U.S. patent application number 11/607153 was filed with the patent office on 2007-06-14 for ventilated roofing tiles.
This patent application is currently assigned to Sierra Madre Marketing Group. Invention is credited to Fred Miekka.
Application Number | 20070130850 11/607153 |
Document ID | / |
Family ID | 38137872 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070130850 |
Kind Code |
A1 |
Miekka; Fred |
June 14, 2007 |
Ventilated roofing tiles
Abstract
Ventilated roofing tiles along with other multilayered energy
saving and/or producing constructions are disclosed. Also disclosed
are insulating bonding constructions having enhanced energy saving
attributes. The ventilated roofing tiles employ heat transfer means
that may include natural and/or forced air convection.
Inventors: |
Miekka; Fred; (Arcadia,
CA) |
Correspondence
Address: |
Frank A. Palase
Suite 203
141 E. Huntington Drive
Arcadia
CA
91006
US
|
Assignee: |
Sierra Madre Marketing
Group
|
Family ID: |
38137872 |
Appl. No.: |
11/607153 |
Filed: |
December 2, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60741834 |
Dec 3, 2005 |
|
|
|
Current U.S.
Class: |
52/198 ; 454/365;
454/366; 52/302.1 |
Current CPC
Class: |
E04D 13/17 20130101;
E04D 2001/309 20130101; Y02E 10/44 20130101; E04D 1/30 20130101;
Y02B 10/20 20130101; E04D 1/28 20130101; F24S 20/69 20180501; Y02A
30/60 20180101; Y02E 10/40 20130101; F24S 20/67 20180501 |
Class at
Publication: |
052/198 ;
052/302.1; 454/365; 454/366 |
International
Class: |
E04H 12/28 20060101
E04H012/28; F24F 7/02 20060101 F24F007/02; E04B 1/70 20060101
E04B001/70; E04B 7/00 20060101 E04B007/00 |
Claims
1. A channel containing ventilated roofing tile for transferring
heat along underline pitch roofing surfaces of buildings
comprising: a rigid multilayer construction having a top surface
and bottom surface; said top surface of said rigid multilayer
construction having light reflective characteristics; said bottom
surface of said rigid multilayer construction having channels and
attachment means; wherein said channels are of suitable geometry
for moving air by natural convection within said channels along
said underlying pitch roofing surfaces, and wherein said attachment
means are suitable for fixedly attaching said bottom surface of
said rigid multilayer construction to said underlying pitched
roofing surfaces.
2. A ventilated roofing tile comprising: (a) a tile; (b) a top
surface; (c) a bottom surface; (d) said top surface is coated with
a material to absorb or reflect sunlight and said bottom surface is
formed with a plurality of beads thereby improving said tiles
ability to attach to a surface.
3. The ventilated tile of claim 2 wherein the bottom surface has
numerous channels attached to said bottom surface thereby enhancing
natural as well as forced air convection.
4. The multi-layered ventilated tile comprising: (a) a first tile;
(b) a second tile; (c) said first tile has a bottom surface and a
top surface, said bottom surface has a plurality of beads formed
into said bottom surface; (d) said second tile has a top surface
and a bottom surface, said top surface a plurality of channels
formed into said second tile said top surface; (e) said first tile
is placed over said second tile whereby said channels form a
convection zone facilitating a laminar flow of air between said
first and said second tiles.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application claims benefit of the
provisional application filed on Dec. 3, 2005 having application
number U.S. 60/741,834
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to building materials and more
particularly to energy saving and/or producing multilayered
construction components. This invention also relates to attachment
means that may have thermal insulating properties. More
particularly this invention relates to energy saving tiles that may
be ventilated and that may employ natural and/or forced air
convection.
[0004] 2. Description of the Related Art
[0005] A significant portion of building construction is carried
out using relatively fast and easy construction techniques. In
addition, much of this construction is done without much emphasis
being placed on the energy efficiency. This often results in
buildings requiring significant heating and/or air conditioning
requirements. The result is a building having high utility
costs.
[0006] Heat and electricity costs have been rising over the past
several years and are expected to continue this upward trend for
years to come. There are several reasons for this trend including
greater energy demand from emerging countries such as India and
China, expanded population growth, limited natural resources,
environmental pressures, and a host of others.
[0007] A significant portion of the American energy diet is
directed towards the heating and air conditioning of buildings.
Furthermore many of today's buildings including the modern ones may
not be very energy efficient.
[0008] Many buildings lack good insulation. Some buildings have
little to no insulation at all. Some buildings having substantial
insulation thickness may still have relatively poor insulating
properties due to moisture contamination and air leaks with the
outside environment.
[0009] Many buildings are designed primarily for aesthetic purposes
rather than energy efficiency. A simple example will now be given
to illustrate this point. The highest volume to surface area ratio
for any shape of any given size is a sphere. Therefore to minimize
construction materials and maximize living space, buildings ideally
should be made in the shape of a sphere or at least a portion of a
sphere. The geodesic dome is a modified sphere or spherical portion
that can be made from linear shaped commercially available
construction components. Buckminster Fuller promoted this
construction geometry based at least in part to practical
engineering.
[0010] The sphere or modified spherical shape of the geodesic dome
provides the maximum internal volume to surface area ratio
attainable for any given size. This provides the least amount of
surface area for heat transfer with the outside environment. In
addition, the substantially curved outside surface of the geodesic
dome may provide added benefits as well. For example, certain
natural disasters such as hurricanes may inflict substantial wind
damage to standard rectangular buildings. On the other hand,
geodesic domes have no large flat surfaces facing in any one
direction thereby at least theoretically reducing damage resulting
from exposure to high winds.
[0011] From an engineering standpoint there is no logical reason
why more buildings are not constructed as geodesic domes. From an
aesthetic point of view however, the story may be somewhat
different. Individuals may find the geodesic dome to be somewhat
ugly and therefore prefer the less efficient but better looking
rectangular shaped architecture.
[0012] It should be noted that for any given volumetric shape, such
as a rectangular prism, as size increases so does the volume to
surface area ratio. Of special interest are apartment buildings.
Apartments are relatively large multi-dwelling buildings that house
several families. This construction allows individual families to
occupy a relatively small space and obtain the added energy saving
benefits of a much larger building. This of course, is not the
focal point of most people when they buy a condominium or rent an
apartment. It is however a substantial added benefit when the
heating and/or air conditioning bill arrives. A specific example
will now be used to illustrate this point.
[0013] A single family occupies an apartment in the center of a
large building. This apartment is completely surrounded on all
sides including the floor and ceiling by other apartments. Let us
assume that the family occupying this apartment has similar comfort
levels with respect to heat and cold as the individuals or families
occupying the adjacent apartments. In this scenario, this family
could permanently turn their heating and air conditioning off and
live in relative comfort. They now have the advantage of living
independently from heating and air conditioning costs. Of course,
most apartments have at least one surface exposed to the outside
environment. This situation is however preferable to having all
surfaces exposed to the outside environment.
[0014] Air conditioning represents substantial electricity use in
the United States. This is particularly true for people living in
the south. The southeast is relatively hot and humid during the
summer months and the southwest is hot and dry. It should be noted
that more and more people are moving into the southern portions of
the United States.
[0015] During many summer days in the relatively dry southwestern
United States, significant cooling can be achieved at relatively
low cost by using swamp coolers. A swamp cooler is a cooling device
that uses the evaporation of water to provide cooling. Swamp
coolers add substantial humidity to the air so they are only
effective in dry arid regions. It should be noted that the heat of
vaporization of water is a substantial 540 calories per gram. The
evaporation of a few gallons of water can provide substantial
cooling to a small building such as a home or mobile home
trailer.
[0016] Evaporation is the mechanism used to provide cooling in
modern air conditioning systems as well. Unlike swamp coolers that
evaporate liquid water into the air, modern air conditioning
systems evaporate Freon or other refrigerants in a closed system
that recycles the vapors and compresses them back into a liquid
state. Evaporation of the refrigerant is an endothermic process (a
thermal process that takes heat) thereby removing it. The
evaporation occurs in a set of coils called the evaporator and
sometimes referred to as the cooling coils. Evaporation of the
refrigerant cools the evaporation coils. A fan is used to blow air
over these coils to transfer heat from the room being air
conditioned to the cold evaporation coils. More often than not, the
temperature of the evaporation coils is below the dew point of the
air in the room. Under these conditions water condenses out of the
air onto the cold evaporation coils. This water gives up its heat
of vaporization in the process and adds to the heat given up to the
evaporation coils. The removal of water from the air also dries it
out resulting in a greater level of comfort in the room being air
conditioned. The evaporated gaseous refrigerant is then compressed
to a high pressure that may exceed 150 pounds per square inch.
Compressing the gaseous refrigerant causes it to heat up. The heat
is then exchanged with the outside atmosphere to get rid of it.
This heat exchange occurs in the compression or heating coils. The
compressed refrigerant may then be expanded in a special valve that
liquefies and/or dissolves the refrigerant into a special liquid.
The liquefied refrigerant then passes into the evaporation coils to
complete the cycle.
[0017] This air conditioning process requires a substantial amount
of energy in the form of electricity. The majority of this energy
is used to compress evaporated refrigerant to high pressure. A
smaller amount of electricity is used by the fans to expel hot air
from the compression coils and to circulate room air over the cold
evaporation coils. Because of the electrical requirements of air
conditioning systems it is desirable to prevent heat from entering
buildings during hot weather.
[0018] There are two primary sources of heat that enter buildings
during hot weather. The first one is radiant heat from the sun. The
second one is heat transferring from the outside to the interior of
the building. It should be noted that these two sources are not
exclusively independent of one another but may be somewhat
intertwined together. For example, sunlight may fall onto a dark
roof surface and heat the attic space underneath.
[0019] The hot air in the attic may then transfer its heat by
convection, conduction, and radiation into the living spaces of the
building. In this way, sunlight indirectly heats the interior of
the building. Alternatively, sunlight may be transmitted through
windows to heat the building interior directly. It should be noted
that a significant portion of sunlight consists of infrared
radiation that falls outside of the visible spectrum. This infrared
light does not add to the lighting of rooms but rather poses an
extra burden of heat to the interior of the building that must be
removed by air conditioning systems during periods of hot
weather.
[0020] Special coatings can be placed onto glass surfaces that
reflect and/or absorb infrared light from sunlight and let in
visible light. In this way sunlight may be used to illuminate the
inside living spaces of buildings while minimizing the addition of
excess heat.
[0021] Buildings in warmer climates may also avoid excessive heat
from sunlight by using outside materials having a high reflectance
and low absorbance. A high reflectance surface is one that reflects
light away rather than absorbing light and turning it into heat.
Light colors such as silver and white reflect most of the light
that falls on its surface. Darker colors such as black absorb most
of the light that falls on exposed surfaces. The deliverable heat
energy from the sun on a clear day at a direct angle is substantial
and amounts to about 1,000 watts per square meter. Reflective
outside building surfaces help to keep sunlight from turning into
unwanted heat that burdens air conditioning systems.
[0022] The use of heavy clay tiles may provide some heat insulating
properties to the outermost layer of roofing surfaces.
Unfortunately, these heavy clay tiles place added weight burden on
the structure, may create a hazardous condition during earthquakes,
have limited insulating properties, and are only partially
effective at keeping heat out of structures such as houses. One
significant advantage offered by these heavy clay tiles is fire
resistance. This may be particularly true in areas often ravaged by
brush fires. Such fire prone areas include numerous hillside
communities surrounding cities in southwestern states such as
California. In addition to fire resistance, clay roofing tiles may
provide some suppression of outside noise.
[0023] Cement and related materials are sometimes employed in the
fastening of clay tiles to roof surfaces and/or each other. While
being somewhat effective in holding them together on to roofing
surfaces there is a tendency for them to come loose during high
wind conditions. It should be noted that hurricanes often damage
these roofing tiles and that other attachment means have been
developed for the purposes of more tightly anchoring roofing tiles
to the roofs of buildings. These new anchoring techniques may
employ screws and/or nails to hold roofing tiles firmly into
place.
[0024] The process used for mounting traditional tiles involves the
application tile cement or other bonding material to the back side
of tiles and/or exposed bonding substrate surfaces. Once a suitable
amount of the bonding agent has been applied, the tiles are pushed
into place and the bonding agent allowed hardening.
[0025] Cement and related materials are sometimes employed in the
fastening of clay tiles to roof surfaces and/or each other. While
being somewhat effective in holding them together on to roofing
surfaces there is a tendency for them to come loose during high
wind conditions. It should be noted that hurricanes often damage
these roofing tiles and that other attachment means have been
developed for the purposes of more tightly anchoring roofing tiles
to the roofs of buildings. These new anchoring techniques may
employ screws and/or nails to hold roofing tiles firmly into
place.
[0026] Tiles may be bonded to each other in place of bonding to sub
flooring surfaces. In such instances, good adhesion between tiles
becomes increasingly important. The bonding between adjacent tiles
in flooring applications may be enhanced to improve durability and
strength. U.S. Pat. No. 4,095,388 awarded to Horner Brealt titled
"Strengthening Inter-Tile Adhesion" employs two rectangular tile
sizes laid in an offset configuration that minimizes the length of
individual straight lines. The result is a greater resistance to
the effects of both temperature changes and humidity over time.
[0027] Tiles having interlocking properties with each other may be
used to improve the weather resistance of roofing surfaces along
with improving overall strength. An example of this can be found in
U.S. Pat. No. 4,949,522 awarded to Shigeru Harada titled "Roofing
Tile". Roofing tiles are disclosed that engage with one another and
interlock to improve strength and weather resistance.
[0028] Numerous bonding compositions may be employed to bond tiles
to each other and to substrates. In many instances cement and
related materials are employed to adhere tiles to their intended
substrates. These materials are often employed in fastening ceramic
tiles to flooring or other surfaces. Many of these materials
require significant time for them to harden. In many instances this
is perfectly acceptable. Under certain circumstances it may be
desirable to have a relatively fast and strong cure. For example,
industrial or commercial applications where long shut down times
may be costly or disruptive. Other examples include vertical or up
side down surfaces where tiles must be held in place during the
cure cycle. U.S. Pat. No. 4,833,178 awarded to Robert E. Schaefer,
Scott C Broney, and Joseph J Chesney Jr titled "Composition and
Method for Setting and Grouting Tile" provides a fast setting tile
bonding composition comprised of filled polymeric resin. The above
described filled resin compositions have cure times ranging from
about one to six hours.
[0029] Considerable attention is often paid toward providing
uniform spacing between tiles. Unfortunately, controlling the
spacing between tiles and their attached substrates is less
commonplace. Difficulties may arise from the use of high viscosity
cement or other related materials used for tile bonding. Many of
these materials flow out with difficulty and therefore may form a
layer of uneven thickness that may go unnoticed until after the
cement has set.
[0030] The use of cement and other related materials to bond tiles
to their substrates may result in poor anchorage. Subsequent
exposure to harsh conditions such as temperature changes and
moisture may result in the delamination of tiles from their
attached substrates. In order to reduce this tendency, interlocking
means may be provided between tiles and their substrate
surfaces.
[0031] One example of interlocking means is disclosed in U.S. Pat.
No. 6,692,813 awarded to Allen H Elder. In this patent, Elder
employs at least one bonding surface having particulates attached
in continuous phase with the surface substrate. The continuous
phase aspect of the surface particulates with the substrate allows
for a substantial amount of surface protrusion coupled with good
strength. Employing this bonding technology to the attachment of
tiles to substrate surfaces may prove useful when using relatively
low viscosity homogeneous bonding agents like epoxy resin. High
viscosity cementing and grouting materials may require further
enhancements in order to optimize tile bonding.
[0032] Difficulties associated with providing uniform tile surfaces
and forming strong bonds between tiles and their substrates has
lead to many of the above described innovations. One particularly
interesting approach for tile bonding is outlined in U.S. Pat. No.
4,932,182 awarded to John R. Thomasson titled "Floor Tile Forming
and Structural Underlayment Device". A one piece plastic molded
sheet having special entrapping designs is used to cast tiles in
situ. This approach is especially appealing due to its versatility.
The mold entrapping designs prevent the release of the cast tiles
thereby eliminating the need to cement individual tiles to the
floor. Tile spacing is provided by the mold with raised portions
giving the appearance of tile grout.
[0033] The use of insulating materials as bonding agents may
provide the added benefit of thermal insulation.
[0034] Generally speaking, roofing tiles are heavy, and do not
provide a substantial amount of insulating properties to the outer
roofing surfaces of buildings. Furthermore, the bonding methods
used for the attachment of roofing tiles do not possess good
insulating qualities either.
[0035] A significant amount of heat may build up in the attic
spaces of buildings due to absorption of solar energy by roofing
surfaces. Because of this, one of the first ways to improve the
usefulness of air conditioning systems is to ventilate the attic
using a fan. Attic fans reduce the heat burden on air conditioning
systems by removing heat in a way that bypasses the air
conditioner. Hot attic air is exhausted and therefore does not
transfer as much heat into interior building living spaces. Many
individuals notice a significant reduction in the heat burden of
air conditioning systems when they install an attic fan.
[0036] Many attics and other top floor building interior spaces are
provided with natural ventilation. Some of these spaces are
provided with slotted openings in the sides. Other approaches
involve cutting a hole in the roof and placing a small turbine that
rotates by outside wind and/or natural convection of heated
air.
[0037] Of particular interest is U.S. Pat. No. 6,491,579 awarded to
Harry T O'Hagin. This patent outlines a system that allows hot air
to escape from an attic without negatively affecting the appearance
of the roof. Vents are installed in the roof deck beneath roofing
tiles. One aspect of the invention involves placing numerous small
holes in specific roofing tiles as part of the ventilation system.
Other aspects of the invention involve the removal of attic air
along spaces between tiles. This invention is particularly
interesting owing to the fact that the majority of roofing
components are standard available parts, the overall system does
not require any moving parts such as attic fans, and the finished
roof is aesthetically pleasing.
[0038] Insulation is often placed along the bottom portions of
attics in an attempt to keep hot attic air from heating living
spaces below. It is interesting to note that insulation is
generally placed along the bottom surfaces of attics but not along
the undersides of roofing surfaces. It appears that more emphasis
is placed on keeping hot attic air and its associated heat out of
living spaces than keeping the heat out of attic spaces in the
first place. This philosophy seems a bit unusual owing to the fact
that building insulation is commonly employed in interior walls
connected with the outside. More will be said on this later.
[0039] One of the oldest and most common methods employed to
prevent excessive sunlight from falling on and heating roofing
surfaces involves the use of one or more trees to provide shade.
This method works because trees often produce good shade. Trees and
other plants tend to grow leaves in a direction that maximizes
their absorption of sunlight. This often results in shade that is
somewhat dense. In addition, trees can provide further cooling by
two mechanisms.
[0040] Radiant energy falling on growing surfaces of plants such as
leaves is actually converted into chemical potential energy by the
well established process of photosynthesis.
[0041] Many trees extract water from the ground and pump this water
up to the leaves where evaporation occurs. This evaporation may
provide additional cooling.
[0042] Many trees grow shade producing leaves in the hot months of
the year and then lose these leaves during the cooler months of the
year. In this way, the roofs of buildings may be shaded in hot
summer months and heated by exposure of solar radiation during the
colder winter months.
[0043] It should be noted that there are certain downsides to
locating trees close to buildings.
[0044] A few problematic issues are summarized below:
Trees can grow to excessive size over time.
Growing trees send out roots that can tear up driveways and
building foundations and may find their way into sewer lines
clogging them up.
Certain trees such as pine trees are flammable and represent a fire
hazard when located close to certain buildings.
Trees often lose leaves that can clog rain catching roofing gutters
and can be a nuisance to clean.
[0045] The shading of roofing surfaces by trees and other plants
may be done for the purposes of reducing the burden on air
conditioning systems from excess radiant heat or alternatively may
not be done for intentional purposes whatsoever.
[0046] Unintentional shading of roofing surfaces is a common
occurrence. In some instances one building may cast its shadow on
the roof of another. This may happen when buildings having
different heights and architecture designs are located next to one
another. Unintentional shading may also occur when solar collectors
and/or electricity generating photovoltaic panels are placed
directly above roofing surfaces. U.S. Pat. No. 6,061,978 awarded to
Thomas L. Dinwoodie titled "Vented Cavity Radiant Barrier Assembly
and Method" discloses roof mounted assemblies containing
photovoltaic modules. The assemblies themselves employ a low
emissivity element and may take numerous forms. This results in a
vented cavity between the building surface and the barrier inner
surface. Mounting methods for use in vented cavity radiant barrier
systems are disclosed in U.S. Pat. No. 6,883,290 awarded to Thomas
L. Dinwoodie titled "Shingle System and Method". It should be noted
that photovoltaic solar panels could be modified by adding liquid
circulating coils to their underside. This option is particularly
interesting owing to the fact that many photovoltaic panels run
more efficiently when they are kept cool. The circulating liquid
could be used to extract heat from the panel thereby improving the
electric output of the device while at the same time producing
useable hot water. The simultaneous production of hot water and
electricity at the same time increases the utility of electricity
producing photovoltaic panels Such panels would produce
electricity, hot water, and provide roofing shade all at the same
time. It should be noted that standard photovoltaic panels and
standard solar heating panels often provide roofing shade by their
very nature. This roofing shade may provide the unintentional added
benefit of reducing the heat burden of air conditioning systems.
Other forms of unintentional roofing shade may be provided by such
things as satellite dishes located on roof tops as well as signs
and billboards.
[0047] A significant amount of sunlight falls on the roofing
surfaces of buildings. During periods of warm weather this radiant
energy can place an unwanted burden to air conditioning systems
causing them to overwork. A common approach used to deal with this
issue is to employ more powerful air conditioning systems to remove
this added burden of heat. Unfortunately, this approach results in
the consumption of excessive amounts of electric power. Other
approaches employ removing hot attic air with various ventilation
systems and/or placing insulation between attic spaces and living
spaces.
[0048] Keeping the heat out of attic spaces and/or other spaces
directly below the roofing in buildings in the first place is not
commonly employed. Deliberate shading by trees is one method in
current use today as is the use of light colors that tend to
reflect rather than absorb sunlight. The above mentioned methods
are commonly employed in buildings to keep unwanted heat from
entering attics and roofing undersurfaces.
[0049] In addition to keeping unwanted heat from entering living
and working spaces of buildings, there is also a need to provide
heat to the living and working spaces of buildings during periods
of cold weather. In this instance, attic ventilation may have the
undesirable effect of removing warm air from the building. This is
particularly troublesome owing to the fact that warm air rises and
cold air sinks. Any leaks between the attic space or any other
space directly under the roof of a building and living and/or
working spaces located underneath represents a significant loss of
heat. This heat loss places an added burden to heating systems.
[0050] Interior heating of buildings is carried out in cold weather
to keep living and working spaces at a comfortable temperature. For
the most part this heat comes from the combustion of flammable
materials. Natural gas is commonly employed in many areas of the
country. Natural gas burns clean and efficiently and is relatively
low in cost. Oil is burned in some areas of the country for heat.
This practice is particularly prevalent in the northeastern United
States. Wood may be burned to generate heat, but in order to be
efficient a good system is required that transfers heat from the
burning wood into living spaces. One of the more familiar systems
is the wood burning stove. A wood burning stove is a cast iron
stove placed in a room that is to be heated. A smoke stack at the
back of the stove is vented outside to remove toxic smoke. The wood
burning stove has adjustments to control air flow and thereby
control the rate of burning. This control allows the user to heat
efficiently without losing large quantities of heat up the smoke
stack.
[0051] A large majority of homes have fireplaces. A fireplace is an
area of a wall that is meant for burning wood or other combustible
material. Unfortunately, burning wood in a fireplace often results
in only a small amount of heat being generated for living spaces
and a relatively large amount of heat going up the chimney. Burning
wood in a fireplace can actually suck more heat out the chimney
than the fire produces. This is because chimneys can suck interior
air right out of building living spaces. A flu damper adjustment is
often provided to minimize this effect, but is only somewhat
effective. In general, fireplaces are used to create a warm
relaxing atmosphere and are rarely used for heating purposes.
Numerous systems have been developed for the purposes of increasing
the heat output of ordinary fireplaces. Many of these systems
employ a set of curved metal pipes. These metal pipes take air from
inside the room and expel hot air out the top and back into the
room. The pipes often surround the fire with the flames passing
over the top portions. Some of these systems use natural convection
while others used forced air from a fan.
[0052] It should be noted that in many areas of the United States
such as the northeast that the coldest winter days occur under
clear skies. This is because cold fronts coming down from Canada
(sometimes called the Canadian express) contain cold and dry air.
This results in numerous cold sunny days throughout the winter
months. This is significant because a large amount of heat is
available in the form of radiant solar energy during numerous cold
days.
[0053] On a clear sunny day the rate of radiant heat falling on
surfaces at right angles to the sun is about one kilowatt per
square meter. In the winter months the sun is at an angle that is
somewhat oblique. Because of this the rate of radiant heat
delivered may be somewhat less. In addition, dark surfaces having a
high level of absorbance still reflect some radiant energy. In
addition, heat losses may occur when moving heat containing liquids
and/or gasses through areas of lower temperature. A good
approximation is that 500 watts of useful heat can be extracted per
square meter for eight hours during each clear winter day.
[0054] The single side of a roof for a small house has about 60
square meters of surface area. The useable amount of heat energy
per day for such a small house will now be calculated. 60 square
meters.times.500 watts/square meter.times.8 hours per day=240,000
watt hours or 240 kilowatt hours of deliverable daily heat energy.
At a cost of 15 cents per kilowatt hour, this represents $30.00
worth of electric heat per day. For the less expensive natural gas
heat this represents almost $10.00 per day of available heat
energy.
[0055] The capture and subsequent use of solar heat has
traditionally involved systems employing a significant amount of
complication. Many of these systems employ a liquid heat transfer
agent such as an antifreeze mixture of water and ethylene glycol. A
solar heat collector consisting of a dark absorbent panel having
liquid filled tubes and a glass cover is often used to collect the
heat. The liquid in the tubes is then pumped to a storage tank.
When the liquid in the storage tank reaches sufficient temperature
it is then pumped to a heat exchanger. The heat exchanger then
transfers this heat to where it is needed. All in all this system
is relatively expensive, bulky, and cumbersome. These solar heating
systems usually deliver a limited amount of heat owing to their
small size.
[0056] Traditional solar heating systems may provide useable heat
in the form of heated liquids that can be used to heat living
spaces and can provide hot water. This tends to be the limit of
utility for these traditional heating systems. It would however to
be desirable to use this heat for other purposes as well. For
example, during winter months in northern climates significant
snowfall may occur onto roofing surfaces. This snowfall may place a
significant weight burden onto buildings. This may be particularly
troublesome for buildings having flat horizontal roofing surfaces.
It may therefore be desirable to use solar heat for the purposes of
melting unwanted snow and ice from roofing surfaces. It should be
noted that this takes place naturally to some extent, however
augmentation of this natural process may provide for faster
removal.
[0057] It is an object of this invention to prevent unwanted heat
from entering the roofing portions of building surfaces during
periods of hot weather.
[0058] It is a further object of this invention to remove unwanted
heat from the roofing surfaces of buildings during periods of hot
weather.
[0059] It is a further object of this invention to extract useable
heat from the roofing surfaces of buildings during periods of cold
weather.
[0060] It is a further object of this invention to provide a tile
bonding system forming interlocking bonds between individual tiles
and their bonding substrates.
[0061] It is a further object of this invention to provide tiles
having bonding surfaces of uniform thickness.
[0062] It is a further object of this invention to provide tiles
having bonding surfaces compatible with traditional tile bonding
agents.
[0063] It is a further object of this invention to provide tiles
that when pushed against substrate surfaces spread bonding agents
to a uniform thickness.
[0064] It is a further object of this invention to provide tile
bonding substrates that form interlocking bonds with bonding
agents.
[0065] It is a further object of this invention to provide thermal
insulating attachment means suitable for the adhesion of tiles
and/or laminate constructions to the roofing surfaces of
buildings.
[0066] Finally, it is an object of this invention to provide a low
cost simple system suitable for extracting and transferring solar
heat from roofing surfaces into the interior spaces of
buildings.
SUMMARY OF THE INVENTION
[0067] In summary, the present invention provides ventilated
roofing tiles that may be used to transfer air of various
temperatures for heating and/or cooling purposes including the heat
management of interior building spaces. The transfer of air may be
purely in the form of natural convection or alternatively may
employ forced air convection from a fan or other source of forced
air motion. Air may be used to remove heat during hot weather or
alternatively, hot air may be collected and transferred into
interior building spaces during periods of cold outside
temperatures. Attachment means may also be employed having numerous
advantages that may include thermal insulation properties. The
ventilated roofing tiles of this invention may have enhanced
thermal insulating properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0068] FIG. 1 shows a ventilated roofing tile suitable for the
removal of excess heat by natural convection.
[0069] FIG. 2 shows a ventilated roofing tile having added
attachment holes suitable for the use of nails and/or screws.
[0070] FIG. 3 shows a ventilated roofing tile employing channels to
facilitate heat transfer by motion of air.
[0071] FIG. 4 shows a ventilated roofing tile employing channels to
facilitate heat transfer by motion of air along with added
beads.
[0072] FIG. 5 shows a ventilated roofing tile employing channels to
facilitate heat transfer by motion of air along with added
beads.
[0073] FIG. 6 shows the tile of FIG. 5 with added attachment
holes.
[0074] FIG. 7 shows a lightweight insulated roofing tile employing
a central insulating layer consisting of closed cell foam.
[0075] FIG. 8 shows a lightweight thermal insulated roofing tile
similar to tile 72 of FIG. 7.
[0076] FIG. 9 shows a lightweight thermal insulated roofing tile
employing channels to further facilitate the removal of heat by
natural and/or forced air convection.
[0077] FIG. 10 shows a lightweight ventilated thermal insulating
roofing tile having a light absorptive top surface and thermal
insulating layer.
[0078] FIG. 11 shows a lightweight ventilated thermal insulating
roofing tile having a light absorptive top surface and thermal
insulating layer.
[0079] FIG. 12 shows a lightweight ventilated roofing tile having a
light absorptive top surface, a thermal insulating layer, and a
beaded bottom surface.
[0080] FIG. 13 shows a simple lightweight ventilated roofing tile
having a dark absorptive top surface.
[0081] FIG. 14 shows a simple lightweight ventilated roofing tile
having a dark absorptive top surface.
[0082] FIG. 15 shows a simple lightweight ventilated roofing tile
having a dark absorptive top surface.
[0083] FIG. 16 shows a ventilated roofing tile similar to that
shown in FIG. 10 with the addition of a light transmitting
insulation layer over the top surface.
[0084] FIG. 17 shows a ventilated roofing tile similar to that
shown in FIG. 11 with the addition of a light transmitting
insulation layer over the top surface.
[0085] FIG. 18 shows the ventilated roofing tile of FIG. 17 with
the addition of beads to the bottom surface.
[0086] FIG. 19 shows a ventilated roofing tile similar to that
shown in FIG. 13 with the addition of a light transmitting
insulation layer over the top surface.
[0087] FIG. 20 shows a ventilated roofing tile similar to that
shown in FIG. 14 with the addition of a light transmitting
insulation layer over the top surface.
[0088] FIG. 21 shows a lightweight ventilated roofing tile similar
to that shown in FIG. 20 With the addition of beads to the bottom
ridges.
[0089] FIG. 22 shows two beaded surfaces facing each other with
interposing surface bonding geometry.
[0090] FIG. 23 shows a sectional view of two beaded surfaces
interposed with a closed cell foam bonding agent.
[0091] FIG. 24 shows a lightweight ventilated thermal insulating
roofing tile having a light absorptive top surface and thermal
insulating layer and a bottom layer of pressure sensitive
adhesive.
[0092] FIG. 25 shows beads that are attached to the underside of
the tile with pressure sensitive adhesive filling in the spaces
between the beads.
[0093] FIG. 26 shows a tile having numerous spherical protrusions
suitable for use with numerous bonding agents.
[0094] FIG. 27 shows the tile of FIG. 1 in an up side down
configuration to more thoroughly illustrate the spherical bonding
surface aspects of the present invention.
[0095] FIG. 28 shows a section of a bonding surface substrate
suitable for bonding the tiles of the present invention.
[0096] FIG. 29 shows a beaded tile facing a substrate having a
matching beaded surface.
[0097] FIG. 30 shows a sectional view of a tile construction
comprised of a beaded tile interposed with a matching beaded
substrate surface and a bonding agent.
[0098] FIG. 31 shows a sectional view of a tile construction
comprised of a beaded tile interposed with a matching beaded
substrate surface and a rigid closed cell foam bonding agent.
[0099] FIG. 32 shows a cross sectional view of a tile having
numerous cavities suitable for use with numerous bonding
agents.
[0100] FIG. 33 shows a sectional view a tile construction comprised
of a multi-cavity tile interposed with a matching beaded substrate
surface and a bonding agent.
[0101] FIG. 34 shows a sectional view of a tile construction
comprised of a multi-cavity tile interposed with a matching beaded
substrate surface and a rigid closed cell foam bonding agent.
[0102] FIG. 35 shows cross sectional view of a tile bonding
substrate having numerous surface cavities.
[0103] FIG. 36 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
beaded tile and a bonding agent.
[0104] FIG. 37 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
beaded tile and a rigid closed cell foam bonding agent.
[0105] FIG. 38 shows a tile having numerous spherical protrusions
with flat top geometry suitable for use with numerous bonding
agents.
[0106] FIG. 39 shows a section of a bonding surface substrate
having numerous spherical protrusions with flat top geometry
suitable for bonding the tiles of the present invention.
[0107] FIG. 40 shows a sectional view a tile construction comprised
of a flat top geometry beaded tile interposed with a matching flat
top geometry beaded substrate surface and a bonding agent.
[0108] FIG. 41 shows a sectional view a tile construction comprised
of a flat top geometry beaded tile interposed with a matching flat
top geometry beaded substrate surface and a rigid closed cell foam
bonding agent.
[0109] FIG. 42 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
flat top geometry beaded tile and a bonding agent.
[0110] FIG. 43 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
flat top geometry beaded tile and a rigid closed cell foam bonding
agent.
[0111] FIG. 44 shows a lightweight flat top geometry beaded
insulated tile employing a central insulating layer consisting of
closed cell foam.
[0112] FIG. 45 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
beaded tile employing a central insulating layer consisting of
closed cell foam and a rigid closed cell foam bonding agent.
[0113] FIG. 46 shows a cross sectional view of one beaded surface
facing another surface having matching holes.
[0114] FIG. 47 shows a building having a pitched roof employing
ventilated tiles having natural convection.
[0115] FIG. 48 shows a building having a pitched roof employing
dark heat absorbing ventilated tiles along with forced air
convection for moving heated air into interior spaces.
[0116] FIG. 49 shows a building having a flat roof employing
ventilated tiles along with forced air convection for the removal
of excess heat.
[0117] FIG. 50 shows a building having a flat roof employing dark
heat absorbing ventilated tiles along with forced air convection
for moving heated air into interior spaces.
DESCRIPTION OF THE INVENTION
[0118] FIG. 1 shows a ventilated roofing tile suitable for the
removal of excess heat by natural convection. Ventilated tile 2 is
shown having a beaded bottom surface 4. Beaded bottom surface 4
provides a space 6 between adjacent beads 8 and 10. Top surface 12
either reflective or absorptive of sunlight. This simple
construction for a roofing tile can be used to provide natural
convection for slanted roofs, or conversely may employ forced air
from a fan. Such roofing tiles may be used in hot weather to remove
heat by atmospheric venting. This simple ventilated tile may also
be used to collect solar heat during cold weather. In this instance
hot air in space 6 between adjacent beads 8 and 10 may be pumped
into interior building spaces. This may be accomplished using a
system employing fans and suitable ducting.
[0119] FIG. 2 shows a ventilated roofing tile having added
attachment holes suitable for the use of nails and/or screws.
Ventilated roofing tile 14 is shown having a top surface 16 and
beaded bottom surface 18. Bead 20 of bottom surface 18 is shown
with a hole 22. Hole 22 of bead 20 is a thru hole and therefore
lends itself for use in attaching tile 14 to a suitable roofing
subsurface substrate (not shown) using roofing nails or dry wall
screws. It should be noted that bead 20 is of sufficient size to
provide useable air space between bottom portion 24 of top surface
16 and the substrate to which the tile is to be attached.
[0120] FIG. 3 shows a ventilated roofing tile employing channels to
facilitate heat transfer by motion of air. Channel containing
ventilated roofing tile 26 is shown having a top surface 28 and
channeled bottom surface 30. Also shown are channels 32 and 34.
Channels 32 and 34 are of a suitable geometry to facilitate the
laminar flow of air within tile 26. Support ridges 36 are also
shown. Support ridges are appropriately spaced to provide for
proper dimensions of channels 32 and 34.
[0121] The tile shown in FIG. 3 has convection channels. These
channels may facilitate laminar flow of air thereby enhancing
natural as well as forced air convection. Adjacent tiles can be
attached to roofing surfaces in a way that provides for long and
continuous convection channels. When employed in slanted roofs, the
channels should point in an upward direction to facilitate natural
convection. The ridge of the roof may have a zone for collecting
this hot air for the purposes of heating building interior spaces.
Alternatively, the ends may be left open to the atmosphere for the
purposes of removing unwanted heat.
[0122] FIG. 4 shows a ventilated roofing tile employing channels to
facilitate heat transfer by motion of air along with added beads.
Channel containing ventilated roofing tile 38 is shown having a top
surface 40 and channeled bottom surface 42. Also shown are channels
44 and 46. Channels 44 and 46 are of a suitable geometry to
facilitate the laminar flow of air within tile 38. Support ridges
48 are also shown. Support ridges are appropriately spaced to
provide for proper dimensions of channels 44 and 46. Bottom beads
are shown attached to support ridges 48. These bottom beads may be
used to increase the vertical dimensions of channel portions 44 and
46 of ventilated tile 38. Alternatively, bottom beads may be used
as attachment means for fastening ventilated tile 38 to roofing
surfaces.
[0123] A beaded geometry may be used to facilitate the fastening of
objects to one another. This may be carried out using bonding
agents such as resins and cement related materials. Such beaded
geometry may be used to provide curved bonding surfaces. Curved
bonding surfaces are less likely to initiate stress fractures than
bonding surfaces containing sharp edges. In addition, beaded
bonding surfaces can be made to mechanically interlock with a
bonding agent. Mechanical interlocking between a bonding agent and
surface substrate may enhance bonding and reduce the need for
chemical compatibility between the bonding agent and surface
substrate.
[0124] FIG. 5 shows a ventilated roofing tile employing channels to
facilitate heat transfer by motion of air along with added beads.
Channel containing ventilated roofing tile 48 is shown having a top
surface 50 and channeled middle layer 52. Also shown are channels
54 and 56. Channels 54 and 56 are of a suitable geometry to
facilitate the laminar flow of air within tile 48. Support ridges
58 are also shown. Support ridges are appropriately spaced to
provide for proper dimensions of channels 54 and 56. Channels 54
and 56 are of fixed dimensions and have lower layer 60 protecting
their bottom portions from encroachment by bonding agents that may
be used for attachment purposes. Bottom beads 62 are shown attached
to the bottom portion 64 of lower layer 60.
[0125] For the tile shown in FIG. 5 the beads are more numerous
than used on the tile shown in FIG. 4. These beads form a layer on
the entire bottom surface of the tile. The bottom beaded surface of
this FIG. 5 illustrated tile can be used for attachment purposes or
alternatively may be used to form a secondary convection zone
beneath the first. In addition, the bottom beaded surface may be
used for both bonding and secondary convection. This may be
achieved by limiting the amount of bonding agent used.
Additionally, the tile of FIG. 5 may employ a thermal insulating
material as a bonding agent. Such thermal insulating materials
include closed cell foams such as polyurethane. Employing closed
cell foam insulating materials as bonding agents provides a low
cost lightweight method of bonding tiles to roofing surfaces while
at the same time providing added heat separation between outer
roofing surfaces and the interior portions of buildings.
[0126] FIG. 6 shows the tile of FIG. 5 with added attachment holes.
Tile 66 is shown having attachment holes 68. Attachment holes 68
are through holes and therefore facilitate the use of nails or
drywall screws for attachment to roofing surfaces. This attachment
method provides for a strong bond and allows for good secondary
convection space between bottom beads 70. Additionally if foam
insulation is employed for attachment purposes, the foam need not
bond the roofing surfaces due to the through hole attachment method
employed.
[0127] FIG. 7 shows a lightweight insulated roofing tile employing
a central insulating layer consisting of closed cell foam.
Lightweight insulated roofing tile 72 is shown having a light
reflective top surface 74. Light reflective top surface 74 reflects
light to reduce the build up of unwanted heat. Also shown is middle
closed cell foam layer 76. This layer provides thermal insulation
and reduces heat transfer within the tile. This lightweight closed
cell foam layer may be made of any number of materials including
clay filled with glass micro-balloons, polyurethane foam or any
other material or combination of materials that may be used to form
a lightweight closed cell foam insulating layer. It should be noted
that it may be desirable to add certain materials to this layer
such as fire retarding agents, anti-mildew agents, coloring agents
and any number of materials to improve the overall properties of
the tile. Bottom layer 78 is also shown. It should be noted that
any number of attachment means may be employed to secure roofing
tile 72 to roofing surfaces. RTV silicone rubber adhesives and
cement materials commonly employed for adhering roofing tiles are
two examples.
[0128] FIG. 8 shows a lightweight thermal insulated roofing tile
similar to tile 72 of FIG. 7. Lightweight thermal insulating
roofing tile 80 is similar to lightweight thermal insulating
roofing tile 72 of FIG. 7 with the addition of numerous beads 82.
Beads 82 may be employed to provide a convection space underneath
tile 80 and/or may assist in adhesion of tile 80 to roofing
surfaces.
[0129] FIG. 9 shows a lightweight thermal insulated roofing tile
employing channels to further facilitate the removal of heat by
natural and/or forced air convection. Roofing tile 84 is shown
having a reflective top surface 86. Also shown is lightweight
thermal insulation layer 88 comprised of a closed cell foam such as
polyurethane. Attached to bottom surface portion 90 are ridges 92.
Channel portions 94 are formed between ridges 92.
[0130] This particular configuration functions on multiple levels
at the same time. A significant portion of incident radiation from
sunlight falling on the reflective top surface is reflected away.
The small amount of absorbed radiation that is converted into heat
is substantially limited to the outer top layer of the tile. The
thermal insulating layer thus acts as a second impediment to heat
absorption of lower roofing surfaces. Finally the channels along
the bottom portion of roofing tile 84 remove more heat by
convective action.
[0131] FIG. 10 shows a lightweight ventilated thermal insulating
roofing tile having a light absorptive top surface and thermal
insulating layer. Roofing tile 96 is shown having a dark surface
layer 98 suitable for absorbing light along with ventilation zone
100 and thermal insulating layer 102. Also shown are beads 104.
Beads 104 form a gap between top absorptive surface 98 and thermal
insulating layer 102 of tile 96. Bottom layer 106 completes the
tile configuration.
[0132] FIG. 11 shows a lightweight ventilated thermal insulating
roofing tile having a light absorptive top surface and thermal
insulating layer. Roofing tile 108 is shown having a dark surface
layer 110 suitable for absorbing light along with ventilation zone
112 and thermal insulating layer 114. Also shown are ridges 116.
Ridges 116 form a gap between top absorptive surface 110 and
thermal insulating layer 114 of tile 108. Bottom layer 118
completes the tile configuration.
[0133] FIG. 12 shows a lightweight ventilated roofing tile having a
light absorptive top surface, a thermal insulating layer, and a
beaded bottom surface. Roofing tile 120 is the same as roofing tile
108 with added beads 122 fixedly attached to bottom surface
124.
[0134] FIG. 13 shows a simple lightweight ventilated roofing tile
having a dark absorptive top surface. Ventilated roofing tile 126
is shown having a dark top surface 128. Dark top surface 128 is
suitable for absorbing ambient sunlight and converting it into
heat. Also shown are beads 130 fixedly attached to bottom surface
132 of tile 126. Also shown is space 134 between beads 130. Space
134 is a convective space that may be also used to facilitate
adhesion to roofing surfaces by employing beads 130 with a suitable
bonding agent.
[0135] FIG. 14 shows a simple lightweight ventilated roofing tile
having a dark absorptive top surface. Ventilated roofing tile 136
is shown having a dark top surface 138. Dark top surface 138 is
suitable for absorbing ambient sunlight and converting it into
heat. Also shown are ridges 140 fixedly attached to bottom surface
142. Also shown is space 144 between ridges 140. Space 144 is a
convective channel that may be used to provide hot air by natural
or forced air convection.
[0136] FIG. 15 shows a simple lightweight ventilated roofing tile
having a dark absorptive top surface. Ventilated roofing tile 146
is shown having a dark top surface 148. Dark top surface 148 is
suitable for absorbing ambient sunlight and converting it into
heat. Also shown are ridges 150 fixedly attached to bottom surface
152. Also shown is space 154 between ridges 150. Space 154 is a
convective channel that may be used to provide hot air by natural
or forced air convection. Attached to ridges 150 are numerous beads
156. Beads 156 are fixedly attached to ridges 150. Beads 156 may be
used to increase the size of space 154. Beads 156 may also be used
to enhance the bonding of ventilated roofing tile 146 to roofing
surfaces using a suitable bonding agent.
[0137] FIG. 16 shows a ventilated roofing tile similar to that
shown in FIG. 10 with the addition of a light transmitting
insulation layer over the top surface. Roofing tile 158 is shown
having a dark surface layer 160 suitable for absorbing light along
with ventilation zone 162 and thermal insulating layer 164. Also
shown are beads 166. Beads 166 form a gap between absorptive
surface 160 and thermal insulating layer 164. Light transmitting
insulating layer 168 is shown fixedly attached to dark surface
layer 160. Light transmitting insulating layer 168 transmits light
along with its associated radiant energy. The transmitted light
falling on dark surface layer 160 provides heat in the same way as
it does for tile 48 in FIG. 10. Light transmitting insulation layer
168 reduces the loss of heat from dark absorptive surface 160. Also
shown is bottom layer 170.
[0138] Light transmitting insulating layer 168 may be formed from
any number of clear light transmitting materials. Of particular
interest is corrugated polycarbonate. Corrugated polycarbonate is a
clear corrugated construction that is readily available,
lightweight, and is relatively low in cost.
[0139] FIG. 17 shows a ventilated roofing tile similar to that
shown in FIG. 11 with the addition of a light transmitting
insulation layer over the top surface. Roofing tile 172 is shown
having a dark surface layer 174 suitable for absorbing light along
with ventilation channels 176 and thermal insulating layer 178.
Also shown are ridges 180. Ridges 180 form a gap between absorptive
dark surface layer 174 and thermal insulating layer 178. Light
transmitting insulating layer 182 is shown fixedly attached to dark
surface layer 174.
[0140] FIG. 18 shows the ventilated roofing tile of FIG. 17 with
the addition of beads to the bottom surface. Roofing tile 184 is
the same as roofing tile 172 of FIG. 17 with the addition of beads
886. Also shown is space 188 between beads 186. Space 188 may be
used to provide some insulation and/or improved adhesion qualities
between roofing tile 184 and roofing surfaces.
[0141] FIG. 19 shows a ventilated roofing tile similar to that
shown in FIG. 13 with the addition of a light transmitting
insulation layer over the top surface. Roofing tile 190 is shown
having a dark surface layer 192 suitable for absorbing light along
with ventilation spaces 194 between beads 196. Also shown is light
transmitting insulating layer 198 fixedly attached to dark surface
layer 192. As usual beads 196 may also be employed to promote
adhesion to roofing surfaces using a bonding agent.
[0142] FIG. 20 shows a ventilated roofing tile similar to that
shown in FIG. 14 with the addition of a light transmitting
insulation layer over the top surface. Roofing tile 200 is shown
having a dark surface layer 202 suitable for absorbing light along
with ventilation channels 204 between beads ridges 206. Also shown
is light transmitting insulating layer 208 fixedly attached to dark
surface layer 202.
[0143] FIG. 21 shows a lightweight ventilated roofing tile similar
to that shown in FIG. 20 With the addition of beads to the bottom
ridges. Roofing tile 210 is the same as roofing tile 200 of FIG. 20
with the addition of beads 212 along ridges 214. As usual beads 196
may also be employed to promote adhesion to roofing surfaces using
a bonding agent.
[0144] FIG. 22 shows two beaded surfaces facing each other with
interposing surface bonding geometry. This particular geometry is
suitable for the attachment of roofing tiles onto roofing surfaces.
In addition, this surface bonding geometry may be used for other
bonding applications as well. Top laminate portion 216 is shown
having beads 218 fixedly attached to bottom surface portion 220 of
top laminate portion 216. Also shown is bottom laminate portion
222. Bottom laminate 222 is shown having beads 224 fixedly attached
to top portion 226 of bottom laminate 222.
[0145] FIG. 23 shows a sectional view of two beaded surfaces
interposed with a closed cell foam bonding agent. Bonded
construction 228 is shown having top beaded laminate construction
230 having beads 232 fixedly attached to bottom surface portion
234. Also shown is bottom beaded laminate construction 236 having
beads 238 fixedly attached to top surface portion 240. Beads 232 of
laminate construction 230 are spaced equally with the same spacing
as beads 238 of laminate construction 236. Closed cell foam bonding
agent 242 is shown filling in gap portion 244.
[0146] This method of bonding may be used for numerous applications
and may be used to provide a low cost way of forming a strong bond
between two surfaces. Closed cell foam is lightweight and affords
the added advantage of being thermally insulating in nature.
Polyurethane foam is one material choice. This foam is available
from building supply houses and hardware stores in the form of a
spray can. Small amounts of foam may be applied to either surface
or both. After the application of the freshly sprayed foam the two
pieces may then be aligned to interpose their beaded surfaces. The
pieces can then be held together while the foam expands. Excess
foam may ooze from the edges during the expanding process. This
excess foam may then be trimmed with a knife or other suitable
cutting implement.
[0147] The above described method may employ other bonding agents
as well. For example, numerous bonding agents may be used with
hollow glass or polymeric micro-spheres.
[0148] Additionally, bonding agents lacking foam properties may be
used as well. It should be noted that foam based bonding agents may
be preferred where lightweight and thermal insulating properties
are desired.
[0149] FIG. 24 shows a lightweight ventilated thermal insulating
roofing tile having a light absorptive top surface and thermal
insulating layer and a bottom layer of pressure sensitive adhesive.
Roofing tile 246 is shown having a dark surface layer 248 suitable
for absorbing light along with ventilation zone 250 and thermal
insulating layer 252. Also shown are ridges 254. Ridges 254 form a
gap between top absorptive surface 248 and thermal insulating layer
252. Bottom layer 256 is covered with layer 258. Release layer 260
completes the tile configuration.
[0150] FIG. 25 shows beads that are attached to the underside of
the tile with pressure sensitive adhesive filling in the spaces
between the beads.
[0151] Roofing tile 262 is the same as roofing tile 246 with added
beads 264 fixedly attached to bottom surface 266. Also shown is
pressure sensitive adhesive layer 268 along with release liner 270.
The use of pressure sensitive adhesives in bonding roofing tiles
may facilitate the rapid construction of roofs.
[0152] FIG. 26 shows a tile having numerous spherical protrusions
suitable for use with numerous bonding agents. Tile 272 is shown
having numerous protrusions 274 in a regular ordered pattern
extending from bonding surface portion 276. Also shown is exposed
top surface portion 278. The regular ordered pattern of spherically
shaped protrusions 274 extending from bonding surface portion 276
is provided by spacing them equidistant from each other in a
regular ordered array. Spherically shaped protrusions 274 are shown
extending outwardly by a factor significantly greater than 50% from
bonding surface portion 276. This large outward extension of
spherically shaped protrusions 274 results in a zone of undercut
280. Undercut zone 280 may be used to provide interlocking
properties to liquid bonding agents (not shown). Spherically shaped
protrusions 274 are shown uniform in size and may be used to space
individual tiles equidistant from substrate surfaces.
[0153] FIG. 27 shows the tile of FIG. 26 in an up side down
configuration to more thoroughly illustrate the spherical bonding
surface aspects of the present invention. Tile 282 is shown having
bonding surface 286 having spherically shaped protrusions 284 in a
regular ordered array.
[0154] FIG. 28 shows a section of a bonding surface substrate
suitable for bonding the tiles of the present invention. Bonding
surface substrate 288 is shown having back side portion 290 along
with tile mounting surface portion 292. Also shown are holes 294
that may be used to mount bonding surface substrate 288 to other
surfaces (not shown) using nails, rivets, screws and the like.
Numerous spherically shaped protrusions 296 are shown extending
outwardly from bonding surface 288. Numerous spherically shaped
protrusions 296 are uniform in size and spaced equidistantly from
each other thereby forming a regular array.
[0155] FIG. 29 shows a beaded tile facing a substrate having a
matching beaded surface. Tile 298 is shown having a bonding surface
302 with uniform size spherical protrusions 300 extending
outwardly. As usual, uniform size spherical protrusions 300 extend
outwardly from bonding surface 302 by more than 50 percent creating
a zone of undercut 304. Tile bonding surface substrate section 306
is shown having a bonding surface 308 with uniform size spherical
protrusions 310 extending outwardly. As usual, uniform size
spherical protrusions 310 extend outwardly from bonding surface 308
by more than 50 percent creating a zone of undercut 312. The
spacing of uniform spherical protrusions 300 on bonding surface 302
of tile 298 is shown matched to the spacing of uniform spherical
protrusions 310 on bonding surface 308 of tile bonding surface
substrate section 306. The matching of interlocking spherical
protrusions between a tile and bonding substrate may be used to
impart good uniform bonding characteristics to the overall finished
construction. An example of the finished tile laminate construction
is shown in FIG. 30.
[0156] FIG. 30 shows a sectional view of a tile construction
comprised of a beaded tile interposed with a matching beaded
substrate surface and a bonding agent. Laminate construction 314 is
shown having tile 316 with uniform size spherical protrusions 318
extending into cured bonding agent portion 320. Also shown is
bonding surface 322 with uniform size spherical protrusions 324
extending into cured bonding agent portion 320. Cured bonding agent
320 is shown interlocking with spherical protrusions 318 and
324.
[0157] FIG. 31 shows a sectional view of a tile construction
comprised of a beaded tile interposed with a matching beaded
substrate surface and a rigid closed cell foam bonding agent.
Laminate construction 326 is shown having tile 328 with uniform
size spherical protrusions 330 extending into cured rigid closed
cell bonding agent portion 332. Also shown is bonding surface 334
with uniform size spherical protrusions 336 extending into cured
rigid closed cell bonding agent portion 332. Cured bonding agent
332 is shown interlocking with spherical protrusions 330 and
336.
[0158] FIG. 32 shows a cross sectional view of a tile having
numerous cavities suitable for use with numerous bonding agents.
Tile 338 is shown having cavities 340 extending into tile bonding
surface 342. Cavities 340 are shown evenly spaced and may be used
to form a strong bond with a matching substrate. Cavities 340 are
shown having straight walls however they may be modified in order
to provide improved interlocking properties toward liquid bonding
agents. For example the cavity may be widened at the bottom. Such
tiles may be formed in numerous ways including casting into rubber
molds. This option is particularly interesting owing to the
flexibility of rubber molding materials. Such materials may be used
to produce interlocking cavities. After the tile has hardened in
the mold, interlocking cavities may be released from the rubber
mold by stretching the mold to a sufficient level to provide
release. Once freed from the mold, clay and ceramic tiles may be
subsequently fired in the usual way.
[0159] FIG. 33 shows a sectional view a tile construction of the
present invention comprised of a multi-cavity tile interposed with
a matching beaded substrate surface and a bonding agent. Laminate
construction 344 is shown having tile 346 with uniform size
cavities 348 extending into cured bonding agent portion 350. Also
shown is bonding surface 352 with uniform size spherical
protrusions 354 extending into cured bonding agent portion 350.
Cured bonding agent 350 is shown interlocking with cavities 348 and
spherical protrusions 354.
[0160] FIG. 34 shows a sectional view of a tile construction
comprised of a multi-cavity tile interposed with a matching beaded
substrate surface and a rigid closed cell foam bonding agent.
Laminate construction 356 is shown having tile 358 with uniform
size cavities 360 extending into cured rigid closed cell foam
bonding agent portion 362. Also shown is bonding surface 364 with
uniform size spherical protrusions 366 extending into cured rigid
closed cell bonding agent portion 362. Cured rigid closed cell
bonding agent 362 is shown interlocking with spherical protrusions
360 and 366.
[0161] FIG. 35 shows cross sectional view of a tile bonding
substrate having numerous surface cavities. Tile bonding substrate
368 is shown having cavities 370 extending into tile bonding
substrate surface 372. Cavities 370 are shown evenly spaced and may
be used to form a strong bond with matching tiles. Cavities 370 are
shown having straight walls however they may be modified in order
to provide improved interlocking properties toward liquid bonding
agents. For example the cavity may be widened at the bottom.
[0162] FIG. 36 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
beaded tile and a bonding agent. Laminate construction 374 is shown
having tile 376 with uniform size spherical protrusions 378
extending into cured bonding agent portion 380. Also shown is
bonding surface 382 with uniform size cavities 384. Cured bonding
agent 380 is shown interlocking with spherical protrusions 378 and
cavities 384.
[0163] FIG. 37 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
beaded tile and a rigid closed cell foam bonding agent. Laminate
construction 386 is shown having tile 388 with uniform size
spherical protrusions 390 extending into cured rigid closed cell
bonding agent portion 392. Also shown is bonding surface 394 with
uniform size cavities 396. Cured rigid closed cell foam bonding
agent 392 is shown interlocking with spherical protrusions 390 and
cavities 396.
[0164] FIG. 38 shows a tile having numerous spherical protrusions
with flat top geometry suitable for use with numerous bonding
agents. Tile 398 is shown having numerous spherically shaped flat
top protrusions 400 in a regular ordered pattern extending from
bonding surface portion 402. Also shown is exposed top surface
portion 404. The regular ordered pattern of spherically shaped flat
top protrusions 400 extending from bonding surface portion 402 is
provided by spacing them equidistant from each other in a regular
ordered array. Spherically shaped flat top protrusions 400 are
shown extending outwardly by a factor significantly greater than
50% from bonding surface portion 402. This large outward extension
of spherically shaped flat top protrusions 400 results in a zone of
undercut 406. Undercut zone 406 may be used to provide interlocking
properties to liquid bonding agents (not shown). Spherically shaped
flat top protrusions 400 are shown uniform in size and may be used
to space individual tiles equidistant from substrate surfaces.
[0165] FIG. 39 shows a section of a bonding surface substrate
having numerous spherical protrusions with flat top geometry
suitable for bonding the tiles of the present invention. Bonding
substrate 408 is shown having numerous spherically shaped flat top
protrusions 410 in a regular ordered pattern extending from bonding
surface portion 412. Also shown is exposed top surface portion 414.
The regular ordered pattern of spherically shaped flat top
protrusions 410 extending from bonding surface portion 412 is
provided by spacing them equidistant from each other in a regular
ordered array. Spherically shaped flat top protrusions 410 are
shown extending outwardly by a factor significantly greater than
50% from bonding surface portion 412. This large outward extension
of spherically shaped flat top protrusions 410 results in a zone of
undercut 416. Undercut zone 416 may be used to provide interlocking
properties to liquid bonding agents (not shown). Spherically shaped
flat top protrusions 410 are shown uniform in size and may be used
to space individual tiles equidistant from bonding substrate
surfaces.
[0166] FIG. 40 shows a sectional view a tile construction comprised
of a flat top geometry beaded tile interposed with a matching flat
top geometry beaded substrate surface and a bonding agent. Laminate
construction 418 is shown having tile 420 with uniform size flat
top spherical protrusions 422 extending into cured bonding agent
portion 424. Also shown is bonding surface 426 with uniform size
flat top spherical protrusions 428 extending into cured bonding
agent portion 424. Cured bonding agent portion 424 is shown
interlocking with flat top spherical protrusions 422 and 428.
[0167] FIG. 41 shows a sectional view a tile construction comprised
of a flat top geometry beaded tile interposed with a matching flat
top geometry beaded substrate surface and a rigid closed cell foam
bonding agent. Laminate construction 430 is shown having tile 432
with uniform size flat top spherical protrusions 434 extending into
cured rigid closed cell foam bonding agent portion 436. Also shown
is bonding surface 438 with uniform size flat top spherical
protrusions 440 extending into cured rigid closed cell foam bonding
agent portion 436. Cured rigid closed cell foam bonding agent
portion 436 is shown interlocking with flat top spherical
protrusions 434 and 440.
[0168] FIG. 42 shows a sectional view of a tile construction
comprised of a multi-cavity tile bonding substrate interposed with
a matching flat top geometry beaded tile and a bonding agent.
Laminate construction 442 is shown having tile 444 with uniform
size spherical protrusions 446 extending into cured bonding agent
portion 448. Also shown is bonding surface 450 with uniform size
cavities 452. Cured bonding agent portion 448 is shown interlocking
with flat top geometry spherical protrusions 446 and cavities
452.
[0169] FIG. 43 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
flat top geometry beaded tile and a rigid closed cell foam bonding
agent. Laminate construction 454 is shown having tile 456 with
uniform size spherical protrusions 458 extending into cured rigid
closed cell foam bonding agent portion 460. Also shown is bonding
surface 462 with uniform size cavities 464. Cured rigid closed cell
foam bonding agent portion 460 is shown interlocking with flat top
geometry spherical protrusions 458 and cavities 464.
[0170] FIG. 44 shows a lightweight flat top geometry beaded
insulated tile employing a central insulating layer consisting of
closed cell foam. Lightweight flat top beaded insulated tile 468 is
shown having flat top bonding beads 470.
[0171] FIG. 45 shows a sectional view a tile construction comprised
of a multi-cavity tile bonding substrate interposed with a matching
flat top spherical beaded tile employing a central insulating layer
consisting of closed cell foam and a rigid closed cell foam bonding
agent. Laminate construction 472 is shown comprised of multi-cavity
bonding substrate 474 and matching flat top spherical beaded tile
476 having a central insulating layer 478.
[0172] FIG. 46 shows a cross sectional view of one beaded surface
facing another surface having matching holes. This particular
geometry is suitable for the attachment of roofing tiles onto
roofing surfaces. In addition, this surface bonding geometry may be
used for other bonding applications as well. Top laminate portion
480 is shown having beads 482 fixedly attached to bottom surface
portion 484 of top laminate portion 480. Also shown is bottom
laminate portion 486. Bottom laminate 486 is shown having holes 488
in top portion 490 of bottom laminate 486.
[0173] Of further interest is the employment of bead protrusions on
one substrate and matching holes on the other as shown in FIG. 37
in cross sectional form. This particular configuration may be used
to bond tiles to roofing surfaces using insulating foam.
[0174] It should be noted that the holes may be modified from
straight wall geometry to a geometry that may represent a hollow
cavity having more of a spherical shape than the standard
cylindrical shape of traditional holes. The spherically modified
holes may be produced in a variety of ways including angled
machining, chemical etching and EDM (electrode discharge milling).
Holes modified in this manner may provide improved anchorage for
the finished part when employing bonding agents.
[0175] FIG. 47 shows a building having a pitched roof employing
ventilated tiles having natural convection. Building 492 is shown
having roof portion 494 along with structural bottom portion 496.
Also shown is door 498 along with windows 500. Roof 494 is covered
by ventilated roofing tiles 502. Tiles 502 are light in color and
reflect sunlight. Ventilated roofing tiles 502 on roof 494 may
conform to any of the ventilated roofing tiles described previously
in the detailed description of this patent application. More
particularly ventilated roofing tiles 502 may conform to the
aspects of this invention involved with the removal of unwanted
heat by natural convection. It should be noted that roofing tiles
502 are not the only external roofing material suitable for
employing the teachings of this invention. Other external roof
covering may be employed using the external ventilation aspects of
the present invention. For example, roofing sections significantly
larger than tiles may be employed as well having natural convection
channels suitable for use on slanted roofs. Ventilated roofing
tiles 502 are shown covering the entire surface of roof portion
494. Ventilation slots 504 are shown along the top ridge portion
506 of roof portion 494. Ventilation slots 504 provide an
atmospheric exit for the natural convective removal of hot air. It
should be noted that it may be desirable to cover ventilation slots
504. Covering ventilation slots 504 may inhibit convection during
cold weather and may also be used to prevent unwanted debris from
clogging ventilated tiles 502 themselves.
[0176] FIG. 48 shows a building having a pitched roof employing
dark heat absorbing ventilated tiles along with forced air
convection for moving heated air into interior spaces. Building 508
is shown having dark angled roof portion 510 along with bottom
structural portion 512. Also shown are windows 514 and door 516.
Dark heat absorbing ventilated roofing top surface 518 is also
shown. Top surface 518 consists of numerous heat absorbing
ventilated tiles 520. Dark heat absorbent ventilated roofing tiles
520 are arranged having their convection channels aligned with one
another along the slanted upward direction of roof portion 510.
Also shown is manifold 522 along with ducting 524. Fan portion 526
is also shown along with thermostat 528. Wires 530 and 532
electrically connect thermostat 528 to fan portion 526. Dark heat
absorbent ventilated roofing tiles 520 draw air from lower edge
portion 534 of roof portion 510. Fan 536 of fan portion 526 creates
negative pressure in ducting 524 and manifold 522. This negative
pressure helps to draw air from lower roofing edge portion 534 and
through the air spaces of heat absorbing ventilated tiles 520. Heat
absorbing ventilated tiles 520 are warm due to exposure to
sunlight. Air traveling through ventilated tiles 520 is heated and
transported through manifold 522 into ducting 524. Hot air then is
then forced into the interior portions of 508. Thermostat 528
controls fan 536. Additional thermostats, timers, and switches may
be employed for further temperature control. It should be noted
that the ducting shown in FIG. 48 is on the outside of the
building. It may be desirable to run the ducting through the inside
of the building in order to reduce heat transfer with the outside
environment. This may be particularly useful during periods of
exceptionally cold weather. It should also be noted in areas of
substantial cold that certain heat producing ventilated tiles may
be more desirable than others. For example, the heat producing
ventilated roofing tile shown in FIG. 17 has a substantial amount
of thermal insulation on the bottom surface and has a light
transmitting insulating layer over the top exposed surface. The
ventilated heat producing tile of FIG. 17 may be a good choice for
producing heat from solar radiation during times of exceptionally
cold weather.
[0177] FIG. 49 shows a building having a flat roof employing
ventilated tiles along with forced air convection for the removal
of excess heat. Building 538 is shown having a lower structural
portion 540 along with reflective roofing portion 542. Also shown
is manifold 544 along with ducting 546. Fan portion 548 is also
shown along with fan 550. Switch 552 is used to turn on and off fan
550. Fan 550 is configured to remove unwanted heat from reflective
ventilated roofing tiles 554 of reflective roofing portion 542.
This particular configuration may employ either negative or
positive pressure in manifold 544. An important aspect of this
particular configuration is the venting of unwanted heat present in
ventilated roofing tiles 554 to the atmosphere by forced air
convection. Fan 550 may suck outside air into fan portion 548 and
push this air with positive pressure into manifold 544 via ducting
546 thereby pushing outside air into ventilated roofing tiles 554
and thus removing heat and venting the hot air to the atmosphere
along edge portion 556 of reflective roofing portion 542.
Alternatively, reversing the airflow would result in the same
transfer of unwanted heat from ventilated roofing tiles 554 to the
atmosphere.
[0178] FIG. 50 shows a building having a flat roof employing dark
heat absorbing ventilated tiles along with forced air convection
for moving heated air into interior spaces. Building 560 is shown
having a lower structural portion 562 along with heat absorbing
roofing portion 564. Also shown is manifold 566 along with ducting
568. Fan portion 570 is shown along with fan 572. Switch 574 is
used to turn and off fan 572. Fan 572 is configured to take air
from manifold 566 via ducting 568. Manifold 566 is under negative
pressure from fan 572. Dark heat absorbing ventilated roofing tiles
576 are shown connected together in a horizontal configuration and
therefore require forced air convection from fan 572 in order to
transfer heat. Edge portion 578 is also shown. Edge portion 578
represents the intake of air from outside into the air spaces of
ventilated roofing tiles 576. As the air travels within the air
spaces within ventilated roofing tiles 576, it heats up as a result
of heat transfer. Hot air then enters manifold 566 at the other end
and is sucked down ducting 568 into fan portion 570 and is blown
into the interior of building 560 by fan 572.
[0179] Those skilled in the art will understand that the preceding
exemplary embodiments of the present invention provide foundation
for numerous alternatives and modifications. These other
modifications are also within the scope of the limiting technology
of the present invention. Accordingly, the present invention is not
limited to that precisely shown and described herein but only to
that outlined in the appended claims.
* * * * *