EP1931841A1 - Systeme de carreaux en beton et son procede de fabrication - Google Patents

Systeme de carreaux en beton et son procede de fabrication

Info

Publication number
EP1931841A1
EP1931841A1 EP06816692A EP06816692A EP1931841A1 EP 1931841 A1 EP1931841 A1 EP 1931841A1 EP 06816692 A EP06816692 A EP 06816692A EP 06816692 A EP06816692 A EP 06816692A EP 1931841 A1 EP1931841 A1 EP 1931841A1
Authority
EP
European Patent Office
Prior art keywords
tile panel
tile
panel
leading edge
edge
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP06816692A
Other languages
German (de)
English (en)
Inventor
Damon Stone
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP1931841A1 publication Critical patent/EP1931841A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/141—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of concrete
    • 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
    • E04D1/26—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
    • E04D1/265—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles the roofing elements being rigid, e.g. made of metal, wood or concrete
    • 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
    • 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
    • E04D1/2918—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 succeeding rows
    • 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
    • E04D1/2956—Means for connecting or fastening adjacent roofing elements by interfitted sections having tongues and grooves
    • 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
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • 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
    • E04D1/34—Fastenings for attaching roof-covering elements to the supporting elements
    • 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
    • E04D1/36—Devices for sealing the spaces or joints between roof-covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
    • E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
    • E04D13/0404—Drainage on the roof surface
    • E04D13/0459—Drainage borders, e.g. dripping edges, gravel stops or dispersers
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
    • E04D13/15—Trimming strips; Edge strips; Fascias; Expansion joints for roofs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • E04D3/358—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation with at least one of the layers being offset with respect to another layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/36—Connecting; Fastening
    • E04D3/365—Connecting; Fastening by simple overlapping of the marginal portions with use of separate connecting elements, e.g. hooks or bolts for corrugated sheets
    • 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
    • E04D1/28—Roofing elements comprising two or more layers, e.g. for insulation
    • 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
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • E04D2001/301—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles at roof edges, e.g. intersections with walls
    • E04D2001/302—Gable tiles
    • 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
    • E04D1/30—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles
    • E04D2001/304—Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles at roof intersections, e.g. valley tiles, ridge tiles
    • E04D2001/305—Ridge or hip tiles
    • 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
    • E04D1/34—Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3408—Fastenings for attaching roof-covering elements to the supporting elements characterised by the fastener type or material
    • E04D2001/3414—Metal strips or sheet metal
    • 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
    • E04D1/34—Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3444—Fastenings for attaching roof-covering elements to the supporting elements characterised by the roof covering or structure with integral or premounted fastening means
    • E04D2001/3447—Fastenings for attaching roof-covering elements to the supporting elements characterised by the roof covering or structure with integral or premounted fastening means the fastening means being integral or premounted to the roof covering
    • 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
    • E04D1/34—Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3452—Fastenings for attaching roof-covering elements to the supporting elements characterised by the location of the fastening means
    • E04D2001/3458—Fastenings for attaching roof-covering elements to the supporting elements characterised by the location of the fastening means on the upper or lower transverse edges of the roof covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
    • E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
    • E04D13/0404—Drainage on the roof surface
    • E04D13/0459—Drainage borders, e.g. dripping edges, gravel stops or dispersers
    • E04D2013/0468—Drip edges
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/03—Undercut connections, e.g. using undercut tongues or grooves
    • E04F2201/035—Dovetail connections

Definitions

  • the subject invention relates to a selectively interlocking tile covering system for homes, buildings, or other structures. Specifically, the subject invention relates to a four- sided interlocking tile panel covering system that utilizes an insulated lightweight concrete tile. The subject invention further relates to a method for manufacturing the concrete tiles and means for utilizing the tiles as a roof covering system.
  • Tile roofing systems have been devised that are more secure, but such systems often require complicated means for manufacturing and installing tiles, see for example U.S. Patents 5,743,059 and 6,604,336; or for securing them to the underlying roof structure, see for example U.S. Patents 5,323,580; 5,522,187; and 5,921,045.
  • the subject invention pertains to tile panels, as well as systems of manufacturing and installing said tile panels.
  • the tile panels of the subject invention are particularly well-suited as a roof covering system.
  • a person with skill in the art after reviewing the following description will recognize a diverse number of other uses for the tile panels and teachings of the subject invention, including for example, as a covering for walls, siding, etc.
  • the tiles are manufactured of a lightweight concrete having sufficient strength to withstand extreme weather and wind conditions, as well as normal handling or foot traffic often required for installation and maintenance, especially when utilized as a roof covering.
  • the subject invention provides a tile panel assembly wherein the tile panels may comprise insulation affixed thereto.
  • the tile panels are constructed so as to present an overlapping configuration that can, preferably, interlock on all four sides to provide resistance to negative pressure wind uplifting.
  • the tile panels utilize a backing material to lend additional strength to the tile panels and, further, to reduce the amount of air space between the underlying roof structure and the panels.
  • a foam, or foam-like, material can be utilized to fill the space under the tiles and reduce air space. Reduction of the available air space can further reduce or eliminate the effects of wind uplift caused by negative pressure, i.e., the Bernoulli effect, and can additionally provide insulation properties to the tiles.
  • the backing material can also be formed to provide a four- sided interlocking tile system that holds and/or stabilizes tile panels against each other and the underlying roof structure(s), as well as reducing the amount of surrounding air space.
  • the sheathing surface can be formed, according to the subject invention, to provide a four-sided interlocking tile system also capable of holding and/or stabilizing tile panels against each other and the underlying roof structure(s).
  • one or more edges of the tiles are cut, shaped or otherwise formed to provide a selectively-interlocking covering, similar to, for example, a mortise and tenon arrangement.
  • the leading edge of a tile of the subject invention is formed to provide an interlock channel, or mortise-like opening
  • the trailing edge is formed to provide an insertion edge, or tenon-like extension.
  • the insertion edge, formed at or near the trailing edge of one tile engages the interlock channel formed at or near the leading edge of another higher adjacent tile, such that the leading edge of the higher tile overlaps the fa-ailing edge of the lower tile.
  • the leading edge overlaps the trailing edge and covers the mounting hole of the first tile, minimizing its exposure to the elements.
  • the means for interlocking the leading edge of one tile with the trailing edge of another, lower tile is located higher (up-roof) than the mounting hole and fastener that are proximal to the fa-ailing edge of the lower tile panel.
  • the tile panels once interlocked, can be attached to an underlying roofing structure, or roof decking utilizing standard roofing nails or screws.
  • the tile system of the subject invention also provides specialized tiles for covering roof apex points, hip lines, and drip edges.
  • Alternative embodiments of the subject invention utilize tiles that have a mortise and tenon (also referred to as tongue-and-groove) type, or similar, configuration.
  • the leading edge of a tile is formed with at least one protrusion or tenon and the trailing edge of one, or conversely two, tiles form at least one corresponding opening or mortise.
  • the tenon(s) of a first tile can be positioned within the mortise(s) of one or more second tile(s), such that the leading edge of the first tile overlaps the trailing edge of the second tile(s).
  • tile brackets that can be affixed to or incorporated into the upper surface of existing prior art tiles, or the novel tiles of the subject invention.
  • the brackets secure the leading edge of tiles to provide greater wind resistance.
  • one or more tile brackets can be affixed to or incorporated into the upper surface of a first tile, at or near its trailing edge.
  • a second tile is positioned to overlap the fa-ailing edge of the first tile such that the leading edge of the second tile is received by the one or more tile brackets positioned on the trailing edge of the first tile.
  • the tile bracket arm is generally designed to extend over the leading edge of the second tile to prevent it from being lifted once positioned in the tile bracket(s).
  • the various embodiments of the subject invention are designed to secure at least the leading edges of installed tiles and, in preferred embodiments, the side and/or trailing edges as well, to prevent wind-uplift and/or the Bernoulli Effect from removing or breaking the tiles during high wind conditions.
  • Figure 1 is a perspective view of an embodiment of the subject invention illustrating a barrel-style tile.
  • Figure 2 A is an end-view of the upwardly-curved side of a tile shown in Figure 1.
  • Figure 2B is an end-view of a flat tile embodiment of the subject invention.
  • Figure 3 A is an end-view of the downwardly-curved side of a tile shown in Figure 1.
  • Figure 3B is a bottom plan view of a flat tile embodiment of the subject invention.
  • Figure 4 is a cross-section of a downwardly-curved section of the tile shown in Figure 1.
  • Figure 5 is a cross-section of an upwardly-curved section of the tile shown in Figure 1.
  • Figure 6A is a side-view of an alternative embodiment of the subject invention illustrating a flat-style tile.
  • Figure 6B is an enlarged view of the connecting means and interlocking mechanism of an embodiment of the subject invention as shown in Figure 6A.
  • Figure 7A is an end-view of an embodiment of a crown panel that can be utilized with the subject invention.
  • Figure 7B is a side-view of an embodiment of a crown panel that can be utilized with the subject invention.
  • Figure 7C is a cross-section of a side-view of an embodiment of a ridge panel that can be utilized with the subject invention.
  • Figure 7D is a side view of an embodiment of the crown panels shown in Figures 7 A,
  • Figure 8A is a perspective view of an embodiment of a hip panel that can be utilized with the subject invention.
  • Figure 8B is a cross-section of a side-view of the embodiment of a hip panel shown in Figure 8A.
  • Figure 9 is a side-view of an embodiment of a drip panel that can be utilized with the subject invention.
  • Figure 10 is a perspective view of the embodiment of a drip panel, as shown in Figure 9.
  • Figure 11 is a perspective view of an embodiment of a roof end panel that can be utilized with the subject invention.
  • Figure 12A is a perspective view of an embodiment of a tenon and mortise (or tongue-and-groove) tile design that can be utilized with the subject invention. This embodiment illustrates a dove-tail configuration.
  • Figure 12B is a view of Figure 12A wherein the full configuration of the tenon and mortise (or tongue-and-groove) of this embodiment can be seen.
  • Figure 12C is a perspective view of an alternative embodiment of a tenon and mortise (or tongue-and-gr ⁇ ove) tile design that can be utilized with the subject invention. This embodiment illustrates an alternate dove-tail configuration.
  • Figure 12D is a view of Figure 12C wherein the full configuration of the tenon and mortise (or tongue-and-groove) of this alternative embodiment can be seen.
  • Figure 13A is a perspective view a tile bracket embodiment of the subject invention.
  • Figure 13B is a perspective view of an alternative embodiment of the tile bracket of the subject invention.
  • Figure 14 is a cross-sectional side view of an alternative embodiment of the tile panel of the subject invention.
  • the subject invention pertains to four-sided interlocking tile panels and systems for utilizing and installing the tile panels.
  • One embodiment utilizes an overlap interlocking system wherein an edge of one tile overlaps and interlocks with an edge of another tile.
  • a second embodiment utilizes a tenon and mortise (or tongue-and- groove) mechanism wherein one or more tenons of one tile can interlock with one or more mortises formed by at least one other tile.
  • a third embodiment provides a tile bracket mechanism that can be affixed to a first tile so as to secure the leading edge of an overlapping second tile. The selectively-interlocking tile panel embodiments and the tile bracket mechanism will be discussed in detail below.
  • the Overlap Interlock tile panels of the subject invention can provide increased durability and resistance to a variety of weather conditions, including extreme environmental events with high wind conditions.
  • the tiles are preferably manufactured from one or more lightweight concretes, known in the art, which allows them to advantageously be utilized in a variety of construction areas, usually without additional reinforcement of the underlying support system, for example a roof decking.
  • the tiles of the subject invention are reinforced with a backing material, for example a foam or foam-like material, that provides additional strength and insulating properties, as well as minimizing airspace beneath the tiles, lending them advantageous characteristics in high wind conditions.
  • the tile panels 10 of the subject invention When installed, the tile panels 10 of the subject invention are secured on all sides, wherein at least two sides utilize a selectively interlocking system and at least two other sides are secured by the overlap of adjacently positioned tiles.
  • the panels are rigid; the rigidity ideally being a characteristic conveyed by the material used to make the sheathing surface, the backing material, or both of them.
  • the tile panels of the subject invention are described as a roof covering. This description should not be construed as a limitation in practicing the subject invention.
  • the tile panels 10 comprise a sheathing surface 12 that overlays a backing material.
  • the sheathing surface 12 can be manufactured from a variety of materials, including, but not limited to, various metals, plastics, glass, woods, as well as natural or petroleum-based products or any combinations or composites thereof, etc., as are well known and would be readily apparent to those skilled in the art.
  • tiles are usually manufactured from clay, concrete, or various composites or blends thereof, and such materials as those and others mentioned herein above may also be utilized in conjunction with the subject invention.
  • Such tiles may also be reinforced with a variety of materials. However, standard clay or concrete, especially if reinforced, tends to be heavy, and may require additional reinforcement of roofing structure and decking. Therefore, it may be preferable, but not required, to use a lighter weight material.
  • the sheathing surface 12 of the tile panel of the subject invention is manufactured from a lightweight concrete, for example, various cellular concrete products, or lightweight aggregate concretes, such as GRANCRETE®, or other similar products as are well known to those skilled in the art.
  • a foaming agent may be incorporated into a concrete mix, as is also known in the art, to reduce weight, without adversely affecting the strength of the concrete necessary for utilization with the subject invention.
  • the methods and techniques of manufacturing tiles are well-known in the art. For example, tiles can be formed in molds, extruded, or stamp constructed.
  • the sheathing surfaces 12 of the subject invention can be manufactured, utilizing standard techniques, to required thicknesses, which will be determined by their ultimate construction application.
  • the sheathing surface 12 when utilized as wall or siding cover, it may be possible to construct the sheathing surface 12 of a relatively thin layer of lightweight concrete. However, for other applications, for example roofing construction, a thicker layer of lightweight concrete could be utilized.
  • the sheathing surface 12 when utilized as roofing tile panels, is approximately 1/8" to about 1/2" in thickness. In a more preferred embodiment, the thickness is from about 1/4" to about 3/8". In a most preferred embodiment, the sheathing surface 12 is about 5/16" in thickness.
  • lightweight concrete provides sufficient durability to allow walking, kneeling, etc. on the tiles during installation. The concrete is also resistant to wind and water.
  • the concrete can also be tinted or colored before, during, or after the manufacture of the tile panels of the subject invention using well- known techniques and products.
  • Utilizing lightweight concrete for the sheathing surface 12 allows the tile panels 10 to be used on standard roofing or decking assemblies 16, usually without the need for reinforcements, which are sometimes necessary with standard clay or concrete tile roofs. It is also possible to utilize existing manufacturing techniques, molds, etc. that would be used with standard clay or concrete tile manufacture. Therefore, the tile panels of the subject invention can save costs on manufacturing, construction materials, and time.
  • a further advantage of lightweight concrete is that it can be molded and shaped to provide almost any desired configuration, for example as shown in Figure 1. In a preferred embodiment, the tile panels of the subject invention are colored and shaped to look like standard clay tiles.
  • the tile panels of the subject invention are a flat or shingle-type style.
  • the shingle tiles of the subject invention are manufactured and colored to mimic standard shingles, slate or other flat or contoured tile designs.
  • each tile panel 10 is secured to the roof decking. This provides resistance to wind-lifting or other forces that could reposition the tiles. Therefore, in a further preferred embodiment, one or more openings or mounting holes 14 are created in the tiles, by techniques known to those with skill in the art, to accommodate their attachment to a roof decking.
  • the holes may be formed in the sheathing surface 12, and/or the backing material during manufacture of a tile panel 10, or alternatively could be created in the tile panel after manufacture.
  • the openings or mounting holes 14 can be fo ⁇ ned at angles, such that the nails or screws are inserted at angles relative to the roof decking 16, rather than perpendicular to the roof decking.
  • the openings or mounting holes 14 are at approximately 40° to about 75°, relative to the roof decking or other support surface. This technique can increase the holding strength of nails or screws. Another consideration is the number of mounting holes created in the tiles, which will vary depending upon the type of tile.
  • the tiles prefferably have a sufficient number of mounting holes 14 so as to provide adequate resistance to wind lifting.
  • the mounting holes 14 extend through the sheathing surface 12 and the associated backing material 20, which will be discussed below.
  • the mounting holes 14 can be in any location on the tile panel. However, for certain tile shapes, for example, barrel- style tiles it is preferable for the mounting holes 14 to be located where there is a minimum distance between the sheathing surface and the support structure, e.g., roof decking. For example, as illustrated in Figures 1 and 5, if utilizing barrel-style tiles, it may be preferable to have mounting holes 14 in the downward-curved areas, preferably at the bottom of a curve, closest to the roof decking.
  • mounting holes 14 be located in an area of the tile that is proximal to its trailing edge so that the mounting hole is covered by the overlap of another tile when in its final assembled configuration, so that exposure of the fastener to the elements is minimized.
  • the tiles can be connected to the roof decking utilizing standard screws or nails and equipment known to those with skill in art.
  • an adhesive, grout, sealing, or similar material can be used in addition to nailing or screwing the tiles to the roof decking. This can assist in maintaining the proper positions of the tile panels, and in regions of more prevalent strong wind conditions, provide desirable additional resistance to wind-lifting.
  • an adhesive such as those known in the art, is applied either to the backing material of the tile panels, the surface of the support structure, or both of them, prior to installation to adhere the tile panels to the roof decking or other support structure.
  • the tiles of the subject invention can be manufactured to a variety of lengths and widths.
  • Tile panels 10 that cover a larger surface area can be easier to install and reduce labor costs.
  • the tile panels 10 of the subject invention could be manufactured to a standard size of approximately 12" in length (from the leading edge 150 to the trailing edge 300) and approximately 18" in width (side-to-side).
  • the tile panels 10 of the subject invention can each cover approximately 3 to 4 feet of surface area.
  • a person with skill in the art will recognize that the length and width of the tiles would be based upon the desired roof style and design. Utilizing moldable lightweight concrete makes it possible to create numerous tile designs, including for example, Roman, Greek, Italian, English, Spanish, etc. designs, or entirely unique tile designs, without significantly altering the methods of the subject invention. Further, the ultimate shape and size of the tiles utilized with any design will be dependent upon the given structure to which the tiles are to be installed.
  • the subject invention utilizes a material on the bottom side 24 of the sheathing surface 12 to reduce the amount of air space under the tiles.
  • the tile panel 10 is less susceptible to lifting by wind.
  • backing materials can be selected from various materials, including plastics, woods, metals, lightweight concretes, ceramics, clays, foams, or combinations or composites thereof.
  • the tile panels are constructed of materials capable of rendering a "cellular solid" product.
  • the tile can be created with any of a variety of decorative outer surface shapes, and styles, but could have a bottom surface 24 that conforms to the shape of the support surface to which it will be attached.
  • a barrel-style tile panel to be utilized on a roof decking could have a rolling or curved top surface 26 and the bottom surface 24 could be substantially flat so as to lay or be adhered flush against the roof decking.
  • a backing material 20 can be utilized with the subject invention.
  • the backing material 20 utilized with the subject invention should be water resistant and easily fomiable to accommodate a variety of shapes of tile panel 10. It should also be of sufficient rigidity to maintain its shape during manufacture and installation of the tile panels and during high wind conditions. Further, a high insulation capability, or R value, is desirable.
  • R value a high insulation capability, or R value.
  • it can be applied, affixed or connected to the sheathing surface by a variety of techniques known in the art.
  • certain types of backing materials 20 can be pre-formed to the required shape of the sheathing surface to which it will be adhered, or alternative means to conform the shape of the backing material 20 to the required shape of the sheathing surface 12 may be utilized.
  • backing materials 20 may be applied to the inside surface of the sheathing surface 12 by various spray techniques known to those with skill in the art, or, as another example, layers of backing material could be stacked and formed to fill the space under the sheathing surface 12.
  • the backing material can be formed in molds compatible with the shape of the bottom side 24 of the sheathing surface 12.
  • the backing material may be extended beyond the edges of the sheathing surface, hi various alternative embodiments, the backing material may be extended beyond one or more edges of the sheathing surface. In generally preferred embodiments, the backing material does not extend beyond, and may be offset from, one or more edges of the sheathing surface.
  • the sheathing surface 12 can be manufactured to have a relatively flat bottom side 24, regardless of the design, contours or shape of the top side 26 of the sheathing surface.
  • backing material can be attached to the bottom side 24 of the sheathing surface 12 using a variety of techniques, without the need to shape or mold the foam to conform to a particular shape of the sheathing layer.
  • the bottom of the sheathing layer 12 can be flat and flat panels of backing material 20 could readily be fixedly attached thereto.
  • the sheathing layer 12 comprises a composite material.
  • a composite material could comprise, for example, foam particulate matter or a foam core encapsulated in concrete, clay, or other material.
  • the sheathing surface 12 could be prepared, as described above, with any variety of top side 26 configurations and a bottom surface 24 that conforms to the shape of the support surface to which it will be attached, hi further alternative embodiments, additional backing material 20 could be affixed to the bottom surface 24 of the composite material to provide additional insulation and/or resistance to wind lifting by thoroughly filling all available air space under the sheathing surface 12.
  • substantially rigid, closed-cell foam is utilized as a backing material 20 with the tile panels 10 of the subject invention, for example, not limited to, polystyrene and/or polyurethane foam.
  • Substantially rigid, closed-cell foam backing material 20 can resist water absorption and/or retention and provide additional strength to the tile panels of the subject invention. Further, it can provide a high insulation capacity and can be made to conform to any shape or style of sheathing surface, flat or otherwise.
  • polystyrene and/or polyurethane foam is used in conjunction with the sheathing surface 12.
  • the tile panels 10 are of a laminate construction, wherein foam backing material 20 is pre-formed to match the shape of the underside 24 of the sheathing surface to which it is to be adhered, for example, as shown in Figures 1-5 and in Figures 6 A and 6B.
  • the backing material can be offset from one or more edges of the sheathing material.
  • the backing material can extend to one or more edges of the sheathing surface or, in a still further alternative embodiment, the backing material can extend over and/or beyond one or more edges of the sheathing surface.
  • the rigid closed-cell foam backing material 20 can be fixedly attached to the sheathing surface in a variety of ways, including using adhesives or tapes, screws, nuts, bolts, nails, etc. It can also be integrated into the sheathing surface, for example by providing a means for the lightweight concrete of the sheathing surface 12 to incorporate into a surface of the foam backing material 20, such as, for example, during the manufacturing process.
  • concrete or other suitable tile material can be poured, sprayed, or otherwise distributed into a tile mold and vibrated to evacuate any air pockets or bubbles in the material.
  • a pre-molded foam surface 22 can then be pressed into, or otherwise brought into contact with the concrete on the eventual bottom side 24 of the sheathing surface before the concrete "sets" into the preferred tile panel shape, hi this embodiment, it is important that the surface of the foam that is to be laminated with the concrete be relatively clean and free of debris so as to ensure good adherence with the concrete or other material.
  • the molded surface 22 of the foam backing material 20 is prepared prior to being pressed into the concrete to provide a corrugated or roughened surface, grooves or other types of depressions for the concrete to enmesh with or adhere to, in order to hold the foam securely against the bottom side 24 of the sheathing surface.
  • an expanding foam liquid material is utilized with the tile panels of the subject invention.
  • any of a variety of foams in a liquid or semi-liquid form, known to those with skill in the art can be poured, sprayed, or otherwise distributed onto at least a portion of the back of a tile sheathing surface. In a preferred embodiment, almost the entire back surface of a tile sheathing surface is covered with expanding foam.
  • the subject invention is utilized with a liquid foam material that forms a closed-cell, rigid, or semi-rigid foam backing material.
  • a liquid foam material that forms a closed-cell, rigid, or semi-rigid foam backing material.
  • urethane or polyur ethane foam liquid are well-known in the art and could be used with the subject invention.
  • a person with skill in the art would be able to determine one or more foam materials that would be suitable for use in the particular environment and/or the intended use of the tile panels of the subject invention.
  • the surface of the bottom side of the backing material 28 can ideally conform to the shape of the roof decking or other support to which it will be adhered.
  • the surface of the bottom side of 28 of a backing material 20 can be flat so as to lie against a standard plywood roof decking 16.
  • tile panels 10 with cross-sections of various heights, such as for example, barrel- or Spanish-style tiles, will have the thickness of the backing material vary across different sections of the tile.
  • Figures 1-5 An example of this embodiment is shown in Figures 1-5, wherein Figure 1 is an example of a tile panel utilizing a curvilinear sheathing surface 12 and Figures 4 and 5 illustrate how the thickness of the backing material 20, such as, for example, foam, will vary at different length-wise cross-sections of the tile panel 10.
  • the backing material 20 such as, for example, foam
  • the tile panels of the subject invention can be manufactured with any of a variety of foam backing materials.
  • one side of the foam backing material can be pre- formed to conform to the shape of the tile sheathing surface.
  • the side of the backing material that will be in contact with the roof decking 16 can also be manufactured in shapes that will conform to the surface shape(s) of the roof decking.
  • the backing material can comprise a liquid expanding foam.
  • the fully expanded and sufficiently cured foam can be cut by techniques known in the art to any shape necessary to conform to a roof decking. For certain applications of the tile panels of the subject invention, such as a roof covering, it may be necessary to adjust the angle at which the tile panels overlap.
  • the backing material 20 can be molded, cut or otherwise formed to achieve an angle sufficient to ensure flush mounting of the installed tiles on a roof.
  • Figures 4 and 5 illustrate flat tile panels wherein the backing material is formed at an angle such that the thickness of the foam material at the trailing edge 300 of the tile panel is less than that at the leading edge. This allows the trailing edges of tile panels to be overlapped by the leading edges of tile panels and still maintain generally complete contact with a roof decking.
  • the tile panels may be secured to an underlying support using nails, screws, etc., optionally along with an adhesive, grout, or similar material.
  • an adhesive, grout, or similar material By maximizing the contact area between the backing material 20 and the underlying support, it allows for a greater surface area between the backing material 20 of the tile panel and the underlying support structure to be held together using an adhesive, grout, or other material.
  • the thickness of the foam can vary depending upon the type or style of sheathing surface utilized, the environmental conditions, available installation space, or type of foam utilized, etc. A person with skill in the art will be able to dete ⁇ nine an appropriate foam thickness to achieve adequate insulation properties and/or tile support.
  • the backing material 20 such as, for example, foam, or other material (composite, cellular solid, etc.) under the sheathing surface is contoured or formed to provide sufficient clearance to accommodate the surrounding tiles.
  • the backing material 20 of foam or other material extends only partially to the edges of the tile panels 10. This provides an insertion gap 30 around the tile panels 10 to accommodate the surrounding tile panels 10.
  • the backing material 20 is extended to the edge of the tile panels 10 a sufficient distance so that, when installed, it will buttress against the backing material 20, for example, foam, or other material, in the surrounding tile panels to create a substantially contiguous, preferably foam, layer across a roof or other structure under the sheathing surface 12. This allows for the interlocking of the tiles during installation, which further increases their resistance to wind-lifting.
  • FIG. 2A and 3 A One example of this embodiment is shown in the barrel-style tile panels in Figures 2A and 3 A, wherein the overlapping side edge 32 of the first sheathing surface 12, shown in Figure 3, is angled to fit over and against the underlying side edge 34 of a second sheathing surface 12 so that the backing material 20 underneath both sheathing surfaces 12 is adjacent to form an essentially contiguous layer.
  • FIGs 2B and 3B A further example of the overlapping side edges 32 and 34 are shown in Figures 2B and 3B, wherein flat-style panels are shown with an overlapping side edge 32 and an underlying side edge 34 shown on a tile panel.
  • interlock channels 36 for example, as shown in Figures 4, 5, 6A and 6B.
  • One or more interlock channels 36 can allow the tile panels 10 to be firmly seated against each other to provide further stability after installation.
  • the one or more interlock channels 36 can further reduce the ability of tile panels 10 to be lifted, twisted or otherwise displaced.
  • the edge of the sheathing surface 12 of an upper located tile panel 10 is positioned above a lower second tile panel 10, which has been mounted on the support structure, and the interlock channel 36 of the upper tile panel engages the edge of the sheathing surface 12 of the lower mounted second tile panel.
  • the offset, preferably foam, backing material 20 on each tile panel when installed will be adjacent to form an essentially contiguous layer under the sheathing surfaces 12.
  • An example of this embodiment is shown in Figures 6A and 6B.
  • a tile panel 10 comprises at least one interlock channel 36 at the leading edge 150 to accommodate the trailing edge of at least one other tile panel 10.
  • an interlock channel is formed under one or more sheathing surfaces wherein the bottom side of the sheathing surface defines some portion of the interlock channel, such that the top side of the trailing edge 300 of one sheathing surface is in contact with the bottom side of the leading edge 150 of a second sheathing surface.
  • the leading edge 150 of a sheathing layer can be modified to include one or more interlock channels.
  • the trailing edge 300 of a first sheathing surface of one tile panel can be positioned within the interlock channel 36 in the leading edge 150 of the sheathing surface of an adjacent tile panel.
  • the sheathing surface 12 can comprise an overall greater thickness, or it can be formed thicker at one or more edges so that an interlock channel 36 can be formed therein.
  • one or more interlock channels 36 can be formed entirely within the backing material 20.
  • the backing material 20 can be sufficiently extended to the leading edge 150 of a first tile panel 10 sheathing surface 12 so that an interlock channel can be formed therein that will accommodate the trailing edge 300 of a second tile panel 10 sheathing surface 12.
  • the edge of the sheathing surface 12 of the second tile panel that is engaged with the interlock channel 36 of the first tile panel will be in contact only with the backing material.
  • the edges of the sheathing surfaces 12 will be substantially covered with backing material and will not be in contact.
  • the backing material of the second tile panel can be extended past the edge, or may even cover or partially surround, the trailing edge 300 of the sheathing surface, for example as shown in Figure 14.
  • the backing material 20 of the interlock channel 36 of the first tile contacts the backing material 20 surrounding, or partially surrounding, the trailing edge 300 of the second tile panel. This can provide an even more airtight seal to prevent windlift.
  • the drip edge of the roof is a weak point which allows the ingress of the elements, particularly wind. It is wind ingress on the leading edge of a roof line that can be particularl)' severe. In high wind conditions, the edge can be lifted from the support structure exposing the underlying roof decking to the elements, or, in extreme circumstances, completely removing the tiles. Therefore, it is desirable to close or seal the drip edge to resist wind-lift.
  • the subject invention provides for a drip edge panel 40 that can secure and protect the leading drip edge tile panels 10.
  • the drip edge panel 40 can comprise a variety of materials, which will become apparent to one with skill in the art. However, in a preferred embodiment, the drip edge panel 40 comprises a lightweight concrete, as described for the sheathing surface.
  • a drip edge panel 40 is an elongated panel comprising a leading edge guard 44 and one or more mounting holes 14.
  • a drip edge panel can comprise a variety of decorative or functional shapes, or surface configurations.
  • a person with skill in the art will readily recognize numerous shapes for drip edge panels or components thereof that would be appropriate for use with the subject invention. Such modifications are contemplated to be within the scope of the present invention.
  • a drip edge panel 40 is designed to be inserted and secured under the tile panels 10 at the edge of a roof, particularly on a roof drip edge. Once installed, the leading edge guard 44 on the drip edge panel 40 provides a "wind-break" on the front side of the leading edge of tile panels 40, which can reduce or eliminate wind-lifting of the leading edge tile panels. Therefore, in a preferred embodiment, the front profile 48 of the leading edge guard 44 is compatible with the profile of the tile panel 10 against which it will be used. For example, if utilized with barrel-style tile panels, the front profile 48 may be curvilinear to match the profile of the barrel-style tile panels. Figure 10 illustrates an example of this type of drip edge panel 40.
  • the drip edge panel 40 comprises at least one interlock flange 42 on the backside 45 of the edge panel that can be inserted into an interlock channel 36, discussed above, in a tile panel 10.
  • An interlock flange 42 for example as shown in Figure 9, can provide further stability to and proper installation of a drip edge panel 40, as well as helping to secure the interlocked tile panel 10 against wind lifting.
  • the interlock flange can be contiguous or comprise one or more sections.
  • a drip edge panel 40 can comprise a drip edge 46 along the front of the leading edge guard 44.
  • the drip edge 46 can be straight, bent or curved to any desired angle and may have a variety of designs or decorations incorporated into or thereon.
  • the drip edge 46 can provide a controlled flow of water from the tile panels 10 away from the roof fascia and sides of a home or building.
  • the drip edge panels can be secured using a variety of techniques and methods. They can be secured to the edge of the roof structure and/or the tile panels 10 at the roof edge.
  • the drip edge panels 40 further comprise mounting holes 14. Once positioned, the drip edge panels can be secured using standard roofing nails or screws in the mounting holes 14. The proximity of the nails and/or screws along the edge of a roof and the use of an interlock flange 42 in an interlock channel 36 lends the tile panel 10 system of the subject invention even further resistance to wind-lifting.
  • Example 2 Ridge Crown Tile Panel Standard roof designs usually have at least one roof ridge which must be sealed, particularly on tile roof designs, to protect underlying roof structure or roof decking from the elements. This can be accomplished with a variety of techniques and devices known to those with skill in the art. Usually overlapping concave curved or rounded tiles are installed along the roof ridge to prevent ingress of water and other elements under the tiles. Often, a beam of 2"x4" or 2"x6" board is positioned along the ridge line to which the curved or rounded tiles may be secured with one or more nails or screws and, often, an adhesive material. However, these techniques, with or without the additional board, create large areas of air space under the tiles making them susceptible negative pressure effects and wind-lift.
  • a crown tile panel 50 can comprise a variety of decorative or functional shapes, or surface configurations.
  • a person with skill in the art will readily recognize numerous shapes for crown tile panels that would be appropriate for use with the subject invention. Such modifications are contemplated to be within the scope of the present invention.
  • a preferred embodiment of the crown tile panel 50 of the subject invention comprises an elongated curved sheathing surface 52, similar to that described above, having a concave bottom side 24 or curved profile that can be installed in an overlapping fashion across a roof ridge.
  • An example of this embodiment is shown in Figures 7 A and 7B.
  • the sheathing surface 12 of the crown panel 10 comprises an interlock method to assist in maintaining the position of the installed tiles along the roof ridge.
  • the top surface 26 or convexly curved profile trailing edge 300 of the crown panel 50 comprises a notch or groove 54 around the convex circumference of the sheathing surface.
  • the leading edge 150 of the tile comprises a collar 56 extending around at least a portion of the concave bottom side of the crown panel 50, and follows the circumference of the curved tile panel 50, for example, as shown in Figure 7B.
  • the collar 56 on a first crown panel can be positioned in the groove 54 of a second crown panel in an essentially straight line along a roof ridge, of which an embodiment of this assembly is shown in Figure 7D.
  • the crown panels 50 of the subject invention can be secured to the roof ridge similarly to the other tiles described above, in that they can be adhered to the tile panels 10 with adhesives, grouts or similar materials.
  • a 2"x4" or 2"x6" board can be positioned along the roof ridge, between the tile panels 10 and the crown panels 50 secured thereto with standard nails or screws, optionally in addition to using an adhesive or similar material.
  • a locking track 58 is incorporated with the crown panels 50 to facilitate better adherence to a roof ridge beam 100, such as a 2"x4" or 2"x6" board or other similar device.
  • the locking track 58 is a substantially U- shaped frame of approximately the same length as a crown panel 50, as illustrated in Figures 7 A, 7B and 7C.
  • the locking track 58 is designed to fit over a roof ridge beam with minimal amount of space between the locking track 58 and the beam.
  • the locking track 58 can, further, be fixedly attached to a beam via an adhesive applied to the inside of the locking track 58, the beam, or both.
  • the dimensions of the locking track 58 utilized with the subject invention can vary. Such variances can be adjusted according to the size, shape and length of the beam, manufacturing and/or installation considerations, construction materials, etc.
  • Crown panels currently known in the art usually sit on a roof ridge beam, such that the only contact between them is where the underside of the crown panel touches the top edge of the roof ridge beam.
  • the dimensions of the locking track 58 which actually straddles at least a portion of the beam and extends along at least a portion of the sides of the beam, are such that there is approximately 25% to about 200% additional surface area or more that can be utilized to contact, hold and/or adhere the crown panel 50 to a beam, hi a further preferred embodiment, the dimensions of the locking track 58 are such that there is at least about 200% more surface area that can be utilized to contact, hold, and/or adhere to the crown panel 50 to a beam.
  • the locking track 58 of the subject invention should comprise material suitable for contact with and, preferably, adherence to, a roof beam, for example, various types of plastics, woods, metals, concretes, foams, or combinations or composites thereof, may be utilized.
  • the locking track 58 comprises a rigid material of sufficient durability and strength to hold a crown panel 50 in place along the roof ridge and withstand environmental conditions for several years. It can be molded into the sheathing surface, or defined in the backing material, or incorporated in addition to the backing material and the sheathing surface.
  • foam or foam-like backing material 20 is utilized with the crown panels on both sides of the locking track to further reduce the amount of air space under the crown panels 50, and provide additional benefits as described above.
  • the foam backing material 20 utilized with the crown panel 50 should be configured so as to accommodate the surrounding roofing tile panels 10 against which it will be set. Therefore, it may be necessary for the foam backing material 20 to be molded or fixedly attached in an accommodating fashion so that the crown panels 50 can be positioned against the roof tile panels 10 so as to reduce the ingress of elements, particularly wind, under the crown panels 50.
  • Figure 7 A depicts a cross-section of a crown panel wherein the foam backing material 20 is molded towards the apex of the curve to accommodate the surrounding roof tile panels against which it would be placed in operation.
  • the locking track 58 is fixedly connected to the crown panel 50. This can be accomplished by several means known in the art, including, but not limited to adhesives, screws, nuts, bolts or other attachment means.
  • the locking track 58 further comprises an anchor end 59 that is pressed, pushed, or otherwise set into the lightweight concrete during the manufacture of the sheathing surface 52.
  • the anchor end 59 comprises ridges, grooves, holes, or other means whereby the concrete can integrate with the anchor end 59 so that, when the lightweight concrete is firm, the locking track 58 is securely affixed to the bottom side 24 of the sheathing surface.
  • crown panel is positioned over the roof beam with the locking track 58.
  • Mounting holes 14 in the crown panel can be used to secure it to the beam. Additionally, an adhesive, grout, additional cement, or similar materials can be used to further secure the locking track 58 to the beam. Additional crown panels are positioned end to end via the tongue 56 and groove 54 mechanisms described above.
  • portions of the backing material 20 or locking track 58, or both of these can extend slightly forward at their leading edge 150 so as to be received under the trailing edge 300 of an adjacent crown panel during installation, thereby providing still further increased resistance to wind lifting.
  • crown panel caps may also be utilized to close, seal or otherwise cover the ends of the curved tile panels at the ends of the roof ridges.
  • the caps utilized with the subject invention will also utilize a locking track 58.
  • the hip of a roof is a point where a roof makes a turn to go in another direction.
  • hip lines extend downward from an essentially horizontal roof ridge. This presents another area that should be sealed against the elements, particularly wind and water.
  • the subject invention utilizes an elongated hip panel 60.
  • a hip panel 60 of the subject invention combines features of the crown panel and the tile panel to provide a secure, wind and weather resistant covering for a roof hip.
  • An example of one embodiment of a hip panel 60 of the subject invention is shown in Figures 8 A and 8B.
  • the hip panels 60 overlap in an end-to-end fashion along the line of a roof hip.
  • a hip tile panel can comprise a variety of decorative or functional shapes, or surface configurations, hi addition, a person with skill in the art will readily recognize numerous shapes for hip tile panels that would be appropriate for use with the subject invention. Such modifications are contemplated to be within the scope of the present invention.
  • a hip panel comprises a sheathing surface 62 with a curved profile, similar to that used for crown panels 50.
  • the concavely curved surface defines the bottom side 24 of the sheathing surface and the convexly curved surface defines the top side 25 of the sheathing surface.
  • the sheathing surface 62 may resemble any shape or configuration, and can include other decorative or functional features as necessary or desired. It is most important that the sheathing surface 62 provide sufficient protection and drainage characteristics to protect the underlying roof support structures.
  • a locking track 64 is integrally connected to the bottom side 24 of the sheathing surface 62, similarly as discussed previously for a crown panel 50.
  • the locking track 64 of the hip panel 60 is of sufficient length to ensure proper and secure placement of the hip panel, but does not interfere with the insertion of additional hip panels above or below it.
  • An example of a locking track 64 used with a hip panel of the subject invention is shown in Figure 8B.
  • a beam for example, but not limited to, a 2"x4" or 2"x6" board, is installed along the length of the roof hip line, between the tile panels 10 on either side of the roof hip line.
  • the beam can be held in place by a variety of techniques and methods that will be apparent to one with skill in the art.
  • the beam utilized with the hip panel 60 of the subject invention is secured to the roof structure with straps of sufficient strength to withstand extreme weather or high wind conditions.
  • hip panels 60 are positioned along the length of the beam using the locking track 64 to ensure proper and secure placement.
  • hip panels 60 can be held in place along the length of the beam utilizing devices or methods known in the art.
  • the hip panels 60 further comprise mounting holes 14, as discussed above, through which standard roofing nails or screws can be used to secure the hip panels 60 to the beam.
  • an adhesive, grout, or similar material is also utilized between the beam and the locking track 64 to further secure the hip panels 60 to the beam.
  • the hip panels 60 comprise foam backing material 20 on the bottom side 24 of the sheathing layer 62, on both sides of the locking track, as described above for the crown panels 50.
  • the foam backing material 20 fills the air space under the hip panels 60 to combat negative pressure effects and provide a further insulation factor.
  • the foam backing material can be formed with locking channel 64 therethrough such that a separate locking channel would not be necày.
  • the foam-formed locking channel 64 is seated and affixed directly onto the beam.
  • the foam backing material 20 is molded, formed or otherwise positioned so as not to interfere with the placement of a hip panel 60 against the tile panels 10 on either side of the roof hip line, for example as shown in Figure 8A.
  • the foam backing material 20 provides an additional means for interlocking the hip panels 60 during installation.
  • the foam backing material 20 of the hip panels 60 further comprises one or more interlock channels 66 at the leading edge 200 of the hip panel 60 for example, as shown in Figures SA and 8B.
  • the trailing edge 400 of the hip panel provides an overlap 68 in the sheathing layer 62 that corresponds to the shape of the interlock channel 66.
  • the hip panels 60 are placed in an ascending over-lapping fashion, wherein the overlap 68 at the trailing edge 400 of a first installed, usually lower, hip panel is inserted under the sheathing surface 62 of a second installed, usually higher, hip panel so that the overlap 68 of said first hip panel inserts into the at least one interlock channel 66 in the foam backing material 20 at the leading edge 200 of the second overlapping hip panel 60.
  • the foam backing material 20 of one hip panel 60 is configured complementary to the foam backing material 20 of the adjacent hip panels forming an essentially continuous layer of foam backing material 20 under the installed hip panels 60. This can help combat negative pressure effects and provide an additional insulation factor. It is also well known in the art to use caps on the ends of the roof hip tiles. In an embodiment of the subject invention, hip panel caps may also be utilized to close, seal or otherwise cover the ends of the hip panels 60 at bottom of roof hip line. In a preferred embodiment, the caps utilized with the subject invention will also have a locking track 68, and the overlapping and interlocking capabilities described for the hip panels to allow proper drainage.
  • a roof with a gabled end is one with a straight slope falling from the roof ridge to the eave creating a peak on the side or front facade.
  • Gabled roofs have rakes on the gabled facades that should be protected to prevent access of rain and wind under the roofing tiles to the underlying roof support structures.
  • the subject invention utilizes a gable end panel 70 to cover and protect this area of a roof.
  • the gable end panel 70 comprises several features of the above- described tile 10, crown 50, and hip 60 panels.
  • One embodiment of a gable end panel 70 of the subject invention is shown in Figure 11.
  • a gable end panel can comprise a variety of decorative or functional shapes, or surface configurations.
  • the gable end panels 70 of the subject invention comprise a curved sheathing surface 72, a leading edge 200 and a trailing edge 400, an outside edge 78 of the sheathing layer 72 that extends over the roof rake and an inside edge 79 that extends over the roof or other structure.
  • the outside edge 78 of the sheathing surface is elongated to cover a greater area of the fascia board or beam, discussed below. This can provide a more controlled drainage of water from the roof.
  • the gable end panels 70 of the subject invention may resemble any shape or configuration, and can include other decorative or functional features as necessary. It is most important that the shape of the gable end panel provide adequate drainage and protection for the underlying roof support from the environmental elements, particularly rain and wind. It will be apparent to one with skill in the art that numerous functional or decorative shapes may be utilized for the sheathing surface 72.
  • a locking track 74 is integrally connected to the bottom side 24 of the sheathing surface 72, similarly as discussed previously for a crown 50 or hip 60 panel.
  • the locking track 74 of the gable end panel 70 should be of sufficient length to ensure proper and secure placement of the gable end panel, but should not interfere with the insertion of additional tile panels above or below it.
  • An example of a locking track 74 used with a tile panel of the subject invention is shown in Figure 11.
  • a beam or fascia board for example, but not limited to, a 2"x4" or 2"x6" board, is fixedly connected along the length of the roof rake line using techniques known in the art.
  • gable end panels 70 are positioned along the length of the beam using the locking track 74 to ensure proper and secure placement.
  • An embodiment of the locking track 74 that can be utilized with the gable end panels 70 is shown in Figure 11.
  • the gable end panels 70 are installed in an ascending end-overlapping-end fashion using the locking tracks 74 to ensure proper and secure placement.
  • the gable end panels 70 comprise mounting holes 14 for securing the gable end panels 70 to a beam.
  • an adhesive, grout or similar material is used between the locking track 74 and the beam to further secure the gable end panels 70.
  • the gable end panels 70 comprise foam backing material 20 on the bottom side 24 of the sheathing layer 72, on both sides of the locking track, as described above for the crown 50 and hip 60 panels.
  • foam backing material 20 can fill air space under the gable end panels 70 to combat negative pressure effects and provide a further insulation factor.
  • the foam backing material 20 can be molded, formed or otherwise positioned so as not to interfere with the placement of gable end panels 70 against the tile panels 10 on edge of gable roof end line, for example as shown in Figure 11.
  • the foam backing material 20 provides an additional means for interlocking the gable end panels 70 during installation.
  • the foam backing material 20 of the gable end panels 70 further comprises one or more interlock channels 76 at the leading edge 200 of the gable end panel 70 for example, as shown in Figure 11.
  • the trailing edge 400 of the gable end panel 70 provides an overlap in the sheathing layer 72 that corresponds to the shape of the interlock channel 76.
  • the gable end panels 70 are positioned similarly as described above for the hip panels 60.
  • the gable end panels 70 are installed in an ascending fashion, wherein the sheathing layer overlap in the distal end 400 of a first installed gable end panel slides under the proximal end 200 of the sheathing layer of a second installed gable end panel, and interlocks with the interlock channel 76 in the foam backing material 20 of the second gable end panel.
  • the foam backing material 20 of one gable end panel 70 is configured to abut against the foam backing material 20 of the adjacent gable end panels forming a substantially continuous layer of foam backing material 20 under the installed gable end panels 70. This can combat negative pressure effects and provide an additional insulation factor.
  • Example 5 Roof Vallev Seal The valley on a roof is created when a roof changes direction. It is the point where the two planes of a roof meet to fo ⁇ n a seam. In current roofing installation, a flashing material is usually installed in this seam area to protect the underlying roof structure from water drainage. However, this technique does not combat negative pressure effects.
  • the subject invention utilizes a grout or mortar based material with sufficient strength to withstand environmental conditions, extreme or otherwise, to seal this area. With the tile panel system and installation of the subject invention, this will provide a roof sealed and protected from the elements, and able to withstand extreme weather and wind conditions.
  • Example 6 Installation Method
  • the tile panels and associated specialized panels described above are preferably installed in a standard overlapping fashion well-known in the art.
  • the tile and other panels of the subject invention are similarly installed.
  • the interlock features for the panels provided with the subject invention require an additional consideration when installing the panels on a structure.
  • the following installation method illustrates use of the tile panels as a roof covering. However, it will be understood by a person with skill in the art that this method can be modified for installation on other structures.
  • the panels of the subject invention are designed to be installed starting from one of the lower edges of a roof.
  • the interlock features are designed so that the panels are installed starting from the right side of one of the lower edges of a roof.
  • the first tile panel should be placed against the support structure, e.g., roof decking, to determine whether it needs to be cut to accommodate the shape of the roof area to be covered. If necessary, the tile should be cut so that the angle of the cut is flush with roof edge against which it will be placed, whether it is a roof valley, hip, or gable end.
  • the tile panels 10 are interconnected with the drip edge panels 40 along the edge of the roof line. Therefore, the initial tile panel 10 should be placed so as to determine where the associated drip edge panel 40 must also be placed. Once this has been determined and the positions fixed for the initial drip edge panel 40, all of the additional drip edge panels can be installed along the roof edge using, preferably, an adhesive as well as nails or screws to hold them in place.
  • the tile panels 10 can then be installed starting against the drip edge panels 40, from the right side all the way to the left side of the roof, preferably using an adhesive along with nails or screws to secure the tile panels in place.
  • the second row of tile panels 10 is also started along the right side of the roof. It is further preferable for the seam of the tile panels 10 in the first row to be situated in the middle of the tile panel of the second, overlapping row of tile panels 10, to create a staggered tile pattern. Therefore, as mentioned above, if it is necessary to cut the tile panel 10, the cut should match as close as possible the angle of the roof edge against which it will be placed, whether it is a roof valley, hip, or gable end.
  • the starting point is a roof valley, it is preferable to leave no more than approximately 1" between the tile panel and the valley edge.
  • the tile panels it is preferable for the tile panels to almost touch the hip or gable beam on which the hip panel and gable panels will later be installed.
  • Tile panels 10 can continue to be installed in this fashion across the roof until the final row along the roof ridge. At this point, it may be necessary to cut the tile panels 10 so that they cover the roof line and almost touch the roof ridge beam on which the crown panels will later be installed. It may also be necessary to drill or otherwise create holes in the tile panels 10 along the roof ridge line, if the ends with the mounting holes 14 must be cut away to accommodate the roof ridge beam. Once the entire roof surface has been covered with the tile panels 10, the hip, gable and ridge crown panels can be installed where necessary.
  • the hip panels 60 are installed beginning from the bottom edge of the roof hip so the panels can be properly attached using the nails or screws before the subsequent hip panel is installed to overlap the first one. Again, it is preferable to use an adhesive along with the nails or screws to secure the hip panels against the beam. Once the first hip panel is in place and secured, subsequent hip panels can be installed using the locking tracks 64 to place and secure the hip panels against the beam and the interlock channel 66 to connect and secure the hip panels in an end-to-end and overlapping fashion along the roof hip line. All of the hip panels 60 should be installed in this fashion.
  • the gable panels 70 are installed similarly to the hip panels 60 beginning from the bottom edge of the roof gable line so they can be properly secured, preferably with an adhesive and nails or screws, and overlapped. As described above, gable panels 70 have an elongated outside edge 78 which should be positioned over the edge of the roof gable line to facilitate water drainage away from the roof and structure. Gable panels are positioned on a beam utilizing a locking track 74, similar to the hip panels, and they interlock using an interlock channel 76. Once the hip 60 and gable panels 70 have been installed, the crown panels 50 are used to close and seal the roof ridge.
  • installation of the crown panels 50 begins on the left side of the roof line, with the groove 54 end towards the right side of the roof line.
  • the crown panels 50 are installed in a left to right fashion using the locking track 58 to place and secure the crown panels with the tongue 56 of one crown panel seated in the groove 54 of the adjacent crown panel 50.
  • the final step is to seal off the valley seams and the ends of the hip, gable or crown panels.
  • Specialized caps as described above can be used to close the ends of the hip, gable or crown panels.
  • grout, cement or similar material can be used to seal these areas, as well as any valley seams.
  • This embodiment utilizes a tenon and mortise interlock system 90, wherein at least one tenon 92 is formed on the bottom side 24 at or near at least one edge of a tile panel 10 and at least one congruously shaped mortise 94 is formed into at least one other edge of the tile.
  • the at least one tenon 92 is formed as part of the leading edge 150 of a tile and the mortise 94 is formed as part of the trailing edge 300 of a tile.
  • a mortise and tenon of the subject application may utilize a variety of shapes capable of being operably engaged or interlocked.
  • the shape and/or configuration of the tenon and mortise will enable the tenon 92 to be engaged with the mortise 94 by sliding the tenon into the mortise
  • the tenon 92 and mortise 94 are formed in a dove-tail configuration, wherein, the tenon 92 is flared such that the base 97 that engages with the mortise 94 is wider than the apex 98 that intersects and fixedly connects with the bottom side 24 of the tile.
  • Such a configuration is well-known in the art and a person with skill in the art will be able to determine the appropriate angle of flare required for the materials utilized for a sheathing surface 12.
  • a corresponding groove or mortise 94 can be formed as part of at least one other edge of a tile, where the circumferential shape of the mortise 94 corresponds to the circumferential shape of the at least one tenon 92, for example, as shown in Figures 12A and 12B.
  • the dimensions of a mortise 94 are sufficiently larger than the dimensions of a tenon 92 to ensure that they can be fit together with general ease without damage to the tile panel 10 or having excessive space for movement or play between the sides of the tenon and the sides of the mortise.
  • a tile panel 10 has at least one tenon 92 positioned at the leading edge 150, but offset from the center line 500 between the leading edge 150 and the trailing edge 300.
  • a corresponding at least one mortise 94 is positioned at the trailing edge 300 of the tile and is offset from the longitudinal center line 500 to the opposite side of the tile as the tenon 92.
  • a preferred embodiment utilizes a modified dove-tail configuration.
  • a tile panel 10 has one tenon 92 centered at the leading edge 150.
  • a correspondingly shaped mortise 94 is divided between the comer edges 99 of the trailing edge 300 of the tile, such that a first side of a mortise 95 is formed at one corner edge 99 of the tile panel and a mirror-image thereof forms the second side of a mortise 96 at the opposite comer edge of the tile panel, hi this embodiment, a complete mortise 94 is formed by two separate tiles, such that when two tiles are positioned side-by-side, with the trailing edges 300 being substantially co-planar, the combined corner edges define a full mortise 94.
  • the tiles when a tenon is interlocked with a mortise, the tiles will preferably be arranged in a staggered and overlapping configuration.
  • the tile panels can be further affixed to a roof decking via techniques and device discussed above.
  • the ability to interlock the leading edges 150 with the trailing edges 300 and by further affixing the tiles to a roof decking or other structure ensures that wind-lifting of the tiles, even in extreme weather and high-wind conditions will be reduced or eliminated.
  • Tile Bracket A further alternative embodiment provides a tile bracket apparatus that can be incorporated into existing tiles or even certain embodiments of the tile panels of the subject invention.
  • an embodiment of a tile bracket 600 of the subject invention is fixedly attached to a tile using a flange 610.
  • the flange can be incorporated into a tile at the time of manufacture or affixed to the tile by a variety of techniques after manufacture, such as for example, with adhesives, screws, nails, bolts, combinations thereof, etc.
  • the tile brackets 610 of the subject invention could even be fixedly attached onto tiles already installed on a structure.
  • Figure 13 A shows an example of a tile bracket that can be incorporated into the tile material.
  • FIG. 13B shows an example of a tile bracket that can affixed to a tile by alternative techniques.
  • a bracket arm 615 is affixed to the flange 610 and extends generally perpendicularly from the flange 610.
  • the bracket arm 615 can extend from the flange 610 to any desirable height. However, in a preferred embodiment, the height of the bracket arm 615 will correspond to the thickness of the tile panels with which it will be used.
  • Fixedly connected to the bracket ami 615 is a tile stop 620 that extends generally perpendicularly from that end of the bracket arm 615 opposite the flange 610.
  • the tile stop 620 is directed towards the trailing edge 300 of a tile and along with the bracket arm 615 forms a notch 630 into which the leading edge 150 of an overlapping tile panel 10 can be placed.
  • the bracket arm 615 prevents the tile from changing position and the tile stop 620 prevents wind-lift of the leading edge.
  • the tile panels can be further affixed to the roof decking 16 or other underlying structure by procedures and methods discussed above to provide further protection against wind-lift and/or repositioning of the tiles.
  • At least one tile bracket 600 is affixed approximately 3 inches to approximately 5 inches from the toiling edge 300 of a tile. This allows the tiles to be overlapped when positioned within the tile brackets 600.
  • the tile brackets 600 can comprise any of a variety of materials having the necessary resistance to environmental conditions, including, for example, various metals, plastics, ceramics, clay, cement, wood, or composites thereof, etc.
  • the tile bracket 600 or components thereof can embody any desired decorative features.
  • the tile brackets can be any of a variety of colors to complement and/or blend with the tiles or tile panels with which they are utilized, and the bracket ami 615 and/or the tile stop 620 can further embody any desired shape.
  • the tile brackets 600 are aluminum and the tile stop 620 is formed as a flattened flange 650 that can lie flush with the top surface 26 of a tile, as shown for example in Figure 13B.
  • any of an assortment of accessories can be affixed to or formed as part of the tile bracket.
  • snow guards are well-known in snowy climates. Therefore, in one alternative embodiment, snow guards can be incorporated into the tile brackets of the subject invention.
  • the tile stop 620 of a tile bracket 600 could be modified to include a snow guard apparatus. It is also well-known in the art to decorate snow guards with various shapes, motifs, styles, colors, and to adjust the angles, widths, etc., to accommodate various expected snowfall amounts. Such decorative or adjustable features could also be used with the snow guards incoiporated into the tile brackets 600 of the subject invention.
  • a further alternative embodiment can incoiporate various blades, vanes or fins for controlling the absorption of thermal energy. It is well-known in the art to utilize various materials to absorb heat and re-direct it away from an underlying structure, such as a roof. Thus, the tile brackets 600 of the subject invention could incoiporate components for absorbing thermal heat and dissipating it into the surround environment. For example, various shaped projections, fins, rods, etc. could extend from the bracket arm 615 and/or the tile stop 620. All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.

Abstract

Ensembles de panneaux de carreaux et systèmes de fabrication et de pose de ces panneaux de carreaux. Les panneaux de carreaux de l’invention peuvent être utilisés comme revêtements de murs, de toitures, de bardages, etc. sur des structures diverses. Dans un mode de réalisation, les carreaux se composent d’un béton léger suffisamment robuste pour résister aux intempéries et aux vents les plus extrêmes ainsi qu’aux opérations de manutention ou à la circulation pédestre nécessaires à la pose et à l’entretien. Dans un autre mode de réalisation, un isolant, de préférence de la mousse, est fixé sur les carreaux de l’invention. Les panneaux de carreaux sont construits de façon à présenter une configuration chevauchante ainsi que des systèmes d’imbrication sélective offrant une résistance au soulèvement par le vent sous pressions négatives et de meilleures propriétés d’isolation. L’invention concerne également un appareil de support de carreau permettant d’immobiliser le bord avant d’un carreau pour en empêcher le soulèvement par le vent.
EP06816692A 2005-10-07 2006-10-10 Systeme de carreaux en beton et son procede de fabrication Withdrawn EP1931841A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US72483105P 2005-10-07 2005-10-07
PCT/US2006/039661 WO2007044775A1 (fr) 2005-10-07 2006-10-10 Systeme de carreaux en beton et son procede de fabrication

Publications (1)

Publication Number Publication Date
EP1931841A1 true EP1931841A1 (fr) 2008-06-18

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EP06816692A Withdrawn EP1931841A1 (fr) 2005-10-07 2006-10-10 Systeme de carreaux en beton et son procede de fabrication

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US (1) US20070107358A1 (fr)
EP (1) EP1931841A1 (fr)
CN (1) CN101351605A (fr)
MX (1) MX2008004619A (fr)
WO (1) WO2007044775A1 (fr)

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CN101351605A (zh) 2009-01-21
US20070107358A1 (en) 2007-05-17
MX2008004619A (es) 2008-10-29
WO2007044775A1 (fr) 2007-04-19

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