U.S. patent application number 16/891218 was filed with the patent office on 2020-12-03 for roofing tile system and method of manufacture.
The applicant listed for this patent is Brava IP LLC. Invention is credited to Billibob Boor, Gerald Edson.
Application Number | 20200378124 16/891218 |
Document ID | / |
Family ID | 1000004925188 |
Filed Date | 2020-12-03 |
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United States Patent
Application |
20200378124 |
Kind Code |
A1 |
Boor; Billibob ; et
al. |
December 3, 2020 |
Roofing Tile System And Method Of Manufacture
Abstract
A synthetic roofing tile or panel is provided that includes one
or more features enhancing the impact resistance and other
desirable properties as well as the ease of installation and/or use
of the roofing tile or panel on a building structure. The roofing
tile is formed in an improved color variation process is provided
with regard to the manufacture of a synthetic material roofing tile
in order to effectively simulate the appearance of the natural
material represented by the synthetic roofing tile. The roofing
tile also can be compression molded such as in a method for
manufacturing a synthetic roofing tile or panel is provide in which
a number of inserts representing the desired appearance for the
roofing tile or panel can be utilized in the manufacturing process
to provide roofing tiles or panels with the desired appearance. The
inserts can be interchanged within the molds in order to provide
different appearances to roofing tiles or panels formed using the
same molds.
Inventors: |
Boor; Billibob; (Neenah,
WI) ; Edson; Gerald; (Terra Haute, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Brava IP LLC |
Neenah |
WI |
US |
|
|
Family ID: |
1000004925188 |
Appl. No.: |
16/891218 |
Filed: |
June 3, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62856248 |
Jun 3, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04D 1/08 20130101; B29L
2031/108 20130101; B29C 43/021 20130101; B29K 2023/065 20130101;
E04D 1/20 20130101; B29K 2509/00 20130101; B29K 2023/0633 20130101;
B29C 43/18 20130101; B29K 2105/0044 20130101; E04D 1/26
20130101 |
International
Class: |
E04D 1/20 20060101
E04D001/20; E04D 1/08 20060101 E04D001/08; B29C 43/02 20060101
B29C043/02; B29C 43/18 20060101 B29C043/18 |
Claims
1. A roofing tile formed in a compression molding process.
2. A roofing tile comprising a body formed of a synthetic material
including a binder blend.
3. The roofing tile of claim 2 further comprising at least on
nailing area thereon
4. The roofing tile of claim 3 wherein the nailing area includes a
positioning guide.
5. A method for forming a roofing tile, the method comprising the
steps of: a) providing a number of inserts approximating the
appearance of a natural material; b) placing the inserted within a
mold; and b) compression molding a material into the shape of a
roofing tile having the appearance of a natural material.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from U.S.
Provisional Patent Application Ser. No. 62/856,248, titled Roofing
Tile, filed on Jun. 3, 2019, the entirety of which is hereby
expressly incorporated herein by reference for all purposes.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to roofing
materials, and more specifically to a roofing tile formed of a
synthetic material that simulates a roofing shingle or tile formed
of a natural material, a roofing system including the roofing tiles
and method of forming thereof.
BACKGROUND OF THE DISCLOSURE
[0003] In building construction, the roof of the structure must be
capable of not only protecting the interior of the structure from
the elements, but also to provide this protection with the desired
aesthetic appearance. Historically a number of different roofing
materials have been employed to achieve these purposes, such as
asphalt shingles, wood shingles, ceramic tiles, and slate tiles,
among others. However, while these materials are effective in
providing weather protection with the desired appearance, the
natural roofing materials often are deficient in durability aspects
that require frequent maintenance, repair and/or replacement of the
natural roofing materials.
[0004] With the advent of modern material processing techniques, it
has become possible to manufacture roofing materials from synthetic
materials that have greatly increased durability aspects in
comparison with these natural materials and maintain the desired
aesthetic appearance of the natural materials. Examples of
synthetic roofing materials of this type are disclosed in U.S. Pat.
Nos. 6,495,635; 6,558,773; 6,703,440; 6,706,366; 7,596,919; and
8,153,045, each of which is expressly incorporated herein by
reference in its entirety.
[0005] Nevertheless, while these prior art references disclose
various configurations for roofing tiles formed from synthetic
materials, each has certain shortcomings with regard to overall
structure or manufacturing process. As such, it is desirable to
develop a roofing tile formed from one or more synthetic materials
that addresses and overcome the shortcomings of the prior art
and/or to provide an improved roofing tile or shingle from those
disclosed in the prior art.
SUMMARY OF THE DISCLOSURE
[0006] According to one aspect of an exemplary embodiment of the
disclosure, an improved color variation process is provided with
regard to the method of manufacture of a synthetic material roofing
tile or shingle or other exterior or interior building panel, such
as siding, in order to effectively simulate the appearance of the
natural material represented by the synthetic roofing tile produced
in the method.
[0007] According to another aspect of an exemplary embodiment of
the disclosure, a synthetic roofing tile, shingle or panel is
provided that includes one or more features enhancing the ease of
installation and/or use of the roofing tile, shingle or panel on a
building structure.
[0008] According to still another aspect of an exemplary embodiment
of the present disclosure, a synthetic roofing tile, shingle or
panel is formed utilizing a material formulation that significantly
improves the impact resistance and other desirable properties of
the roofing tile, shingle or panel.
[0009] According to a further aspect of an exemplary embodiment of
the present disclosure, a method for manufacturing a synthetic
roofing tile, shingle or panel is provided in which the synthetic
roofing tile, shingle or panel can be compression molded.
[0010] According to still a further aspect of an exemplary
embodiment of the present disclosure, a method for manufacturing a
synthetic roofing tile, shingle or panel is provided in which a
number of inserts representing the desired appearance for the
roofing tile, shingle or panel can be utilized in the manufacturing
process to provide roofing tiles, shingles or panels with the
desired appearance. The inserts can be interchanged within the
molds in order to provide different appearances to roofing tiles,
shingles or panels formed using the same molds.
[0011] Numerous additional aspects, features and advantages of the
present disclosure will be made apparent from the following
detailed description taken together with the drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The drawings illustrate the best mode currently contemplated
of practicing the present invention.
[0013] In the drawings:
[0014] FIG. 1 is schematic view of a first exemplary embodiment of
a color variation process for use as part of a manufacturing
process for forming a synthetic roofing tile, shingle or other
building panel according to the present disclosure.
[0015] FIG. 2 is schematic view of a second exemplary embodiment of
a color variation process for use as part of a manufacturing
process for forming a synthetic roofing tile, shingle or other
building panel according to the present disclosure.
[0016] FIG. 3 is schematic view of a third exemplary embodiment of
a color variation process for use as part of a manufacturing
process for forming a synthetic roofing tile, shingle or other
building panel according to the present disclosure.
[0017] FIG. 4 is schematic view of a fourth exemplary embodiment of
a color variation process for use as part of a manufacturing
process for forming a synthetic roofing tile, shingle or other
building panel according to the present disclosure.
[0018] FIG. 5 is a top plan view of a first exemplary embodiment of
a roofing tile constructed according to the present disclosure.
[0019] FIG. 6 is a bottom plan view of the roofing tile of FIG.
5.
[0020] FIG. 7 is a partially broken away top plan view of the
roofing tile of FIG. 5.
[0021] FIG. 8 is a top plan view of a second exemplary embodiment
of a roofing tile constructed according to the present
disclosure.
[0022] FIG. 9 is a bottom plan view of the roofing tile of FIG.
8.
[0023] FIG. 10 is a perspective view of a lower mold and inserts
utilized therein in constructing a roofing tile according to the
present disclosure.
[0024] FIG. 11 is a partially broken away, perspective view of the
lower mold inserts of FIG. 10.
[0025] FIG. 12 is a perspective view of a cover and cover insert
for the mold of FIG. 10.
[0026] FIG. 13 is a partially broken away, perspective view of the
cover of FIG. 13.
[0027] FIG. 14 is a perspective view of the cover of FIG. 12 with
the cover insert removed.
[0028] FIG. 15 is a perspective view of a component insert of the
mold of FIG. 10.
[0029] FIG. 16 is a perspective view of a component insert of the
mold of FIG. 10.
[0030] FIG. 17 is a perspective view of a component insert of the
mold of FIG. 10.
DETAILED DESCRIPTION OF THE DRAWINGS
[0031] With reference now to the drawing figures in which like
reference numerals designate like parts throughout the disclosure,
FIGS. 1-4 schematically represent variations of different color
variation process for use as part of methods of forming roofing
tiles, shingles or building panels having desired color
characteristics for use as part of methods of manufacturing roofing
tiles in accordance with the present disclosure.
Color Variation Processing
[0032] The color variation processes or methods schematically
illustrated in FIGS. 1-4 are new and unique to the roofing and
building product industry. They have never been used for composite
roofing or siding, nor in injection or compression molded
processes.
[0033] The processes presently disclosed, alone or in combination
with other aspects of building and/or roofing products/material
manufacturing, such as the particular molding process employed
and/or the mold design, among others, aid in eliminating the
pattern effect previously offset in the relevant prior art by
utilizing the mold volume calculation method. The processes
presently disclosed additionally add further abilities to the
formation of the building products with color development providing
a finished look to the resulting roofing tile or shingle or
building panel, such as siding. In utilizing the novel processes
disclosed herein, and illustrated in exemplary embodiments in FIGS.
1-4, it has been possible to take colors of real wood from existing
roofs, match those base colors as individual components, and then
look at the overall roof pattern from a photograph and mimic the
color look by adjusting those solid colors in the disclosed
processes as they run through the machine, e.g., the extruder 12.
This is done in the disclosed processes by varying how much color
is added at one time, and/or how far down the feed throat 10 of the
extruder 12 the color moves before feeding the next color to the
mixture. The amount of material being placed in the extruder 12 to
achieve the color hue desired and also how far down the feed throat
10 we allow the material to flow before adding the next color
affects the overall blending and visual perception of the color
seen in the end product. For example, if we load the first color
material high in the feed throat 10 and then place another color
directly on top of the first, the two materials will immediately
begin to blend with each other as they go down the feed throat 10
creating a new color hue between the two of them. If the first
color material is loaded further toward the bottom of the feed
throat 10 before placing the next color material on top of it you a
more drastic division of the colors as they have less time to mix
so as they exit the extruder 12 they resemble a highlight or
lowlight affect in the end product.
[0034] For example, while the colors yellow and blue together make
green, if a yellow color material and then blue color material
added on top are initially added high in the feed throat 10 then
end affect in the end product will be some yellow, the same amount
of green as the yellow material and blue material are well mixed in
the feed throat 10, and then blue will come out. If we load yellow
and then blue on top lower in the feed tube you will see clean
yellow come out, then very little green hue at all due to the
limited mixing of the yellow and blue, and then blue almost as if
the materials were painted separate colors. It is possible to
adjust these color loadings to have whatever color effect we want
for the end product thus providing the ability to match almost any
natural color look of historical slates and wood roofs and/or
sidings with very little effort or cost. With this discussion
providing the general aspects of the improved color variation
process aspect of the present invention, the following is a
discussion of a number of exemplary embodiments of the
implementation of the color variation process.
Method 1:
[0035] As shown in the exemplary illustrated embodiment of FIG. 1,
the device 11 for mixing the materials utilized in the formation of
the building product/roofing tile/shingle/siding 100 is
schematically illustrated. The device 11 includes the feed throat
10 that is attached to an inlet 14 of an extruder 12 at one end and
that supports a hopper 16 at the opposite end. The hopper 16 is
primarily utilized for the addition of the non-color materials,
such as the recycled materials hereinafter specified for the
various building component compositions, utilized in the
manufacture of the building products 100 (FIG. 5) of the present
disclosure, but may additionally be used for the addition of
certain color materials. The materials added in the hopper 16,
which can be added to the hopper 16 in any form, such as powders or
pellets, among other suitable forms, pass under the influence of
gravity through the feed throat 10 to the inlet 14 of the extruder
12, where the materials are mixed by a screw (not shown) present in
the extruder 12 and optionally heated prior to exiting the extruder
12 through the outlet 18. The device 11 also includes a number of
color feeders 18 and 20 engaged with the feed throat 10. The color
feeders 18 and 20 can be secured at various points along the feed
throat 10 in order to enable color materials to be added at
different points along the length of the feed throat 10. The
feeders 18 and 20 can be permanently secured to the feed throat 10,
or can be releasably secured to the throat 10. The feeders 18 and
20 are formed similarly to the hopper 16 and has a body 21 formed
of a suitable material, such as a metal or hard plastic, among
others, that includes an open inlet end 22 into which the selected
color material can be introduced and an outlet end 24 that
dispenses the color material from the feeder 18 and/or 20 into the
throat 10. The outlet end 24 is aligned with a suitable opening
(not shown) in the feed throat 10 to enable the color material to
pass into the interior of the throat 10. For releasably securing
the feeder 18 and/or 20 to the throat 10 in alignment with the
opening in the throat 10, any suitable mechanism can be employed.
For example, the outlet end 24 of the feeder 18 and/or 20 can be
formed to be smaller than the opening in the feed throat, such that
the outlet 24 is inserted through the opening into the interior of
the throat 10. The body 21 can include a mechanical device 26, such
as a bracket 28, that is engaged with a complementary structure 30,
such as a hook 32, on the exterior of the throat 10 in order to
retain the feeder 18 and/or 20 on the throat 10 in alignment with
the opening.
[0036] In these configurations, gravity operates to draw the color
material from the body 21 of the feeders 18 and/or 20 into the
throat 10 for mixing with the remainder of the material(s) used in
forming the end product 100 and the other color materials. In one
exemplary embodiment, the color material is added in the form
pre-colored pellets (not shown), which are completely formed
finished material of various colors, in stages to achieve the
desired coloration or pattern effect for the end product. In an
alternative embodiment, a non-pelleted dry color mix or powder can
also be dispensed from the feeders 18 and/or 20 in the same gravity
feed manner as the pellets.
Benefits of Method 1:
[0037] Providing customized color pattern or appearance in building
products using pre-colored pelletized or powdered material with a
sequencing method in which powder colorant or colored pellet is
introduced into the manufacturing process for the building product
at the throat of the mixing machine/extruder without the need of
mold volume calculations to reduce patterns [0038] Implementation
of the process of material flow color variation with layering of
the materials to achieve the desired color output.
[0039] As shown in the exemplary illustrated embodiment of FIG. 2,
method 2 involves an apparatus/addition to method 1 still utilizing
the overall process of method 1 shown in FIG. 1, but using
non-colored, natural pellets, color feeders, and a mixing section.
The idea of using non-colored pellets, which have the same
composition as the colored pellets but without the colored oxides,
allows for better inventory control as it can be turned to any
color throughout the process, whereas pre-colored pellets can only
provide the color initially provided to the pre-colored pellet.
Thus, it is often undesirable to have to maintain inventory stocks
of all pre-colored pellets, when some colors may be utilized
seldomly, if at all, resulting in a significant amount of dead
inventory for the low demand colors. The use of non-colored pellets
greatly reduces this problem by allow inventory to be reduced to
the non-colored pellets and the various color materials or charges,
again having the same composition as the colored pellets or
materials or charges but without the colored oxides enabling
manufacturers to more constantly flip material inventory and to
react to orders quickly.
[0040] In the device 11' of FIG. 2, the modifications made to the
device 11 of FIG. 1 include the positioning of a non-colored pellet
feeder 30 below the hopper 16. The device 11' also includes a pair
of color charges 32 and 34 attached to the throat 10 below the
feeder 30 to introduce the colors into the throat 10, and a mixer
36 disposed below the color chargers 32 and 34 to mix the colors
from the chargers 32 and 34 with the non-colored pellets and the
other materials used to form the building components 100 added into
the hopper 16, and described previously. The feeder 30 and/or
charges 32 and 34 turn on and off through sensors that can tell
when the feed throat 10 is emptying of the materials. The metering
is then done through timing via a computer (not shown) but operably
connected to the feeder 30 and/or charges 32 and 34. The colors and
other materials can be retained in the mixer 36 for an amount of
time prior to moving into the remainder of the throat, and/or can
be continuous through the mixer 36. For example, if the device 11'
or extruder 12 slows down, consequently slowing the flow of
material into the inlet 14 of the extruder 12, the computer (not
shown) can slow down the flow through the mixer 36 to match or
pause feed rates. But all blending or mixing of the colors is done
in the feed throat 10 by gravity.
[0041] Below the feeder 30, the color is introduced into the throat
10 from the chargers 32 and 34. Depending upon the form of the
color material, e.g., a liquid color or a solid color, the chargers
32 and 34 can take different forms, such as similar to the feeders
18 and 20 in FIG. 1, or a suitable liquid injection device, secured
in a fixed or releasable manner to the exterior of the throat
10.
[0042] In operation, the required amount of non-colored pellets and
other materials are charged to the hopper 16 of the device 11' to
accommodate the run of material for forming the building product(s)
100. After the materials are positioned within the feeder 30, the
feeder 30 is operated to dispense the materials into the throat 10.
As the volume of non-colored pellets are dropped and/or fed into
the mixing section/mixer 36, the color(s) needed for that material
run is also introduced into the mixing section 36 at the same time
by the color chargers 32 and/or 34. The mixer 36 combines the
color(s), the non-colored pellets and the other materials in order
to achieve the desired color profile for the building product 100,
with any residence time of the materials in the mixer 36 being
determined by different preset times associated with the desired
color and/or look for each shingle or building product 100. When
the prior charge of materials and color reaches a particular height
within the feed throat 10 below the mixer 36, as monitored by a
proximity or level switch (not shown) positioned on the throat 10
below the mixer 36, the mixer 36 dispenses or drops its material
charge into feed throat 10 for further processing in the extruder
12. Once the mixer 36 drops the charge held within it, the feeder
30, which has been pre-loaded with additional non-colored pellets
and other materials, and the color chargers 32 and 34, which have
also been pre-loaded with additional color materials, begin loading
the materials into the mixer 36 to form the next building product
material charge.
Benefits of Method 2:
[0043] Usage of non-colored pelleted material with a sequencing
method of coloring through powder colorant or colored pellet being
introduced into the process at the throat of the machine without
the need of mold volume calculations to reduce patterns. [0044]
Usage of color feeders/chargers and a mixing section to allow for
powdered or pelleted colorants where previously pre-batched
industry standard color dispersions was the method. [0045]
Implementation of the process of material flow color variation with
layering of the materials to achieve the desired color output.
[0046] As shown in the exemplary illustrated embodiment of FIG. 3,
method 3 employs a device 1000 including the hopper 16, the throat
10 and the extruder 12. However, instead of the color feeders or
chargers disposed on the throat 10 as in the prior embodiments, the
device 1000 in method 3 has the color feeders 1018-1028 disposed
directly on the extruder 12, downstream from the inlet 14 of the
extruder 12. non-colored natural pellets or non-pelleted dry mix in
the same way. Although dry mix is a bit dustier for manufacturing
it does save cost. With this method the natural material is loaded
non-metered into the feed throat. As the materials are extruded
downstream within the extruder itself color feeders are used to
introduce the colors and to control the color pattern or
sequence.
Benefits of Method 3:
[0047] 1.sup.st in composite roofing industry to adapt non-colored
pelleted or powdered material to be color sequenced through
downstream color feeders on the extruder itself during the shingle
manufacturing process allowing for many color variations
[0048] As shown in the exemplary illustrated embodiment of FIG. 4,
method 4 is a device 1001 that is a combination of method 2 and
method 3 allowing for many colors and almost infinite versions to
be run with subtle changes and drastic highlight/lowlights to be
done at the same time.
Benefits of Method 4:
[0049] 1.sup.st in composite roofing industry to adapt non-colored
pelleted or powdered material with a sequencing method of coloring
through powder colorant or colored pellet being introduced into the
process at the throat of the machine without the need of mold
volume calculations to reduce patterns as we have overcome that
need. [0050] 1.sup.st in the composite industry to use color
feeders and a mixing section to allow for powdered or pelleted
colorants where previously pre-batched industry standard color
dispersions was the method. [0051] 1.sup.st in composite roofing
industry to adapt downstream color feeders on the extruder itself
in conjunction with the throat color feeders during the shingle
manufacturing process allowing for many color variations. [0052]
1.sup.st in composite roofing industry to implement the process of
material flow color variation with layering of the materials to
achieve the desired color output. [0053] 1st in industry to combine
methods 2 and 3 giving virtually unlimited color ability with
subtle hue changes and drastic low and highlighting at the same
time all while sequencing colors to eliminate patterns and to match
historical product looks.
[0054] With regard to the composition of the roofing tiles of the
present disclosure, whether made using the previously described
methods or by other methods, the roofing tile includes recycled
components, as described in the prior art, and includes a blend of
binders as identified below in certain exemplary embodiments. The
binder blend is used to manipulate the polymers in the recycled
component to achieve the desired characteristics of the material
that we want. We can use a wider range of materials and then modify
them through the binder blend to achieve the same elevated output
performance above the performance of our historical materials.
Previously such as the Edson patents EPDM was used an impact
modifier of 20 to 30% as rubber to increase impact. The problem is
rubber also burns and does not bond to the plastics at the level
that we require. We are the first in the composite rooting molding
world to be able to utilize these unique components.
TABLE-US-00001 TABLE 1 Composition of Spanish Style Roofing Tiles
(w/w %) Class A Fire Class C Fire Mag Hydroxide 30-45% 0-20%
Calcium 400 mesh particle size or smaller 5-15% 25-45% Wollastonite
1-5% 1-5% Blend of binders from below 8-12% 8-12% Dow Engage
Ethylene Octene Dow Versify Polypropelene Ethylene copolymer Dow
Affinity Polyolefin Plastorner Dow Infuse Olefin Block Copolymer
Ethylene vinyl acetate 10-20 melt 3-5% 3-5% (10-28% VA Content)
LDPE 2-4 melt 10-15% 10-15% HDPE 8-15 melt 20-28% 20-28% Tinuvin
783 UV .4% .4% Chimasorb 81 UV .2% .2% Irganox b225 antioxidant .1%
.1% Talc 1-10% 1-10% LLDPE 3-19% 3-19% Zinc Stearate 0.5-3% 0.5-3%
Balance is colorant
TABLE-US-00002 TABLE 2 Composition of Slat/Cedar Shake Style
Roofing Tiles (w/w %) Class A Fire Class C Fire Mag Hydroxide
30-40% 0-20% Calcium 1000 mesh particle size 4-10% 20-45%
Wollastonite 1-5% 1-5% Blend of binders from below 22-38% 22-38%
Dow Engage Ethylene Octene Dow Versify Polypropelene Ethylene
copolymer Dow Affinity Polyolefin Plastomer Dow Infuse Olefin Block
Copolymer Ethylene vinyl acetate 10-20 melt 5-10% 5-10% (10-28% VA
Content) LDPE 2-4 melt 12-20% 12-20% HDPE 8-15 melt 15-18% 15-18%
Tinuvin 783 UV 0.5% 0.4% Chimasorb 81 UV 0.2% 0.2% Irganox b225
antioxidant 0.1% 0.1% Talc 1-10% 1-10% LLDPE 3-19% 3-19% Zinc
Stearate 0.5-3% 0.5-3% Balance is colorant
[0055] Referring now to FIGS. 5-7, one exemplary embodiment of a
roofing tile 100 formed within the scope of the present disclosure,
such as by any of the prior described methods and/or using any of
the previously described formulations. The tile 100 does not
include preformed nail holes same as required in traditional
concrete and clay roofing tiles and other composite tiles. The tile
100 instead can be formed with a nailing area 102 that is raised
and thicker to add strength to the area of the tile 100 where the
nail (not shown) is to be inserted. The nailing area 102 includes a
round nail and screw target 104 formed therein that is self-sealing
when the nail or other fastener is inserted therein to avoid damage
to the tile 100. Without needing a raised preformed nail hole
and/or vertical support ribs as in prior art tiles, the fulcrum can
be at a maximum distance from the top of the tile increasing wind
performance of the tile 100. The nailing area 102 can additionally
be formed with a rib/positioning guide 106 that is used to readily
locate the nail or nail gun (not shown) with regard to the target
104 This rib 106 allows an installer to simply abut the nail gun
against the rib 106 and pull the trigger to properly insert the
nail within the target 104 in the tile 100. The tile 100 can also
be formed with an additional third nailing area 108 for additional
wind uplift properties.
Benefits of Roofing Tile 100:
[0056] 1. No Preformed nail holes as with traditional Spanish.
Concrete, clay, and previous composite barrel tiles have preformed
nail holes due to material limitations. Material performance with
product design is unique allowing for the first Spanish tile that
is gun nailable without damage. 1.sup.st in composites and V in
compression molding of Spanish tiles. [0057] 2. Raised nail hole
pad adding strength to the nail area while keeping the rest of the
tile light for material savings. Also doubles as water deflector
keeping wind driven water from reaching the nail area. [0058] 3.
1.sup.st composite barrel tile without raised fixed nail hole
allowing for the fulcrum point of the tile to be moved down
increasing wind uplift capability. [0059] 4. Raised nail gun guide
for automatic positioning of nail by guiding the installers nail
gun position. Nail guide also serves as a water deflector for
wind-driven rain secondary to the gun alignment feature. [0060] 5.
Material performance allows for lighter yet higher performing
product [0061] 6. Material performance allows for highest of impact
performance without adding rubber or EPDM as a impact modifier like
previous materials in the market. [0062] 7. Third nail hole in
bottom left rain track. 1.sup.st in and tile. 1.sup.st in
composites, 1.sup.st in compression molding. This allows for a
hidden fastener that increases wind uplift without compromising
product water shedding performance. [0063] 8. 1.sup.st ever to
achieve this shape of Spanish tile in the composite market either
through injection or compression molding. [0064] 9. 1.sup.st ever
barrel design allowing fasteners to penetrate through the material
self-sealing around the nail helping to eliminate leaks and to
increase wind uplift performance. [0065] 10. For hand nailing and
screwing a Nail and screw target location identified with an
indented "circle" is on the tile marking fastener location.
Process of Manufacture for Tile of FIGS. 5-7:
[0065] [0066] If color variation is desired the color process
method 1-4 will be used [0067] Utilizes ultra-fine particle fillers
to aid in impact and strength [0068] Utilizes proprietary binder
material blend adding to strength and performance. [0069] Material
is a new and unique formulation never having been produced or sold
before.
[0070] Referring now to FIGS. 8-9, another exemplary embodiment of
a tile 200 constructed according to the present disclosure is
illustrated. This tile 200 is formed with an appearance
approximating a shake, slate, concrete or other flat material for a
natural roofing tile and can be formed by any of the prior
described methods and/or using any of the previously described
formulations. The tile 200 includes solid from top to bottom
fastener locations 202, an integral water drain channel 204, a
water lock nail location 206 and an under tuck tab 208.
[0071] Further, referring now to FIGS. 10-17, in manufacturing the
tile 200 the use of a compression molding process as described
previously, or optionally an injection molding process or other
suitable forming process, enables different inserts 302-306 to be
placed within a cavity 301 formed in a mold 300 for the tile 200 in
order to provide different appearances to the tile 200 without
having to utilize entirely different molds. As shown in FIGS. 10-11
and 15-17, the mold 300 includes a cavity 301 in which inserts 302,
303, 304 and 306 are placed. The insert 302 assists in forming the
fastener locations 202 and drain channel 204, the insert or side
rail 303 are interchangeable allowing them, along with the other
inserts 302, 304 and 306 to be quick changed for repairs and/or
tile style modifications which provides longer wear for the inserts
302-306, the insert 304 provides the desired appearance to the tile
200, and the insert 306 assists in forming the water lock nail
location 206. The inserts 302-306 can be removed and interchanged
with one another to provide the desired appearance and
functionality to the resulting tile 200, without having to provide
an entirely different mold 300.
[0072] Also, the mold 300 includes a cover 308, best shown in FIGS.
12-14, that is positioned over the inserts 302-306 on the mold 300
to compression mold the tile 200. The cover 308 supports an insert
310 that is releasably secured to the cover 308 and that provides
the desired appearance and functionality to the rear surface of the
tile 200, as shown in FIGS. 12 and 13.
Benefits of Flat Roofing Tile 200:
[0073] 1. 1.sup.st in composites Image insert Panel Design allows
for infinite number of images and widths [0074] 2. 1.sup.st ever
use of Image Insert tooling technology allows for changing from
staggered to non-staggered imaging, or from slate to shake within
the same tooling, or even other imaging, allowing for quick
changeovers and lower tooling cost from product line to product
line. For example, running shake and slate separate tooling would
run around $250,000 for our process. The Image insert technology
lowers that cost to $135,000 for both sets. For an injection
molding comparable tooling for 2 lines would be in excess of
$2,000,000 for two profiles. Our Image Insert technology would
lower tooling cost to about $1,100,000. [0075] 3. 1.sup.st ever in
composite roofing product using Cast Image Insert technology
allowing for "Real" images from mother nature such as true wood
imaging or slate imaging giving our products the true to life look
verses previous molds that require computer designing and metal
machining of the image which is never true to mother nature's look.
The Cast Image Insert makes this composite shingle the first to
have real imaging from mother nature. [0076] 4. Image Insert
technology allows for quick change for image repairs lowing
lifecycle maintenance of molding tools [0077] 5. 1.sup.st ever
panel design in composite compression molded roofing products.
[0078] 6. 1st ever composite roofing panel that is a true taper
allowing for a solid accessories to be used on gables and valleys
where previous panel designs like BB light weight patent needed
either a metal flashing or other closure to hide the fact it is a
panel [0079] 7. 1.sup.st ever non nail through tab for tucking
under the shingle next to it for increased wind uplift. [0080] 8.
1.sup.st ever nail location on the water lock lower side of a
composite roofing shingle. Add this with the under tuck tab and top
nails and you have all 4 corners of the shingle being held down for
superior wind performance, verses the traditional 2 fastener
location on other products. This allows for increased wind
performance and will lower material cost in high wind areas by not
having to shrink exposure like previous products. [0081] 9. Can be
installed at different exposures without modifying the panel unlike
other panel designs that build in steps on the back side for
alignment and strength purposes. [0082] 10. Nailing areas are solid
from top to the bottom of the nail location without hollow areas
like on competitive panels. This eliminates panel deflection and
distortion during installation. Eliminating the tattle tale marks
of a fake panel by seeing deflection in the nail areas like other
panels in the market
Process of Manufacture for Tile 200:
[0082] [0083] if color variation is desired the color process
method 1-4 will be used [0084] Utilizes ultra-fine, i.e., 325 mesh
size or smaller, and optionally 200 mesh size, particle fillers to
aid in impact and strength [0085] Utilizes proprietary binder
material blend adding to strength and performance. [0086] Material
is a new and unique formulation never having been produced or sold
before.
Benefits of Compression Insert Mold:
[0086] [0087] 1. 1.sup.st ever compression molded shingle design
with insertable imaging tooling. This allows for quick repairs in
imaging and also image changes using the same tooling which greatly
reduces mold cost from product to product line. For example, the
same tool base could run the following bolt in and out images. Hand
split shake, rough sawn shake, slate, concrete tile etc. Saving
hundreds of thousands of dollars in tooling costs. [0088] 2.
1.sup.st ever compression molded shingle and possibly injection
molded shingle with modular tooling design allowing for quick and
efficient mold maintenance. For example after so much run time a
mold will begin to flash from wear and tear. Instead of building a
completely new tool set spending a hundreds of thousands dollars we
would actually unbolt the damaged area and replace them. So instead
of 8 weeks of having new molds made we can unbolt and bolt in quick
repairs using in stock shelf items in an afternoon with an overall
estimated cost of 5 to 10 thousand dollars for the entire tooling
set repair saving time and money. [0089] 3. 1.sup.st ever
compression molded shingle and possibly injection molded shingle
using cast image inserts. The casting process allows for true to
life imaging. This can be done using bronze, aluminum, steel or
other materials. This can also be a machined image insert verses
cast. [0090] 4. 1.sup.st ever molded shingle using a non-nail
through under tuck tab locking down the shingle corner [0091] 5.
1.sup.st ever molded shingle with lower water lock fastening
location locking down all four corners when installed. [0092] 6.
1.sup.st ever shingle panel design allowing for a solid accessory
shingle eliminating the need for fake accessories that are normally
not used with slate or shake installations making our design the
most realistic looking panel design on the market. [0093] 7.
1.sup.st ever panel design to meet all testing criteria where the
formulation can be made from 100% recycled polymer material.
[0094] Various other alternatives are contemplated as being within
the scope of the following claims particularly pointing out and
distinctly claiming the subject matter regarded as the
invention.
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