member 25 A of a third tile placed horizontally to the right of the first tile. The upwardly directed ledge portion 27 A of the third tile is received into the channel 31 A of the first tile. The channel 26 A of the third tile serves to divert water from the first and third tiles to the tile below the first and third tiles. As discussed below in relation to FIGS. 9 and 12 , the engagement portion 29 A of tile 20 A can mate with an engagement portion 30 B of an adjacent tile having a “B” profile configuration.
- the engagement portion 30 A of tile 20 A can mate with an engagement portion 29 B of an adjacent tile having a “B” profile.
- engagement member 25 A extends from the right portion 24 A and engagement member 29 A extends from the left portion 23 A.
- the embodiment of the tile described above has a Grade 1 Weathering Index of greater than 500 (see ASTM C1167-96, Table 1) due at least in part to the improved strength to weight ratio and the ability of the tile to channel water and debris.
- FIGS. 9 through 16 illustrate an embodiment of a single roofing tile having a “B” profile.
- the “B” profile tile 20 B includes an upper face, a lower face, a head end 32 B, a nose end 33 B, and a body 36 B.
- the body 36 B and the nose end 33 B include a simulated wood grain design and the nose end 33 B further includes the gaps and shadows that are expected in a wood shake roof such that two overlapping tiles have irregular clearance, as shown in FIG. 13 .
- the body 36 B includes a left portion 23 B, a right portion 24 B, and a center portion 22 B.
- tile 20 B has a depressed center portion 22 B, as shown in FIGS. 9 and 13 .
- the head end 32 B, the left portion 23 B, and the right portion 24 B slope downwardly towards the center portion 22 B such that the head end 32 B, the left portion 23 B, and the right portion 24 B are higher in elevation than the center portion 22 B, and the depressed center portion 22 B extends to the nose end 33 B of the tile 20 B.
- the left 23 B and right portions 24 B adjacent to the nose end 33 B have a slightly higher elevation than the head end 32 B, as shown in FIGS. 15 and 16 .
- the length of the 20 B tile from the head end 32 B to the nose end 33 B varies between the left 23 B and right portions 24 B and the center portion 22 B.
- the length of the center portion 22 B from the head end 32 B to the nose end 33 B is shorter than the length of the left 23 B and right portions 24 B from the head end 32 B to the nose end 33 B.
- the left 23 B and right portions 24 B of the tile 20 B extend to substantially the same length as the tile 20 A, and the elevation of the left portion 23 A and the right portion 24 A of the tile 20 A and the elevation of the left 23 B and right portions 24 B of the tile 20 B are substantially the same.
- the decreased elevation and reduced length of the center portion 22 B contrasted with the higher elevations and longer length of the left 23 A, 23 B and right portions 24 A, 24 B of the tile 20 A and 20 B creates the desired shadowing and appearance to simulate the overlapping of wood shakes.
- a staggering effect is created. This staggering effect gives the impression that the center portion of the tile 20 B is one tile, the left portion of the tile 20 B and the tile 20 A to the left of the tile 20 B are one tile, and the right portion of the tile 20 B and the tile 20 A to the right of the tile 20 B are one tile.
- tile 20 B further includes two transverse ridges 250 B, 251 B that extend across the head end 29 B of tile 20 B.
- These ridges 250 B, 251 B are similar to the transverse ridges 250 A, 251 A of the tile 20 A discussed above in relation to FIG. 2 .
- the substantially similar arrangement of the transverse ridges 250 A, 250 B, 251 A, 251 B and the lower touch surface 312 A, 312 B facilitates the placement of the nose end 33 A, 33 B of tile 20 A, 20 B atop the head end 32 A, 32 B of tile 20 A, 20 B during installation.
- tiles 20 A and tiles 20 B are interchangeable in the installation, which provides a more rustic appearance and better simulates the appearance of a wood shake roof.
- the tile 20 B includes an upwardly facing, sidewardly extending engagement member 25 B and a downwardly facing, sidewardly extending engagement member 29 B, as shown in FIGS. 9, 12 , 15 , and 16 .
- Engagement members 25 B and 29 B are configured similarly to engagement members 25 A and 29 A described above.
- engagement member 25 A mates with the engagement member 29 B.
- the upwardly directed ledge portion 27 A of engagement portion 25 A is received into the channel 31 B of adjacent engagement member 29 B.
- engagement member 29 A mates with engagement member 25 B.
- the downwardly directed ledge portion 30 A of engagement member 29 A is received into the channel 26 B of adjacent engagement member 25 B.
- the lower face of the tile 20 B includes a plurality of strategically placed structural ribs 300 B to provide lightweight yet structurally sound support for the tile 20 B.
- Two edge ribs 301 B extend along the length of the tile 20 B, similar to the nose rib 307 A and the edge ribs 301 A of the tile 20 A described above in relation to FIG. 4 .
- the central ribs 303 B and the secondary ribs 305 B of the tile 20 B are configured differently than the corresponding ribs 303 A, 305 A of the tile 20 A due, at least in part, to the lower elevation of the center portion 22 B and the need to support the center portion 22 B and the transition areas between the center portion 22 B and the left 23 B and right portions 24 B and head end 32 B.
- tile 20 B includes two center ribs 303 B that extend the full length of the tile 20 B, and the two center ribs 303 B increase in width under the center portion 22 B of the tile 20 B.
- three secondary ribs 305 B which are shorter than center ribs 303 B, are spaced intermittently between the edge ribs 3011 and the center ribs 303 B adjacent the body 36 B.
- One of the secondary ribs 305 B is positioned near the elevation transition from the left portion 23 B to the center portion 22 B to support the transition, and one of the secondary ribs 305 B is positioned near the elevation transition from the right portion 24 B to the center portion 22 B.
- the center ribs 303 B and the secondary ribs 305 B of the tile 20 B are shorter than the corresponding ribs 303 A, 305 A of the tile 20 A because the center portion 22 B of the tile 20 B is shorter than the center portion 22 A of tile 20 A.
- the tile 20 B includes touch points 307 B, 3111 B that extend from the lower face of the tile 20 B and engage upper touch surfaces 312 B, 310 B, respectively, of a tile 20 B stacked below the tile 20 B, such as the touch points 307 A, 311 A and touch surfaces 312 A, 310 A of tile 20 A described above in relation to FIG. 3 .
- two of the upper touch points 3111 B are part of a rib 300 B, and one of the upper touch points 3111 B is separate from the ribs 300 B.
- the upper touch points 3111 B like upper touch points 311 A, can all be separate from the ribs 300 B or can all be part of the ribs 300 B.
- the tile 20 B may include one or more touch points 307 B, 3111 B.
- the touch surfaces 310 A, 310 B, 312 A, 312 B, and the touch points 311 A, 3111 B, 307 A, 307 B are in substantially similar positions, allowing the tiles 20 A, 20 B to be vertically stacked together or laid together in a random arrangement in each horizontal course while maintaining proper alignment of each course.
- FIGS. 17 and 18 combine to illustrate an exemplary method of manufacturing tiles using raw, unmolded clay material to produce two similar tile forms suitable for kiln firing.
- a rotating mold 10 accepts clay bats 13 and forms them into tile shapes, such as those shapes described above. After being dried and kiln fired, these tiles can be installed in an overlapping manner as shown in FIG. 19 atop an inclined support surface, such as support surface 43 .
- a clay composition is extruded from a pugmill/extrusion machine in a column (not shown) and has a moisture content sufficient to provide adequate plasticity.
- the percentage of moisture content found to be acceptable in one embodiment is 17 to 19%.
- the extrusion process evacuates substantially all of the air from the clay mixture to discourage delamination.
- the column is then cut into short lengths to create the bats 13 for pressing.
- the press structure includes a rotating drum 10 having a hexagonal cross-section and defining six outwardly directed drum faces.
- One “A” lower mold cavity 11 A and one “B” lower mold cavity 11 B are provided on each drum face, totaling twelve mold cavities, to provide an aesthetically pleasing variation on the installed appearance of the tiles, which is discussed above in relation to FIGS. 1 and 9 .
- the net result is a 50—50 mix of tiles having an “A” profile and tiles having a “B” profile, such as those tiles 20 A and 20 B discussed above.
- the clay bats 13 enter the press and are deposited in the lower molds 11 A, 11 B when the molds 11 A, 11 B are in the 10 o'clock position.
- the drum 10 is configured to rotate about a substantially horizontal axis, such that upon drum rotation, the bats 13 are moved into the 12 o'clock position. While in the 12 o'clock position, a top mold member 14 comes down and presses the bats 13 into the shapes of the tiles 20 , and then withdraws upwardly.
- the drum 10 then rotates the pressed tile forms 20 to the 2 o'clock position, where a vacuum picker (not shown) moves in and simultaneously trims off the excess clay around the edges of the tiles 20 and punches nail holes as needed. It removes the tiles 20 from the drum face and deposits them on drying trays (not shown) that are passed under the picker on a synchronized conveyor.
- the wet tiles, on their individual dryer trays, are then sent through a dryer where the moisture content is reduced to less than 4%.
- the dry “greenware” is then transported to the kiln for firing.
- the vitrified tiles 20 A, 20 B, as shown in FIGS. 1 and 9 are then placed directly into their shipping pallets.
- the combination of the touch points 311 A, 311 B and the transverse ridges 250 A, 250 B, 251 A, 251 B allows the tiles 20 A, 20 B to be stacked vertically relative to each other while preventing the tiles 20 A, 20 B from moving relative to each other, which prevents chipping and scratching of tiles 20 A, 20 B during shipping.
- tiles according to one embodiment of the invention are dimensioned to optimize the strength to weight ratio.
- the optimized dimensions allow the tiles to be manufactured with more tolerance for distortion while continuing to meet building code specifications for weight.
- FIGS. 19 through 21 combine to illustrate the tile installation process according to the present invention.
- the tiles 20 A, 20 B are typically installed horizontally in interlocked courses, with each horizontal course overlapping the one immediately below it.
- the overlap is typically about 2.25 inches, although other overlap lengths are contemplated without departing from the spirit and scope of the present invention.
- the lower ridge 251 A, 251 B and the adjacent lower touch surface 312 A, 312 B facilitate the proper alignment of the next-laid course.
- the ribs 300 A, 300 B extending from an upper tile 20 A, 20 B have a level resting surface on the lower ridge 251 A, 251 B of a lower tile 20 A, 20 B when installed, and the touch point 307 A, 307 B of the upper tile 20 A, 20 B seats on the lower touch surface 312 A, 312 B of the lower tile 20 A, 20 B.
- having the ribs 300 A, 300 B of the upper tile 20 A, 20 B resting on the lower ridge 251 A, 251 B directs water to the exposed surface of the tile 20 A, 20 B below it, thus preventing the water from backing up behind the lower tile 20 A, 20 B.
- the tiles are attached to a supporting surface 43 (such as plywood) by nails or other suitable fasteners engaged into apertures 260 A, 260 B, 261 A, 261 B.
- a common eave-riser metal drip edge 42 is used at the bottom of the roof to support the bottom horizontal course of tiles 20 A, 20 B.
- the edge portions 35 of the tiles 20 A, 20 B are offset from the edge portions 35 of the tiles 20 A, 20 B below them to facilitate the diversion of water and debris.
- installers may need to cut a tile 20 A, 20 B lengthwise. In one embodiment, the installers can cut between the two center primary ribs 303 B for tile 20 B or between the center primary rib 303 A and one of the secondary ribs 305 A for the tile 20 A.
- the rib design provides flexibility as to where the tiles 20 A, 20 B may be cut, which results in faster installation without compromising too much strength.
- hip trim tiles are provided in varying widths.
- the hip trim tiles are used along the edge of the roof leading up to the ridge of the roof.
- Two configurations of hip trim tiles may be used according to one embodiment, a “C” configuration and a “D” configuration, wherein the “C” configuration hip trim tile has a width that is less than the width of the “D” configuration hip trim tile.
- Alternating the use of the “C” configuration hip trim tile and the “D” configuration hip trim tile with each horizontal course will result in the edge portions 35 of each course being offset from the course below or above it.
- the number of hip trim tile configurations may be greater than two, depending on the needs of the installation.
- one embodiment of the tiling system further includes hip trim starter tiles and ridge trim tiles.
- Hip trim starter tiles are used on the bottom course at the bottom corners of the roof.
- the hip trim starter tiles provide a clean finish for the bottom corners of the roof.
- Ridge trim tiles are installed along the ridge of the roof and overlap the horizontal course of tiles below them.
- the present invention overcomes deficiencies in the prior art by providing roofing tiles which can be produced in mass quantities, yet have the appearance of traditional wood shakes with the structural properties of fired clay.
- the tiles have the strength of standard tiles, but weigh significantly less than standard tiles.
- the present invention provides touch points on each tile that engage receiving portions on a vertically adjacent tile for preventing the relative movement of tiles. While this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be affected within the spirit and scope of the invention as described in the appended claims.
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Abstract
Description
- This application claims priority from provisional U.S. Application No. 60/573,708 entitled “Method and Apparatus for Manufacturing and Installing Improved Roofing Tiles,” which was filed on May 20, 2004 and which is hereby incorporated by reference in its entirety.
- This invention relates in general to roofing, and particularly relates to the use of lightweight yet structurally sound clay material roofing tiles that simulate wood shake roofing.
- In the field of roofing, it is well known to use wood shakes as roofing elements. Typically, the wood shakes are installed in an overlapping manner to divert water. However, wood shakes have disadvantages, including their flammability and their tendency to leak after sufficient weathering. Nevertheless, consumers have shown a preference towards wood shakes due to their desirable appearance.
- Roofing elements that simulate wood shakes and are comprised of nonflammable materials, such as concrete, metal, or clay (sometimes called “terracotta”), have become known. However, roofing elements made to date with these alternative materials present additional disadvantages. For example, roofing tiles made of concrete or clay tend to be heavy, weighing between 8 and 11 pounds per square foot, making them unsuitable for remodeling or re-roofing roofs that previously used lighter roofing elements, such as wood shakes or asphalt roofing tiles. In addition, previous attempts to reduce the weight of the concrete or clay tiles significantly have resulted in a reduction in the flexural strength of the tiles. Furthermore, known concrete and clay roofing tiles are categorized as a lower grade of building material because of their inability to provide adequate protection for severe climate weathering. For example, known tiles are typically characterized as having a
Grade 1 Weathering Index of less than 500 (see ASTM C1167-96, Table 1). - As another example, metal pressed roofing tiles tend to be limited to shapes with identical contours on both the top and bottom surfaces. Further, tiles made with alternate materials, such as concrete and metal, have a tendency to rub against one another during shipping, causing unwanted scratching and chipping on the surfaces of the tiles.
- Therefore, there is a need in the art to provide roofing elements that simulate wood shakes and have improved weathering capabilities and an improved strength to weight ratio.
- The present invention overcomes deficiencies of the prior art by providing an improved roofing system and roofing tile that simulate the appearance of a wood shake roof and have improved weathering capabilities, an improved strength to weight ratio, and improved packing, or shipping, characteristics. One embodiment of the roofing tile system includes tiles having one or two unique profiles, an “A” profile and a “B” profile, that are alternately or randomly installed adjacent each other to simulate the appearance of wood shakes. Each tile having an “A” profile has a uniform cross-section throughout the body of the tile, and each tile having a “B” profile has a depressed center portion and two raised side portions throughout at least a portion of the body of the tile, wherein the two raised side portions have substantially the same cross-section as the tiles having an “A” profile.
- In addition, each tile includes a plurality of ribs that extend from a lower face of the tile. By positioning the plurality of ribs on the lower face of the tile below portions of the tile that have reduced flexural strength, the weight of each tile is reduced while the strength of each tile is maintained. The width of each rib may also be varied along the length of the rib to provide additional strength to portions of the tile that have reduced flexural strength.
- Furthermore, each tile includes upper touch points that prevent the tiles from moving relative to each other when vertically stacked together and lower touch points that provide a headlap alignment guide for the next-laid course in a roofing installation. The upper and lower touch points extend from the lower face of the tile and seat adjacent to upper and lower touch surfaces, respectively, on a tile positioned vertically adjacent to the tile.
- Other features and advantages of the present invention will become apparent upon reading the following detailed description of exemplary embodiments of the invention when taken in conjunction with the drawings.
-
FIG. 1 is a perspective view ofunique tile configurations 20A according to one embodiment of the invention; -
FIG. 2 is a top view of the upper face oftile configuration 20A ofFIG. 1 ; -
FIG. 3 is a perspective view of a lower face oftile configuration 20A ofFIG. 1 ; -
FIG. 4 is a top view of the lower face oftile configuration 20A ofFIG. 1 ; -
FIG. 5 is an front view oftile configuration 20A ofFIG. 1 ; -
FIG. 6 is a end view oftile configuration 20A ofFIG. 1 ; -
FIG. 7 is a side view of the left side oftile configuration 20A ofFIG. 1 ; -
FIG. 8 is a side view of the right side oftile configuration 20A ofFIG. 1 ; -
FIG. 9 is a perspective view ofunique tile configuration 20B according to one embodiment of the invention; -
FIG. 10 is a top view of the upper face oftile configuration 20B ofFIG. 9 ; -
FIG. 11 is a perspective view of a lower face oftile configuration 20B ofFIG. 9 ; -
FIG. 12 is a top view of the lower face oftile configuration 20B ofFIG. 9 ; -
FIG. 13 is an front view oftile configuration 20B ofFIG. 9 ; -
FIG. 14 is a end view oftile configuration 20B ofFIG. 9 ; -
FIG. 15 is a side view of the left side oftile configuration 20B ofFIG. 9 ; -
FIG. 16 is a side view of the right side oftile configuration 20B ofFIG. 9 ; -
FIG. 17 is a perspective view of an exemplary rotatingmold 10 that includes multiple tile-shaped cavities -
FIG. 18 is an end view of themold 10 ofFIG. 17 , viewed along its axis of rotation and illustrating its interaction with a reciprocatingtop mold member 14; -
FIG. 19 is a side view illustrating an exemplary installation of tiles atop asupport surface 43; -
FIG. 20 is a plan view illustrating an exemplary installation of tiles atop a support surface; and -
FIG. 21 is a perspective view of an exemplary installation of tiles atop a support surface. - The present invention addresses the above needs and achieves other advantages by providing a roofing system that includes roofing tiles that have one of at least two profiles. In one embodiment, a portion of the tiles has an “A” profile, and a portion of the tiles has a “B” profile. When the tiles having an “A” profile are installed alternately or in a random fashion with tiles having a “B” profile, the tiles simulate the appearance of a wood shake roof, as shown in
FIG. 21 . The structures of each of the profiles according to one embodiment are described below in the section “Tile Structure,” and exemplary methods of manufacturing the tiles and installing the tiles are described below in the sections “Method of Manufacturing the Tiles” and “Method of Installing the Tiles,” respectively. - Tile Structure
-
FIGS. 1 through 8 illustrate an embodiment of a singe roofing tile having an “A” profile. The “A”profile tile 20A includes an upper face, a lower face, a “head”end 32A, a “nose”end 33A, and abody 36A extending between thehead end 32A andnose end 33A. As shown inFIGS. 1, 2 and 6, the upper face of thetile 20A is substantially flat, with the exception of the simulated wood grain design on thebody 36A and thenose end 33A. The simulated wood grain design gives eachtile 20A the appearance of a conventional wood shake member with natural variances. Further, as shown inFIG. 5 , the gaps and shadows that are expected in a wood shake roof are maintained at thenose end 33A of thetile 20A, such that two overlapping tiles have irregular clearance. - The
body 36A includes aleft portion 23A, aright portion 24A, and a center portion 22A that extends between theleft portion 23A and theright portion 24A, as illustrated inFIG. 1 . The center portion 22A has substantially the same elevation as the left andright portions body 36A and extending towards thenose end 33A. Further, the upper face of thenose end 33A is level and has a slightly higher elevation than thehead end 32A of thetile 20A, which is shown inFIGS. 7 and 8 . - As shown in
FIGS. 2 and 6 , thehead end 32A includes twotransverse ridges tile 20A. Theridges lower ridge 251A is substantially straight so as to provide a “straight edge” and stable support for tiles that are placed atop thelower ridge 251A in the next-laid course. The portion of thetile 20A between thelower ridge 251A and thebody 36A defines alower touch surface 312A for receiving alower touch point FIGS. 3 and 11 . Theupper ridge 250A jogs back and forth, defining upper touch surfaces 310A for receivingupper touch points FIGS. 3 and 11 . In addition, theupper ridge 250A provides a water barrier for preventing water from backing up behind thetile 20A or from reaching behind thetile 20A in the case of wind driven rain. - The upper 250A and
lower ridge 251A further define anintermediate channel 255A that provides a water channel for wind driven rain. Theintermediate channel 255A diverts the rain to the edges of the left side of thetile 20A and intochannel 26A ofengagement member 25A or to the right side of thetile 20A and off of downwardly directedledge 30A ofengagement member 29A.Channels 26A,ledge 30A, andengagement members FIGS. 1, 4 , 7, and 8. - In addition,
apertures lower ridges 251A, respectively. Fasteners are engaged through theapertures tile 20A to the roof. As shown inFIG. 2 ,aperture 260A is located in a portion of theupper ridge 250A andaperture 261A is located in a portion of thelower ridge 251A. The additional cross sectional area of eachridge tile 20A, reducing its tendency to split. Additionally, theridges - As shown in
FIGS. 3 and 4 , the lower face of thetile 20A includes a plurality of strategically placedstructural ribs 300A to provide lightweight yet structurally sound support for thetile 20A. Theribs 300A, which extend normally from the lower face of thebody 36A, include twoedge ribs 301A, onecenter rib 303A, and threesecondary ribs 305A that extend along the length of thetile 20A. The twoedge ribs 301A extend the length of thetile 20A from thehead end 32A to the nose end 33A to provide support for the edges of thetile 20A, and thecenter rib 303A extends the length of thetile 20A from thehead end 32A to the nose end 33A to provide support for the center portion 22A. The threesecondary ribs 305A, which are shorter than theedge ribs 301A and thecenter rib 303A, extend lengthwise and adjacent thebody 36A oftile 20A. Further, the threesecondary ribs 305A are interspaced between theedge ribs 301A and thecenter rib 303A to provide intermediate support to the portions of thetile 20A between the left 23A andright portions 24A and the center portion 22A. Thus, by having a reduced length and being positioned between theedge ribs 301A and thecenter rib 303A, thesecondary ribs 305A provide additional strength for thetile 20A between theedge 301A and thecenter portions 301A without adding unnecessary weight. - The
ribs tile 20A is subjected to flexural strength testing or actual field conditions, such as exposing the tiles to foot traffic. In addition, thesecondary ribs 305A and the centerstructural rib 303A vary in width such that the width of eachrib tile 20A that have a reduced flexural strength. For example, as shown inFIGS. 3 and 4 , the width of eachrib body 36A and decreases as therib head end 32A and thenose end 33A. As a further example, the width of eachrib rib ribs tile 20A described above can support the same load as most standard tiles, but has an installed weight of less than 6 pounds per square foot, which is about 40% lighter than most standard tiles. - The number and structure of the ribs may vary depending on the size, aesthetic design, and intended use of the tile. Accordingly, the concepts of varying the width and length of the ribs and strategically positioning the ribs to support the tile where the flexural strength may be compromised are within the scope of this invention.
- In addition to the ability of the
ribs 300A to improve the flexural strength of the tiles, thesecondary ribs 305A further improve certain manufacturing characteristics. As may be understood, when thetiles 20A are initially produced, they are not completely solidified, and can sag in certain instances, especially in locations that include unsupported spans. Thesecondary ribs 305A, if they are supported, can provide support to prevent such sagging. Therefore, thesecondary ribs 305A provide support for an otherwise unsupported horizontal portion. - In addition to the
ribs 300A, the lower face of thetile 20A further includestouch points tile 20A. In the embodiment of thetile 20A shown inFIGS. 1 through 8 , upper touch points 311A are adjacent to thehead end 32A, and one of theupper touch points 311A is part of theribs 300A and one of theupper touch points 311A is separate from theribs 300A. Whentiles 20A are stacked vertically adjacent one another, such as when being shipped from the manufacturer to the job site, theupper touch points 311A ofupper tile 20A seat within the upper touch surfaces 310A oflower tile 20A. This configuration prevents movement of stacked tiles relative to one another, thereby preventing adjacent tiles from scratching or damaging each other. In addition, theupper touch points 311A andupper touch surfaces 310A reduce the height of vertical stack of tiles, which allows more tiles to be included in a shipment. Furthermore, the upper touch points 311A are not visible once thetile 20A is installed, thus maintaining the simulated appearance of wood shakes. -
Lower touch point 307A is positioned transverse across thenose end 33A. When atile 20A is positioned in the next-laid horizontal course above alower tile 20A during installation, thelower touch point 307A seats upon thelower touch surface 312A of thelower tile 20A. Thelower touch point 307A and thelower touch surface 312A provide a headlap alignment guide for the roofing installers. - In other embodiments, all of the
upper touch points 311A can be part of theribs 300A, all of theupper touch points 311A can be separate from theribs 300A, thelower touch point 307A can comprise a plurality of protrusions that seat against thelower touch surface 312A, or thetile 20A can include one or moreupper touch points 311A. - To facilitate the mounting of tiles horizontally adjacent to one another, the
tile 20A also includes an upwardly facing, sidewardly extendingengagement member 25A and a downwardly facing, sidewardly extendingengagement member 29A, as shown inFIGS. 1, 4 , 7, and 8.Engagement member 25A extends to the left of theleft portion 23A, defines achannel 26A, and includes an upwardly directedledge portion 27A.Engagement member 29A extends to the right of theright portion 24A, defines achannel 31A, and includes a downwardly directedledge portion 30A.Engagement member 25A of a first tile mates with theengagement member 29A of a second tile placed horizontally to the left of the first tile. The downwardly directedledge portion 30A of the second tile is received by thechannel 26A of the first tile. Additionally, thechannel 26A serves to divert water from the first and second tiles to the tile below the first and second tiles. Similarly,engagement member 29A of the first tile mates with theengagement member 25A of a third tile placed horizontally to the right of the first tile. The upwardly directedledge portion 27A of the third tile is received into thechannel 31A of the first tile. Thechannel 26A of the third tile serves to divert water from the first and third tiles to the tile below the first and third tiles. As discussed below in relation toFIGS. 9 and 12 , theengagement portion 29A oftile 20A can mate with anengagement portion 30B of an adjacent tile having a “B” profile configuration. Similarly, theengagement portion 30A oftile 20A can mate with anengagement portion 29B of an adjacent tile having a “B” profile. In an alternative embodiment,engagement member 25A extends from theright portion 24A andengagement member 29A extends from theleft portion 23A. Thus, the embodiment of the tile described above has aGrade 1 Weathering Index of greater than 500 (see ASTM C1167-96, Table 1) due at least in part to the improved strength to weight ratio and the ability of the tile to channel water and debris. -
FIGS. 9 through 16 illustrate an embodiment of a single roofing tile having a “B” profile. Like thetile 20A described above, the “B”profile tile 20B includes an upper face, a lower face, ahead end 32B, anose end 33B, and abody 36B. In addition, similar to thetile 20A, thebody 36B and thenose end 33B include a simulated wood grain design and thenose end 33B further includes the gaps and shadows that are expected in a wood shake roof such that two overlapping tiles have irregular clearance, as shown inFIG. 13 . - The
body 36B includes aleft portion 23B, aright portion 24B, and a center portion 22B. However, unlike the substantially flat upper face oftile 20A,tile 20B has a depressed center portion 22B, as shown inFIGS. 9 and 13 . Thehead end 32B, theleft portion 23B, and theright portion 24B slope downwardly towards the center portion 22B such that thehead end 32B, theleft portion 23B, and theright portion 24B are higher in elevation than the center portion 22B, and the depressed center portion 22B extends to thenose end 33B of thetile 20B. In addition, the left 23B andright portions 24B adjacent to thenose end 33B have a slightly higher elevation than thehead end 32B, as shown inFIGS. 15 and 16 . - Further, as shown in
FIG. 9 , the length of the 20B tile from thehead end 32B to thenose end 33B varies between the left 23B andright portions 24B and the center portion 22B. In particular, the length of the center portion 22B from thehead end 32B to thenose end 33B is shorter than the length of the left 23B andright portions 24B from thehead end 32B to thenose end 33B. In addition, the left 23B andright portions 24B of thetile 20B extend to substantially the same length as thetile 20A, and the elevation of theleft portion 23A and theright portion 24A of thetile 20A and the elevation of the left 23B andright portions 24B of thetile 20B are substantially the same. Thus, the decreased elevation and reduced length of the center portion 22B contrasted with the higher elevations and longer length of the left 23A, 23B andright portions tile tiles 20A are placed on either side of atile 20B, a staggering effect is created. This staggering effect gives the impression that the center portion of thetile 20B is one tile, the left portion of thetile 20B and thetile 20A to the left of thetile 20B are one tile, and the right portion of thetile 20B and thetile 20A to the right of thetile 20B are one tile. - As shown in
FIGS. 10 and 14 ,tile 20B further includes twotransverse ridges head end 29B oftile 20B. Theseridges transverse ridges tile 20A discussed above in relation toFIG. 2 . The substantially similar arrangement of thetransverse ridges lower touch surface nose end tile head end tile tiles 20A andtiles 20B are interchangeable in the installation, which provides a more rustic appearance and better simulates the appearance of a wood shake roof. - Like the
tile 20A, thetile 20B includes an upwardly facing, sidewardly extendingengagement member 25B and a downwardly facing, sidewardly extendingengagement member 29B, as shown inFIGS. 9, 12 , 15, and 16.Engagement members engagement members tile 20A is laid to the right of thetile 20B,engagement member 25A mates with theengagement member 29B. More specifically, the upwardly directedledge portion 27A ofengagement portion 25A is received into thechannel 31B ofadjacent engagement member 29B. Similarly, in an exemplary installation in which thetile 20A is laid to the left of thetile 20B,engagement member 29A mates withengagement member 25B. More specifically, the downwardly directedledge portion 30A ofengagement member 29A is received into thechannel 26B ofadjacent engagement member 25B. - As shown in
FIGS. 11 and 12 , the lower face of thetile 20B includes a plurality of strategically placedstructural ribs 300B to provide lightweight yet structurally sound support for thetile 20B. Twoedge ribs 301B extend along the length of thetile 20B, similar to thenose rib 307A and theedge ribs 301A of thetile 20A described above in relation toFIG. 4 . However, thecentral ribs 303B and thesecondary ribs 305B of thetile 20B are configured differently than thecorresponding ribs tile 20A due, at least in part, to the lower elevation of the center portion 22B and the need to support the center portion 22B and the transition areas between the center portion 22B and the left 23B andright portions 24B andhead end 32B. For example,tile 20B includes twocenter ribs 303B that extend the full length of thetile 20B, and the twocenter ribs 303B increase in width under the center portion 22B of thetile 20B. In addition, threesecondary ribs 305B, which are shorter thancenter ribs 303B, are spaced intermittently between the edge ribs 3011 and thecenter ribs 303B adjacent thebody 36B. One of thesecondary ribs 305B is positioned near the elevation transition from theleft portion 23B to the center portion 22B to support the transition, and one of thesecondary ribs 305B is positioned near the elevation transition from theright portion 24B to the center portion 22B. Furthermore, thecenter ribs 303B and thesecondary ribs 305B of thetile 20B are shorter than thecorresponding ribs tile 20A because the center portion 22B of thetile 20B is shorter than the center portion 22A oftile 20A. - Furthermore, the
tile 20B includes touch points 307B, 3111B that extend from the lower face of thetile 20B and engage upper touch surfaces 312B, 310B, respectively, of atile 20B stacked below thetile 20B, such as the touch points 307A, 311A andtouch surfaces tile 20A described above in relation toFIG. 3 . In the embodiment illustrated inFIG. 11 , two of the upper touch points 3111B are part of arib 300B, and one of the upper touch points 3111B is separate from theribs 300B. However, the upper touch points 3111B, likeupper touch points 311A, can all be separate from theribs 300B or can all be part of theribs 300B. In addition, thetile 20B may include one or more touch points 307B, 3111B. Furthermore, in the embodiment shown inFIGS. 2 and 10 , the touch surfaces 310A, 310B, 312A, 312B, and the touch points 311A, 3111B, 307A, 307B are in substantially similar positions, allowing thetiles - The Manufacturing Process
- Reference is now made to
FIGS. 17 and 18 , which combine to illustrate an exemplary method of manufacturing tiles using raw, unmolded clay material to produce two similar tile forms suitable for kiln firing. A rotatingmold 10 acceptsclay bats 13 and forms them into tile shapes, such as those shapes described above. After being dried and kiln fired, these tiles can be installed in an overlapping manner as shown inFIG. 19 atop an inclined support surface, such assupport surface 43. - A clay composition is extruded from a pugmill/extrusion machine in a column (not shown) and has a moisture content sufficient to provide adequate plasticity. The percentage of moisture content found to be acceptable in one embodiment is 17 to 19%. The extrusion process evacuates substantially all of the air from the clay mixture to discourage delamination. The column is then cut into short lengths to create the
bats 13 for pressing. - The press structure includes a
rotating drum 10 having a hexagonal cross-section and defining six outwardly directed drum faces. One “A”lower mold cavity 11A and one “B”lower mold cavity 11B are provided on each drum face, totaling twelve mold cavities, to provide an aesthetically pleasing variation on the installed appearance of the tiles, which is discussed above in relation toFIGS. 1 and 9 . The net result is a 50—50 mix of tiles having an “A” profile and tiles having a “B” profile, such as thosetiles - As shown in
FIG. 18 , the clay bats 13 enter the press and are deposited in thelower molds molds drum 10 is configured to rotate about a substantially horizontal axis, such that upon drum rotation, thebats 13 are moved into the 12 o'clock position. While in the 12 o'clock position, atop mold member 14 comes down and presses thebats 13 into the shapes of thetiles 20, and then withdraws upwardly. Thedrum 10 then rotates the pressedtile forms 20 to the 2 o'clock position, where a vacuum picker (not shown) moves in and simultaneously trims off the excess clay around the edges of thetiles 20 and punches nail holes as needed. It removes thetiles 20 from the drum face and deposits them on drying trays (not shown) that are passed under the picker on a synchronized conveyor. - The wet tiles, on their individual dryer trays, are then sent through a dryer where the moisture content is reduced to less than 4%. The dry “greenware” is then transported to the kiln for firing. The
vitrified tiles FIGS. 1 and 9 , are then placed directly into their shipping pallets. The combination of the touch points 311A, 311B and thetransverse ridges tiles tiles tiles - Furthermore, because tiles composed of clay may shrink when drying, tiles according to one embodiment of the invention are dimensioned to optimize the strength to weight ratio. The optimized dimensions allow the tiles to be manufactured with more tolerance for distortion while continuing to meet building code specifications for weight.
- The Installation Process
- Reference is now made to
FIGS. 19 through 21 , which combine to illustrate the tile installation process according to the present invention. Thetiles lower ridge lower touch surface ribs upper tile lower ridge lower tile touch point upper tile lower touch surface lower tile ribs upper tile lower ridge tile lower tile - The tiles are attached to a supporting surface 43 (such as plywood) by nails or other suitable fasteners engaged into
apertures metal drip edge 42 is used at the bottom of the roof to support the bottom horizontal course oftiles - As is shown in
FIG. 20 , theedge portions 35 of thetiles edge portions 35 of thetiles size tiles edge portions 35 can be offset from thosetiles tile primary ribs 303B fortile 20B or between the centerprimary rib 303A and one of thesecondary ribs 305A for thetile 20A. The rib design provides flexibility as to where thetiles - In an alternative embodiment (not shown), hip trim tiles are provided in varying widths. The hip trim tiles are used along the edge of the roof leading up to the ridge of the roof. Two configurations of hip trim tiles may be used according to one embodiment, a “C” configuration and a “D” configuration, wherein the “C” configuration hip trim tile has a width that is less than the width of the “D” configuration hip trim tile. Alternating the use of the “C” configuration hip trim tile and the “D” configuration hip trim tile with each horizontal course will result in the
edge portions 35 of each course being offset from the course below or above it. The number of hip trim tile configurations may be greater than two, depending on the needs of the installation. - In addition to including hip trip tiles, one embodiment of the tiling system further includes hip trim starter tiles and ridge trim tiles. Hip trim starter tiles are used on the bottom course at the bottom corners of the roof. The hip trim starter tiles provide a clean finish for the bottom corners of the roof. Ridge trim tiles are installed along the ridge of the roof and overlap the horizontal course of tiles below them.
- Therefore it may be seen that the present invention overcomes deficiencies in the prior art by providing roofing tiles which can be produced in mass quantities, yet have the appearance of traditional wood shakes with the structural properties of fired clay. In addition, by having one or more structural support ribs, the tiles have the strength of standard tiles, but weigh significantly less than standard tiles. Furthermore, the present invention provides touch points on each tile that engage receiving portions on a vertically adjacent tile for preventing the relative movement of tiles. While this invention has been described in specific detail with reference to the disclosed embodiments, it will be understood that many variations and modifications may be affected within the spirit and scope of the invention as described in the appended claims.
Claims (7)
Priority Applications (1)
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US11/134,086 US20050257477A1 (en) | 2004-05-20 | 2005-05-20 | Roofing system and roofing tile |
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US57370804P | 2004-05-20 | 2004-05-20 | |
US11/134,086 US20050257477A1 (en) | 2004-05-20 | 2005-05-20 | Roofing system and roofing tile |
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US20050257477A1 true US20050257477A1 (en) | 2005-11-24 |
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US11/134,086 Abandoned US20050257477A1 (en) | 2004-05-20 | 2005-05-20 | Roofing system and roofing tile |
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Cited By (7)
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US20080034705A1 (en) * | 2006-08-02 | 2008-02-14 | Andrew Truss | Stacking bar for roofing elements |
USD738541S1 (en) * | 2014-02-12 | 2015-09-08 | Metrolite Manufacturing | Steel sheet roof tile |
US9243408B2 (en) * | 2011-08-16 | 2016-01-26 | Joseph Robert Nicholson | Roof element |
JP2017008559A (en) * | 2015-06-19 | 2017-01-12 | 株式会社鶴弥 | Plain tile |
USD821614S1 (en) * | 2017-03-31 | 2018-06-26 | Tesla, Inc. | Photovoltaic roof tile |
USD833382S1 (en) * | 2016-10-28 | 2018-11-13 | Solarcity Corporation | Photovoltaic roof tile |
US10508448B2 (en) | 2017-09-11 | 2019-12-17 | Lala Khajani | Tile and method of production |
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US20080034705A1 (en) * | 2006-08-02 | 2008-02-14 | Andrew Truss | Stacking bar for roofing elements |
US9243408B2 (en) * | 2011-08-16 | 2016-01-26 | Joseph Robert Nicholson | Roof element |
USD738541S1 (en) * | 2014-02-12 | 2015-09-08 | Metrolite Manufacturing | Steel sheet roof tile |
JP2017008559A (en) * | 2015-06-19 | 2017-01-12 | 株式会社鶴弥 | Plain tile |
USD833382S1 (en) * | 2016-10-28 | 2018-11-13 | Solarcity Corporation | Photovoltaic roof tile |
USD821614S1 (en) * | 2017-03-31 | 2018-06-26 | Tesla, Inc. | Photovoltaic roof tile |
US10508448B2 (en) | 2017-09-11 | 2019-12-17 | Lala Khajani | Tile and method of production |
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