WO2000046463A1 - Tuile et procede de fabrication - Google Patents

Tuile et procede de fabrication Download PDF

Info

Publication number
WO2000046463A1
WO2000046463A1 PCT/GB2000/000165 GB0000165W WO0046463A1 WO 2000046463 A1 WO2000046463 A1 WO 2000046463A1 GB 0000165 W GB0000165 W GB 0000165W WO 0046463 A1 WO0046463 A1 WO 0046463A1
Authority
WO
WIPO (PCT)
Prior art keywords
tile
roof tile
composite
adhesive
composite roof
Prior art date
Application number
PCT/GB2000/000165
Other languages
English (en)
Inventor
Michel Bernard Marie Leborgne
Eric Arthur Rirsch
Jacquolyn Lesley Hailey
Original Assignee
Lafarge Braas Research & Development Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lafarge Braas Research & Development Ltd. filed Critical Lafarge Braas Research & Development Ltd.
Priority to AU30658/00A priority Critical patent/AU3065800A/en
Publication of WO2000046463A1 publication Critical patent/WO2000046463A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0046—Machines or methods for applying the material to surfaces to form a permanent layer thereon to plastics
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/28—Roofing elements comprising two or more layers, e.g. for insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/29—Means for connecting or fastening adjacent roofing elements
    • E04D1/2907—Means for connecting or fastening adjacent roofing elements by interfitted sections
    • E04D1/2914—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements
    • E04D1/2916—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements the fastening means taking hold directly on adjacent elements of the same row

Definitions

  • the present invention is concerned with roof tiles and a method for the manufacture of such roof tiles .
  • Conventional concrete roof tiles are manufactured by the well known extrusion process in which a plurality of release coated tile pallets are fed seriatim to a mortar hopper of a tile making machine whereat tile mortar is extruded onto the pallets as they pass through the hopper to form a ribbon of tile mortar on said pallets. Downstream of the hopper the ribbon of mortar is cut to provide a discrete "green state" tile on each of the pallets. Thereafter the pallets and "green state” tiles are fed to a curing chamber whereat the tiles are cured.
  • the improved composite tile is lighter per square metre in use on a roof, and/or has a superior finish to its upper surface and/or has the added advantages that, in one method of manufacture, it may conveniently be made on a carrier plate from which it may be removed before curing thereof .
  • the tile provided by this invention may comprise features for facilitating its installation on a roof.
  • the present invention thus provides a composite roof tile comprising a laminate of a layer of cementitious material and a surface element, characterised in that an adhesive is provided between the cementitious material and the surface element.
  • the adhesive may be a cold quick-set thermosetting or thermoplastics adhesive and may conveniently be chosen from a heat activated adhesive, an alkali activated adhesive or a moisture curing adhesive.
  • the element may be of tray-like configuration.
  • the element may conveniently provide a base layer, that is the underside in use, for the composite roof tile, or, the element may conveniently provide an upper layer, that is the upper side in use, for the composite roof tile.
  • the element consists of a unitary moulding.
  • the element comprises a multi-part moulding.
  • the element may comprise: I) side lock means; and/or ii) head lap means; and/or iii) tile fixing means; and/or iv) tile location features; and/or v) weather bars .
  • the element may be formed as a moulding of a plastics material having a thickness of from 25 ⁇ m to 7mm and such a plastics material may be selected from recycled or virgin grades of polyvinylchloride, polystyrene, polyethylene, polyester, polyolefin, phenolic, acrylic, epoxy or fibre reinforced plastics.
  • a plastics material may be selected from recycled or virgin grades of polyvinylchloride, polystyrene, polyethylene, polyester, polyolefin, phenolic, acrylic, epoxy or fibre reinforced plastics.
  • the element may be formed as moulding of glass .
  • the invention also conveniently provides a method of manufacturing a composite roof tile comprising a laminate of cementitious materials and a surface element, characterised in that the method includes the provision of an adhesive between the surface element and the layer of cementitious material.
  • Figure 1 is a diagrammatic side view of a tile making machine ;
  • Figure 2a is a side elevation of a conventional concrete roof tile and pallet
  • Figure 2b is a side elevation of a composite tile manufactured in a similar way to the conventional tile of Figure 2a;
  • Figure 2c is a side elevation of a composite tile manufactured upside down compared to the method used for the tile of Figure 2a;
  • Figure 3 is an exploded upper perspective view of a first composite tile and carrier plate
  • Figure 4 is an upper end perspective view of an interlocking pair of the composite tile of Figure 3;
  • Figure 5 is an underside perspective view of the tile shown in Figure 3 ;
  • Figure 6 is an exploded upper perspective view of a second composite tile and carrier plate
  • Figure 7 is an underside perspective view of the tile shown in Figure 6 ;
  • Figure 8 is a fragmentary underside perspective view of the tile shown in Figure 6 and 7;
  • FIG. 9 is a fragmentary upper side perspective view of the tile shown in Figures 6, 7 and 8;
  • Figure 10 is an exploded upper perspective view of a third composite tile and carrier plate
  • Figure 11 is an underside perspective tail end view of the composite tile of Figure 10;
  • Figure 12 is an underside perspective head end view of the composite tile of Figure 10;
  • Figure 13 is an upper perspective left-hand side view of the composite tile of Figure 10;
  • Figure 14 is an upper perspective right-hand side view of the composite tile of Figure 10;
  • Figure 15 is a fragmentary upper end view of two interlocked composite tiles shown in Figure 10.
  • Figure 16 is a fragmentary upper perspective view of a roof assembly made up of the third composite tiles.
  • concrete roof tiles 2 are produced in a tile making machine comprising a conveyor on which metal pallets 4 are fed seriatim to a mortar hopper whereat tile mortar is compacted onto upper surfaces of the pallets 4 to form a continuous ribbon of mortar thereon. Subsequently, the ribbon of mortar is cut downstream of the mortar hopper to form a discrete "green state" tile 2 on each pallet 4. Thereafter, the pallets 4 and "green state” tiles 2 are placed in a curing chamber for sufficient time to effect curing of the tiles. After curing the tiles 2 are separated from their respective pallets 4 prior to packaging and despatch, the pallets 4 being recirculated about a circuitous conveyor to return once again to the mortar hopper of the tile making machine.
  • Tiles 2 made in this way are generally rectangular in plan, or substantially so, and comprise undersurfaces 6 formed by the tile pallets 4. Upper surfaces 8 of the tiles 2 are substantially rectilinear from a head-lap end 10 to a toe- end 12 thereof, see Figure 2a. However, the tiles 2 may be provided with a contoured cross-section across the tiles from side to side thereof, e.g. the tiles may be of a "Bold Roll” or "Double Roman” curvature. Alternatively, the tiles may be formed as a substantially planer configura ion. Such tiles may also be provided with hanging nibs on the underside thereof, which nibs are moulded by an upper surface of the pallets 4.
  • the tiles 2 may be provided with interlocking side- lock features formed along an underside edge of the tiles 2 by the upper surfaces of the pallets 4 and along an opposite upper side edge of the tiles as the upper surface of the ribbon of mortar is formed on the tile pallets 4 when they are fed seriatim under the mortar hopper of the tile making machine.
  • conventional concrete roof tiles are relatively heavy and the present invention provides a novel method by which composite tiles of substantially less weight than conventional concrete tiles but of comparable strength may be made.
  • the novel method makes use of a tile making machine 20, see Figure 1, comprising a conveyor 22, a surface element dispenser 24, an adhesive applicator 26 downstream of said dispenser 24 and a mortar hopper 28 downstream of the applicator 26.
  • the surface element dispenser 24 is essentially a magazine from which surface elements 30 are dispensed one at a time onto associated carrier plates 32 fed thereunder by the conveyor 20 in the direction of the arrow "A" in Figure 1.
  • the carrier plates 32 Downstream of the dispenser 24, the carrier plates 32 carry the surface elements 30 in end to end juxtaposition beneath the adhesive applicator 26 whereat a "cold-set” or “heat- activated” adhesive 34 is applied onto upper surfaces 36 of the elements 30.
  • the carrier plates 32 together with the surface elements 30 pass in end to end juxtaposition beneath the mortar hopper 28 whereat tile mortar 38 is compacted onto the adhesive coated elements 30.
  • the compaction of the tile mortar is effected by a conventional pack-shaft 40, a roller 42 and a slipper 44 of the hopper 28.
  • a ribbon 46 of tile mortar is formed over the surface elements 30.
  • the ribbon 46 of tile mortar is cut to form "green-state” composite tiles "T” .
  • the carrier plates 32 with the "green-state" composite tiles T are thereafter conveyed to a curing chamber where the tiles are cured prior to being removed from the carrier plates 32 and packaged for despatch to an end user.
  • the tiles T may be removed from their carrier prior to curing. This alternative method releases the carrier plates 32 for immediate return to the dispenser 24.
  • the surface elements 30 are advantageously made from 25 ⁇ m to 7mm in thickness and are made from recycled or virgin grades of the following plastics: polyvinyl chloride, polystyrene, polyethylene, polyester, polyolefin, phenolic, acrylic, epoxy and fibre reinforced plastics.
  • thermosets viz. epoxy resins, polyester resins, polysulphides , polyurethanes , polychloroprene cements; and
  • thermoplastics viz. styrene butadiene rubbers, acrylic resins, acrylic resins in conjunction with polymer modified concrete .
  • heat activated adhesives such as moisture curing polyurethanes may be used.
  • the preferred method of application of the adhesives is spraying, however, application may also be by curtain coating or roller coating.
  • the quantity of adhesive applied to the surface elements 30 will of course depend upon the adhesive itself, but application rates of between 20g to 120g per metric tile would be normal, i.e. 20g to 120g to 0.126sqM.
  • the tile mortar 38 is a conventional mixture of aggregate, cement and water having a moisture content of 7% to 15% by weight of the composition mixture. Obviously, the moisture content may advantageously be chosen to give the composite tiles good "green strength" thereby enabling removal from the carrier plates 32 prior to curing of the "green-state” tiles.
  • the thickness of the tile mortar applied to the surface elements is normally greater than 5mm to give the required strength to the finished products.
  • the innovative method has been described with respect to the provision of the surface element merely as an adjunct to the tile mortar from which the tiles are made.
  • the products produced by the novel method of the present invention may be;
  • the element may be moulded to include provisions for:
  • Figures 3 to 5 show a first composite tile Tl in which the surface element 30 and carrier plate 32 are configured to facilitate the manufacture of a combined downwardly facing side-lock 50 along one side 52 of the tile Tl with an upwardly facing side-lock 54 being formed in the mortar layer along an opposite side 56 thereof.
  • the surface element 30 and carrier plate 32 are configured to facilitate the manufacture of a combined downwardly facing side-lock 50 along one side 52 of the tile Tl with an upwardly facing side-lock 54 being formed in the mortar layer along an opposite side 56 thereof.
  • the surface elements 30 of the tile Tl also have hanging nibs 60 moulded thereon by which the tile Tl may be hung on a tile batten in use.
  • Figures 6 to 9 show a second composite tile T2 in which the surface element 30 is configured along its opposite side edges 70 and 72 to have a tongue 73 and a groove 74 which, when the tile T2 is in use on a roof, interlock with the tongues 73 and grooves 74 of other sideways adjacent tiles T2.
  • the mortar layer which provides the upper layer of the composite tile T2 in use, does not have any side lock features.
  • the surface element 30 of the tile T2 is also provided with moulded hanging nibs 76 and a batten engaging clip 78, see Figures 7 and 9.
  • Figures 10 to 16 show a third composite tile T3 in which the surface element 30 is provided with interlocking upwardly and downwardly facing side-locks 80 and 82 respectively along opposite side edge portions thereof.
  • the tile T3 is provided with two batten engaging clips 84 to facilitate the attachment of the tiles T3 to the tile battens on a roof .
  • the tiles T3 are suited for broken-bond laying on a roof. To this end the tiles T3 are each provided with a tile clip
  • tile clip 86 extending upwardly, as shown in Figures 13, 14, 15 and 16, and which tile clip 86 is adapted to be engaged in a longitudinal slot 88 of hook-shaped cross-section provided in the underside of a tile T3 located there-above, in use on a roof, as shown in Figure 16.
  • tile Tl, T2 and T3 The manufacture of the tiles Tl, T2 and T3 , by the novel method of the present invention, has been particularly described with reference to the use of a conventional concrete tile extrusion machine.
  • tile T2 may be made by a dedicated extrusion technique
  • tile T3 may be made by a dedicated extrusion technique, it is more likely to be made by a mortar spray technique.
  • the surface elements may be pre-coated with a heat or chemically activated adhesive thereby obviating the need for an adhesive applicator between the dispenser 24 and the tile mortar hopper 28.
  • the surface elements may be of robust construction leading to the carrier plates being superfluous to requirements .
  • the surface elements 30 are described as unitary elements.
  • the surface elements may be of multi-part construction.
  • the surface elements 30, whether of unitary or multi-part construction may be bonded to the tile mortar in a post extrusion step of the process of manufacture.
  • the adhesive 34 may be applied to the extruded tile mortar 38 immediately downstream of the hopper 28 and the surface elements 30 are thereafter applied to the "green state" tile mortar 38 to complete the tile structure.
  • the adhesive 34 can also be applied to the tile mortar 38 after curing of the tile mortar whereupon the elements are adhered to the cured tile mortar to complete the tile structure.
  • the bond between the tile mortar and the surface element has been described as an adhesive bond but it may be complemented by a mechanical bond provided by elements moulded on the surface elements and arranged to form a keying bond with the tile mortar laid there-over during the manufacture of the composite tiles.
  • the material from which the surface elements are made may be transparent or opaque and may be of any suitable colour.
  • the surface elements may be moulded from toughened glass which may be clear or opaque and may also be of any suitable colour.
  • the adhesive used may be a silicate based adhesive.
  • the surface elements may be moulded from a ceramic material .
  • Colouring of the surface elements whether they are moulded from plastics, glass or ceramic material is particularly advantageous where the elements provide the upper layer of the composite tile in use.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)

Abstract

L'invention concerne une tuile composite (2) fabriquée à l'aide d'un matériau à base de ciment (38). Un élément de surface (30), sous forme de partie unitaire ou en plusieurs parties, est fixé à ladite tuile, avant ou après le durcissement, à l'aide d'un adhésif (34). L'élément de surface (30) peut constituer une couche de base qui, en service, est le dessous de la tuile composite (2) ou il peut également constituer une couche supérieure qui correspond au côté supérieur de la tuile composite (2) en service.
PCT/GB2000/000165 1999-02-02 2000-01-21 Tuile et procede de fabrication WO2000046463A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU30658/00A AU3065800A (en) 1999-02-02 2000-01-21 Roof tile and method of manufacture

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9902257.6 1999-02-02
GBGB9902257.6A GB9902257D0 (en) 1999-02-02 1999-02-02 Roof tile and method of manufacture

Publications (1)

Publication Number Publication Date
WO2000046463A1 true WO2000046463A1 (fr) 2000-08-10

Family

ID=10846935

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2000/000165 WO2000046463A1 (fr) 1999-02-02 2000-01-21 Tuile et procede de fabrication

Country Status (3)

Country Link
AU (1) AU3065800A (fr)
GB (2) GB9902257D0 (fr)
WO (1) WO2000046463A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3156202A1 (fr) 2015-10-15 2017-04-19 Etex Holding GmbH Dalles de béton

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL7305809A (en) * 1973-04-26 1974-10-29 Composite building blocks and tiles - obtd. by bonding relatively dry concrete mixt. to polyester laminate
US4132043A (en) * 1977-02-22 1979-01-02 H. B. Fuller Company Structural units
DE3228278A1 (de) * 1982-07-29 1984-02-09 Karl-Friedhelm Dr. 5600 Wuppertal Schmidt Dachziegel sowie verfahren zu seiner herstellung
FR2542785A1 (fr) * 1983-03-15 1984-09-21 Hoang Andre Tuiles et briques renforcees ayant des caracteres de resistance et isothermiques considerables
US4752520A (en) * 1986-12-15 1988-06-21 Builder's Research And Development Corporation Reinforced concrete tile and its method of manufacture
GB2249112A (en) * 1990-10-25 1992-04-29 Thomas Sidney Brown Roof slating
WO1994025237A2 (fr) * 1993-04-29 1994-11-10 Redland Technologies Limited Tuiles de beton renforcees et leurs procedes de fabrication

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9808558D0 (en) * 1998-04-23 1998-06-24 Gibson Gary S Tile

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL7305809A (en) * 1973-04-26 1974-10-29 Composite building blocks and tiles - obtd. by bonding relatively dry concrete mixt. to polyester laminate
US4132043A (en) * 1977-02-22 1979-01-02 H. B. Fuller Company Structural units
DE3228278A1 (de) * 1982-07-29 1984-02-09 Karl-Friedhelm Dr. 5600 Wuppertal Schmidt Dachziegel sowie verfahren zu seiner herstellung
FR2542785A1 (fr) * 1983-03-15 1984-09-21 Hoang Andre Tuiles et briques renforcees ayant des caracteres de resistance et isothermiques considerables
US4752520A (en) * 1986-12-15 1988-06-21 Builder's Research And Development Corporation Reinforced concrete tile and its method of manufacture
GB2249112A (en) * 1990-10-25 1992-04-29 Thomas Sidney Brown Roof slating
WO1994025237A2 (fr) * 1993-04-29 1994-11-10 Redland Technologies Limited Tuiles de beton renforcees et leurs procedes de fabrication

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3156202A1 (fr) 2015-10-15 2017-04-19 Etex Holding GmbH Dalles de béton

Also Published As

Publication number Publication date
GB9902257D0 (en) 1999-03-24
GB0001451D0 (en) 2000-03-08
GB2346395A (en) 2000-08-09
AU3065800A (en) 2000-08-25

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