US20090266023A1

US20090266023A1 - Adhesive projection points for roofing elements

Info

Publication number: US20090266023A1
Application number: US12/108,188
Authority: US
Inventors: Tat-On Man
Original assignee: Individual
Current assignee: Monier Technical Centre Ltd
Priority date: 2008-04-23
Filing date: 2008-04-23
Publication date: 2009-10-29

Abstract

A roofing element such as a concrete tile is provided that includes a body portion extending between a head end and a nose end. The body portion includes a lower surface, an upper surface, and a protrusion that is disposed substantially adjacent the nose end and extends downwardly from the lower surface. The protrusion is disposed on the lower surface such that when a nose end of a second roofing element is installed vertically above a head end of a first roofing element and overlapping by at least 3 inches, the protrusion of the second roofing element is positioned substantially above an aperture defined in the head end of the first roofing element. The protrusion reduces a distance between the aperture of the first roofing element and the nose end of the second roofing element, which increases the likelihood that the adhesive will securely join the first roofing element with the second roofing element.

Description

BACKGROUND

1. Field of the Disclosure
The disclosure relates to an improvement in the design of roofing elements, and more particularly to roof tiles having a projecting structure on the underside of a tile that provides an improved connection between tiles when secured together with adhesives.
2. Related Art
In the installation of concrete roofing elements, such as field tiles and trim tiles, a nose end of a second course tile is positioned to overlap a head end of a first course tile to cover one or more apertures in the head end of the first course tile. The apertures in the head end of the tiles receive fasteners such as nails or screws, for securing the tiles to the roof surface, and the overlap of the nose end of the second course tile over the head end of the first course tile discourages rain and debris from leaking through the apertures. For example, when installing field tiles, a second field tile is installed as part of a second horizontal course of field tiles that are installed upward on a sloped roof surface relative to a first horizontal course of field tiles of which a first field tile is a part. When installing trim tiles, which are tiles that are typically installed along the ridge, rake, or edge of the roof surface, a second trim tile is installed such that the nose end of the second trim tile is stacked vertically above the head end of a previously-installed first trim tile.
Good practice, or code regulations in certain jurisdictions, may require that installers apply an adhesive material onto the apertures at the head end of each tile after the fastener has been engaged in the aperture, to secure the nose end of the next course of tiles to the head ends of the tiles and to reduce the amount of rain and debris that may penetrate below the next course tile and through the apertures. Applying the adhesive layer between courses of tiles increases material costs and installation time for the installers. In addition, a large amount of adhesive may be required to secure the head end of the lower course tile to the nose end of the upper course tile. Thus, a need exists in the art for a roofing element design that reduces the amount of adhesive used between courses of roofing elements installed on the roof surface and ensures that the applied adhesive secures the roofing elements together.

BRIEF SUMMARY

Various disclosed embodiments provide an improved roofing element that reduces the amount of adhesive needed in a roof installation, reduces the installation time for installers, and increases the likelihood that the adhesive applied will contact and securely join adjacent roofing elements. In particular, according to various embodiments, a number of different roofing elements are provided for installing on a sloped roof. Each of the roofing elements includes (1) a head end defining one or more apertures therethrough for receiving a fastener to secure the roofing element to the sloped roof, (2) a nose end opposite the head end, and (3) a body portion extending between the head end and the nose end. The body portion includes a lower surface, an upper surface opposite the lower surface, and a protrusion. The protrusion is disposed adjacent the nose end and extends downwardly from the lower surface. In particular, the protrusion is disposed on the lower surface such that when a nose end of a second roofing element is installed vertically above a head end of a first roofing element, the protrusion of the second roofing element is positioned above at least one of the one or more apertures defined in the head end of the first roofing element. The protrusion reduces a distance between the aperture(s) and the nose end such that an amount of adhesive required to secure the head end of the first roofing element to the nose end of the second roofing element is reduced and the likelihood that the adhesive will contact and securely join the nose end of the second roofing element with the head end of the first roofing element is increased.
In a particular embodiment, the body portion also defines a front edge segment adjacent the nose end, and the front edge extends downwardly from the lower surface and is shaped to substantially conform to the upper surface adjacent the head end. The protrusion is disposed inward of the front edge segment toward the head end, preferably along a longitudinal axis of the roofing element. In a further embodiment, the front edge segment extends a first distance from the lower surface and the protrusion extends a second distance from the lower surface, and the first distance is greater than the second distance such that the front edge segment substantially hides the protrusion when installed on the roof surface.
Building codes typically require the nose end of a tile in an upper course to overlap the head end of the next lower tile by at least a predetermined distance, currently three inches (3″). Therefore, according to one aspect, the protrusion is shaped and arranged on the lower tile surface such that even when the tiles overlap by a predetermined distance, which may be as much as 3″ or more, the protrusion on the lower surface of the upper tile will be located above the aperture in the lower tile, that is, disposed for fastening the upper tile to the lower aperture with an adhesive. In other words, the protrusion is spaced far enough from the nose end of the tile, or extends far enough from the nose end toward the head end of the tile, that the protrusion can be placed over the aperture of the next lower tile even when the upper tile overlaps the lower tile by the predetermined distance, such as 3″ or more. Preferably the protrusion is disposed on the lower surface at a location at least (3-D) inches from the nose end, wherein D is a distance between the aperture and the head end.
According to various embodiments, the roofing elements includes trim tiles, such as ridge tiles for installing along a ridge of a sloped roof surface or rake tiles for installing along a rake of a sloped roof surface, or field tiles, which are installed on the main portion of the roof surface. In addition, the roofing elements may be formed from concrete or other suitable material, such as wood, slate, metal, or polymeric material.
According to other aspects, a mold pallet and a manufacturing method for manufacturing the files will also be described.
Other features and advantages will become apparent from the following description of embodiments which refers to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 are longitudinal cross-sectional views showing two installed ridge tiles in two different relative positions;

FIG. 3 is a perspective view of a lower surface of a trim tile according to one embodiment of the invention;

FIG. 4 is a perspective view of a lower surface of a trim tile according to another embodiment of the invention;

FIG. 5 is a perspective view of a lower surface of a trim tile according to yet another embodiment of the invention;

FIG. 6 is a perspective view of the upper surface of a field tile according to another embodiment of the invention;

FIG. 7 is a bottom plan view of the lower surface of the field tile shown in FIG. 6;

FIG. 8 is an exploded view of a mold pallet, a roller, and a slipper for manufacturing the trim tile shown in FIG. 3 according to various embodiments of the invention;

FIG. 9 is an exploded view of a mold pallet, a roller, and a slipper for manufacturing the ridge trim tile shown in FIG. 4 according to various embodiments of the invention;

FIG. 10 is an exploded view of a mold pallet, a roller, and a slipper for manufacturing the rake trim tile shown in FIG. 5 according to various embodiments of the invention; and

FIG. 11 is an exploded view of two trim tiles according to the embodiment shown in FIG. 3, installed relative to each other according to one embodiment of the installation method.

DETAILED DESCRIPTION

Various embodiments have been developed to provide an improved roofing system and roofing element.
In the embodiments, a roofing element is provided wherein at least one protrusion extends downwardly from the lower surface of the roofing element, to reduce the distance below the nose end of a second roofing element installed vertically above the head end of a first roofing element. The reduced distance between the roofing elements reduces an amount of adhesive to be applied between a head end of an upper surface of the first roofing element and the lower surface of the nose end of the second roofing element to secure the roofing elements together, and increases the likelihood that the adhesive will contact and secure the roofing elements together. The protrusion is shaped and arranged on the lower tile surface such that even when the tiles overlap by 3″, or more, the protrusion on the lower surface of the upper tile will be accessible, located above the aperture in the lower tile, for fastening the upper tile to the lower aperture with an adhesive. Preferably the protrusion is disposed on the lower surface at a location at least (3-D) inches from the nose end, wherein D is a distance between the aperture and the head end.
Various embodiments provide roofing elements (e.g., field tiles and trim tiles) having protrusions that reduce the distance between the nose end of a second roofing element installed vertically above the head end of a first roofing element, which reduces the amount of adhesive to be applied between courses of roofing elements during installation on a sloped roof surface and increases the likelihood that the adhesive will contact and secure the roofing elements together. According to various embodiments, the roofing elements include trim tiles, such as ridge tiles for installing along a ridge of a sloped roof surface or rake tiles for installing along a rake of a sloped roof surface, or field tiles, which are installed on the main portion of the roof surface. The roofing elements may be formed from concrete or other suitable material, such as clay, concrete, wood, slate, metal, or polymeric material.
FIG. 1 shows two installed ridge tiles 100, 102 in a longitudinal cross-section. The first ridge tile 100 lays with its head end 104 on a ridge tree 106 and with its nose end (not shown) it overlaps a neighboring ridge tile. Close to its head end 104 the first ridge tile 100 is provided with a nail hole 108. The first ridge tile 100 is secured on the ridge tree 106 with a nail 110. The nail 110 is inserted into the first ridge tile's nail hole 108 and driven into the wooden ridge tree 106. The head 112 of the nail 110 covers the nail hole 108, but stands up from the upper surface 114 of the first ridge tile 100 and cannot prevent the penetration of water through the nail hole 108. To solve this problem, it is a common practice to apply an adhesive 116, such as a plastic adhesive, on the nail head 112 to seal the nail hole 108 against water penetration.
The second ridge tile 102 has a design which is identical with that of the first ridge tile 100. The second ridge tile 102 has a head end 118 with a nail hole 120 and a nose end 122 that overlaps the head end 104 of the fixed first ridge tile 100. The ridge tiles 100, 102 are installed with a maximum overlap of greater than a predetermined distance, for example 3″. In the overlapping area the second ridge tile 102 is provided with a protrusion 124 projecting from the lower surface 126. Due to the projecting protrusion 124 of the second ridge tile 102 the distance 128 between the protrusion 124 's surface 130 and the upper surface 114 of the fixed first ridge tile 100 is significantly reduced compared to the distance 132 between the lower surface 126 of the second ridge tile 102 and the upper surface 114 of the first ridge tile 100. Therefore less adhesive 116 is required to bridge the gap between the two ridge tiles 100, 102.
The distance 128 should be at least 1 mm, preferably 2 mm. This will ensure that the protrusion 124 is not in direct contact with the nail 110's head 112. During the installation of the second ridge tile 102 its protrusion 124 is pressed onto the plastic adhesive 116 applied to the nail 110's head 112. Therefore the adhesive 116 penetrates into the nail hole 108 and encapsulates the nail 110's head 112. Furthermore the adhesive 116 forms a large-area adherent, which ensures a strong glue connection 134 between the ridge tiles 100, 102 at the protrusion 124.
FIG. 2 shows the two installed ridge tiles 100, 102 known from FIG. 1 in a longitudinal section, but installed with a minimum overlap which, according to building codes, will be at least a predetermined distance, for example 3″. When the ridge tiles 100, 102 are laid with the minimum overlap the glue connection 134 is formed close to the weatherbar 136. If the ridge tiles 100, 102 are laid with the maximum overlap—as shown in FIG. 1—the glue connection 134 is formed close to the inner edge 138 of the protrusion 124. To ensure in the light of the variable overlap that there will be always a match between the protrusion 124 of the second ridge tile 102 and the nail hole 108 of the first ridge tile 100, the protrusion 124 has an extension X in the longitudinal direction (nose end to head end) that is at least long enough to permit an overlap of the predetermined distance required by building codes.
In other embodiments, the protrusion need not extend continuously upward from the nose end toward the head end of the tile as shown in FIGS. 1 and 2. Instead, one or a plurality of discontinuous protrusions may be provided. At least one protrusion is spaced far enough from the nose end of the tile, or extends far enough from the nose end towards the head end of the tile, so that the protrusion can be placed over the aperture of the next lower tile even when the upper tile overlaps the lower tile by 3″ or more.
The dimensions of each protrusion need only be large enough to cover the corresponding aperture.
The technical function of the protrusion 124 and the achieved commercial benefits are identical with the protrusions shown in the other FIGS. 3, 4, 5 and 6.
In the embodiment shown in FIG. 3, a trim tile 10 is provided that can be used along a ridge of a sloped roof surface or along the rake or edges of the roof surface. The trim tile 10 includes a head end 11, a nose end 12, and a body portion 13 that extends between the head end 11 and nose end 12. A cross section of the body portion 13 transverse to a longitudinal axis A of the tile 10 is generally arcuate-shaped, and the body portion 13 comprises a lower surface 15, an upper surface 19 opposite the lower surface 15, and a protrusion 16 that is disposed proximate the nose end 12 and extends downwardly from the lower surface 15. The protrusion 16 is disposed on the lower surface 15 such that when the nose end 12 of a second trim tile 10 is installed vertically above the head end 11 of a first trim tile 10, the protrusion 16 of the second trim tile 10 is positioned substantially above an aperture 14 defined in the head end 11 of the first trim tile 10. The protrusion 16 reduces the distance between the nose end 12 of the second trim tile 10 when the second trim tile 10 is installed vertically above the aperture 14 of the head end 11 of the first trim tile 10, which reduces an amount of adhesive to be applied between the aperture 14 and the nose end 12 to secure the nose end 12 of the second trim tile 10 to the head end 11 of the first trim tile 10 and increases the likelihood that the adhesive will contact and secure the second trim tile 10 to the first trim tile 10. In the embodiment shown in FIG. 3, the head end 11 defines one aperture 14 and the body portion 13 comprises one protrusion 16, but it should be understood by those of ordinary skill in the art that in various embodiments of the invention, the tile 10 may define more than one aperture 14 and more than one corresponding protrusion 16 for positioning above the apertures 14 during installation with at least 3″ of overlap as described above.
In a further embodiment, the tile 10 further comprises a front edge segment 18 adjacent the nose end 12 that extends downwardly from the lower surface 15 and is shaped to substantially conform to the upper surface 19 adjacent the head end 11. The protrusion 16 is disposed inward of the front edge segment 18 toward the head end 11 along a longitudinal axis A of the trim tile 10. The front edge segment 18 extends further from the lower surface 15 than the protrusion 16 such that the front edge segment 18 substantially hides the protrusion 16 and adhesive below the tile 10 when installed on the roof surface with at least 3″ of overlap as described above.
Another exemplary roofing element is shown in FIG. 4. According to the embodiment shown, a trim tile 20 is provided that can be used along a ridge of a sloped roof. The trim tile 20 includes a head end 21, a nose end 22, and a body portion 23 that extends between the head end 21 and nose end 22. The body portion 23 comprises three walls such that a first wall 53 a and third wall 53 c extend outwardly and at an angle from the second wall 53 b. When installed, the second wall 53 b is positioned vertically atop the ridge of the roof, and the first wall 53 a and the third wall 53 c extend downwardly from the second wall 53 b toward the sloped roof surface and field tiles installed thereon. The walls 53 a-c define a lower surface 25 of the body portion 23 and an upper surface 29 of the body portion 23 that is opposite the lower surface 25. The second wall 53 b defines an aperture 24 adjacent the head end 21 for securing the trim tile 20 to the roof surface, and the second wall 53 b defines a protrusion 26 that is disposed substantially adjacent the nose end 22 and extends downwardly from the lower surface 25. The protrusion 26 is disposed on the lower surface 25 such that when the nose end 22 of a second trim tile 20 is installed vertically above the head end 21 of a first trim tile 20, the protrusion 26 of the second trim tile 20 is positioned substantially above the aperture 24 defined in the head end 21 of the first trim tile 20. The protrusion 26 reduces the distance between the nose end 22 of the second trim tile 20 when the second trim tile 20 is installed vertically above the aperture 24 of the head end 21 of the first trim tile 20, which reduces an amount of adhesive to be applied between the aperture 24 and the nose end 22 to secure the nose end 22 of the second trim tile 20 to the head end 21 of the first trim tile 20 and increases the likelihood that the adhesive will contact and secure the second trim tile 20 to the first trim tile 20 with at least 3″ of overlap as described above.
In the embodiment shown in FIG. 4, the head end 21 defines one aperture 24 and the lower surface 25 defines one protrusion 26, but it should be understood by those of ordinary skill in the art that in various embodiments, the tile 20 may define more than one aperture 24 (e.g., on the second wall 53 b or on one or more of the other walls 53 a, 53 c) and corresponding protrusion 26 for positioning above the aperture 24 during installation.
In a further embodiment, the three walls 53 a-c also define a front edge segment 28 disposed adjacent the nose end 22, and the front edge segment 28 extends downwardly from the lower surface 25 and is shaped to substantially conform to the upper surface 29 adjacent the head end 21. The protrusion 26 is disposed inward of the front edge segment 28 toward the head end 21 along a longitudinal axis B of the trim tile 20. The front edge segment 28 extends further from the lower surface 25 than the protrusion 26 such that the front edge segment 28 substantially hides the protrusion 26 and adhesive below the tile 20 when installed on the roof surface.
Yet another exemplary roofing element is shown in FIG. 5. According to the embodiment shown, a trim tile 30 is provided that can be installed along a ridge or a rake or edge of the roof surface. The trim tile 30 includes a head end 31, a nose end 32, and a body portion 33 that extends between the head end 31 and nose end 32. The body portion 33 comprises two walls such that a first wall 63 a and a second wall 63 b are formed together along a common longitudinal edge (or interface) of the first wall 63 a and the second wall 63 b at an angle substantially equal to 90°. The walls 63 a, 63 b define a lower surface 35 of the body portion 32 and an upper surface 39 of the body portion 33 that is opposite the lower surface 35. The interface between the first wall 63 a and the second wall 63 b defines a ridge aperture 34 adjacent the head end 31 for securing the trim tile 30 to the ridge of the roof surface. The body portion 33 further defines a protrusion 36 that extends downwardly from the lower surface 35 and is disposed proximate the interface between the first wall 63 a and the second wall 63 b and substantially adjacent the nose end 32. In particular, the protrusion 36 is disposed on the lower surface 35 such that when the nose end 32 of a second trim tile 30 is installed vertically above the head end 31 of a first trim tile 30, the protrusion 36 of the second trim tile 30 is positioned substantially above the aperture 34 defined in the head end 31 of the first trim tile 30. The protrusion 36 reduces the distance between the nose end 32 of the second trim tile 30 when the second trim tile 30 is installed vertically above the aperture 34 of the head end 31 of the first trim tile 30 with at least 3″ of overlap as described above, which reduces an amount of adhesive to be applied between the aperture 34 and the nose end 32 to secure the nose end 32 of the second trim tile 30 to the head end 31 of the first trim tile 30 and increases the likelihood that the adhesive will contact and secure the second trim tile 30 to the first trim tile 30.
In the embodiment shown in FIG. 5, the head end 31 defines one aperture 34 and the body portion 33 comprises one protrusion 36, but it should be understood by those of ordinary skill in the art that in various embodiments of the invention, the tile 30 may define more than one aperture 34 (e.g., along the interface between the first wall 63 a and second wall 63 b or on the first wall 63 a or the second wall 63 b) and corresponding protrusion 36 for positioning above the aperture 34 during installation.
In a further embodiment, the first wall 63 a and the second wall 63 b comprise a front edge segment 38 that is adjacent the nose end 32. The front edge segment 38 extends downwardly from the lower surface 35 and is shaped to substantially conform to the upper surface 39 adjacent the head end 31. The protrusion 36 is disposed inward of the front edge segment 38 toward the head end 31 along a longitudinal axis C of the tile 30. The front edge segment 38 extends further from the lower surface 35 than the protrusion 36 such that the front edge segment 38 substantially hides the protrusion 36 and adhesive below the tile 30 when installed on the roof surface.
In the embodiment shown in FIGS. 6 and 7, a field tile 40 is provided that can be installed along the main portion of the sloped roof. The field tile 40 includes a head end 41, a nose end 42, and a body portion 43 that extends between the head end 41 and nose end 42. The body portion 43 comprises a lower surface 45 and an upper surface 49 opposite the lower surface 45, and the upper surface 49 is substantially flat. The body portion 43 further comprises at least one protrusion 46 that is disposed substantially adjacent the nose end 42 and extends downwardly from the lower surface 45. The protrusion 46 is disposed on the lower surface 45 such that when the nose end 42 of a second field tile 40 is installed vertically above the head end 41 of a first field tile 40, the protrusion 46 of the second field tile 40 is positioned substantially above at least one aperture 44 defined in the head end 41 of the first field tile 40 with at least 3″ of overlap as described above. The protrusion 46 reduces the distance between the nose end 42 of the second field tile 40 when the second field tile 40 is installed vertically above the aperture 44 of the head end 41 of the first field tile 40, which reduces an amount of adhesive to be applied between the aperture 44 and the nose end 42 to secure the nose end 42 of the second field tile 40 to the head end 41 of the first field tile 40 and increases the likelihood that the adhesive will contact and secure the second field tile 40 to the first field tile 40. In the embodiment shown in FIGS. 6 and 7, the head end 41 defines two apertures 44 and the body portion 43 comprises two protrusions 46 that correspond to each aperture 44, but it should be understood by those of ordinary skill in the art that in various embodiments of the invention, the field tile 40 may define only one aperture 44 and one corresponding protrusion 46 or more than two apertures 44 and corresponding protrusions 46 for positioning above the apertures 44 during installation. In addition, various embodiments may provide one or more elongated protrusions across the nose end that are configured for spanning across the one or more apertures defined by the lower course tile upon installation, for example, or other suitable configurations.
In a further embodiment, the body portion 43 also comprises a front edge segment 48 adjacent the nose end 42, and the front edge segment 48 extends downwardly from the lower surface 45 and is shaped to substantially conform to the upper surface 49 adjacent the head end 41. The protrusion 46 is disposed inward of the front edge segment 48 toward the head end 41 along a longitudinal axis D of the field tile 40. The front edge segment 48 extends further from the lower surface 45 than the protrusion 46 such that the front edge segment 48 substantially hides the protrusion 46 and adhesive below the tile 40 when installed on the roof surface.

Installation Process

FIG. 11 illustrates an exemplary installation of trim tiles, such as the trim tiles 10 shown in FIG. 3, along a ridge 105 of a sloped roof surface 100 according to various embodiments. The first trim tile 10 a is positioned such that its nose end 12 is adjacent an edge 102 of the ridge 105 of the roof 100 and its head end 11 is inward of the edge 102. The first trim tile 10 a is secured to the ridge 105 of the roof surface 100 by engaging a fastener (not shown) through the aperture 14 (not shown) in the head end 11 of the tile 10 and into the roof 100. Adhesive 17 is then applied onto the upper surface 19 of the first tile 10 a above the fastener, and the protrusion 16 at the nose end 12 of a second tile 10 b is positioned substantially vertically above the aperture 14 and adhesive 17 of the first tile 10 a. The head end 11 of the second tile 10 b positioned further inward along the ridge 105 of the roof surface 100 and is secured to the ridge using another fastener. The process continues until trim tiles 10 have been installed along the length of the ridge 105.

Manufacturing Process

The roofing elements described in FIGS. 1 to 7 can be formed in clay by a pressing process or formed in concrete by an extrusion process. To produce concrete roof tiles an endless ribbon of green (not yet hardened) concrete is extruded on an endless string of mold pallets. FIGS. 8-10 show single mold pallets 70, 80, 90 suitable to form differently shaped concrete tiles. The upper surface of each mold pallet 70, 80, 90 defines the shape of the lower surface of the corresponding trim tile 10, 20, 30. A roller 72, 82, 92 is positioned above the string of mold pallets 70, 80, 90 and has a surface that is substantially the shape of the upper surface of the mold pallet 70, 80, 90. To force the green concrete between the roller 72, 82, 92 and the mold pallet 70, 80, 90, the roller 72, 82, 92 is spun at a speed slightly faster than the speed at which the mold pallet 70, 80, 90 is moving below the roller 72, 82, 92. The green concrete is compressed between the roller 72, 82, 92 and the mold pallet 70, 80, 90 to form a rough shape of the tile 10. Next, the mold pallet 70, 80, 90 moves below a slipper 74, 84, 94 which forms the upper surface of the tile 10, 20, 30 in more detail and within specified tolerances.
To provide each concrete tile 10, 20, 30 with a protrusion the mold pallet 70, 80, 90 is provided at the nose end with a cavity 200, 210, 220 forming the protrusion.
When the molds pass the roller, the fresh concrete is pressed by the roller into the cavities of the molds, which form the reverse of the roof tile including weather bars, hanging nibs, the described protrusions and/or other surface features. Simultaneously the roller forms the upper surface of the roof tile. When the molds pass the slipper behind the roller, the upper surface of the roof-tile shaped concrete ribbon is further compressed by the slipper. This improves further the compaction and surface smoothness of the roof tiles prior to the coating application.
After the forming process the mould pallets are conveyed into a cutting device in which the compressed concrete ribbon will be chopped into single concrete tiles so that each mold pallet bears a single concrete tile. Next, the concrete tiles will be cured, released from the mold pallets and packed for the shipping.
It should be understood that the shapes of the mold pallets 70, 80, 90, rollers 72, 82, 92, and slippers 74, 84, 94 may be modified to manufacture tiles having differently shaped profiles.

CONCLUSION

It may be seen that the various disclosed embodiments overcome deficiencies in the prior art by providing roofing tiles that reduce the distance between the aperture of the first course tile and a portion of the nose end of the second course tile installed vertically above the aperture, even with an overlap of 3″ or more. Reducing the distance reduces the amount of adhesive needed between roofing elements during installation to secure the roofing elements together and increases the likelihood that the adhesive applied will contact and secure the adjacent roofing elements together. While various embodiments have been described in specific detail, it should be understood that the invention is not limited to the disclosed embodiments, and that many variations and modifications may be effected within the full spirit and scope of the invention.

Claims

1. A roofing element for installing on a sloped roof, said roofing element comprising:

a head end defining one or more apertures therethrough for receiving a fastener to secure said roofing element to said sloped roof;

a nose end opposite said head end;

a body portion extending between said head end and said nose end; and

said body portion comprising a lower surface, an upper surface opposite said lower surface, and a protrusion, said protrusion disposed substantially adjacent said nose end and extending downwardly from said lower surface,

wherein said protrusion is disposed on said lower surface such that when a nose end of a second roofing element is installed vertically adjacent a head end of a first roofing element and overlapping by at least a predetermined distance, said protrusion of said second roofing element is positioned substantially above said one or more apertures defined in said head end of said first roofing element, and

wherein said protrusion is configured to reduce a distance between said one or more apertures and said nose end lower surface such that an amount of adhesive needed to secure said nose end of said second roofing element to said head end of said first roofing element is reduced and a likelihood that the adhesive will contact and securely join said nose end of said second roofing element with said head end of said first roofing element is increased.

2. The roofing element of claim 1, comprising a trim element.

3. The roofing element of claim 2, comprising a ridge element, said ridge element configured for being installed along a ridge of said sloped roof.

4. The roofing element of claim 3, wherein:

said ridge element comprises a first wall, a second wall, and a third wall,

said first wall and said third wall extend substantially outwardly and downwardly from opposite edges of said second wall.

5. The roofing element of claim 3, wherein a cross-section of said ridge element transverse to a longitudinal axis of said ridge element is substantially arcuate in shape.

6. The roofing element of claim 2, comprising a rake element.

7. The roofing element of claim 6, wherein said rake element comprises a first wall and a second wall, said first wall and said second wall being formed together along a common longitudinal edge of each of said first wall and said second wall at an angle substantially equal to 90°.

8. The roofing element of claim 1, comprising a field tile.

9. The roofing element of claim 1, wherein each of said roofing elements is formed of a concrete material.

10. The roofing element of claim 1, wherein said body portion further comprises a front edge segment disposed adjacent said nose end, said front edge segment extending downwardly from said lower surface and being shaped to substantially conform to said upper surface adjacent said head end, said protrusion being disposed inward of said front edge segment toward said head end along a longitudinal axis of said roofing element.

11. The roofing element of claim 10, wherein said front edge extends a first distance from said lower surface and said protrusion extends a second distance from said lower surface, wherein said first distance is greater than said second distance.

12. The roofing element of claim 1, wherein said predetermined distance is three inches.

13. The roofing element of claim 12, wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end.

14. The roofing element of claim 1, wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end.

15. The roofing element of claim 1, comprising a plurality of protrusions spaced from each other along a longitudinal direction of said roofing element.

16. The roofing element of claim 1, comprising a plurality of protrusions spaced from each other along a lateral direction of said roofing element.

17. The roofing element of claim 1, wherein said protrusion extends continuously from said nose end along a longitudinal direction of said roofing element.

18. The roofing element of claim 1, wherein said protrusion protrudes from said lower surface at a location spaced away from said nose end and separated from said nose end by a portion of said lower surface that does not protrude from said lower surface.

19. The roofing element of claim 18, wherein said protrusion extends on said lower surface along a lateral direction of said roofing element.

20. A mold pallet for manufacturing a roofing element, for installing on a sloped roof, said mold pallet having an upper surface configured for molding a roofing element comprising:

a nose end opposite said head end;

a body portion extending between said head end and said nose end; and

21. The roofing element of claim 20, wherein said predetermined distance is three inches.

22. The roofing element of claim 21, wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end.

23. The roofing element of claim 20, wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end.

24. A method of manufacturing a roofing element, said method comprising the steps of:

providing a roofing element having a head end, a nose end opposite said head end, an upper surface, and a lower surface opposite said upper surface, and

providing a protrusion disposed substantially adjacent said nose end and extending downwardly from said lower surface;

said protrusion being disposed on said lower surface such that when a first roofing element is installed on a sloped roof, by inserting a fastener through at least one aperture in said head end and into said sloped roof and a second roofing element is installed substantially vertically adjacent the first roofing element and overlapping by at least a predetermined distance, said protrusion of the second roofing element is positioned vertically above said fastener and said aperture of the first roofing element.

25. The method of claim 24, further comprising the steps of:

providing a front edge disposed adjacent said nose end and extending downwardly from said lower surface, said front edge being shaped to substantially conform to said upper surface adjacent said head end, and said protrusion being disposed inward of said front edge toward said head end along a longitudinal axis of said roofing element.

26. The method of claim 25, wherein said front edge extends a first distance from said lower surface and said protrusion extends a second distance from said lower surface, wherein said first distance is greater than said second distance.

27. The method of claim 24, said roofing element being provided by the steps of:

providing a mold pallet, the mold pallet having an upper surface shaped for molding a lower surface of said head end, nose end and body portion, including a cavity in said upper surface shaped for forming said protrusion;

compressing green concrete into said mold pallet; and

curing said green concrete.

28. The method of claim 27, wherein said green concrete is pressed into a series of said mold pallets, and further comprising the step of cutting said green concrete between said mold pallets.