U.S. patent application number 16/117245 was filed with the patent office on 2018-12-27 for roof tiles and roof tile structures and methods of making same.
The applicant listed for this patent is Wilbur Dale McIntire, Carlos Torres. Invention is credited to Wilbur Dale McIntire, Carlos Torres.
Application Number | 20180371757 16/117245 |
Document ID | / |
Family ID | 42990847 |
Filed Date | 2018-12-27 |
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United States Patent
Application |
20180371757 |
Kind Code |
A1 |
Torres; Carlos ; et
al. |
December 27, 2018 |
Roof Tiles and Roof Tile Structures and Methods of Making Same
Abstract
A roof tile having a mesh covered foam core with a cement-based
protective coating, a roof covering formed from such tiles and
methods for making same.
Inventors: |
Torres; Carlos; (Madera,
CA) ; McIntire; Wilbur Dale; (Bakersfield,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Torres; Carlos
McIntire; Wilbur Dale |
Madera
Bakersfield |
CA
CA |
US
US |
|
|
Family ID: |
42990847 |
Appl. No.: |
16/117245 |
Filed: |
August 30, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15450229 |
Mar 6, 2017 |
10087631 |
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16117245 |
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14246446 |
Apr 7, 2014 |
9624669 |
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15450229 |
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12803365 |
Jun 24, 2010 |
8728609 |
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14246446 |
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11747911 |
May 13, 2007 |
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12803365 |
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11348173 |
Feb 6, 2006 |
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11747911 |
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60717608 |
Sep 17, 2005 |
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11348173 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D 1/28 20130101; E04D
1/34 20130101; Y10T 428/24612 20150115; Y10T 428/3154 20150401;
Y10T 428/24967 20150115; E04D 2001/3426 20130101; E04D 1/08
20130101; Y10T 428/24331 20150115; E04D 1/10 20130101; Y10T
428/24496 20150115; Y10T 428/249953 20150401; Y10T 428/249991
20150401; E04D 1/04 20130101; Y10T 428/24777 20150115; Y10T
428/24488 20150115; Y10T 442/10 20150401; Y10T 428/24628 20150115;
E04D 2001/3458 20130101 |
International
Class: |
E04D 1/08 20060101
E04D001/08; E04D 1/04 20060101 E04D001/04; E04D 1/10 20060101
E04D001/10 |
Claims
1. A roof tile, a plurality of which can provide a weather membrane
for a roof structure comprising; a foam core member comprising a
plurality of surfaces including an upper surface and a spaced-apart
lower surface bounded by a first lateral edge surface and an
opposing spaced-apart second lateral edge surface and a first end
surface and a spaced-apart second end surface; a coating of
cement-based material over one or more of the foam core member
surfaces including over the first end surface forming a first
abutment member; and including over the second end surface forming
a second abutment member; wherein the first abutment member and the
second abutment member are so shaped that when one tile in a course
abuts an adjacent tile in the same course, the adjacent abutment
members engage one another, forming an overlapping, flexible
connection whereby adjacent roof tiles in a course are able to
change position relative to one another.
2. The roof tile of claim 1 wherein the first and second abutment
members are generally L-shaped.
3. The roof tile of claim 2 wherein the first L-shaped abutment
member and the second L-shaped abutment member face in generally
opposite directions.
4. The roof tile of claim 1 wherein all of the foam core member
surfaces are coated with a cement-based material.
5. The roof tile of claim 1 wherein a plurality of foam core member
surfaces are coated with a cement-based material and further
wherein the thickness of the cement-based material is not the same
for all coated surfaces.
6. The roof tile of claim 1 wherein the foam core member is
generally flat and the upper surface is coated with a cement-based
material textured and colored to simulate a cedar shingle.
7. The roof tile of claim 1 wherein the foam core member is
generally flat and the upper surface is coated with a cement-based
material that is textured and colored to simulate a slate
shingle.
8. The roof tile of claim 1 wherein the upper surface is shaped to
simulate a Spanish tile and coated with a cement-based material
colored and textured to simulate a Spanish tile.
9. The roof tile of claim 1 wherein all of the surfaces are coated
with a cement-based material.
10. The roof tile of claim 1 wherein all of the surfaces except the
lower surface are coated with a cement-based material.
11. The roof tile of claim 1 certified to carry the UL Class A
listing mark for Prepared Roof Covering Materials.
12. The roof tile of claim 1 certified Class A fire resistant under
the UL 790 standard.
13. The roof tile of claim 1 further described as able to absorb
the forces of a piercing fastener without cracking, breaking or
otherwise compromising the structural integrity of the tile.
14. The roof tile of claim 1 wherein one or more surfaces have
multiple layers of cement-based material applied to them.
15. A roof tile, a plurality of which can provide a weather
membrane for a roof structure comprising; a foam core member
comprising a plurality of surfaces including an upper surface and a
spaced-apart lower surface bounded by a first lateral edge surface
and an opposing spaced-apart second lateral edge surface and a
first end surface and a spaced-apart second end surface; and a
coating of cement-based material over one or more of the foam core
member surfaces.
16. The roof tile of claim 15 wherein the foam core member is
generally flat and the upper surface is coated with a cement-based
material textured and colored to simulate a cedar shingle.
17. The roof tile of claim 15 wherein the foam core member is
generally flat and the upper surface is coated with a cement-based
material textured and colored to simulate a slate shingle.
18. The roof tile of claim 15 wherein the upper surface is shaped
to simulate a Spanish tile and coated with a cement-based material
colored and textured to simulate a Spanish tile.
19. The roof tile of claim 15 wherein all of the surfaces except
the lower surface are coated with a cement-based material.
20. The roof tile of claim 15 wherein one or more surfaces have
multiple layers of cement-based material applied to them.
Description
CLAIM OF PRIORITY
[0001] The present application is a continuation of allowed U.S.
patent application Ser. No. 15/450,229, filed Mar. 6, 2017, by
inventors Carlos Torres and Wilbur McIntire, which is a
continuation of Ser. No. 14/246,446, filed Apr. 7, 2016 which was
issued as U.S. Pat. No. 9,624,669, which is a continuation of
allowed U.S. application Ser. No. 12/803,365, filed Jun. 24, 2010
which was issued as U.S. Pat. No. 8,728,609 on May 20, 2014, which
is a continuation-in-part of abandoned U.S. patent application Ser.
No. 11/747,911, which is a continuation-in-part of abandoned U.S.
patent application Ser. No. 11/348,173 filed on Feb. 6, 2016, which
claims the benefit of U.S. provisional patent application
60/153,917, filed on Sep. 6, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates to roof tiles, roof coverings
and methods of making and installing same. The roof tiles of the
present invention are insulating roof tiles that are lightweight,
highly fire resistant, strong and durable. The roof tiles to which
the present invention pertains are those that are of a size common
in the industry and which are used to cover a roof structure by
arranging a plurality of such tiles in overlapping relationships to
each other. The industry standards for roof tiles of the type to
which the present invention relate are typically 15 to 20 inches
long (along the roof pitch), 10 to 20 inches wide and 1 to 2 inches
thick, all depending on the shape of the tile and the aesthetic
appearance desired. Such tiles are not load-bearing elements of a
roof structure but are themselves a roof structure load.
[0003] As used throughout, the terms "roof tile" and "tile", unless
otherwise specified, mean an individual element generally of the
dimensions set out above designed to be arranged, along with a
plurality of like elements, in overlapping relationship to each
other to form a waterproof covering or membrane over a roof
structure.
BACKGROUND OF THE INVENTION
[0004] Tiles of various compositions have been used since ancient
times to provide a protective membrane over building roof
structures of all kinds.
[0005] Fire resistant roof tiles are typically made of clay, cement
or metal. Although aesthetically, clay and cement tiles are
preferred, their major drawbacks are that they are extremely heavy
and very fragile, making installation difficult and expensive and
requiring more robust support structures than for known lighter
roof coverings. On the other hand, clay and cement tiles have the
advantage of durability and fire resistance. The present invention
provides a roof tile that has the durable and fire resistant
qualities of cement and clay while being as much as 40% lighter and
vastly stronger.
SUMMARY OF THE INVENTION
[0006] The present invention comprises a roof tile of industry
standard size having a foam core covered with a strengthening
material (e.g., fiberglass mesh) and a thin outer cement-based
protective coating (cured cement slurry). The cement-based
protective coating includes one or more additives that impart
excellent water repellant properties to the tile surface and
increases its strength, durability and aesthetic appeal. The tile
of the present invention has exceptional strength for its weight,
which decreases shipping costs, virtually eliminates breakage
during shipping and installation and requires only normal roof
support structures.
[0007] In one embodiment, a cement-based slurry is applied to a
mesh-covered foam core and cured to hardness, forming a non-porous
coating that inhibits the intake of moisture thereby preventing
deterioration from freezing/thaw cycles that are the bane of clay
and cement tiles. In addition, the foam core of the tiles of the
present invention provide greater insulating properties than cement
or clay tiles, keeping interiors warmer in the winter and cooler in
the summer. Although the tiles of the present invention are
significantly lighter than clay or cement tiles, they provide
greater strength and the same or greater fire resistance.
[0008] The roof tile of the present invention is lightweight,
strong, has a high fire-resistance rating and a high insulation
rating and can be easily formed into various cross-sectional shapes
to increase aesthetic appeal and offers ventilation to the
underside of the tiles. Thus, a roof tile, roof tile system
(covering) and method of making and installing the same are
provided in accordance with the invention, providing several
structural, manufacturing and installation advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A is a perspective view of a roof tile according to
the present invention;
[0010] FIG. 1B is a side sectional view taken along the line 1B-1B
of FIG. 1, with certain dimensions exaggerated for ease of
understanding;
[0011] FIG. 1C is an enlarged view of one end of the sectional view
of FIG. 1B indicated 1C;
[0012] FIG. 1D is an enlarged view of the other end of the
sectional view of FIG. 1B indicated 1D;
[0013] FIG. 2A is a perspective view of the foam core member of the
tile of FIG. 1A with a side wall thereof having a strengthening
material applied thereto;
[0014] FIG. 2B is a left side view of FIG. 2A;
[0015] FIG. 2C is an enlarged view of one end of the side view of
FIG. 2B indicated 2C;
[0016] FIG. 2D is an enlarged view of the other end of the side
view of FIG. 2B indicated 2D;
[0017] FIG. 3A is a perspective view of the core member of FIG. 2A
shown in the process of being covered with a strengthening material
and in relation to a production jig blade;
[0018] FIG. 3B is the same as FIG. 3A, with the core member flipped
over and more of the strengthening material applied to the core
member;
[0019] FIG. 4A is a partial side view of FIG. 3A illustrating the
jig blade used to apply the strengthening material;
[0020] FIG. 4B is the same as FIG. 4A, with the jig blade
illustrated engaging the strengthening material;
[0021] FIG. 5A is the same as FIG. 2A, but with the upper and lower
surfaces of the core member covered with a strengthening
material;
[0022] FIG. 5B is a sectional side view of FIG. 5A taken along the
line 5B-5B of FIG. 5A;
[0023] FIG. 6A is a perspective illustration of a tier of several
tiles of the invention on a roof structure that are interlocked at
their margins;
[0024] FIG. 6B is the same as FIG. 6A with a second tier of
tiles;
[0025] FIG. 6C is the same as FIG. 6B with a third tier of
tiles;
[0026] FIG. 7 is a sectional side view taken along the line 7-7 of
FIG. 6C;
[0027] FIG. 8 is an enlarged view of the interlocking margins of
two adjacent tiles as illustrated in FIG. 7;
[0028] FIG. 9 is a sectional view of one tier of interlocking flat
tiles;
[0029] FIG. 10 is a sectional view taken along the line 10-10 of
FIG. 6C;
[0030] FIG. 11A is a side view of a tile of the invention having an
arcuate section illustrating its variation in thickness;
[0031] FIG. 11B is a side view of two tiles of FIG. 11A in a nested
relationship; and
[0032] FIG. 12 is a side view of two tiles of the prior art shown
in a nested relationship.
DETAILED DESCRIPTION OF THE DRAWINGS
[0033] Referring to FIGS. 1A, 1B, 1C and 1D, a roof tile 11 of the
present invention comprises a foam core member 12 covered by a
strengthening material 13 and a hardened cement-based protective
coating 14. The drawings are not to scale and the relative
thicknesses of the core 12, the strengthening material 13 and
cement-based protective coating 14 are exaggerated for ease of
illustration and better understanding.
[0034] While the particular shape of foam core 12 illustrated has
certain advantages as more fully described below, many other shapes
are possible within the teachings of the invention, with each shape
having particular advantages and/or aesthetic appeal. Shapes that
are primarily flat and shapes that are arcuate or include arcuate
sections are all within the teachings of the invention.
[0035] Referring to FIGS. 2A-2D, the foam core 12 has an upper
surface 16 bounded by a first lateral edge 17, a spaced-apart
second lateral edge 18, a first end edge 19 and a spaced-apart
second end edge 21. The length of core 12 is the distance between
lateral edge 17 and lateral edge 18. The width of core 12 is the
distance between end edge 19 and end edge 21. The foam core 12
further includes a lower surface 22 opposing and spaced apart from
the upper surface 16 where the distance between the upper surface
16 and the lower surface 22 (as measured along a normal to the
surfaces) determines the thickness 23 (FIG. 2A) of the foam core 12
at any point. The core lower surface 22 is bounded by a first
lateral edge 24, a spaced-apart second lateral edge 26 (not shown),
the first end edge 19 and the second end edge 21. As explained more
fully below, for tiles having an arcuate section 15 with an upper
surface 15a and a lower surface 15b (FIG. 2B), the thickness 23 (as
measured along a normal to the surfaces) will vary whereby like
tiles 11 can be overlapped and closely nested with each other with
a portion of the lower surface of one tile fitting closely with a
portion of the upper surface of another tile as more fully
described below.
[0036] A first core side wall 33 has an upper edge 34 coextensive
with the first upper surface lateral edge 17 and a spaced-apart
lower edge 36 coextensive with the lower surface first lateral edge
24. A second side wall 38 (which is a mirror image of side wall 33
but not shown) spaced apart from the first side wall 33 has an
upper edge 39 coextensive with the upper surface second lateral
edge 18 and a spaced-apart lower edge 41 (FIG. 2B) coextensive with
the lower surface second lateral edge 26.
[0037] The foam core member 12 has, at one end, a first slot
forming end member 28 and, at the other end, a second slot forming
end member 29. A first slot 43 (FIG. 2C) is formed between the foam
core upper surface 16 and lower surface 22 in first end member 28
and has a closed slot end 45. A first slot surface 44 and lower
core surface 22 define a first major end extension member 46 having
a distal end 47. A second slot surface 48 spaced apart from and
opposing the first slot surface 44 and upper core surface 16 define
a first minor end extension member 49 that is shorter than major
end extension 46 and has a distal end 51. The end 51 of first minor
end extension 49 extends beyond closed slot end 45, but not as far
as major extension end 47. In a preferred embodiment, end 51 of
first minor extension 49 is approximately between one-sixth and
one-third of the distance from closed slot end 45 as the distal end
47 of first major extension 46 is from closed slot end 45.
[0038] A second slot 53 (FIG. 2D) is formed in end member 29
between the upper core surface 16 and lower core surface 22 and has
a closed slot end 55. A first slot surface 54 and upper surface 16
define a second major end extension member 56 having a distal end
57. A second slot surface 58 spaced apart from and opposing first
slot surface 54 and lower surface 22 define a second minor edge
extension member 59 that is shorter than second major end extension
56 and has a distal end 61. The end 61 of second minor end
extension 59 extends beyond closed slot end 55, but not as far as
second major extension end 57. In a preferred embodiment, end 61 of
second minor extension 59 is a distance from closed slot end 55
approximately between one-sixth and one-third of the distance that
the distal end 57 of second major extension 56 is from closed slot
end 55.
[0039] The slots 43 and 53 in end members 28 and 29, respectively,
play an important role in connection with the cement-based
protective coating in forming reliable inter-tile connections as
more fully described below.
[0040] In ways known in the art, the foam core 12 can be formed in
a variety of shapes including, but not limited to, substantially
flat to simulate a cedar or slate roof shingle (FIG. 9); curved to
simulate a classic Spanish tile (FIG. 11A); or any other shape that
permits multiple tiles to be arranged in overlapping relationship
to provide a weatherproof covering and create a desired aesthetic
(FIG. 10). The cement-based protective coating 14 can be textured,
colored and finished to create the look of Spanish tile, cedar
shingles, or any other roof tile now known or imagined.
[0041] A wide range of aesthetic choices are possible by virtue of
the ease of forming the foam core 12 and the ability to color and
texture the protective coating. This is in addition to the
exceptional performance of the tile as a weather barrier, an
insulator, an insect resister and a fire retardant. In all of these
respects, the tile 11 of the present invention equals or
out-performs equivalent tiles made of clay or cement while being
anywhere from 30 to 60 percent lighter and significantly more
damage resistant during transportation and installation. The tiles
11 are so strong that they easily support the weight of installers
standing on them during installation. At the same time, the tiles
can be nailed to the underlying roof structure without pre-drilling
and without breaking or cracking. Further, they can be trimmed to
size where needed with a handsaw.
[0042] In one embodiment, the foam core 12 is expanded polystyrene
(EPS). EPS is generally produced from a mixture of about 95%
polystyrene and 5% gaseous blowing agent (e.g. pentane). Other
types of foam such as high density foam, Styrofoam.RTM., blue
board, polystyrene, injection foams, MDI monomer, polyurethane
resins, extruded foam, expanded polystyrene, expanded plastic foam,
expanded polyethylene and nylon can be used. As used herein unless
indicated otherwise, the term "foam" includes EPS and its suitable
substitutes.
[0043] In one embodiment, the foam core 12 is cut from a large
block of foam with a computer-driven hot wire cutting machine
specifically designed for such operations. In other embodiments,
the foam core 12 can be extruded, molded or cast. It is the ability
of the foam to be formed into a desired shape and size that gives
the tile 11 of the present invention its ability to emulate the
aesthetic appearance and shape of known roof tiles, as well as
novel shapes not easily formed of clay or cement, while offering
superior performance characteristics as pointed out above and more
fully described below.
[0044] After the foam core member 12 is formed, including end
member slots 43 and 53, the strengthening material 13 (FIGS. 5A and
5B) is applied. In a preferred embodiment, strengthening material
13 is a commercially available self-adhesive fiberglass mesh. The
mesh provides the foam core with added strength and additional
surface texture for the cement-based protective coating 14. Other
strengthening materials may also be used including: polypropylene
fiber mesh, polyurethane mesh, nylon mesh, and polymer-based mesh.
Non-mesh strengthening materials may also be applied to the
exterior of the foam as, for example, the copolymer known in the
trade as Elotex.RTM. FX2320 (a redispersible binder based on a
copolymer of ethylene and vinyl acetate). In the cured state, this
polymer has a high strength, an excellent freeze-thaw cycling
resistance and is very flexible and impact resistant. It also
adheres very strongly to foam. Alternatively, Elotex.RTM. product
FX2300 can be used in place of FX2320. All of these various
strengthening materials applied to the surfaces of the foam core
member 12 to increase its strength are within the meaning of
"strengthening materials" as used herein.
[0045] Referring to FIGS. 2A-2D, in one embodiment of the
invention, one portion of the strengthening material 13 is a strip
of mesh material 71 applied to the first side wall 33 of foam core
member 12 and a small section 72 of the immediately adjacent upper
surface 16 and a similar small section 73 (not shown) of the
immediately adjacent lower surface 22. It is advisable for the
strip 71 not to cover any portion of slots 43 or 53. Thus, strip 71
does not cover the entire side wall 33. Applying a similar mesh
strip to the second side wall 38 is optional.
[0046] Referring to FIGS. 3A, 3B, 4A and 4B, after the mesh strip
71 is adhered as described above, another portion of the
strengthening material, mesh material sheet 76, is applied to the
foam core member 11 to cover the upper surface 16 and the lower
surface 22. The mesh sheet 76 has a first end edge 77, a second end
edge 78, a first lateral edge 79 and a second lateral edge 81,
wherein the lateral edges 79 and 81 are approximately parallel to
each other, as are the end edges 77 and 78. The width of sheet 76
(as measured between lateral edges 79 and 81) is approximately
equal to the distance between the foam core lower surface first
lateral edge 24 and lower surface second lateral edge 26 (also
upper surface first lateral edge 17 and upper surface second
lateral edge 18).
[0047] In one embodiment of the invention, in applying the mesh
sheet 76 to the core 16, the first end edge 77 of mesh sheet 76 is
located and secured at the approximate midsection of lower surface
22, with the mesh sheet lateral edges 79 and 81 immediately
adjacent to lower surface first lateral edge 24 and lower surface
second lateral edge 26, respectively. The sheet 76 is drawn towards
the second core end member 29 and draped over the distal end 57 of
second major extension 56 (FIG. 4A). A jig blade 83 is used to urge
the mesh sheet 76 firmly into the slot 53 and onto slot surfaces 54
and 58 to which the mesh sheet 76 adheres (FIG. 4B). In the same
way, the sheet 76 is secured within slot 43. It is the securing of
sheet 76 into slots 43 and 53 that assures a proper shape to the
end members 28 and 29 when the cement-based coating 14 is applied,
as more fully described below (FIGS. 1C and 1D).
[0048] Referring also to FIG. 3B, after the mesh sheet 76 is
secured within slot 53, the core member 12 is turned over
(end-over-end) whereby the sheet 76 is disposed over and secured to
foam core upper surface 16 and draped over slot 43. In the same way
as described above with regard to slot 53, blade 83 is used to urge
the mesh sheet 76 firmly into the slot 43 and onto slot surfaces 44
and 48 to which the mesh sheet 76 adheres (FIG. 5B). After the
sheet 76 is secured in slot 43, it is applied to the rest of foam
core lower surface 22, with second end edge 78 located beyond the
first end edge 77 onto the already adhered portion of the mesh
sheet 76 such that a short overlap section 84 is formed (FIG. 5B).
The entire upper surface 16, lower surface 22, and slots 43 and 53
of foam core member 12 are in this way covered with a mesh material
13 (FIG. 5A) to give the core added strength.
[0049] It will be appreciated by those skilled in the art that the
geometry of a foam core member 12 that does not have generally
parallel side walls and/or parallel end edges will require a mesh
sheet 76 of appropriate geometry to cover the foam core upper
surface and lower surface within the boundary of the lateral edges
and end edges. In some cases, the mesh sheet 76 may have to be
applied in more than one piece.
[0050] For those embodiments of the roof tile 11 of the present
invention that include a convex arcuate section 15 (FIGS. 1A and
2B), a ventilation channel 64 is automatically formed when the tile
is operatively disposed on a roof structure 66 (FIGS. 6A and 7).
The ventilation channel 64 reduces the amount of condensation on
the underside (lower surface 22) of the tile 11, which eliminates
or reduces the deleterious effects of condensation.
[0051] After mesh materials 71 and 76 are secured to the foam core
12, a cement-based slurry is applied to cover foam core surfaces 16
and 22 (all the way to and including end edges 19 and 21) and first
side wall 33 and, optionally, second side wall 38. When cured to
hardness, the cement-based slurry becomes protective coating 14
(FIGS. 1A-1D), providing the tile 11 with the attributes, among
others, of structural integrity, strength, fire and pest resistance
and durability. The ability to color and texture the coating 14
allows the tile 11 to have a variety of aesthetic appearances.
Furthermore, the tile 11 so constructed can be cut to size and
fastened in place by driving a nail or screw through it (as more
fully described below) without cracking, shattering or otherwise
compromising the structural integrity of tile 11.
[0052] A cement coating is applied to the surface of the foam and
may provide one or more of the following general attributes:
appearance, protection and strength. Specific attributes may
include high compressive and tensile strength, corrosion
resistance, temperature durability, inertness and
colorfastness.
[0053] The protective coating is made from a cement mixture.
Specifically, the mixture may include, in addition to cement, one
or more of the following components that are added to water: [0054]
Sand and/or ground glass, [0055] fly ash or lime, [0056] pigment,
[0057] anti-efflorescence compound, [0058] resin and saline-based
efflorescence-reducing and waterproofing agent, [0059]
redispersible binders including those based on a copolymer of vinyl
acetate, vinyl versatate and butyl acrylate.
[0060] In one embodiment of the invention, the cement coating
comprises the following dry ingredients expressed in relative
amounts by weight:
[0061] 34% cement; 58% sand; 5% redispersible binder and 3% lime.
It will be understood by those skilled in the art that these
relative percentages will adjust should the coating material have
other components added, although their relative amounts will stay
fairly constant.
[0062] Other embodiments are within the following ranges: cement
20-35%; sand 55-71%; redispersible binder 4-5% and lime 3-5%. When
used, the resin and saline-based efflorescence-reducing and
waterproofing agent constitutes a fraction of 1%, as does the
anti-efflorescence compound.
[0063] It will be appreciated by those skilled in the art that
small deviations from the percentages expressed above will not
materially alter the overall performance of the protective coating
and are therefore within the scope of the invention.
[0064] In some embodiments, it may be advantageous to coat the
entire tile. For example, where condensation may collect on the
interior surface of the tile, a coating material may help protect
the integrity of the foam. Another alternative is to apply the
coating to only the surface of the foam that will be exposed to the
elements. Also, different coatings may be applied to different
surfaces to optimize the resilience of the tile. For example, in
one embodiment, a less durable coating may be applied to surfaces
that are not exposed to the elements, while a more durable coating
is applied to the surfaces that are so exposed. Also, one or more
layers of the same or different coatings may be used. For example,
in another embodiment, the mixture shown in Table 1 is used to form
a slurry that is applied to the mesh-covered foam core member 12 in
two separate applications. A 1/8'' coating (for example) is applied
to the top surface and allowed to cure. A second 1/16'' thick
coating is applied to the top surface and the bottom surface and
allowed to cure. Other combinations of thicknesses of a first
coating and a second coating are within the teachings of the
invention.
[0065] Referring to FIGS. 1A-1D, when the cement-based slurry dries
and hardens, it forms a protective coating 14 that covers all or
some of the surfaces of the foam core member 12. In all cases,
there is an upper surface protective coating 86 that covers the
first end member 28, including the first major end extension member
46 and first minor end extension member 49. The upper surface
protective coating 86 further extends over the core member upper
surface 16 and the second end member 29, including the second minor
end extension member 59, and second major end extension member 56.
In one embodiment, a lower surface protective coating 87 is also
formed and covers the entire lower core surface 22. A first side
wall protective coating 85 is also applied. Together, upper surface
protective coating 86, lower surface protective coating 87 (when
present) and first side wall protective coating 85 comprise the
cement-based protective coating 14 on the surfaces of the
mesh-covered foam core 12. In some embodiments, it may be possible
to eliminate all or a portion of the lower surface protective
coating 87 that is not exposed directly to the elements. A
protective coating on second side wall 38, which is typically
covered by another tile, is optional.
[0066] The protective coating 86 fills in the end member slot 43,
covers the first major extension member 46 and first minor end
extension 51, forming a first L-shaped flange 88 having a first
flange engagement member 90 extending generally along the width of
the tile 11 and having a first flange engagement surface 89 and a
distal end 92. Also formed is a first flange abutment member 93
generally perpendicular to the first flange engagement member 89
and having a first abutment surface 91 generally perpendicular to
the first engagement surface 89. The flange surfaces 89 and 91 and
end 92 are contiguous with and part of upper surface protective
coating 86.
[0067] Likewise, the protective coating 86 fills in the second end
member slot 53, covers the second major extension member 56 and
second minor end extension member 59, forming a second L-shaped
flange 94 having a second flange engagement member 95 extending
generally along the width of the tile 11 having a second flange
engagement surface 96 and a distal end 98. Also formed is a second
flange abutment member 99 generally perpendicular to the second
flange engagement member 95 and having a second flange abutment
surface 97 generally perpendicular to the second flange engagement
surface 96. The flange surfaces 97 and 96 and end 98 are contiguous
with and part of upper surface protective coating 86.
[0068] The first generally L-shaped flange 88 and second generally
L-shaped flange 94 are opposite facing (flange 88 having its
engagement surface 89 facing upwardly, while flange 94 has its
engagement surface 96 facing downwardly).
[0069] As illustrated in FIGS. 1A-1D and 7, 8, 9 and 10, the
connections 103 between adjacent tiles is the abutment of two
cement-coated flange engagement members 88 and 94. When these
members are in an abutting relationship, they are not affixed to
one another in a way that prevents them from moving (such as
pivoting) relative to one another and, as such, the connection
between two abutting adjacent tiles is flexible. There is no solid
joint formed that created a monolithic structure between adjacent
tiles that could be stressed to breaking in response to movements
of the underlying roof structure.
[0070] As best seen in FIGS. 6A-6C, 7 and 8, when tiles 11 are
placed adjacent to each other, an upwardly facing first engagement
surface 89 of one tile can be positioned to overlap with and engage
a downwardly facing second engagement surface 96 of an adjacent
tile. The first flange end 92 abuts second abutment surface 97 of
the adjacent tile 11, while second flange end 93 abuts first
abutment surface 91 of the adjacent tile 11 (FIG. 8). An
interlocking connection 103 is thus formed by which all of the
tiles so interlocked together create a weather covering 101 over
the roof structure 66. Because the covering 101 is formed by only a
slight overlap of the lateral edges of tiles 11, the number of
tiles 11 required to cover a given area of roof structure 66 is
fewer than prior art tiles requiring a greater lateral overlap.
[0071] While the structures of end members 28 and 29, including
flanges 88 and 94, have been illustrated in connection with a roof
tile 11 having arcuate sections, the same structure and advantages
are applicable to a flat tile 11, as best seen in FIG. 9.
[0072] Referring to FIG. 7, one of the advantages of the tiles 11
of the present invention is their ability to absorb the forces of a
piercing fastener (e.g., nail or screw) 102 without cracking,
breaking or otherwise compromising the structural integrity of the
tile. For tiles having an arcuate section 15, fasteners can be
advantageously placed where the arcuate section contacts the
underlying roof structure. This ability to be so fastened allows
each lightweight tile 11 to be quickly and efficiently individually
secured directly to the underlying roof structure 66 and thereby
kept in place, both relative to the roof structure and to other
tiles even under severe weather conditions. Being able to nail (or
screw) down each tile 11 permits the elimination of support
structures typically required for traditional clay and cement
tiles. Because the tiles are sturdy enough to support the weight of
an installer, their installation is less labor-intensive than
traditional clay or cement tiles and can be completed without tile
breakage that unavoidably accompanies the installation of cement
and clay tiles.
[0073] A weather covering 101 for a roof structure 66 is formed
with a plurality of tiles 11 of the present invention arranged in
overlapping tiers. Each tier is formed by a plurality of tiles
arranged in side-by-side relationship with their respective
adjacent end members interlocked.
[0074] Referring to FIGS. 6A-6C, 7, 8 and 9, a first tier 104 of
interlocked tiles 11 is secured to the roof structure 66 by driving
a fastener 102 through each tile (without pre-drilling a hole) and
into the roof structure 66 (FIGS. 6A and 7). As shown, the fastener
102 is placed near the leading edge (second side wall 38) of the
tile and in a location where a tile of the next tier of tiles 11
will cover it and thereby prevents it from being exposed to
precipitation.
[0075] A second tier 106 of tiles 11 (FIG. 6B) is disposed in
overlapping relationship to the tiles of tier 104 so as to cover
fasteners 102. These second tier tiles are secured to the
underlying roof structure 66 by driving fasteners 107 through the
tiles into the roof structure 66. Additional tiers 108 of tiles 11
are added in the same manner (FIG. 6C) until the roof structure 66
is covered. The trailing edge of a tile 11 (side walls 33) that is
uncovered by a subsequent tier tile 11 has a cement-based
protective coating 85 (FIG. 1A), while it is optional to so coat
the leading edge (side wall 38) being that it is covered.
[0076] Referring to FIG. 10, for tiles such as tiles 11 that have
an arcuate section 15, the present invention provides that the
cross-sectional thickness of the tile be varied in a particular
manner so that the lower surface 110 of each tile fits over and
nests with substantially the entire upper surface 111 of the tile
onto which it is disposed.
[0077] Referring to FIG. 11A, a tile 121 has an arcuate section 122
with an arcuate upper surface 123 and an arcuate lower surface 124.
The arcuate lower surface 124 generally traces the arc of a circle
having a radius R.sub.1 and a center C.sub.1, while the arcuate
upper surface 123 generally traces the arc of a circle having a
radius R.sub.2 and a center C.sub.2 where R.sub.1 and R.sub.2 are
generally equal, while centers C.sub.1 and C.sub.2 are at different
locations. The distance between the two centers C.sub.1 and C.sub.2
is approximately the same as the thickness of the tile 121 at the
apogee 126 of its arc. This formulation provides like tiles with
lower surfaces 124 that closely approximate in size and shape upper
surfaces, which allows them to be nested in close relationship as
illustrated in FIG. 11B. This feature allows the tiles of one tier
to be placed at any location along the length of a lower tier tile
whereby the amount of overlap can be varied to satisfy aesthetic
considerations.
[0078] While the variable thickness feature of the tile 121 has
been illustrated and described in connection with a tile that is
primarily a simple arcuate shape, it will be understood by those
skilled in the art that the same applies to any arcuate section of
a tile, including those that are only a portion of the tile and not
the entire tile such as the tile 11 of FIG. 1A.
[0079] In the prior art, as shown in FIG. 12, tiles 131 with an
arcuate section 132 are typically formed to have a non-variable
thickness 133 (a singe center C.sub.1 but different radii R.sub.1
and R.sub.2, with the radii difference being equal to the thickness
133 of the tile). As shown, such tiles will not nest in close
relationship. To accommodate this, prior art tiles are typically
tapered along their lengths so that tiles can be stacked in close
relationship, but only at one location along their length.
[0080] It will be understood by those skilled in the art that the
materials involved do not permit geometric or dimensional precision
and, thus, the modifier "generally" is used to accommodate the
difference between ideal dimensions and geometric relationships and
those possible in the real world. The roofing tiles described
herein are designated by Underwriters Laboratories Inc. .RTM. (UL)
for installation as a Class A prepared roof covering under the
UL790 standard for use on either combustible or noncombustible roof
decks when the roofing surface is applied as intended. The
combination of light weight (due to EPS composition) and superior
fire resistance allows someone additional time to exit a burning
building without fear of the roof caving in as it may in the case
of heavier clay and concrete roofing tiles.
[0081] The roofing surface's Class A resistance to external fire
provides significant assurances and greatly increases its
effectiveness. The roofing tiles of the present invention have
passed three rigorous UL certification tests to attain a Class A
certification; specifically, the roofing tiles passed Intermittent
Flame tests during which a 1400 degree F. gas flame was
intermittently applied to the roofing tile during 15 four-minute
cycles and a 12 mile-per-hour air current flowed over the roofing
tile. No portion of the roofing tile was blown or fell off the roof
deck in the form of flaming or glowing brands, nor was the roof
deck exposed by breaking, sliding, cracking or warping of the
roofing tiles. No part of the combustible 15/32'' plywood roof deck
(the roof deck used during the certification process) fell away in
the form of glowing particles, nor did it sustain flaming on its
underside.
[0082] The roofing tiles of the present invention also passed
Burning Brand tests in which a 12''.times.12'' brand was ignited
and placed on the roofing tiles. Test observations were made until
the brand was consumed and testing ceased. No portion of the roof
tiles was blown or fell off the roof deck in the form of flaming or
glowing brands, and the roofing tiles protected the roof deck such
that it was not exposed by breaking, sliding, cracking or warping
of the roofing surface. The underside of the roof deck experienced
no sustained flaming, and no portions of the roof deck fell away in
the form of glowing particles.
[0083] In a Spread of Flame test, the roofing tiles were exposed to
a gas flame of 1400 degrees F. for ten minutes. With a maximum
spread of flame of 3.5 feet and no significant lateral spread of
the flame from the path directly exposed to the test flames, the
roofing tiles of the present invention passed the test. As with the
other tests, no portion of the tiles was blown or fell off the roof
deck in the form of flaming or glowing brands, the roof deck was
not exposed by breaking, sliding, cracking or warping of the roof
surface, and no portions of the tiles fell away in the form of
glowing particles.
[0084] Thus, the roofing tiles of the present invention are
certified to carry the UL Class A listing mark for Prepared Roof
Covering Materials. This certifies the roofing tiles of the present
invention are effective against severe fire test exposures under
which it affords a high degree of fire protection to the roof deck.
The tiles are also certified not to slip from their position and
are not expected to produce flying brands during severe fire test
exposure. In sum, this significant degree of fire resistance is a
particularly advantageous and effective feature of the roof tiles
of the present invention.
[0085] The embodiments described provide a roofing surface that is
certified Class A fire resistant under the stringent UL 790
standard. The tiles are strong, lightweight and resist insects,
including termites and carpenter ants. The tiles promote a
healthier environment because they are lightweight, which (1) cuts
down on transportation exhaust emission and (2) requires less
lumber to support the surface. Also, the foam used in the tiles act
as an insulator that cuts down on construction costs (less
insulation needed elsewhere, smaller heating and air conditioning
equipment, etc.) and cuts down on the ongoing building energy
needs.
[0086] Having described the methods and structures in detail and by
reference to several preferred embodiments thereof, it will be
apparent that modifications and variations are possible without
departing from the scope of the invention defined in the following
claims.
* * * * *