US20120085053A1

US20120085053A1 - Lightweight tile with tapered support

Info

Publication number: US20120085053A1
Application number: US13/267,266
Authority: US
Inventors: Frank Barone
Original assignee: ROOFTECH TILE LLC
Current assignee: ROOFTECH TILE LLC
Priority date: 2010-10-08
Filing date: 2011-10-06
Publication date: 2012-04-12

Abstract

The present invention is directed to a lighweight the with a tapered support angle reverse, to the angle of the roof, a tile having uniform contact with the roof surface that does not require battens and can be walked on without the fear of breaking. This the can be fabricated in several materials including concrete, ceramic, porcelain or clay. By increasing the surface area of the underside of this tile with numerous cavities and ribs, the capability for dissipating heat is greatly increased. The lightweight tile has the option of incorporating a breathable, underlying cushioning/insulating With this system of interlocking and overlapping tiles, when the top tile overlaps the tile below the top tile cantilevers and lays flat on the tile below it, greatly reducing the vulnerability to stress fracture because of the reverse angle and supporting ribs structure of the tile.

Description

FIELD OF THE INVENTION

This application provides a lightweight tile with tapered support predominately, but not restricted, to be used in the process of roofing of structures, particularly involving removing material on the underside of the tile to reduce weight and increase surface area along with the addition of tapered supporting ribs.

BACKGROUND OF THE INVENTION

Tiles are generally used for covering roofs, floors, walls or showers. The word is derived from the French word tuile, which is, in turn, from the Latin word tegula, meaning a roof tile composed of baked clay. Tiles are most often made from ceramic, with a hard glaze finish, but other materials are also commonly used, such as glass, marble, granite, slate, and reformed ceramic slurry, which is cast in a mould and fired. Recently some roofing tiles have been made of concrete, but they remain very heavy and have a tendency of cracking when stepped on improperly. The earliest kinds of roof tiles in archaic Greece are documented from a very restricted area around Corinth (Greece), where fired tiles began to replace thatched roofs at two temples of Apollo and Poseidon between 700-650 BC. Early roof tiles showed an S-shape, with the pan and cover tile forming one piece. These early roof tiles were very heavy, weighing around 30 kilograms (or around 66 pounds) each. Tiling was extensively used by the Sinhalese kings of ancient Sri Lanka. Tiles have found their way into other varying applications, such as interior decorating, especially in commercial uses such as sidings and other decorative designer applications.
Today, the average weight of a clay or concrete tile is about 4 kg to 6 kg (or between 8 and 14 pounds) per square foot. There is a growing need for a lighter weight tile that can be used in exterior and interior construction. Most homes and commercial buildings that have been designed for the application of composition shingles do not have the built-in structural strength to hold up the conventional existing tile roofs, although a tile roof would greatly improve the fire resistance, appearance and value. The lightweight tile with tapered support of this application will be placed in parallel alignment in addition to the conventional staggered alignment of composition roofing materials. By designing this unique tile with a tapered support angle reverse to the angle of the roof, the inventor has created a tile having uniform contact with the roofs surface that can be walked on without the fear of breaking. By increasing the surface area of the underside of this tile with numerous cavities and ribs the capability for dissipating heat has been greatly increased. In addition the lightweight tile, with tapered support will have the option of incorporating a breathable, underlying cushioning/insulating member that will be made from a variety of conventional insulating materials.
Numerous innovations for the tile roofing have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present design as hereinafter contrasted. The following is a summary of those prior art patents most relevant to this application at hand, as well as a description outlining the difference between the features of the lightweight tile with tapered support and the prior art.
U.S. Pat. No. 5,070,671 of John A. Fifield et al. describes an interlocking roof tile of which the leading end portion, at least as far as the lower end and including the underlock is tapered in the direction of the leading edge of the tile.
This patent describes an interlocking tapered roof tile made of a cementitious mixture that requires horizontal battens fixed to the roof rafters for support and has no reverse tapered support members that make contact with the roof's surface. This invention differs in that it has been designed to provide an interlocking roof tile which can be laid in a staggered relationship.
U.S. Pat. No. 5,214,895 of John A. Fifield describes interlocking roof tile which can be made by extrusion, pressing or moulding that has an upper edge; a lower edge which is visible in use when the tile is laid in overlapping relationship with at least one tile of a next adjacent line of the tiles; an upper surface; a lower surface; a supporting understructure; two oppositely facing side edges; an underlock extending along one of the side edges and an overlock extending along the other of the side edges, the underlock having a lower end and an under surface which forms part of the under surface of the tile, and a lower edge portion having an under surface which includes a part of the under surface of the underlock, and which overlaps, in use, at least one tile of the next adjacent line of the tiles, characterized in that the upper surface of the tile extends continuously from the lower edge to the upper edge, in that the upper and lower surfaces are cambered from the lower edge to the upper edge and are substantially flat when considered in cross-section taken along a line extending between the side edges, in that the lower edge portion including the underlock has a taper which extends in the direction of the lower edge of the tile at least as far as the lower end of the underlock.
This patent also describes an interlocking roof tile made of a cementitious mixture that requires horizontal battens fixed to the roof rafters for support and has no reverse tapered support members that make contact with the roof surface. This invention differs in that it has been designed to provide an interlocking roof tile which can be laid in a staggered relationship. It does not offer the unique breathable, underlying cushioning/insulating member of the lightweight tile with tapered support of this application and does not offer the optional ceramic or porcelain applications.
U.S. Pat. No. 5,323,581 of Karl W. Jakel describes a lightweight roofing shingle or tile having an elongated body with top and bottom surfaces that taper lengthwise of the body, the body having laterally spaced, elongated edges; the body having a mid-region and a recess sunk upwardly into the mid-region, from the bottom surface; the recess extending widthwise of the body to intersect the body laterally spaced edges whereby the recess is adapted to receive a batten to support the body mid-region when installed on a roof. A secondary taper on the tile bottom surface engages the roof to provide leverage resisting wind up-lift forces exerted on the lightweight tile acting to rotate the tile about a nailing point fulcrum.
This patent describes a lightweight roofing shingle or tile made of a cementitious or other material that requires horizontal battens for additional support and although it has a tapered configuration it does not make contact with the roof surface having unsupported recess portions forward and rearward of the battens.
U.S. Pat. No. 6,178,703 of Michael J. Noone describes a lightweight, preferably clay roofing tile, preferably having surface configurations to simulate the thick heavyweight of natural slate, or to simulate natural wood shakes, or other natural materials, is provided, constructed so as to be molded from materials with weight-reducing zones, and strengthening webs, integral with the tile, such that each tile is of unitary, molded, one-piece construction. The placement, type and number of webs enable the cutting of the tiles to form tile accessory pieces, at ends of laid-up courses, hips, ridges and the like, to minimize or eliminate the necessity of inventorying large numbers of special accessory pieces. The webs provide strengthening while the hollow zones reduce weight, with at least some of the webs being located to provide strength to the tiles along newly cut edges. An interlock design at tile edges facilitates reduction in weight by eliminating the need for a double coverage overlap. A series of bosses with depressions facilitate nailing when the tile is cut at an angle to form hip pieces.
This patent describes a lightweight, preferably clay roofing tile that has been designed so that it can be cut to be used as ridge members and other additional components in the roofing process. It does not have the reverse taper of the supporting members to make full contact with the roof's surface so that it will be more subject to cracking when stepped on.
U.S. Pat. No. 7,770,354 of Thuan H. Bui describes a lightweight cementitious panel/tile that is provided with increased bending stiffness and less weight than conventional construction panels. The cementitious panel is constructed of a cementitious surface (which may be reinforced with wood fiber or other materials) supported by an integrated stiffener grid on the underside to absorb stresses and loads.
This patent describes a lightweight cementitious panel/tile with an integrated metal stiffening system attached to a cementitious plate. It does not have the reverse taper contact with the roofs surface and does not offer the unique breathable, underlying cushioning/insulating member of the lightweight tile with tapered support of this application.
None of these previous efforts, however, provides the benefits attendant with the lightweight tile with tapered support. The present design, achieves its intended purposes, objects and advantages over the prior art devices through a new, useful and unobvious combination of method steps and component elements, at a reasonable cost to manufacture, and by employing readily available materials.
In this respect, before explaining at least one embodiment of the lightweight tile with tapered support in detail it is to be understood that the design is not limited in its application to the details of construction and to the arrangement, of the components set forth in the following description or illustrated in the drawings. The lightweight tile with tapered support is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing of other features, methods and processes for carrying out the several purposes of the present design. It is important, therefore, that the claims be regarded as including such equivalent construction insofar as they do not depart from the spirit and scope of the present application.

SUMMARY OF THE INVENTION

The principal advantage of the lightweight tile with tapered support is that it does not require heavy beam structural construction.
Another advantage is with the reverse angular support, from that of the angle of the roof, it allows a uniformly even support between the tile and the roof surface.
Another advantage in the lightweight tile with tapered support is that with the unique design of the underside it increases the surface area providing greater dissipation of heat and moisture through evaporation.
Another advantage in the lightweight tile with tapered support is that it does not require the horizontal battens for attachment or additional support.
Another advantage in the lightweight tile with tapered support is that the mounting holes are through rib sections which is in direct contact with the roof's surface reducing breakage upon installation.
Another advantage in the lightweight tile with tapered support is that it can be supplied with a breathable, underlying cushioning/insulating member.
Another advantage in the lightweight tile with tapered support is having a breathable, underlying cushioning/insulating member that is more impact resistant.
Another advantage in the lightweight tile with tapered support even using the breathable, underlying cushioning/insulating material there is more than adequate area for air circulation.
Another advantage in the lightweight tile with tapered support is that it is easier to install than the conventional tile roofing.
Another advantage of the lightweight tile with tapered support is that it can replace composition shingles on a structure of a lighter construction.
Another advantage of the lightweight tile with tapered support is the increased value it brings to the structure.
Another advantage of the lightweight tile with tapered support is the new interior and exterior design capabilities that it offers.
Another advantage of the lightweight tile with tapered support is the increased fire protection it brings to the structure.
Another advantage of the lightweight tile with tapered support is the improved appearance of the structure.
Another advantage of the lightweight tile with tapered support is the reduction of shipping weight, and because of this reduced weight, one can ship twice the number of tiles in a container or truck, as compared to a conventional concrete tile.
Another advantage of the lightweight tile with tapered support is the reduction of storage space required.
Another advantage of the lightweight tile with tapered support is the reduction of materials costs.
Another advantage is the longevity of the lightweight tile with tapered support.
Yet another advantage is the durability of the lightweight tile with tapered support.
And still another advantage is to create a lightweight tile with tapered support that can be walked on without it cracking,
A further advantage is to create a lightweight tile with tapered support made of a variety of differing compounds and manufacturing processes such as concrete, porcelain and ceramic.
Another advantage is with the unique design of the underside of the tile when made of porcelain and ceramic, it can be fired in a kiln without deforming.
And yet another advantage is the reduction in the costs of manufacturing a quality lightweight tile roofing material.
These together with other advantages of the lightweight tile with tapered support along with the various features of novelty, which characterize the design, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. In this respect, before explaining at least one of the embodiments of the lightweight tile with tapered support in detail it is to be understood that the design is not limited in its application to the details of construction and to the composition set forth in the following description or illustrated in the drawings. The lightweight tile with tapered support is capable of other embodiments and of being practiced and carried out in various ways. In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
The preferred embodiment of the lightweight tile with tapered support will be a tile used for, but not restricted, to roofing. These tiles can be used for a variety of additional design concepts and still remain within the scope of this application. The preferred material used for the lightweight tile with tapered support will be a unique formulated concrete, but a variety of additional materials can be used in the process of manufacturing including clay, mortar, ceramic and porcelain and additionally remain within the scope of this application. The upper surface will be available in a variety of conventional textures with the unique feature being the design of the underside of the lightweight tile with tapered support where a great percentage of the material has been removed to create the lightweight feature and allow the tiles to be fully supported by the flat roof structure where no horizontal battens are required. Additionally by the removal of this material the surface area has been increased providing greater dissipation of heat and moisture through evaporation. A variety of cavities have been created leaving tapered ribs with concave reliefs making a bridgework type of supporting structure while decreasing the weight significantly. The polarity of ribs on the lower surface has staggered recesses to additionally remove more material while maintaining the required uniform support. The supporting rib structure of the underside is at a slight reverse angle from the angle of the roof allowing the tiles to interconnect and still make a uniform supporting contact with the roof surface. The mounting holes for the lightweight tile with tapered support have been located in the upper end on two of the ribs where there is full contact with the roofs surface reducing the possibility of breakage during installation.
Several patterns of the lower surface incorporate tapered intermittent ribs with staggered recesses that have been created with similar elements used on bridge structures where all the corners and recesses have concave radius's, creating a significantly thinner roof material that can be walked on without the fear of cracking the tiles. Another outstanding feature is the trough on one side that creates the unique interlocking mating edge of the tiles. Notches removed on the opposite corners work as a locater and stop for the next course of tiles while also creating a step in the trough for any water to travel down that might enter between the tiles. The use of concrete on roofing tiles is not new, but those tiles remain very thick and heavy along with being subject to fracture due to their unsupported bottom surfaces. A triangular area created under each prior art tile between each courses creates a gap where if stepped on will fracture. The use of concrete on the thin lightweight tile with tapered support is new in that there have been vast improvements in design of the lightweight tile with tapered support in the field of concrete mixtures. The lightweight tile with tapered support is formed in a pressurized mold with a relatively dry mixture of the concrete materials and water.
There have been many types of concrete created by varying the proportions of the main ingredients. By varying the proportions of materials, or by substitution for the cementitious and aggregate phases, the finished product can be tailored to its application with varying strength, density, or chemical and thermal resistance properties. It is a construction material composed of commonly Portland cement and other cementitious materials such as fly ash and slag cement, aggregate, plus a fine aggregate such as sand), water, and chemical admixtures. Concrete is strong in compression, as the aggregate efficiently carries the compression load. However, it is weak in tension as the cement holding the aggregate in place can crack, allowing the structure to fail. Reinforced concrete used in the manufacturing of the lightweight tile with tapered support solves these problems by adding, steel fibers, glass fiber, or plastic fiber to carry tensile loads.
There are inorganic materials that also have pozzolanic or latent hydraulic properties. These very fine-grained materials are added to the concrete mix to improve the properties of concrete (mineral admixtures), or as a replacement for Portland cement. Silica fume a by-product of the production of silicon and ferrosilicon alloys is also used on the lightweight tile with tapered support. Silica fume is similar to fly ash, but has a particle size 100 times smaller. This results in a higher surface to volume ratio and a much faster pozzolanic reaction. Silica fume is used to increase strength and durability of concrete and generally requires the use of superplasticizers for workability. Plasticizers/superplasticizers (water-reducing admixtures) increase the workability of plastic or “fresh” concrete, allowing it to be worked more easily, with less consolidating effort. Typical plasticizers are liginsulfate, polyol type. Alternatively, plasticizers can be used to reduce the water content of a concrete while maintaining workability. Such treatment improves its strength and durability characteristics. Superplasticizers are a class of plasticizers that have fewer deleterious effects when used to significantly increase workability. Representative superplasticizers are sulfonated naphthalene formaldehyde condensate, sulfonated melamine, formaldehyde condensate, and acetone formaldehyde condensate. More advanced superplasticizers are polycarboxylate types.
The first alternate embodiment of the lightweight tile with tapered support will be constructed of ceramic or porcelain material in a slightly different configuration where the upper surface will have a variety of conventional decorative textures with the underside having a plurality of flat ribs with intermittent recesses along with repeating contours and depressions to lighten the tile and increase the surface area. In addition by having the plurality flat ribs with intermittent recesses along with repeating contours the tile can be fired in the kilns without deforming, which has been a major problem in the past. With the reverse angular configuration of the full tile, instead of just the ribs being tapered in this embodiment, and being of a ceramic or porcelain material, the tile can be very thin and maintain full contact with the roof surface. The step in the lower end of the first alternate embodiment of the lightweight tile extends over the tapered upper end of the adjoining tile, maintaining the full surface contact on the roof and creating uniform and a full contact stop for the next course of tiles. Another outstanding feature is the angled trough created by the interlocking mating edges of the tiles. A notch on the corners is not necessary due to the overlap of the angled mating edges. The unique angle of the mating edges creates a trough where water can travel down if it seeps through the edges of the tiles. The mounting holes for the lightweight tile with tapered support will additionally be located in the upper end on two of the ribs where there is full contact with the roof's surface reducing the possibility of breakage during installation.
Ceramic materials are inorganic, non-metallic materials and things made from them. They may be crystalline or partly crystalline. They are formed by the action of heat and subsequent cooling. Clay was one of the earliest materials used to produce ceramics, but many different ceramic materials are now used in domestic, industrial and building products.
Traditional ceramic raw materials include clay minerals such as kaolinite, whereas more recent materials include aluminum oxide, more commonly known as alumina. The modern ceramic materials, which are classified as advanced ceramics, include silicon carbide and tungsten carbide. Both are valued for their abrasion resistance, and hence find use in applications such as the wear plates of crushing equipment in mining operations. Advanced ceramics are also used in the medicine, electrical and electronics industries.
Porcelain is used for a wide range of household and industrial products. Porcelain is a ceramic material made by heating raw materials, generally including clay in the form of kaolin, in a kiln to temperatures between 1,200° C. (2,192° F.) and 1,400° C. (2,552° F.). The toughness, strength, and translucence of porcelain arise mainly from the formation of glass and the mineral mullite within the fired body at these high temperatures.
A second alternate embodiment of the lightweight tile with flat support ribs will be constructed of ceramic or porcelain in a slightly different configuration where the upper surface will have a variety of conventional decorative textures with the underside similar to the preferred embodiment by having a plurality of ribs with intermittent recesses but the ribs are not tapered. All the recesses have been created with similar elements used on bridge structures where the corners have concave radius's, creating a thinner ceramic or porcelain tile roof that is very strong. Another outstanding feature is the trough on the side that creates interlocking mating edges on the tiles. A notch removed on the upper corner of the second alternate embodiment also works as a locater and stop for the next course of tiles while also creates a step in the trough for any water that might enter between the tiles.
A third alternate will be a conventional double barrel style of roofing tile with the addition of the unique tapered rib supports with intermittent recesses where instead of having a gap under each tile between each course, there is a uniform support throughout the full length of the tile. The main purpose of the reverse taper rib supports is to keep the tiles from breaking when they are stepped on during installation or maintenance of the roof.
A fourth alternate will be the conventional “S” configuration of roofing tile with the addition of the unique tapered rib supports with intermittent recesses where instead of having a gap under each tile between each course there is a uniform support throughout the full length of the tile. The main purpose of the reverse taper rib is that it supports tiles from breaking when they are stepped on during installation or maintenance of the roof.
The foregoing has outlined rather broadly the more pertinent and important features of the present lightweight tile with tapered support in order that the detailed description of the application that follows may be better understood so that the present contribution to the art may be more fully appreciated. Additional embodiments and features of the design will be described hereinafter which form the subject of the claims of this disclosure. It should be appreciated by those skilled in the art that the conception and the disclosed specific embodiments may be readily utilized as a basis for modifying or designing other structures and methods for carrying out the same purposes of the present design. It should also be realized by those skilled in the art that such equivalent constructions and methods do not depart from the spirit and scope of this application as set forth in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the lightweight tile with tapered support and together with the description, serve to explain the principles of this application.

FIG. 1 depicts a perspective view of the top side of a prior art roofing tile.

FIG. 2 depicts a perspective view of the lower surface of a prior art roofing tile.

FIG. 3 depicts a perspective view of the top of the preferred embodiment of the lightweight tile with tapered support illustrating the interlocking drain trough.

FIG. 4 depicts a side view through the length of the lightweight tile illustrating the tapered reverse angle support in relation to the angled slope of the conventional roof.

FIG. 5 depicts an exploded view of the preferred embodiment of the lower surface of a lightweight tile with tapered support and the optional insulating member.

FIG. 6 depicts a top plan view of the first design pattern of the preferred embodiment of the lightweight tile with tapered support.

FIG. 7 depicts a cross section through the length of the lightweight tile with tapered support illustrating the angled support ribs.

FIG. 8 depicts a cross section through the length of the lightweight tile with tapered support incorporating the optional insulating member.

FIG. 9 depicts a top plan view of the second design pattern on the lower surface of the preferred embodiment of the lightweight tile with tapered support.

FIG. 10 depicts a typical end view of the preferred embodiment of the lightweight tile with tapered support.

FIG. 11 depicts a plan view illustrating the lower surface of the flat lightweight tiles with tapered support in a parallel alignment and their interlocking features.

FIG. 12 depicts a perspective view of the first alternate embodiment of the lightweight tile with the third design pattern on the lower surface fabricated in a ceramic or porcelain material with a thin reverse tapered configuration having unique interlocking side members.

FIG. 13 depicts a side view of the first alternate embodiment of the lightweight tile with a reverse tapered configuration.

FIG. 14 depicts an end view of the first alternate embodiment of the lightweight tile with tapered support illustrating the side edge engagement.

FIG. 15 depicts a perspective bottom view of the second alternative embodiment of the lightweight tile with flat support members having the third design pattern on the lower surface.

FIG. 16 depicts a perspective top view of the second alternative embodiment of the lightweight tile illustrating the interlocking drain trough and the notch.

FIG. 17 depicts a top plan view of the second design pattern of the first alternate embodiment of the lightweight tile with the third design pattern on the lower surface.

FIG. 18 depicts a cross section through the length of the second alternate embodiment of the lightweight tile illustrating the first design pattern of the small rib member.

FIG. 19 depicts a cross section through the length of the second alternate embodiment of the lightweight tile illustrating the depressed groove.

FIG. 20 depicts a side view of the second alternate embodiment of the lightweight tile.

FIG. 21 depicts a cross section through the width of the second alternate embodiment of the lightweight tile.

FIG. 22 depicts an end view of the second alternate embodiment of the lightweight tile.

FIG. 23 depicts a top plan view of the second alternate embodiment of the lightweight tile with the fourth design pattern on the lower surface.

FIG. 24 depicts a top perspective view of a conventional double barrel roofing tile.

FIG. 25 depicts a perspective view of the lower surface of the conventional double barrel roofing tile with the incorporation of three of the unique reverse tapered ribs supporting the central area of the tile.

FIG. 26 depicts a perspective view of the lower surface of the conventional “S” configuration roofing tile with the incorporation of two of the unique reverse tapered ribs supporting the central area of the tile.

FIG. 27 depicts a top plan view of a straight-row installed configuration of the lightweight tile with tapered support.

FIG. 28 depicts a top plan view of a staggered-row installed configuration of the lightweight tile with tapered support.

For a fuller understanding of the nature and advantages of the lightweight tile with tapered support, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the design and together with the description, serve to explain the principles of this application.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

100831 Referring now to the drawings, wherein similar parts of the embodiments of the lightweight tile with tapered support 10A, 11B, 10C, 10D and 10E are identified by like reference numerals.
FIG. 1 a perspective view of the top side of a prior art concrete roofing tile.
FIG. 2 depicts a perspective view of the lower surface of a prior art concrete roofing tile.
FIG. 3 depicts a perspective view of the upper surface 12 of the preferred embodiment of the lightweight the with tapered support 10A illustrating the upper end 14 and the lower end 16 with the left side 18 and the right side 20 with the interlocking drain trough 22. The upper left corner 24 and the lower right corner 26 have notches 28 and 30 for the purpose of locaters for the installation process and to create a step in the interlocking drain trough 22. The upper surface 12 will come in a variety of conventional textured surfaces. These tiles will not require battens attached to the roofs surface for the purpose of installation.
FIG. 4 depicts a side view through the length of the lightweight tile with tapered support 10A illustrating the tapered reverse angle support of the tile in relation to the angled slope of the conventional roof structure 34. The lower surface 36 of the lightweight tile with tapered support 10A will have the unique configuration consisting of a polarity of reverse tapered ribs 38 that have intermittent recesses 40 aiding in the reduction of the weight while giving the support in the central area where it is required. The reverse angle of the tapered ribs, differing from the angle of the roof structure 34, is for the purpose of making a uniform contact with the roof surface 42.
FIG. 5 depicts an exploded view of the lower surface 32 with the design pattern 36A of the preferred embodiment of the lightweight tile with tapered support 10A and the optional mating insulating member 44 constructed of a variety of conventional insulating materials raised above it. The insulating member 44 with the lower surface 46 will have a plurality of grooves 48 for the purpose of air circulation. The top surface 50 of the optional insulating member 44 will conform to the configuration of the lightweight tile with tapered support 10A. Additionally the insulating member 44 acts as a cushion during shipping and handling.
The lower surface 32 of the lightweight tile with tapered support 10A has been relieved of a great deal of material by the means of its unique configuration. The design pattern 36A incorporates a plurality of reverse angled tapered ribs 38 with intermittent recesses 40 that incorporate curved surfaces 52 eliminating the sharp corners that tend to propagate cracks. A polarity of rectangular recesses 54 are spaced between the reverse angled tapered ribs 38 with smaller ribs 56 in an “X” pattern. Smaller rectangular recesses 58 with a curved inner surface remove additional excess material. On the left side 18 is the mating edge 60 of the lightweight tile with tapered support 10A that interlocks with drain trough 22 on the right side 20. At the lower end 16 of the lightweight tile with tapered support 10A is a perpendicular recess 62 to remove more material with series of crossing ribs 64. The major purpose of the recesses is to keep relatively close cross sectional areas in the lightweight tile with tapered support 10A, and to increase the surface area dissipating heat and to promote an even drying time of the material while maintaining maximum strength. A perpendicular supporting member 66 with similar intermittent recesses 68 extends across the lower end of the lightweight tile with tapered support 10A for the purpose of giving maximum support in this area. The mounting holes 69 for the lightweight tile with tapered support 10A have been located in the upper end 14 on two of the ribs 38 where there is full contact with the roof's surface 42 reducing the possibility of breakage during installation.
FIG. 6 depicts a top plan view of the preferred embodiment of the lightweight tile with tapered support 10A having a lower surface 32 with the design pattern 36A with a plurality of angled tapered ribs 38 with intermittent recesses 40 that incorporate curved surfaces 52. A polarity of rectangular recesses 54 are spaced between the reverse angled tapered ribs 38 with smaller ribs 56 in an X pattern. Smaller rectangular recesses 58 with a curved inner surface remove additional excess material at various locations of the lower surface 32 increasing the surface area to dissipate heat. On the left side 18 is the mating edge 60 of the lightweight tile with tapered support 10A that interlocks with drain trough 22 on the right side 20 of the adjacent tile when they are installed on a roof. At the lower end 16 of the lightweight tile with tapered support 10A is a perpendicular recess 62 to remove more material with series of crossing ribs 64. The mounting holes 69 for the lightweight tile with tapered support 10A have been located in the upper end on two of the angled tapered ribs 38 where there is full contact with the roofs surface 42 reducing the possibility of breakage during installation.
FIG. 7 depicts a cross section through the length of the lightweight tile with tapered support 10A illustrating the reverse angled tapered ribs 38 with intermittent recesses 40 that incorporate curved surfaces 52. The rectangular recesses 54 with smaller ribs 56 serve the purpose of removing more material and reducing the cross sectional area while increasing the surface area and maintaining adequate strength through the length of the tile.
FIG. 8 depicts a cross section through the length of the lightweight tile with tapered support 10A incorporating the optional insulating member 44 where it extends over the reverse angled tapered ribs 38 a crushing distance 70 depending upon the density of the insulating member 44 which may be between 0.125 and 0.250 of an inch. This view also further illustrates how the insulating member 44 acts as a cushion member during shipping and handling.
FIG. 9 depicts a top plan view of the second design pattern 36B of the preferred embodiment of the lightweight tile with tapered support 10A illustrating the lower surface 32 with the upper end 14, the lower end 16 with the left side 18 and the right side 20 having the interlocking drain trough 22. The upper left corner 24 and the lower right corner 26 have notches 28 and 30 for the purpose of locaters for the installation process and to create a step in the interlocking drain trough 22. The upper surface 12 will come in a variety of conventional textured surfaces. Differences'in the second design pattern 36B being a sample of the varied shapes of the recesses 72 which have a triangular design pattern 36B. The mounting holes 69 for the lightweight tile with tapered support 10A have been located in the upper end on two of the reverse angled tapered ribs 38 where there is full contact with the roof's surface 42 reducing the possibility of breakage during installation.
FIG. 10 depicts a typical end view of the preferred embodiment of the lightweight tile with tapered support 10A illustrating the perpendicular supporting member 66 with the intermittent recesses 68.
FIG. 11 depicts a plan view illustrating the parallel alignment of the flat lightweight tile with tapered support 10A and their interlocking features where the tiles are shown in parallel alignment not staggered as in the composition shingle roofing pattern.
FIG. 12 depicts a perspective view of the first alternate embodiment of the lightweight tile with reverse tapered configuration 10B in a ceramic or porcelain material with third design pattern 36C having a reverse tapered lower surface 80. It will be in a similar configuration with the upper end 82, a lower end 84, a right side 86 and a left side 88. The upper surface 90 will come in a variety of conventional textured surfaces. A plurality of ribs 96 with concave recesses 98, traverse the length of the tile. A series of longitudinal small ribs 100 and grooves 102 are evenly spaced between the ribs 96. Multiple contoured elements 104 along both sides of the lightweight tile with tapered support 10B provide additional support while increasing the surface area. Unique interlocking angled side members 106 and 108 supply the interlocking means where a trough 110 is created to transport any moisture down that might seep between the mating tiles. An overlapping ledge 112 is at the lower end 84 where it engages with the upper end 82 of the next course of tiles. These tiles will also not require battens attached to the roofs surface for the purpose of installation.
FIG. 13 depicts a side view of the first alternate embodiment of the lightweight tile with tapered support 10B illustrating the reverse angle of the tile and the overlapping ledge 112 engaging with lower end 84.
FIG. 14 depicts an end view of the first alternate embodiment of the lightweight tile with reverse tapered configuration 10B illustrating the side edge engagement between the angled edges 106 and 108 with the location of the trough 110. The purpose of the trough is to transport any moisture down that might seep between the mating tiles.
FIG. 15 depicts a perspective bottom view of the second alternative embodiment of the lightweight tile 10C with a flat support and the third design pattern 36D on the lower surface 118 constructed of a ceramic or porcelain material. It will be in a similar configuration with the upper end 120, a lower end 122, a right side 124 and a left side 126. The upper surface 128 will come in a variety of conventional textured surfaces. The lower surface 118 will have plurality of ribs 130 with concave recesses 132 that traverse the length of the tile. A series of longitudinal small ribs 134 and grooves 136 are evenly spaced between the ribs 130. Multiple contoured elements 138 along both sides of the lightweight tile 10C provide additional support while increasing the surface area. A notch 140 will be in the left side 126 adjacent to the upper end 120. There will be an interlocking trough 142 along the right side 124 for the purpose of draining moisture that will seep through the crack between the tiles. These tiles will not require battens attached to the roof's surface for the purpose of installation.
FIG. 16 depicts a perspective top view of the second alternative embodiment of the lightweight tile 10C illustrating the interlocking drain trough 142 and the notch 140.
FIG. 17 depicts a top plan view of the second alternate embodiment of the lightweight tile 10C with the third design pattern 36D on the lower surface 118. The tile is shown having a plurality of ribs 130 with concave recesses 132 that traverse the length of the tile. A series of longitudinal small ribs 134 and grooves 136 are evenly spaced between the ribs 130. Multiple contoured elements 138 along both sides of the lightweight tile 10C provide additional support while increasing the surface area. A notch 140 will be in the left side 126 adjacent to the upper end 120. There will be an interlocking drain trough 142 along the right side 124.
FIG. 18 depicts a cross section through the length of the second alternate embodiment of the lightweight tile 10C with the third design pattern 36D on the lower surface 118 illustrating small rib 134 and grooves 136.
FIG. 19 depicts a cross section through the length of the second alternate embodiment of the lightweight tile 10C with the third design pattern 36D illustrating the groove 136.
FIG. 20 depicts a side view of the second alternate embodiment of the lightweight tile 10C with notch 140.
FIG. 21 depicts a cross section through the width of the second alternate embodiment of the lightweight tile 10C with ribs 130, small rib 134 and grooves 136 along with the interlocking drain trough 142 on the lower surface 118.
FIG. 22 depicts an end view of the second alternate embodiment of the lightweight tile 10C illustrating the ribs 130, with the interlocking drain trough 142 on the lower surface 118.
FIG. 23 depicts a top plan view of the second alternate embodiment of the lightweight tile 10C with the forth design pattern 36E on the lower surface 118. This tile is shown having a plurality of ribs 130 with concave recesses 132 that traverse the length of the tile. A series of longitudinal small ribs 134 and grooves 136 are evenly spaced between the ribs 130. Multiple contoured elements 138 along both sides of the lightweight tile 10C provide additional support while increasing the surface area. This tile incorporates a series of X-bracing ribs 144 providing additional strength across the width of the tile. A notch 140 will be in the left side 126 adjacent to the upper end 120.
There will be an interlocking drain trough 142 along the right side 124.
FIG. 24 depicts a top perspective view of a conventional double barrel roofing tile 10D with the upper surface 150.
FIG. 25 depicts a perspective view of the lower surface 152 of the tapered support ribs on existing conventional double barrel roofing tile 10D with the incorporation of three of the unique reverse tapered ribs 154 having a series of concave recesses 156 supporting the central area of the tile.
FIG. 26 depicts a perspective view of the lower surface 152 of the tapered support ribs on existing conventional “S” configuration roofing tile 10E incorporation of two of the unique reverse tapered ribs 154 having a series of concave recesses 156 supporting the central area of the tile.
FIG. 27 depicts a top plan view of a straight-row configuration 160 of the lightweight tiles with tapered support. The tiles can be configured in this way, that is in straight rows, or they may be installed staggered, as shown in FIG. 28 (please see below). When in this configuration, the lightweight tiles with tapered support lend themselves well to interlocking and overlapping.
FIG. 28 depicts a top plan view of a staggered-row configuration 170 of the lightweight tiles with tapered support. Thus, the system may be installed in straight rows or in staggered rows, or any other configuration. The disclosed reverse angle and overlapping system for lightweight tiles with tapered support can be used with any overlapping tile, made from any material, with the interlocking feature as shown in the above drawing figures, or without interlocking.
The lightweight tile with tapered support 10A, 10B, 10C, 10D and 10E shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing a lightweight tile with tapered support 10A, 10B, 10C, 10D and 10E in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

Claims

1. A lightweight tile comprising:

a) a tile having an upper surface, a lower surface, an upper end portion, a lower end portion and a right side and a left side;

b) a plurality of reverse angle tapered ribs located on the lower surface and running from said upper end portion to said lower end portion, wherein said ribs taper in a reverse angle resulting in said upper end portion resting flat on a tile mounting surface and said lower end portion held cantilevered above said tile mounting surface, allowing overlap of said tile upper end portion to said tile lower end portion; and

c) a plurality of grooves, concave recesses and smaller support ribs integral to said lower surface in both said reverse angle tapered ribs and said tile lower surface;

whereby the resulting tile is stronger, more impact resistant and lighter in weight than conventional tiles, yet allows overlapping and greater support on any mounting surface.

2. The lightweight tile according to claim 1, wherein an insulating member is affixed to said tile lower surface.

3. The lightweight tile according to claim 1, wherein upper end portion further includes a notch located in said upper end portion in the upper left corner of the lightweight tile.

4. The lightweight tile according to claim 1, wherein lower end portion further includes a notch located in said lower end portion in the lower right corner of the lightweight tile.

5. The lightweight tile according to claim 1, wherein drain trough is located along said right side of the lightweight tile.

6. The lightweight tile according to claim 5, wherein a mating surface is located along said left side of the lightweight tile, allowing the mating and overlapping of said mating surface located on said left side of a first lightweight tile and the drain trough located on said right side of another lightweight tile placed adjacent to said first lightweight tile.

7. The lightweight tile according to claim 1, wherein said lightweight tile is fabricated using materials selected from the list including concrete materials, ceramic materials, porcelain materials and clay materials.

8. A lightweight roofing tile comprising:

a) a double barrel tile configuration having an upper surface and a lower surface, and a central area;

b) said lower surface including integral tapered support ribs wherein said tapered support ribs are reverse tapered ribs; and

c) wherein said reverse tapered support ribs include a plurality of concave recesses supporting said central area of the lightweight double barrel roofing tile.

9. The lightweight roofing tile according to claim 8, wherein said double barrel roofing tile is configured in a conventional “S” configuration roofing tile and incorporates two reverse tapered ribs each having a plurality of concave recesses supporting said central area of the conventional “S” configuration roofing tile.

10. The lightweight tile according to claim 8, wherein said lightweight roofing tile is constructed from press molded ceramic materials.

11. A method for making a lightweight tile, according to comprising the steps of:

a) providing a tile having an upper surface, an upper end portion, a lower end portion and a right side and a left side;

b) providing a plurality of reverse angle tapered ribs located on the lower surface and running from said upper end portion to said lower end portion, wherein said ribs taper in a reverse angle resulting in said upper end portion resting flat on a tile mounting surface and said lower end portion held cantilevered above said tile mounting surface, allowing overlap of said tile upper end portion to said tile lower end portion; and

c) providing a plurality of grooves, concave recesses and smaller support ribs integral to said lower surface in both said reverse angle tapered ribs and said tile lower surface;

12. The method for making a lightweight tile according to claim 11, wherein an insulating member is affixed to said tile lower surface.

13. The method for making a lightweight tile according to claim 11, wherein upper end portion further includes a notch located in said upper end portion in the upper left corner of the lightweight tile.

14. The method for making a lightweight tile according to claim 11, wherein lower end portion further includes a notch located in said lower end portion in the lower right corner of the lightweight tile.

15. The method for making a lightweight tile according to claim 11, wherein drain trough is located along said right side of the lightweight tile.

16. The method for making a lightweight tile according to claim 15, wherein a mating surface is located along said left side of the lightweight tile, allowing the mating and overlapping of said mating surface located on said left side of a first lightweight tile and the drain trough located on said right side of another lightweight tile placed adjacent to said first lightweight tile.

17. The method for making a lightweight tile according to claim 11, wherein said lightweight tile is fabricated using materials selected from the list including concrete materials, ceramic materials, porcelain materials and clay materials.

18. A method for making a lightweight roofing tile according to claim 11, further comprising the steps of:

a) providing a double barrel tile configuration having an upper surface and a lower surface, and a central area;

b) providing said lower surface including integral tapered support ribs wherein said tapered support ribs are reverse tapered ribs; and

19. The method for making a lightweight roofing tile according to claim 18, wherein said double barrel roofing tile is configured in a conventional “S” configuration roofing tile and incorporates two reverse tapered ribs each having a plurality of concave recesses supporting said central area of the conventional “S” configuration roofing tile.

20. The method for making a lightweight tile according to claim 18, wherein said lightweight roofing tile is constructed from press molded ceramic materials.