U.S. patent application number 13/527564 was filed with the patent office on 2013-12-19 for modular roofing system.
The applicant listed for this patent is Kelvin D. Elisary. Invention is credited to Kelvin D. Elisary.
Application Number | 20130333303 13/527564 |
Document ID | / |
Family ID | 49754639 |
Filed Date | 2013-12-19 |
United States Patent
Application |
20130333303 |
Kind Code |
A1 |
Elisary; Kelvin D. |
December 19, 2013 |
Modular roofing system
Abstract
A modular roofing system includes a lower set of co-adjacent
rectangular panels locked together by an upper set of co-adjacent
hexagonal tiles made from a light-weight rigid urethane foam
material coated with a durable outer layer of non-foam polyurethane
plastic. The tiles can carry photovoltaic cells that interconnect
at opposite ends to adjacent tiles. The cells can be replaced on
the existing installed tiles using an aligned locking structure for
aligning electrical contacts and sealing the cells. Length
adjustable modular gutter tiles terminate an array of tiles along a
lower roof edge.
Inventors: |
Elisary; Kelvin D.;
(Oroville, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Elisary; Kelvin D. |
Oroville |
CA |
US |
|
|
Family ID: |
49754639 |
Appl. No.: |
13/527564 |
Filed: |
June 19, 2012 |
Current U.S.
Class: |
52/11 ; 52/173.1;
52/173.3; 52/309.4; 52/588.1 |
Current CPC
Class: |
Y02B 10/10 20130101;
Y02E 10/47 20130101; Y02B 10/12 20130101; F24S 2025/6007 20180501;
Y02B 10/20 20130101; H02S 40/36 20141201; H02S 20/25 20141201; Y02E
10/50 20130101; H02S 20/23 20141201; F24S 25/632 20180501; F24S
20/69 20180501 |
Class at
Publication: |
52/11 ; 52/588.1;
52/309.4; 52/173.3; 52/173.1 |
International
Class: |
E04D 13/18 20060101
E04D013/18; E04D 13/064 20060101 E04D013/064; E04H 14/00 20060101
E04H014/00; E04D 1/34 20060101 E04D001/34; E04C 2/20 20060101
E04C002/20 |
Claims
1. A roofing system which comprises: a first set of laterally
abuttable, uniformly shaped and dimensioned lower support panels; a
second set of laterally matable, uniformly shaped and dimensioned
roofing tiles; wherein an abutted pair of said panels forms a
mutual ridge extending upwardly along their abutting edges; and,
wherein a mated pair of said tiles has a common, co-linear bottom
channel shaped and dimensioned to intimately nest onto said mutual
ridge.
2. The system of claim 1, which further comprises: said abutted
pair of panels having co-planar upper support surfaces astride said
ridge; and, said mated pair of tiles having co-planar lower
surfaces astride said channel; and, wherein said lower surfaces are
bearingly supported by said upper surfaces.
3. The system of claim 2, which further comprises: said mutual
ridge being formed by uniformly shaped and dimensioned prominences
extending upwardly along said abutting edge.
4. The system of claim 3, wherein said abutted pair of panels
planarly slidingly abut along a pair of substantially planar
contact surfaces oriented substantially orthogonally to said upper
support surfaces.
5. The system of claim 4, wherein said panels abut in absence of a
tongue-in-groove interface.
6. The system of claim 5, which further comprises: said first set
of panels being uniformly shaped and dimensioned; and, said second
set of tiles being uniformly shaped and dimensioned.
7. The system of claim 6, wherein said mated pair of tiles mate
along tongue-in-groove interface.
8. The system of claim 7, wherein said tiles modularly combine to
form a contiguous planar array.
9. The system of claim 8, wherein a first of said tiles interlock
with a second adjacent one of said tiles along a first side wall
and wherein said first of said tiles interlocks with a third
adjacent one of said tiles along a second side wall, and wherein
said first and second side walls are non-parallel.
10. The system of claim 9, wherein each of said panels are
substantially rectangularly shaped and each of said tiles are
substantially hexagonally shaped.
11. The system of claim 10, which further comprises: a second
abutted pair of panels; wherein said first abutted pair of panels
abut latitudinally; wherein said second abutted pair of panels abut
latitudinally; and wherein said first abutted pair of panels
interlocks longitudinally with said second abutted pair of
panels.
12. The system of claim 10, wherein each of said tiles comprises a
core consisting of a rigid polyurethane foam material and an upper
protective coating layer of a non-foam polyurethane material
contacting said core; and wherein said rigid polyurethane foam
material has a density of no greater than 240 kilograms per cubic
meter.
13. The system of claim 12, wherein said tile comprises a
photoelectric module releasably secured to said tile within a
recess formed into a substantially planar upper surface of said
tile; wherein said module has a substantially planar upper surface
which is substantially co-planar with said tile upper surface when
the module is secured within said recess.
14. The system of claim 13, wherein said tile comprises: a first
pair of electrical contacts located within said recess and said
module comprises a second pair of electrical contacts shaped,
dimensioned and located to electrically interconnect with said
first pair when said module is secured to said tile; and, a pair of
electrical contact wells formed into said first side wall; and, a
pair of dual ended electrical contact pins shaped and dimensioned
to intimately and conductively engage said wells and a second pair
of wells located on said second one of said tiles.
15. The system of claim 14, which further comprises: a locking
mechanism for securing said module within said recess, where said
locking mechanism comprises: alignment tabs extending from a
peripheral boundary located to engage commensurately shaped and
dimensioned alignment slots formed on a periphery of said recess;
and, a sloped track having an endstop located to restrict angular
movement of at least one of said tabs.
16. The system of claim 9, wherein said first side wall has a
groove which transitions to a second side having a tongue proximate
to a vertex; and wherein said groove preferentially extends beyond
said vertex of said side to eliminate said tongue; and, wherein
said groove extends along three contiguous sides of said tile and
said tongue extends along three contiguous side walls of said
tile.
17. The system of claim 11, which further comprises: a gutter tile
having an upper surface co-planar with a top surface of said tile
array; an aperture passing through said upper surface in
communication with a gutter; and, wherein said gutter comprises: a
plurality of unformly shaped and dimensioned U-shaped stacked
gutter ribs.
18. A roofing system comprises: a substantially continuous planar
array of uniformly shaped and dimensioned co-adjacent lower panels;
a substantially continuous planar array of uniformly shaped and
dimensioned co-adjacent upper tiles; and, said lower panels being
locked to one another by said tiles.
19. The system of claim 18, wherein each of said panels comprises
opposite substantially parallel edges, wherein each of said edges
has a raised prominences; and, wherein each of said tiles comprises
an undersurface shaped to have a medial channel shaped and
dimensioned to intimately engage a laterally adjacent pair of said
prominences; and, wherein said panels are substantially rectangular
and said tiles are substantially hexagonal.
20. A roofing assembly comprises: a plurality of tiles, each having
a front edge, a back edge, and left and right lateral side edges,
lying contiguously to one another in partially superimposing
latitudinal rows; means for forming a right lateral edge of each
tile to a left lateral edge of an adjacent tile; each of a group of
said tiles comprising; a photoelectric cell; first and second
electrical interconnects to said cell; a laterally extending groove
supporting said first interconnect; and, a laterally extending
tongue supporting said second interconnect.
21. I claim the design of FIGS. 18-56.
Description
FIELD OF THE INVENTION
[0001] The invention relates generally to modular roofing tiles,
and more particularly to roofing tile systems which can provide
solar power options.
BACKGROUND
[0002] Roofing systems have likely existed since soon after humans
moved out of caves millennia ago. Modernly, preferred systems
should be inexpensive, easy to manufacture, install, repair and
maintain, and are reasonably effective at keeping the weather out
of a dwelling. Other desirable qualities for roofing systems are
that they be light-weight, durable, and provide insulation against
temperature extremes.
[0003] One relatively recent improvement to roofing systems
involves adaptions which generate electricity from solar power and
are adapted for use on slanted roofs typically used on single
family dwellings. A substantial amount of research and development
has been carried out for the purpose of producing practical and
economical photovoltaic voltage generating units for roofing
systems. Conventional methods of forming photovoltaic modules for
installation in roofing systems often involve forming and
installing one module at a time to an existing pre-installed
roofing system. Such methods can be expensive to manufacture and
install. Further, the installation can result in damage or rapid
wear of an existing roof, thus reducing its weather protective
quality.
[0004] Integrated photovoltaic generating roofing systems are
well-known and described, for example, in U.S. Pat. Nos. 4,040,867
and 4,321,416, both of which are incorporated herein by reference.
These systems include a plurality of tiles connected to one another
in accordance with a predetermined wiring arrangement to form an
array to make their generated power available at output terminals
of the array. The array of modules may serve as shingles that are
secured to the roof or other surfaces of a structure by relatively
complicated means including for example fasteners and oversized
washers that are positioned and located relative to inactive
portions of the photovoltaic modules. Thus, the shingles can be
difficult and costly to install and replace.
[0005] There is a need for an improved modular roofing system which
can provide a more simple means for being interconnected, both
mechanically and electrically; which can be less expensively
manufactured, installed, maintained and repaired; which can be
light-weight; which can provide improved insulating
characteristics; and/or which can provide improved protection
against weather extremes in combination with the electricity
generating capability.
[0006] The instant invention results from an attempt to address one
or more of the above identified disadvantages of prior systems.
SUMMARY
[0007] The principal and secondary objects of the invention are to
provide an improved roofing system. These and other objects are
achieved by, for example, a modular roofing system having an array
of lower panels which interlock and support an array of
interlocking upper tiles.
[0008] The content of the original claims is incorporated herein by
reference as summarizing features in one or more exemplary
embodiments.
[0009] In some embodiments there is provided a roofing system which
comprises: a first set of laterally abuttable, uniformly shaped and
dimensioned lower support panels; a second set of laterally
matable, uniformly shaped and dimensioned roofing tiles; wherein an
abutted pair of said panels forms a mutual ridge extending upwardly
along their abutting edges; and, wherein a mated pair of said tiles
has a common, co-linear bottom channel shaped and dimensioned to
intimately nest onto said mutual ridge.
[0010] In some embodiments the roofing system further comprises:
said abutted pair of panels having co-planar upper support surfaces
astride said ridge; and, said mated pair of tiles having co-planar
lower surfaces astride said channel; and, wherein said lower
surfaces are bearingly supported by said upper surfaces.
[0011] In some embodiments the roofing system further comprises:
said mutual ridge being formed by uniformly shaped and dimensioned
prominences extending upwardly along said abutting edge.
[0012] In some embodiments said abutted pair of panels planarly
slidingly abut along a pair of substantially planar contact
surfaces oriented substantially orthogonally to said upper support
surfaces.
[0013] In some embodiments said panels abut in absence of a
tongue-in-groove interface.
[0014] In some embodiments the roofing system further comprises:
said first set of panels being uniformly shaped and dimensioned;
and, said second set of tiles being uniformly shaped and
dimensioned.
[0015] In some embodiments said mated pair of tiles mate along
tongue-in-groove interface.
[0016] In some embodiments said tiles modularly combine to form a
contiguous planar array.
[0017] In some embodiments a first of said tiles interlock with a
second adjacent one of said tiles along a first side wall and
wherein said first of said tiles interlocks with a third adjacent
one of said tiles along a second side wall, and wherein said first
and second side walls are non-parallel.
[0018] In some embodiments each of said panels are substantially
rectangularly shaped and each of said tiles are substantially
hexagonally shaped.
[0019] In some embodiments the roofing system further comprises: a
second abutted pair of panels; wherein said first abutted pair of
panels abut latitudinally; wherein said second abutted pair of
panels abut latitudinally; and wherein said first abutted pair of
panels interlocks longitudinally with said second abutted pair of
panels.
[0020] In some embodiments each of said tiles comprises a core
consisting of a rigid polyurethane foam material and an upper
protective coating layer of a non-foam polyurethane material
contacting said core; and wherein said rigid polyurethane foam
material has a density of no greater than 240 kilograms per cubic
meter.
[0021] In some embodiments said tile further comprises a
photoelectric module releasably secured to said tile within a
recess formed into a substantially planar upper surface of said
tile; wherein said module has a substantially planar upper surface
which is substantially co-planar with said tile upper surface when
the module is secured within said recess.
[0022] In some embodiments said tile further comprises: a first
pair of electrical contacts located within said recess and said
module comprises a second pair of electrical contacts shaped,
dimensioned and located to electrically interconnect with said
first pair when said module is secured to said tile; and, a pair of
electrical contact wells formed into said first side wall; and, a
pair of dual ended electrical contact pins shaped and dimensioned
to intimately and conductively engage said wells and a second pair
of wells located on said second one of said tiles.
[0023] In some embodiments the roofing system further comprises: a
locking mechanism for securing said module within said recess,
where said locking mechanism comprises: alignment tabs extending
from a peripheral boundary located to engage commensurately shaped
and dimensioned alignment slots formed on a periphery of said
recess; and, a sloped track having an endstop located to restrict
angular movement of at least one of said tabs.
[0024] In some embodiments said first side wall has a groove which
transitions to a second side having a tongue proximate to a vertex;
and wherein said groove preferentially extends beyond said vertex
of said side to eliminate said tongue; and, wherein said groove
extends along three contiguous sides of said tile and said tongue
extends along three contiguous side walls of said tile.
[0025] In some embodiments the roofing system further comprises: a
gutter tile having an upper surface co-planar with a top surface of
said tile array; an aperture passing through said upper surface in
communication with a gutter; and, wherein said gutter comprises: a
plurality of unformly shaped and dimensioned U-shaped stacked
gutter ribs.
[0026] In some embodiments there is provided a roofing system which
comprises: a substantially continuous planar array of uniformly
shaped and dimensioned co-adjacent lower panels; a substantially
continuous planar array of uniformly shaped and dimensioned
co-adjacent upper tiles; and, said lower panels being locked to one
another by said tiles.
[0027] In some embodiments each of said panels comprises opposite
substantially parallel edges, wherein each of said edges has a
raised prominences; and, wherein each of said tiles comprises an
undersurface shaped to have a medial channel shaped and dimensioned
to intimately engage a laterally adjacent pair of said prominences;
and, wherein said panels are substantially rectangular and said
tiles are substantially hexagonal.
[0028] In some embodiments there is provided a roofing device which
comprises: a plurality of coplanarly interlocking upper tiles; a
plurality of coplanarly interlocking lower support panels; wherein
each of said panels comprises opposite parallel edges wherein each
of said edges has an upwardly extending prominence; wherein each of
said tiles comprises a bottom surface shaped and dimensioned to
have an upwardly extending channel; and, wherein said channel has a
width commensurate an abutted pair of said prominences.
[0029] In some embodiments there is provided a roofing assembly
comprises: a plurality of tiles, each having a front edge, a back
edge, and left and right lateral side edges, lying contiguously to
one another in partially superimposing latitudinal rows; means for
forming a right lateral edge of each tile to a left lateral edge of
an adjacent tile; each of a group of said tiles comprising; a
photoelectric cell; first and second electrical interconnects to
said cell; a laterally extending groove supporting said first
interconnect; and, a laterally extending tongue supporting said
second interconnect.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a diagrammatic exploded perspective view of a
modular roofing system according to an exemplary embodiment of the
invention.
[0031] FIG. 2 is a diagrammatic perspective view of a pair of
longitudinally interlocking coplanar support panels.
[0032] FIG. 3 is a diagrammatic partial perspective view of a pair
of latitudinally abutted coplanar support panels.
[0033] FIG. 4 is a diagrammatic perspective view of a pair of
longitudinally and coplanarly matable tiles over a pair of
latitudinally abuttable coplanar support panels.
[0034] FIG. 5 is a diagrammatic perspective view of a pair of
longitudinally and coplanarly mated tiles over a pair of
latitudinally abutted coplanar support panels.
[0035] FIG. 6 is a diagrammatic partial cross-sectional side view
of coplanarly mated tiles nestingly supported by coplanarly abutted
panels.
[0036] FIG. 7 is a diagrammatic top view showing the shaping and
dimensioning of the tiles and panels.
[0037] FIG. 8 is a diagrammatic top view showing a tiles and its
tongue and groove structure.
[0038] FIG. 9 is a diagrammatic top and side view showing a tiles
and its tongue and groove structure.
[0039] FIG. 10 is a diagrammatic top view of partial hex tile roof
edge pieces.
[0040] FIG. 11 is a diagrammatic perspective view of a square
shaped interlocking and nestable tile.
[0041] FIG. 12 is a diagrammatic partial perspective view of a
ridge capping tile nested upon the ridge formed by abutted coplanar
panels.
[0042] FIG. 13 is a diagrammatic perspective view of a roof
terminating gutter tile structure.
[0043] FIG. 14 is a diagrammatic side view of a gutter rib
element.
[0044] FIG. 15 is a diagrammatic exploded perspective view of a
hexagonal tile adapted to carry a photocell module.
[0045] FIG. 16 is a diagrammatic partial cross-sectional side view
of tile of FIG. 15 having its photocell secured.
[0046] FIG. 17 is a diagrammatic exploded perspective view of a
group of coplanarly mated hexagonal tiles and a replacement
tile.
[0047] FIGS. 18-25 show an embodiment of my design for a roofing
system interlocking continuous array-forming support panel.
[0048] FIGS. 26-33 show an embodiment of my design for a roofing
system interlocking continuous array-forming hexagonally shaped
tile.
[0049] FIGS. 34-41 show an embodiment of my design for a roofing
system interlocking continuous array-forming square shaped
tile.
[0050] FIGS. 42-48 show an embodiment of my design for a roofing
system interlocking longitudinally interlocking ridge-capping
tile.
[0051] FIGS. 49-56 show an embodiment of my design for a roofing
system lower edge gutter-carrying termination tile.
DESCRIPTION OF THE EXEMPLARY EMBODIMENT OF THE INVENTION
[0052] Referring now to the drawing there is shown in FIG. 1 a
modular roofing system according to an exemplary embodiment of the
invention. The system 1 includes a plurality of modular elements 2
which interlock in a stratified, co-nested manner. In other words,
some of the elements include a set of underlying panels 3 which
interlock and abut in a laterally co-adjacent, co-planar manner to
form a continuous array as a substantially planar first layer 4,
while other elements include a set of overlying tiles 5 which
interlock in a laterally co-adjacent, co-planar manner to form a
continuous array as a substantially planar second layer 6 which is
nestingly superimposed over and supported by the first layer.
[0053] As shown in FIGS. 1-3, each of the panel elements 3 has a
substantially planar rectangular top surface 14 parallely spaced
apart from a substantially planar bottom surface 15 oriented to
bear against the typically planar upper-facing surface 7 of the
roof of a structure. Each panel has a front edge 16, a parallely
opposite back edge 17, and two parallely spaced apart side edges
18,19. A pair of prominences 22,23 run linearly along the entire
longitudinal length of the opposite side edges. Each prominence can
have an oblong quadrangular shape having a height H dimension and
width W dimension. The front edge 16 of each panel can have a
groove structure 26 while the back edge 17 has a corresponding
tongue structure 27. In this way, longitudinally adjacent panels
10,11 can mate in a front edge-to-back edge manner in the
longitudinal direction 8 to form a longitudinal row 20 of panels
where the seam 28 formed between longitudinally adjacent panels is
a tongue-in-groove seam which provides additional strength by
spreading certain loads to adjacent panels, is more water
resistant, and keeps the panel side edges in alignment. This
arrangement also prevents one panel from sliding latitudinally with
respect to its longitudinally mated adjacent panel. This
arrangement provides a non-sliding contact along the seam.
[0054] As shown in FIG. 3, when two panels or rows of panels are
brought latitudinally together in a common plane where the
prominence of each panel abuts the other, the two adjacent
prominences form an upwardly projecting ridge structure 29. Thus
rows 20,21 of longitudinally mated panels can abut against one
another in a side edge-to-side edge manner in the latitudinal
direction 9 thus forming a substantially continuous planar array of
panels as shown in FIG. 1.
[0055] It shall be noted that the side edges 18,19 can be formed to
have substantially planar side surfaces 24,25. In this way, after a
co-planar array of panels has been installed, a panel 34 can be
slid longitudinally 32 with respect to its latitudinally abutted
panels. Thus some of the panels in the longitudinal row 33
containing the slid panel 34 are also slid. In this way, the panel
34 at an end of the slid panels can be removed from an emplaced
array of lower panels. This can save time during installation by
allowing for adjustment of panels and can facilitate repair of
damaged panels. Further an entire row of panels can be replaced
without disturbing adjacent rows of panels.
[0056] As shown in FIGS. 1 and 4-6, each of the tile elements 5 can
have a substantially planar regular hexagon-shaped top surface 44
parallely spaced apart from a substantially planar bottom surface
45 oriented to bear against the typically planar upper-facing
surfaces 14 of panels 61,62 when latitudinally abutted. Each tile
has six hexagonally oriented side walls including a front wall 46,
a parallely opposite back wall 47, and four angled side walls
48,49,50,51 opposite pairs of which, namely 48,50 and 49,51 are
parallely spaced apart. The side walls transition to an adjacent
side wall at a vertex.
[0057] A central elongated longitudinal channel 55 is formed
upwardly from the bottom surface 45 and extends longitudinally 8
between the front wall 46 and the back wall 47 bisecting the bottom
surface 45, thus creating a pair of co-planar lower surfaces 52,53
astride the channel which are oriented to bear against and be
supported by the co-planar upper surfaces 56,57 of a pair of
latitudinally abutted panels astride the mutual ridge 58 formed
therebetween.
[0058] Thus the channel 55 can be shaped and dimensioned to have a
height H' dimension and width W' dimension selected to allow the
channel to be intimately engaged by the ridge formed between
abutted panels. The height H' of the channel can be equal to or
slightly larger than the height H of the prominences forming the
ridge so that the tile is supported by the co-planar surfaces 56,57
and possibly the tops of the ridges rather than the tops of the
ridges exclusively. The width W' of the channel can be slightly
larger than the width of the ridge which is approximately double
the width W of a prominence. A ridge having a constant height H and
width W will allow a tile or groups of tiles to be slid
longitudinally along the ridge while remaining in substantial
engagement.
[0059] As shown in FIG. 4, a pair of laterally abuttable, uniformly
shaped and dimensioned lower support panels 61,62 are laterally and
co-planarly brought together in a side-to-side manner. And, a pair
of laterally matable, uniformly shaped and dimensioned roofing
tiles 63,64 are laterally and co-planarly brought together in a
front-to-back manner so that their channels are in substantial
alignment thus forming a common, co-linear bottom channel extending
longitudinally on the undersurface of the mated tiles.
[0060] As shown in FIGS. 5 and 6, the mated pair of tiles 63,64 can
be lowered downwardly onto the abutted pair of panels so that the
channels of the tiles are intimately engaged by the ridge and the
tiles are supported by the panels in an interlocked, stratified,
and co-nested manner.
[0061] It shall be noted that the abutment of latitudinally
adjacent panels can still occur even though a small gap 59 is
formed between the mutually facing side surfaces so long as the
tiles are longitudinally continuous and the seams between adjacent
tiles are designed to be water-tight such as through the use of
tongue-in-groove mating.
[0062] Referring now to FIGS. 1 and 6-7, the dimensions of each
panel 3 and each tile 5 are selected to allow a contiguous array of
tiles to nest upon and be supported by a contiguous array of
panels. Thus in the present embodiment the length Lt of side walls
of each tile 3 is selected to be one third the length Lp of the
separation of the side surfaces 24,25 of each panel 5.
[0063] As shown in FIGS. 4, 6 and 8-9, a tongue-in-groove interlock
structure 70 can be formed into the side walls 46-51 of each tile
5. Thus, the front wall 46 and its adjacent side walls 48,51 can
have a groove structure 71 while the back wall 47 and its adjacent
side walls 49,50 can have a corresponding tongue structure 72. The
depth G of the groove is at least as large as the width T of the
tongue.
[0064] It is important to note that for secure interlocking of a
co-adjacent array of tiles and to keep the shape and dimensioning
of the tiles substantially universal, the tongue should not extend
beyond the width Wt of the overall tile. In this way, it can be
said that the groove structure takes precedence over the tongue
structure at the transition 78 near the vertex 75 between side
walls 48,49 so that the groove 71 extends beyond the end of its
side wall 48 to eliminate the tongue 72 before it reaches the end
of its side wall 49. In other words, the tongue structure does not
pass over a line 76 perpendicular to the front and back side walls
46,47 and passing through the vertex 75 between the side walls
where a transition from tongue to groove occurs. A similar
transition occurs near the opposite vertex 77. The words
"substantially universal" are used because some tiles can be made
with photocell modules as will be described in greater detail
below. However, such tiles can still be used interchangeably for
structural purposes.
[0065] The tiles should have a common angular orientation so that
the front walls of an array of tiles are all parallely oriented.
Longitudinally adjacent tiles can mate laterally in a front
wall-to-back wall manner in the longitudinal direction 8 to form a
longitudinal row of tiles where the seam formed between
longitudinally adjacent tiles is a tongue-in-groove seam which
provides additional strength by spreading certain loads to adjacent
tiles, and is more water resistant. Adjacent tiles having a
latitudinal component to their planar location can also mate in a
honeycomb manner where a tongued side wall interlocks with a
grooved side wall of an adjacent tile.
[0066] As shown in FIG. 10, partial tiles 65-68 having
appropriately located side walls 69. can be used to create linear
edges to an array of hex tiles.
[0067] It shall be noted that the prominences of the panels can
have other shapes so long as they come together to form a ridge
shaped to intimately engage the channel in the tiles. It can be
important that the ridge and channel have uniform height and width
along its length so that the tile can move longitudinally along the
ridge while remaining fully seated. In this way successive tiles
can be added and brought together while seated on a ridge. This can
help with tile alignment for easier installation.
[0068] The stratified dual interlocking layers enhance strength and
leak avoidance so that lighter weight materials such as rigid
urethane or polyurethane foam can be used to form the elements.
This material can be inexpensively manufactured as uniformly shaped
and dimensioned modules. For example, the elements can be made
primarily out of injection molded, closed-cell, rigid polyurethane
foam commercially available from General Plastics Manufacturing Co.
of Tacoma, Wash. under the brand name LAST-A-FOAM. The rigid foams
can be low density in order to reduce weight on the roof of the
structure, and closed cell to be water resistant. Other advantages
of this type of material include its mold resistance, termite
resistance, and its insulating characteristics. Densities can range
from about 25 kilograms per cubic meter (about 1.5 pounds per cubic
foot) and about 400 kilograms per cubic meter (about 25 pounds per
cubic foot). For many common roofing applications involving a
balance of parameters such as strength, durability, material cost
and weight, it has been found that the density is preferably
between about 80 to 320 kilograms per cubic meter (about 5 to 20
pounds per cubic foot) and more preferably between about 160 to 240
kilograms per cubic meter (about 10 to 15 pounds per cubic
foot).
[0069] As shown in FIG. 6, the durability and strength of the rigid
foam body core can be improved by forming a layer 80 of semirigid
non-foam polyurethane or polyvinyl material on the outer surface 81
of each tile 5. Such polyurethane coating material is commercially
available from Scorpion Protective Coatings, Inc. of Cloverdale,
Ind. For many common roofing applications involving a balance of
parameters such as strength, durability, material cost and weight,
it has been found that the thickness is preferably between about 1
millimeter and about 5 millimeter, and more preferably between
about 2 millimeters and about 3 millimeters. The thickness can be
selected so that the top surface 82 of the coated tile is
substantially co-planar with the other tiles in the array. Other
durable materials such as metal particle infused polyester can also
act as the coating layer.
[0070] Other shapes and dimensioning of tiles can be used having
underside channels which fit over the ridges formed between two
adjacent panels. Some sets of tiles can be uniformly shaped and
co-planarly mate together with similar tiles to form a continuous
planar array of interconnected tiles similar to the hexagonal tiles
described above. One example is a square-shaped tile 85 as shown in
FIG. 11.
[0071] Other types of tiles 90 as shown in FIG. 12 can mate
longitudinally and linearly along and cap only the ridge portion of
the underlying latitudinally abutted panels 93,94. The seam formed
between tiles mated at their front 91 and back 92 walls can be a
tongue-in-groove seam. Although the medial upper surface of the
panels is exposed the seams between the panels are tongue-in-groove
seams as well. In this way, only the more water-resistant
tongue-in-groove seams are exposed to the elements. In other words
when viewed from above all exposed seams whether they are
tile-to-tile seams or panel-to-panels seams are tongue-in-groove
seams.
[0072] Referring now to FIGS. 13 and 14 the lower edge of a peaked
roof can terminate in a modular gutter structure 100 formed by a
substantially quadrangular upper gutter tile 101 which can be
supported and interface with the array of panels. The gutter tile
has an aperture 102 extending latitudinally proximate to and along
its lower edge 103. The aperture is covered by a durable steel
screen 104 to prevent leaves and other debris passing through the
aperture and into an underhanging gutter 105 formed by
latitudinally stacked gutter ribs 106. Each rib 106, as shown in
FIG. 14 is substantially U-shaped where the ends 107 of the
upwardly extending arms 108 contact and bond to the underside of
the gutter tile straddling the aperture. Each rib can have a
tongue-in-groove structure 111 to help seal the seam between
adjacent stacked ribs and to help align the stacked ribs to one
another. In this way water running down the roof passes through the
aperture to collect in the gutter and flow downstream toward a
lateral opening 109 leading to an adjacent gutter. The gutter can
be capped at an end by a solid capping rib 110. Although the ribs
are shown contiguously stacked to one another, those skilled in the
art will appreciate that the ribs can be latitudinally spaced apart
and cradlingly support an elongated gutter trough.
[0073] Referring now to FIGS. 15-16 there is shown a coplanarly
matable and nestable hexagonally shaped upper tile element 120
adapted to carry a photocell module 121 thereon. The tile body 123
is shaped and dimensioned similarly to one of the tiles of FIG. 1.
The substantially cylindrical photocell module is carried within a
substantially cylindrical recess 122 so that when the photocell is
fully seated and secured within the recess in an operational
orientation the substantially planar top surface 124 of the
photocell is coplanar with the substantially planar to surface 125
of the outer protective layer 127 of the tile body 123. The gap
between the recess wall and the peripheral wall of the photocell
module is sealed by a resilient washer 126 made from rubber,
plastic or other durable, resilient and substantially water-proof
material. Alternately, or in addition to the washer, the gap can be
sealed with a flexible water-proof caulk such a silicone
sealant.
[0074] The photocell module can be locked in place within the
recess in a proper angular orientation which aligns the electrical
contact bumps with there respective pads by means of a keyed pair
of radially extending tabs 128 engaged and tracked along a threaded
guideway 129. Entry of the tabs into the guideway occurs through a
pair of slots 151 shaped, sized and spaced apart to allow passage
of the tabs therethrough when the module is in angular alignment
with the recess. Once engaged the module can be rotated with
respect to the tile body causing the tabs to ride within the
threaded track until one of the tabs reaches an endstop 150. The
endstop is angularly located to cause rotation to stop when the
pads and bumps are in contact.
[0075] Electrical interconnection between the photocell module 121
and the tile body 123 occurs through a pair of metal electrical
contact bumps 130 extending from a bottom surface 133 of the
photocell module. The bumps are located shaped and dimensioned to
contact a corresponding pair of metal electrical contact pads 131
set into the upwardly facing bottom surface 132 of the recess when
the photocell module is fully seated within the recess.
[0076] Electrical interconnection between the photocell carrying
tile element 120 and the rest of the system occurs through adjacent
tiles either through wires 140 running within an open channel 141
or though pairs of electrical contact pins 142 engaging
corresponding wells 143 set into the front and back side walls
144,145 of the tile body 123. Each pin includes a pair of metal
contact prongs 146 extending coaxially from opposite ends of the
pin. A medial insulating sleeve 147 provides a finger grasp point
to facilitate insertion of the pin into the well. The
interconnection of a plurality of interconnect photocell-equipped
tiles occurs in a manner similar to that disclosed in Tennent, U.S.
Pat. No. 4,321,416 already incorporated herein by reference or
through other means well-known in the solar electric energy
generating field.
[0077] Damaged photocells can be repaired by cutting and removing
any sealant, if present, and removing the resilient retaining ring.
The photocell module can then be removed by unscrewing it from the
recess. A replacement module can then be screwed into place and the
retaining ring and an optional new bead of caulk or other sealant
applied.
[0078] One or more damaged tiles can be removed by first cutting
the damaged tiles into pieces and removing them. Care should be
taken to avoid damaging underlying panels that are undamaged. Of
course, damaged panels can be replaced as previously described once
the overlying tiles have been removed. If a plurality of adjacent
damaged tiles are removed, it is possible to replace some of the
tiles at the periphery of the zone of removed tile with undamaged
tiles. However, this may not be possible for those sites in the
zone where the tongue-and-groove structure of emplaced tiles
interfere with installing an undamaged tile. This scenario occurs
when only one tile is to be replaced.
[0079] As shown in FIG. 17 the space 160 left be a single removed
damaged tile in an existing emplacement 159 can be filled by a
partial tile 161 having only the top surface portion 162 and
peripheral underlying grooves 163. Three tongue inserts 164 can be
placed into the corresponding grooves (indicated by the arrows) of
the emplaced tiles to provide a peripheral ledge upon which the
replacement partial tile is supported. A bead of sealing adhesive
such as silicone caulk can be used to bond the inserts in place and
to bond the partial tile to its adjacent tiles. A surrounding bead
of sealant can ensure the watertight emplacement of the partial
tile. If the damaged tile was a photoelectric tile, the electrical
connector pins can be removed and a pair of jumper wires 165 can be
used to bridge the electrical connector wells bordering the space
of the damaged tile.
[0080] FIGS. 18-25 show an embodiment of my design for a roofing
system interlocking continuous array-forming support panel.
Specifically, FIG. 18 is back, right, top oblique view thereof.
FIG. 19 is front, left, bottom oblique view thereof. FIG. 20 is top
plan view thereof. FIG. 21 is bottom plan view thereof. FIG. 22 is
back plan view thereof. FIG. 23 is front plan view thereof. FIG. 24
is left plan view thereof. FIG. 25 is right plan view thereof.
[0081] FIGS. 26-33 show an embodiment of my design for a roofing
system interlocking continuous array-forming hexangonally shaped
tile. Specifically, FIG. 26 is front, right, top oblique view
thereof. FIG. 27 is back, left, bottom oblique view thereof. FIG.
28 is top plan view thereof. FIG. 29 is bottom plan view thereof.
FIG. 30 is back plan view thereof. FIG. 31 is front plan view
thereof. FIG. 32 is right plan view thereof. FIG. 33 is left plan
view thereof.
[0082] FIGS. 34-41 show an embodiment of my design for a roofing
system interlocking continuous array-forming square shaped tile.
Specifically, FIG. 34 is front, right, top oblique view thereof.
FIG. 35 is back, left, bottom oblique view thereof. FIG. 36 is top
plan view thereof. FIG. 37 is bottom plan view thereof. FIG. 38 is
front plan view thereof. FIG. 39 is back plan view thereof. FIG. 40
is right plan view thereof. FIG. 41 is left plan view thereof.
[0083] FIGS. 42-48 show an embodiment of my design for a roofing
system interlocking longitudinally interlocking ridge-capping tile.
Specifically, FIG. 42 is front, left, top oblique view thereof.
FIG. 43 is back, right, bottom oblique view thereof. FIG. 44 is top
plan view thereof. FIG. 45 is bottom plan view thereof. FIG. 46 is
front plan view thereof. FIG. 47 is back plan view thereof. FIG. 48
is left plan view thereof, the right side being a mirror image
thereof.
[0084] FIGS. 49-56 show an embodiment of my design for a roofing
system lower edge gutter-carrying termination tile. Specifically,
FIG. 49 is front, right, top oblique view thereof. FIG. 50 is back,
left, bottom oblique view thereof. FIG. 51 is top plan view
thereof. FIG. 52 is bottom plan view thereof. FIG. 53 is front plan
view thereof. FIG. 54 is back plan view thereof. FIG. 55 is right
plan view thereof. FIG. 56 is left plan view thereof.
[0085] While the exemplary embodiments of the invention have been
described, it should be understood that modifications can be made
and other embodiments may be devised without departing from the
spirit of the invention and the scope of the appended claims.
* * * * *