U.S. patent application number 12/858980 was filed with the patent office on 2011-04-28 for light weight molded roof tile.
Invention is credited to Carmen Bellavia.
Application Number | 20110094169 12/858980 |
Document ID | / |
Family ID | 43897187 |
Filed Date | 2011-04-28 |
United States Patent
Application |
20110094169 |
Kind Code |
A1 |
Bellavia; Carmen |
April 28, 2011 |
LIGHT WEIGHT MOLDED ROOF TILE
Abstract
An improved roof tile that is composed of a polymeric isocyanate
and water blown component, mineral fiber or fiberglass, said roof
tile being molded producing a roof tile with a high R-value thermal
insulation and being very light weight. Each tile includes a flat
bottom surface including a groove of a predetermined pattern that
receives poly foam adhesive for attaching each tile to a roof
substrate.
Inventors: |
Bellavia; Carmen; (Pompano
Beach, FL) |
Family ID: |
43897187 |
Appl. No.: |
12/858980 |
Filed: |
August 18, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61255629 |
Oct 28, 2009 |
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Current U.S.
Class: |
52/173.3 ;
52/173.1; 52/309.5; 52/518 |
Current CPC
Class: |
Y02B 10/20 20130101;
E04D 1/20 20130101; E04D 1/205 20130101 |
Class at
Publication: |
52/173.3 ;
52/309.5; 52/518; 52/173.1 |
International
Class: |
E04D 3/18 20060101
E04D003/18; E04C 2/20 20060101 E04C002/20; E04D 1/20 20060101
E04D001/20; E04D 13/18 20060101 E04D013/18 |
Claims
1. A molded polyurethane foam, mineral fiber, or fiber glass roof
tile comprising: a relatively thin substantially rectangular body
said body having a top surface, a flat bottom surface, top and
bottom edges, parallel side edges, the bottom flat surface having a
groove for receiving a poly foam adhesive used to attach the roof
tile to a roof surface.
2. A molded roof tile as in claim one wherein: said roof tile is
composed of a polymeric isocyanate and a water-based blown
component, said roof tile having a high R-value related to the
thermal insulation and being lightweight.
3. A molded roof tile as in claim one wherein: said roof tile flat
bottom surface groove is shaped like an asterisk.
4. A molded roof tile that may be embedded with various solar
devices can be coated with solar paints.
5. A molded roof tile that is finished with gel coat, silicone, or
elastomeric coatings.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to building exterior roof
tiles and specifically to an improved building roof tile that is
lightweight, durable, has a high R-value providing insulation
against heat and cold and is easily installed.
[0003] 2. Description of the Prior Art
[0004] Exterior building roofs have used different materials for
protecting a building from inclement weather such as rain, solar
energy, heat, cold, snow, ice, and wind damage.
[0005] Typical roofs are made of plywood, tarpaper and shingles.
Tiles are also used to cover the plywood and tarpaper. Tiles are
made in small pieces and are often made of terra-cotta or other
cementious material. Tiles create a great weight on the building
structure requiring a more sturdy construction of the building.
Installing tile is labor-intensive on roofs and requires hauling
and lifting heavy loads of tile pieces and yards of cement for the
setup work.
[0006] The present invention overcomes the problems of previously
used tiles made of cement and clay materials by providing a
lightweight poly based molded cut tile that is durable, has
excellent R-value for insulation and is easy and inexpensive to
install on a building exterior having a plywood or plank base
roof.
[0007] A. Polyurethane based foams are the most insulating roofing
systems available today. These products are only available on flat
roofs because of limitations of fire resistance on pitched roofs
and the surface cannot be satisfactorily finished. The invention
will address this problem by molding and cutting "tiles" out of
polyurethane, mineral fiber, or fiberglass high insulating core
material creating the only highly energy efficient tiles for any
sloped roof.
[0008] B. The flammability ratings of available coatings for
existing urethane systems do not apply to any roof pitch over 2''
on 12''. The current configuration and manufacturing process solves
this by utilizing a flame retardant resin with a flame retardant
treatment, finished with a flame retardant gel coat mixture,
acrylic, or silicone coating.
[0009] C. Solar systems penetrate roof systems thus requiring
special flashings, create additional weight on structures, require
separate installation, adds no insulation, and creates potential
drafting and leak points in a roof surface. The invention solves
these issues by incorporating a lightweight, high insulating roof
panel with embedded solar cells or paintable solar coating.
Individual tiles are easy to replace, and very affordable
eliminating the need to ever replace any large solar panels.
[0010] D. Available tile roof systems need frequent maintenance and
leak after a short service time. The invention solves this problem
by overlapping the tiles in a manner which makes water penetration
much more difficult if not altogether impossible.
[0011] E. Available pitched roof systems cannot hold up to category
4 hurricane winds. Huge numbers of buildings are in areas where
catastrophic damage occurs. The invention solves this problem with
its unique tile design. The tiles have been independently tested to
withstand over 260 mph winds without suffering any damage.
[0012] F. Hail storms damage all roof systems often allowing major
water penetration into the building and massive interior damage.
The invention solves that problem because of its hardness,
thickness and density. When struck, even if hard enough to crack or
dent the tiles, water penetration is not immediately possible
because of the characteristics of the tiles core. The tiles can be
easily repaired or replaced as needed.
[0013] Concrete and terra cotta roof tiles are subject to
degradation due to the composition of the products and the effect
of the elements. This causes the tiles to become brittle and
routinely fracture and break when basic maintenance is performed.
The invention solves this problem by eliminating breakage due to
its composition and unique design characteristics.
[0014] Typical Tile roof systems are highly material and labor
intensive. The invention solves these problems because it is
lightweight, has a more simplified installation, and requires only
poly foam adhesive and caulking to install.
SUMMARY OF THE INVENTION
[0015] An array of pre-molded poly foam tiles configured to fit
together to complete a building exterior roof covering that appears
to be aesthetically a conventional tile, slate, or shake roof.
[0016] Each molded tile is configured for placement at a
predetermined location on the roof structure such as the roof peaks
or top, bottom rows of the roof and field tiles, which are
installed between the bottom row of the roof and the peak or hip
and ridge tiles.
[0017] The present invention uses poly foam or comparable material
from which each of the tile pieces are made in separate molds. In
one embodiment composition of the tile that is molded uses a
complementary system of polymeric isocyanate "A"-component and a
composite water-based (HCFC-245fa) blown "B"-component. Using these
ingredients, the mixture produces a tile that has lightweight and
excellent thermal insulation characteristics. Other compositions
for specific roof applications involve modifications to the
polyurethane A and B mix as well as mineral fiber and fiberglass
cores. Additives for flame resistance and mold control are examples
of modifications. Each tile can also include a finish coat that
includes gelcoat and similar additives.
[0018] The tiles can utilize solar paint or embedded solar panels
for partial or total solar coverage of the structure. There is a
metal "Z" bar which is installed at the top of a completed bottom
row of tile. These bars can comprise the "grid" for the solar
option. Final connections to the panel can be made by a certified
electrician.
[0019] There is a different mold for the field tile, a different
mold for the bottom row tile and a different mold for the hip or
ridge tile. All of the tile pieces for the roof are pre-molded and
coated before being delivered to the building site where they are
attached to the roof as described herein.
[0020] As an example a home or residential building may have a
wooden frame with a plywood sheet roof. A substrate may be prepared
and applied to the roof with a hot mop for granular type material
or any other type of suitable substrate to which the tiles will be
attached. Once a substrate has been installed, poly foam adhesive
is used that is put on the substrate and to which the tiles are
attached whether it be the hip tile, the field tile or the bottom
row roof tile.
[0021] The field tiles and the roof bottom row tiles each have on
their back sides recessed or grooved areas that are of a
predetermined pattern that receives the poly foam adhesive that is
applied to the roof substrate for attaching each tile to the roof
permanently. The foam adhesive has a setup time. Each of the roof
tiles manually receives the poly foam adhesive on the under side of
each tile in the domed star shaped area of grooves which is then
manually attached to the roof and roof substrate. During the
process, the poly foam adhesive must setup and the poly foam
adhesive is allowed to harden, firmly attaching the roof tiles to
the poly foam adhesive and to the substrate. The roof tiles are
installed manually from the bottom up on the roof in a conventional
fashion. The first row is installed against the roof edge which
contains the bottom row tiles. The field tiles are then overlapped
row by row from bottom to top. At the very top of the roof the hip
and ridge tiles are adhered to the roof using poly foam adhesive.
Note that the field tiles and the bottom row tiles have additional
side overlapped portions so that not only are they overlapped from
top from bottom, they are also interlocked in a side-to-side
fashion. The tiles are also staggered in a brick like format from
row to row. Hip and ridge tiles will be installed over roof peaks
and adjoining field tile areas.
[0022] It is an object of this invention to provide an improved
molded roof tile made of poly foam, mineral fiber or fiberglass
that includes polymeric isocyanate and a water-based blown
component that is lightweight, has a high R-value for thermal
insulation, is pre-molded into individual units, and is easy to
install.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows a bottom perspective view of the field tile
used in the present invention.
[0024] FIG. 2 shows a bottom perspective view of the bottom row
tile used in the present invention
[0025] FIG. 3 shows a bottom perspective view of the tile used on
the roof peak or the hip and ridge tile.
[0026] FIG. 4 shows a bottom plan view of the bottom of the field
tile shown in FIG. 1.
PREFERRED EMBODIMENT OF THE INVENTION
[0027] Referring now to the drawings and in particular FIG. 1, a
field tile 10 is shown as it would appear after molding from a
polyurethane material preferably polymeric isocyanate and a
water-based (HCFC-2455fa) blown component. The field tile 10 shown
in FIG. 1 includes a bottom flat surface 12 and a lower recessed
overlap portion 14 which is used to overlap the tile below the tile
shown in FIG. 1 when a roof is done. The tile 10 includes a side
recessed edge portion 16 that is used to interlock each field tile
with an adjacent tile having a recessed portion 20 so that the
tiles interlock in a side-by-side row fashion. The end 18 is flat.
FIG. 1 shows a recessed groove 12a in the surface 12 that receives
a foam adhesive (not shown) that is used to attach tile 10 to a
roof surface.
[0028] FIG. 1 and FIG. 4 shows the tile back side 12 and grooved or
recessed pattern 12a that looks like an asterisk that is basically
a groove 12a that is molded in the bottom surface of tile 10 as
shown in FIG. 1 that is sufficiently deep to receive poly foam
adhesive while the foam is setting up in the semi fluid stage to
allow each tile to be firmly attached to the roof substrate. To
attach the tiles 10 to a roof substrate, the tile 10 bottom surface
12 is placed in direct contact with a substrate (not shown) and
with the groove pattern 12a filled with foam adhesive that binds
the tile bottom 12 to the roof substrate. The poly foam adhesive is
applied to the tile groove pattern 12a and to a substrate on the
roof. During the adhesive foam setup, the tile groove is filled
with poly foam adhesive to be pressed against the roof substrate
and upon foam set up, the foam adhesive sets up and the tile is
firmly attached to the roof substrate. The groove pattern 12a could
be 5/8 inch deep, or sufficiently deep to attach the tile to the
substrate. The field tile 10 shown in FIG. 1 is the primary tile
used with the present invention and is used in all the areas on the
roof except the very peak of the roof and the very last bottom row
of tiles on the roof. The tile 10 shown in FIG. 1 can be hand sawed
to change the length or to fit along the side edge if necessary.
The R-value of the tile shown 10 in FIG. 1 is extremely high for
insulation against heat and cold and is also extremely light weight
because each tile 10 is made of molded polyurethane foam like
material.
[0029] Referring now to FIG. 2, tile 30 is shown that is used as
the bottom row of roof tiles. Tile 30b configured different than
tile 10 due to its placement at the bottom edge of the roof to
provide an aesthetic shape. The bottom row tile 30 includes a
bottom surface 32 which shows in FIG. 2 the recessed grooves 32a
for receiving poly foam adhesive for attaching the bottom row roof
tile 30 to the roof substrate. The tile 30 bottom edge portion has
an overhanging extended bottom edge 34 as the last tile at the
bottom of the roof. The tile 30 also has side edge recesses 36 and
38 so that tiles can be interlocked side-by-side together during
the installation process along the bottom of the roof. The top
surface 40 of the bottom roof tile is shown. The bottom row roof
tile 30 is made of and molded from the same material as the field
tile 10 FIG. 1 which is a polyurethane foam described above which
is individually molded for each piece and is extremely lightweight.
The tile 30 also provides an aesthetic look like a conventional
clay, cement, slate or wood shake tile. FIG. 2 shows the recessed
groove pattern 32a which looks like an asterisk * in the bottom
surface 32 of the tile 30 shown in FIG. 2 to receive measured poly
foam adhesive (not shown) during setup phase for firmly attaching
the tile 30 to the roof after the foam adhesive sets up which is
forced into the recessed grooves 42 in each tile.
[0030] Referring now to FIG. 3, the molded hip and ridge tile 50 is
shown which is used where different fields of tile meet and at the
very top of the roof peak for covering the upper row of field
tiles. The ridge tile 50 is molded and made of the same material as
the field tile 10 FIG. 1 and is very light weight. A flat bottom
surface 58 of ridge tile 50 can also receive adhesive foam along
its bottom for attaching the ridge tile 10 to the adjacent field
tiles 10 FIG. 1 at the peak of the roof. Tile 50 can also be
overlapped through recessed portion 54 at one end.
[0031] Using the field tile 10 FIG. 1, the bottom row tile 30 FIG.
2, and the ridge tile 50 an entire roof structure can be installed
quickly and easily using pre-molded tile made of a very light
weight material and foam adhesive which allows for quick setup and
attachment to the roof structure.
[0032] Available tile roof systems need frequent maintenance and
leak after a short service time. The invention solves this problem
by overlapping the tiles in a manner which makes water penetration
much more difficult if not altogether impossible.
[0033] The instant invention has been shown and described herein in
what is considered to be the most practical and preferred
embodiment. It is recognized, however, that departures may be made
therefrom within the scope of the invention and that obvious
modifications will occur to a person skilled in the art.
* * * * *