AU2004203147B2 - Roof tile - Google Patents

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) Name of Applicant(s): BAKER, Kevin John of 18 Dobbin Circuit, Nicholls, ACT 2913 Actual Inventor(s): BAKER, Kevin John Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, of 1 Nicholson Street, Melbourne, Victoria 3000, Australia Invention Title: "Roof tile" Details of Associated Provisional Application Nos: AU 2003903630 filed 14 July 2003 AU 2003907081 filed 19 December 2003 The following statement is a full description of this invention, including the best method of performing it known to us. Q\OPER\Sgw\Jul-Sep 2004\12464920 cap filing.doc - 13/7/04 C \NRPortbl\DCCILU 32136 LDOC-4f/2ll) Roof Tile Field of the Invention 5 The present invention relates to the provision for ventilation of exhaust gases from within a building having a tiled roof. Usually the exhaust gases take the form of air containing undesirable odours or moisture. Background 10 Ventilation through roofing is commonly used to remove heat, moisture or undesirable odours from within a building. In the case of a tiled roof this is typically achieved by a tubular structure extending vertically through the tiles. This necessitates cutting tiles and fitting flashing around the tubular structure. The 15 tubular structure is unsightly, particularly if fitted with a cover to prevent ingress of large objects. Problems also arise when exhaust gases from inside a building, for example from a bathroom or kitchen, are extracted into the roofing cavity. These exhaust gases 20 are often not fully extracted from the roofing cavity due to many factors including poor circulation and/or ventilation despite there being a roof ventilation structure. This can create some problems, for example increased moisture in the roofing cavity which increases mould growth and may produce undesirable smells which are hard to remove. 25 To overcome the aesthetic problems, roof tiles with flow passages through the body of the tile have been used. These are typically moulded to the profile of the existing roof tiles and simply substituted for original roof tiles.

C:\NRPonbl\DCC\JL\2832136 iDOC4n/2oio -2 For example, UK patent application 2 262 295 shows a roof ventilating tile of the same shape and size as a conventional roof tile. The tile has a through duct which opens at opposite ends of the tile. The tile is intended to be laid so that the duct is open to the exterior at the lower end of the tile and is open to the interior of the 5 roof at the upper end. In another example, UK patent application 2 279 675 shows a hollow roofing tile which is shaped externally identically with adjacent solid tiles. Arrangements have previously been proposed for connecting exhaust ducts to roofs. For example GB 2 262 949 shows a ventilator for a tiled roof with a circular 10 section pipe. In another example, WO 98/15701 shows a covert roof ventilator with an upper wall of shape complementary to roof tiles with which it is to be used. The ventilator also has an apertured lower wall spaced from the upper wall with an elongate aperture formed at a toe portion of the ventilator having a combined grill and baffle. A spigot extends from the aperture which when in use may be 15 connected to a soil pipe. The grill prevents small mammals and birds from entering the ventilator while the baffle prevents the ingress of driven rain and snow. An upstanding wall further prevents the ingress of driven rain and snow. The baffle and wall mean greater complexities in the manufacturing process, including more intricate mouldings. Further, the baffle and wall create a complex 20 flow path for the exhaust gases. Additionally, a separate upper wall is required for each style of tile. This leads to uneconomical production costs and assembly problems. Therefore, it would be desirable for a roof tile to remove the exhaust gas from the 25 building directly to the outside of the roof, and to be aesthetically pleasing whilst being simple in construction.

C:\NRPortbT\DCC\JI32136I.DOC-n/20 n -3 Summary of the Invention According to the invention, there is provided a roof tile configured to substitute for a roof tile in an array of roof tiles, having a length, a width and a thickness, 5 including an inclined passage having a substantially unobstructed pathway from an outlet at the lower end of the passage to an inlet at an upper end of the passage and being provided with a connector which defines a downwardly extending passage communicating with the inlet and is adapted to connect to a duct, wherein the inclined passage occupies substantially the entirety of the length 10 and width of the tile and has a substantially greater width than thickness. Preferably, the inlet is arranged adjacent the downwardly extending passage and to the same side of the downwardly extending passage as the outlet. Preferably, the inlet is positioned to be located at a lower level than a course of tiles which is 15 adjacent the roof tile as installed and is positioned higher up the roof. Preferably, the roof tile includes an insect barrier. Preferably, the roof tile further includes a sealing section adjacent said lower end, 20 the sealing section being shapeable to conform with an external tile profile in an adjacent lower course of tiles. Preferably, the sealing section comprises a plate arranged transverse to the inclined passage and below the outlet, the plate being able to be cut by snippers so as to be shaped. 25 Preferably, the inclined passage is orientated generally perpendicularly to the downwardly extending passage. Preferably, the connector is cylindrical. 30 Preferably, the connector is shaped for connection to at least two differently sized ducts.

C:\NRPo1bt\DCC WU832136I DOCM20j0 -4 Preferably, the ratio of length to width to thickness is 16:12:1. In a preferred embodiment of the invention, the roof tile is separably coupled to the connector. However, the roof tile may be integrally formed with the connector. 5 Preferably, the connector is made from plastic. Preferably, the roof tile is made from metal. 10 Preferably, the tile is of unitary construction. Preferably, the tile is a substitute for a tile of an array of interlocked roof tiles and is configured to interlock with tiles of the array adjacent thereto. 15 Preferably, the tile has at one lateral side an upturned longitudinal edge and at the other lateral side a downturned longitudinal edge, to be interlockable with tiles to either side thereof. Brief Description of the Drawings 20 Preferred embodiments of the present invention will now be described, by way of non-limiting example only, with reference to the following drawings, in which: Figure 1 is a perspective view of the outer surface of a roof tile provided with a 25 connector, according to one embodiment of the invention; Figure 2A is a cross-sectional view B - B of the roof tile shown in Figure 1; Figure 2B is a cross-sectional view B - B of the roof tile shown in Figure 1; Figure 3 is a cross-sectional view A - A of the roof tile shown in Figure 1. Figure 4 is a perspective view of a roof tile provided with a connector, according to 30 another embodiment of the invention; Figure 5 is a plan view of the underside of a roof tile provided with a connector, C:\NRPonbl\DCC\J,\2832136_1.DOC-4/7/2010 -5 according to another embodiment of the invention; and Figure 6 is a representative drawing of the roof tile as shown in Figure 1 installed in a tiled roof. 5 Detailed Description The roof tile in the embodiments of the present invention is suited to enable exhaust gases to be vented an outside space through an inclined tiled roof. The roof tile replaces an existing normal tile and is ideally connected to an exhaust gas 10 duct. Referring to Figure 1, the roof tile 1 generally has the same shape as the existing roof tiles. It is generally rectangular in shape, being defined by a length, a width and a thickness. Generally such tiles have a greater length than width and a 15 substantially greater width than thickness. For example, a length:width:thickness ratio of 16:12:1 is common. The roof tile has an inlet 2 near the upper end 3 and outlet 4 at the lower end 5. When the roof tile 1 is installed, the inlet 2 is at a higher level than the outlet 4. An 20 inclined passage 6 extends from the outlet 4 to the inlet 2. This passage is substantially unobstructed, allowing generally free air flow from the inlet 2 to the outlet 4. This passage extends substantially the full length of the tile. A connector 7, defining a downwardly extending passage, is connected to the inlet 2 and is adapted to be connected to a duct, not shown. As a consequence, the flow path is 25 from the passage in connector 7 through the inlet and along the length of the tile to the outlet. The downwardly extending passage in connector 7 is orientated relative to the inclined passage 6 such that the flow resistance of exhaust gas is reduced when 30 the air flow is in the direction from the inlet 2 to the outlet 4, and increased when the air flow is in the direction from the outlet 4 to the inlet 2.

C:\NRPorb\DCCd fl32136 DOC-40I20I0 -6 The design and position of the downwardly extending passage varies from application to application depending upon various factors such as the exhaust gas temperature, pressure and flow rate, and physical limitations on the passage such as a roofing truss support or additional devices in the roofing cavity, eg hot water 5 service. The position of the downwardly extending passage is generally at or near the upper end 3 of the roof tile 1. As shown in Figure 6, the roof tile 61 may extend beyond the normal length of the ordinary roof tiles so that the inlet 62 and downwardly extending passage 63 are below the course of tiles above the roof tile 64 when installed on the roof. The cross-section of the downwardly extending 10 passage could also be any suitable shape, for example rectangular, square or circular. With reference to Figure 1, a sealing section 8 can be shaped to conform to the profile 9 of the existing tiles. Shaping of the sealing section 8 may be done by 15 cutting away part of the sealing section 8 so that the profile 9 is obtained. For example, the profile 9 could be obtained by abutting an existing tile end to the sealing section 8, marking the profile 9, removing the existing tile and cutting along the profile markings 9 using tin snips. The shaped sealing section 65 is shown in Figure 6. This shape-conformable sealing section means that the tile can be 20 installed universally, regardless of the shape of the existing tiles. Referring to Figure 2A, the flow of an exhaust gas 20 through the roof tile 21 can be seen by arrows indicating the direction of the flow. The exhaust gas may be from an apparatus within the roofing cavity, such as a heating/cooling apparatus, 25 or from an internal space in the building, such as a bathroom. The exhaust gas may contain water and any other material which could cause an unpleasant odour or condition in the roofing cavity. One example is a bathroom exhaust fan which extracts water vapour from a 30 bathroom so that the mirrors in the bathroom do not fog up with the vapour whilst a person has a hot shower. The vapour may accumulate in the roofing cavity if the C:WRfonbDCClL\2832136_ I.DOC-4n/201 -7 cavity does not have adequate ventilation and create a build-up of condensed water. This may cause problems such as weakening of ceiling plaster, unsightly damp spots in the ceiling of the building, and mould growth, which may cause health problems. All of these problems are undesirable in many buildings. 5 In the embodiment shown in Figure 1, a duct would be connected to the exhaust fan so that the extracted vapour-containing air would flow through the duct to the downwardly extending passage of the roof tile, through the inclined passage and out to the atmosphere. This eliminates any additional dampness in the roofing 10 cavity from the bathroom vapour. Referring to Figure 2B, air flow from the atmosphere 22, such as wind, is restricted due to the length of the roof tile 23. This is without the need for additional baffles or complexity in the construction of the roof tile 1. 15 Referring to Figure 3, the roof tile 30 includes a single-piece outer section 31 and a single-piece underneath section 32. This construction allows for a simple yet strong tile to be formed. A central brace 33 may also be included to strengthen the exhaust roof tile 30. The inclined passage 34 extends substantially the width 20 and thickness of the roof tile 30. The outer section 31 and underneath section 32 can be joined by any appropriate means such as welding, including resistance spot and laser welding, or by mechanical means such as screws, bolts or rivets. 25 Referring to Figure 4, the roof tile 40 includes an outer section 41, an underneath section 42 and a sealing section 43. A mesh 46 may also be included near the lower end 44 to prevent foreign materials and animals, particularly insects, from travelling up the roof tile 40. The roof tile also includes a downwardly extending 30 passage 45 which is connected to the outer section 41 and underneath section 42 and is adapted to be connected to a duct, not shown.

C:NRPonblDCC\IL12232136 I.DOC-4/7/2io -8 It may also be necessary for a sealant to be applied around the exhaust roof tile 40 when installed, to increase the weather resistance of the roof. Further, it may be necessary for sections of the tile or tiles above the exhaust roof tile to be removed so that a flat surface is on the underside of the tile or tiles is obtained. 5 The roof tile and connector can be made from any suitable material; for example, plastic or metal. A roof tile made from a metal may also have a protective coating, for example zinc coated steel or galvanised steel. Zincanneal@ made by BHP Steel has been found to be beneficial in certain circumstances as it is fire resistant, 10 especially in bush fire-prone areas. The roof tile may then be painted to match the colour of the existing roof tiles so as to be more aesthetically pleasing. A roof tile made from plastic is also beneficial as the weight of the tile is reduced. A plastic roof tile also allows for colouring and more intricate shapes to be formed through moulding. However, a combination of metal and plastic components whilst 15 maintaining the advantages of both materials is also beneficial. For example, having a tile body made from metal provides fire resistance and the connector from plastic so as to involve more intricate shaping is especially beneficial. A roof tile made from plastic may also include a light-transmitting portion, for 20 example a transparent plastic portion, to provide light to the roof cavity or another part of a building. Alternatively, the tile may be made form a non-opaque plastic, for example polycarbonate or acrylic. The foregoing describes only certain embodiments of the present invention and 25 modifications obvious to those skilled in the art can be made thereto without departing from the scope of the present invention. The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of 30 the common general knowledge.

C:\NRPtblDCC\JL\232 1361. DOC-4f/20 1) -9 Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or 5 group of integers or steps.

Claims (13)

1. A roof tile configured to substitute for a roof tile in an array of roof tiles, having a length, a width and a thickness, including an inclined passage having a 5 substantially unobstructed pathway from an outlet at the lower end of the passage to an inlet at an upper end of the passage and being provided with a connector which defines a downwardly extending passage communicating with the inlet and is adapted to connect to a duct, wherein the inclined passage occupies substantially the entirety of the length and width of the tile and has a substantially 10 greater width than thickness.

2. A roof tile according to claim 1, wherein the inlet is arranged adjacent the downwardly extending passage and to the same side of the downwardly extending passage as the outlet. 15

3. A roof tile according to claim 2, wherein the inlet is positioned to be located at a lower level than a course of tiles which is adjacent the roof tile as installed and is positioned higher up the roof. 20

4. A roof tile according to any one of the previous claims, wherein the roof tile includes an insect barrier.

5. A roof tile according to any one of the previous claims, further including a sealing section adjacent said lower end, the sealing section being shapeable to 25 conform with an external tile profile in an adjacent lower course of tiles.

6. A roof tile according to claim 5, wherein the sealing section comprises a plate arranged transverse to the inclined passage and below the outlet, the plate being able to be cut by snippers so as to be shaped. 30

7. A roof tile according to any one of the previous claims, wherein the inclined C:\NRPonbTlDCOIL\2936737 _DCc.55nfalo -11 passage is orientated generally perpendicularly to the downwardly extending passage.

8. A roof tile according to any one of the previous claims, provided with the 5 connector being cylindrical.

9. A roof tile according to any one of claims 1 to 7, provided with the connector being shaped for connection to at least two differently sized ducts.

10 10. A roof tile according to any one of the previous claims wherein the ratio of length to width to thickness is 16:12:1.

11. A roof tile according to any one of the preceding claims, provided with the connector being made from plastic. 15

12. A roof tile according to any one of the previous claims, wherein the roof tile is made from metal.

13. A roof tile substantially as described herein with reference to the drawings.