Patent Application
20240141648
This application claims priority to U.S. application Ser. No. 17/171,245, filed on 9 Feb. 2021, and Ser. No. 17/471,238, filed on 10 Sep. 2021, the disclosures of each of which are herein incorporated by reference in their entirety.
The invention further relates to a ceramic roof tile, i.e. a roof tile comprising a ceramic body, preferably made of porcelain, and to a roof covering comprising porcelain roof tiles.
US 2017/0218632, U.S. Pat. No. 10,618,156 and U.S. Ser. No. 16/100,900 disclose roof tiles having a body made of porcelain. Such kind of materials improve the weather/frost resistance and durability of the roof tile with respect to other kinds of ceramic materials like red body ceramic, for example terracotta.
In order to improve waterproofness of the roof covering said roof tile are installed above a polymeric underlayment that is disposes below each row of roof tiles in the roof covering. In practice, said row of the roof covering comprises one strip of underlayment below multiple tiles so to impermeabilize the joint between roof tiles on the same row. Anyway, the placement and securing of said underlayment provides is a time-consuming operation that slows down the roof covering installation operation.
In one aspect, the present invention provides a roof tile comprising a decorative layer, having at least a ceramic body, and a support layer disposed below the decorative layer, wherein the roof tile comprises an upper edge, a lower edge which is opposite to the upper edge and two opposite side edges, said side edges being transverse to the upper edge, the roof tile further comprising at least a first coupling element configured for being coupled to an adjacent roof tile in a roof covering and wherein said first coupling element is provided at least at one side edge of the roof tile.
In another aspect, the present invention provides a roof tile comprising a decorative layer, having at least a ceramic body, and a support layer disposed below the decorative layer, wherein the roof tile comprises an upper edge, a lower edge which is opposite to the upper edge and two opposite side edges, said side edges being transverse to the upper edge, wherein said roof tile comprises at least one anchoring element for anchoring the roof tile to a structure or framework.
In another aspect, the present invention provides a roof tile comprising:
These and other objects, features and advantages of the present invention will become more apparent upon reading the following specification in conjunction with the accompanying description, claims and drawings.
The accompanying Figures, which are incorporated in and constitute a part of this specification, illustrate several aspects described below.
To facilitate an understanding of the principles and features of the various embodiments of the invention, various illustrative embodiments are explained below. Although exemplary embodiments of the invention are explained in detail, it is to be understood that other embodiments are contemplated. Accordingly, it is not intended that the invention is limited in its scope to the details of construction and arrangement of components set forth in the following description or examples. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the exemplary embodiments, specific terminology will be resorted to for the sake of clarity.
It must also be noted that, as used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural references unless the context clearly dictates otherwise. For example, reference to a component is intended also to include composition of a plurality of components. References to a composition containing “a” constituent is intended to include other constituents in addition to the one named. In other words, the terms “a,” “an,” and “the” do not denote a limitation of quantity, but rather denote the presence of “at least one” of the referenced item.
As used herein, the term “and/or” may mean “and,” it may mean “or,” it may mean “exclusive-or,” it may mean “one,” it may mean “some, but not all,” it may mean “neither,” and/or it may mean “both.” The term “or” is intended to mean an inclusive “or.” Also, in describing the exemplary embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. It is to be understood that embodiments of the disclosed technology may be practiced without these specific details. In other instances, well-known methods, structures, and techniques have not been shown in detail in order not to obscure an understanding of this description. References to “one embodiment,” “an embodiment,” “example embodiment,” “some embodiments,” “certain embodiments,” “various embodiments,” etc., indicate that the embodiment(s) of the disclosed technology so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may.
As used herein, the term “about” should be construed to refer to both of the numbers specified as the endpoint (s) of any range. Any reference to a range should be considered as providing support for any subset within that range. Ranges may be expressed herein as from “about” or “approximately” or “substantially” one particular value and/or to “about” or “approximately” or “substantially” another particular value. When such a range is expressed, other exemplary embodiments include from the one particular value and/or to the other particular value. Further, the term “about” means within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, i.e., the limitations of the measurement system. For example, “about” can mean within an acceptable standard deviation, per the practice in the art. Alternatively, “about” can mean a range of up to ±20%, preferably up to ±10%, more preferably up to ±5%, and more preferably still up to +1% of a given value. Alternatively, particularly with respect to biological systems or processes, the term can mean within an order of magnitude, preferably within 2-fold, of a value. Where particular values are described in the application and claims, unless otherwise stated, the term “about” is implicit and in this context means within an acceptable error range for the particular value.
Throughout this disclosure, various aspects of the invention can be presented in a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have specifically disclosed subranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 2.7, 3, 4, 5, 5.3, and 6. This applies regardless of the breadth of the range.
Similarly, as used herein, “substantially free” of something, or “substantially pure”, and like characterizations, can include both being “at least substantially free” of something, or “at least substantially pure”, and being “completely free” of something, or “completely pure”.
By “comprising” or “containing” or “including” is meant that at least the named compound, element, particle, or method step is present in the composition or article or method, but does not exclude the presence of other compounds, materials, particles, method steps, even if the other such compounds, material, particles, method steps have the same function as what is named.
Throughout this description, various components may be identified having specific values or parameters, however, these items are provided as exemplary embodiments. Indeed, the exemplary embodiments do not limit the various aspects and concepts of the present invention as many comparable parameters, sizes, ranges, and/or values may be implemented. The terms “first,” “second,” and the like, “primary,” “secondary,” and the like, do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.
It is noted that terms like “specifically,” “preferably,” “typically,” “generally,” and “often” are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention. It is also noted that terms like “substantially” and “about” are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “50 mm” is intended to mean “about 50 mm.”
It is also to be understood that the mention of one or more method steps does not preclude the presence of additional method steps or intervening method steps between those steps expressly identified. Similarly, it is also to be understood that the mention of one or more components in a composition does not preclude the presence of additional components than those expressly identified.
The materials described hereinafter as making up the various elements of the present invention are intended to be illustrative and not restrictive. Many suitable materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of the invention. Such other materials not described herein can include, but are not limited to, materials that are developed after the time of the development of the invention, for example. Any dimensions listed in the various drawings are for illustrative purposes only and are not intended to be limiting. Other dimensions and proportions are contemplated and intended to be included within the scope of the invention.
The present invention aims in the first place at an alternative roof tile, of the aforementioned type, whereby, according to various preferred embodiments, solutions are offered for problems with roof tiles known in the art.
Thereto, the present invention, according to a first independent aspect, relates to a roof tile comprising a decorative layer, having at least a ceramic body, and a support layer disposed below the decorative layer, wherein the roof tile comprises an upper edge, a lower edge which is opposite to the upper edge and two opposite side edges, said side edges being transverse to the upper edge, wherein said roof tile comprises at least one first coupling element configured for being coupled to an adjacent roof tile in a roof covering and wherein said first coupling element is provided at least at one side edge of the roof tile. Preferably said roof tile comprises firsts coupling elements provided at opposite side edges. Since the first coupling elements are provided at side edges of the roof tile, they are directed of coupling each other roof tiles on the same row of roof tiles in the roof covering. In this way the joint between multiple tiles on the same row in the roof covering can be reduced or deleted thereby improving the waterproofness of the roof covering. Moreover, said impermeabilization is obtained during the installation of the roof tile without the need of any previous operation thereby improving the speed of the roof covering installation. As another advantage, easy installation is obtained, since the coupling elements may hold the roof tile in place for attaching or fastening it to the framework of the roof. Other advantages that may be obtained are improved walking resistance, improved uplift wind resistance and/or improved thermal insulation. Moreover, it is to be noted that by installing the roof tile to the supporting structure of the roof solely with the nails can cause leveling defects between roof tiles of the same row. This leveling issue can cause aesthetic defects in the roof covering and even expose the roof tiles to wind lift up. The coupling between roof tiles cause the roof tiles to be properly leveled each other.
In the context of the present application, the term “upper edge” refers the edge that in use is directed to be disposed in an upper position compared to the other edges. Said upper row is intended to be disposed substantially horizontally in the roof covering. The term “row of roof tiles” in the roof covering refers to a succession of roof tiles that are placed one beside the other along a substantially horizontal line.
Preferably, the first coupling elements can be partially or completely formed in the support layer. In this way, in case said coupling elements are destined to forming a mechanical coupling, it may be possible to manufacture and shape said coupling elements in a material that is tougher and/or more elastic, or in general showing properties that are more suitable for forming the coupling element than the ceramic material of the body. In this way the manufacturing of the roof tile can also be simplified.
The upper and lower edges as well as the opposite side edges of the roof tile may be provided with coupling elements. In particular in a preferred embodiment, the roof tile can comprise at least one second coupling element and/or at least one third coupling element. Said second coupling element and/or at least one third coupling element may be, preferably, adapted to couple an adjacent roof tile on a different row in a roof covering, more preferably and overlapping or overlapped roof tile. In particular said second coupling element is configured for being coupled with a third coupling element of an adjacent roof tile. Preferably said second and third coupling elements are disposed close to, and preferably parallel to, the lower and the upper edges of the roof tile respectively. Said second and third coupling elements can provide for a simplified installation of the roof tile since they can provide for an immediate and precise overlapping between tiles belonging to different rows in the roof covering and can help maintaining this position before fixing the roof tile to the roof structure.
In a preferred embodiment, said second coupling element can be at least partially provide on, more preferably formed in, the decorative layer, for example in the upper surface of the decorative layer. More preferably, said second coupling can be made in the ceramic body. In this way the second coupling element can provide for a very precise overlapping between roof tiles of different rows in the roof covering. For example, said coupling element can be in the form of a groove realized in the decorative layer.
Said second coupling element can be provided at a predetermined distance from the upper edge, of the roof tile, preferably of the decorative layer. In this way said predetermined position can be selected in order to minimize or maximize the overlapping the between the roof tiles. It is to be noted that large overlapping provides for higher wind uplift resistance and better impermeability of the roof covering, whereas reduced overlapping provides for lower weight on the roof covering and a reduced number of roof tile thereby reducing the cost of the roof covering and speeding up the installation. Due to the coupling, the wind uplift can be reduced and impermeability can be improved and it is generally possible to minimize the overlapping. Preferably, said predetermined distance is less than one half, more preferably less than one third, for example equal or less than 26% of the width of the roof tile, wherein the width is defined as the dimension in a direction parallel to the side edge.
It is also possible that the roof tile comprises a further second coupling element that is substantially parallel to the side edges. In this case, said further second coupling element is configured for being coupled with one of the firsts coupling element of an overlapping roof tile. This is preferably the case when the overlapping tiles, i.e., belonging to different rows in the roof covering, are disposed offset each other. In this way a precise offset positioning of overlapping tile can be achieved together with an improved impermeability. Preferably, the further second coupling element runs along a limited portion of the width of the tile, for example it runs substantially from the second coupling element to the upper edge of the decorative layer.
Said third coupling element can be provided close to, and preferably parallel to, the lower edge of the roof tile. The third coupling element can be adapted for coupling with an overlapped roof tile, i.e., with a roof tile on a different row in the roof covering that is disposed partially below the roof tile. In a preferred embodiment, the third coupling element is disposed substantially in correspondence of said lower edge. In this way the coupling of the third coupling element with the second coupling element of an adjacent tile can provide for an extremely precise positioning of overlapping roof tile. Moreover, said coupling can further limit open interspaces between overlapping roof tiles thereby improving impermeability. In a preferred embodiment, said third coupling element can be at least partially, preferably completely disposed below said decorative layer, in such a way to be hidden from external view once coupled.
In an embodiment, at least one of the opposite side edges of the support layer may extend beyond the ceramic body, for example in such a way that its associated coupling element is situated, partially or completely, beyond the ceramic body. In a preferred embodiment, both the side edges of the support layer can extend, partially or completely, beyond the ceramic body for example in such a way that their associated coupling elements are situated, partially or completely, beyond the ceramic body. In this way, during installation, coupling is simplified since the coupling elements are at least partially visible and not hidden by the ceramic body. In a most preferred embodiment, the at least one of said coupling element extends only partially beyond the edge of the decorative layer. In this way in a coupled condition, the decorative layers can be closer to each other, thereby reducing a gap between said decorative layers and improving waterproofness of the roof covering.
The roof tile can be such that in a coupled configuration of two roof tiles in the same row, an interspace is established at least between the decorative layers, preferably such that the decorative layers are placed at a determined distance each other. In this case, it is preferable that said determined distance between the decorative layer is less than 5 mm, more preferably less than 3 mm so as to not be visible from the outside. It is to be noted that said determined distance is a consequence of the configuration of the coupling element.
The aforementioned coupling elements may be performed according to one or more of the following possibilities, inasmuch these are not contradictory:
In a first preferred embodiment, the coupling elements are provided with a locking system, which, in the coupled condition of two of such roof tiles, is only active in the direction parallel to the plane of the roof covering and perpendicular to the coupled edges, which means that the mutual moving apart of two of such coupled roof tiles in said direction is limited and possibly prevented, and wherein the coupling elements are configured such that they allow to couple two of such roof tiles by means of a downward movement of one roof tile with respect to the other. In particular at least one of said coupling elements can be, for example, upward concave shaped, for example in form of an upward V-notch, or upward hook shaped, and being adapted to receive at least a portion of the coupling element of the adjacent tile by a downward movement. In this way, when they are coupled, locking surfaces are formed between the coupling elements that limit or prevent mutual moving apart of two of such coupled roof tiles a direction parallel to the plane of the roof covering.
In a first preferred embodiment, the coupling elements on opposite sides of the roof tile can have a similar shape, preferably they both have an upward concave shape, for example in form of an upward V-notch. This shape is relatively simple to manufacture and provides for a sufficient locking. Moreover, especially in case of the V-notch shape, the coupling elements can be very easy to being coupled since the inclined wall of the concave part can help insertion of one coupling element into the other.
In a most preferred configuration of the first preferred embodiment, the coupling elements on opposite sides of the roof tile can be slightly different, especially in dimension, to simplify coupling. For example, one of the two opposite coupling element can show a deeper concavity than the other. Moreover, at least one of said coupling element can extend only partially beyond the edge of the decorative layer, so that the said decorative layer partially overlaps the upward concave shape. In this way in a coupled condition, the decorative layers can be closer each other thereby reducing a gap between said decorative layers and improving waterproofness of the roof covering. In this way it is also possible that the portion of the lower surface of the decorative layer that partially overlap the coupling element, in the coupling condition, can form a locking surface that limit or prevent a mutual movement of the rooftile in a direction that is perpendicular to the plane of the roof covering.
In a second preferred embodiment the coupling elements are in form of an adhesive strip. Said adhesive is adapted to fix a portion, preferably a portion of a lower surface, of an adjacent roof tile. In this case the coupling element of one roof tile does not have to necessarily cooperate with coupling element of another roof tile. For example, the adhesive can be thermosetting adhesive or thermoplastic adhesive. In the preferred embodiment, said adhesive can be a pressure sensitive adhesive, examples of pressure sensitive adhesive are natural rubber PSA, synthetic rubber PSA, acrylic PSA, silicone PSA, blends of different polymers etc. in the preferred embodiment the adhesive is synthetic rubber based PSA. Preferably, the adhesive can be covered by a peelable sheet or lining that is adapted to be peeled off at the moment of installation. In some examples the adhesive can be a low tack adhesive to allow easy removal or substitution of a roof tile. For example adhesive can show a tensile strength lower than 1000 N/m, preferably lower than 700 N/m, even more preferably lower than 30 N/m, for example comprised between 80 N/m e 270 N/m. Said adhesive may be preferably directed upward, for example it can be provided on an upper surface of the roof tile, in particular of the support layer and/or of the decorative layer. This can be especially the case when the first coupling element and/or the second coupling element are in form of the adhesive strip. In some embodiments said adhesive strip may be directed downward, for example it is provided on a lower surface of the roof tile, in particular of the support layer and/or of the decorative layer. This can be especially the case when the first coupling element and/or the third coupling element are in form of the adhesive strip.
In this second embodiment, the extending portions of the support layer provided with the adhesive strip can be substantially flat.
Preferably said coupling elements can run, continuously or discontinuously, substantially along the whole edge of the roof tile. In this way, relative positioning of the coupling elements and installation of the roof tile can further be simplified and a water-tight seal obtained between adjacent tiles.
In case of coupling elements being present at the upper and lower edges as well as at the opposite side edges of the support layer situated below the ceramic body, the coupling elements at the upper and lower edges may be of a different type than the coupling parts at the side edges. However, in the preferred case, the coupling elements on opposite sides may show substantially the same shape and dimension, more preferably they can be slightly different, especially in dimension, to simplify coupling. For example, coupling elements on opposite sides in the form of an upward concave shape can have one coupling element slightly smaller than the other for being easily coupled together.
In some embodiments, the roof tile can comprise coupling elements adapted to form a mechanical coupling as well as coupling elements provided with an adhesive strip, e.g., a first coupling element for mechanical coupling and a second or third coupling element in the form of an adhesive strip. It is also possible that in some embodiments the coupling elements are provided by a combination of mechanical coupling and adhesive strip. For example, the coupling elements can be in the form of an upward concave shape wherein an adhesive strip is provided on a surface of the upward concave shape.
In a preferred embodiment, the support layer comprises a portion extending beyond the upper edge of the decorative layer. Said extending portion can provide for a tough portion of the roof tile that can be nailed or screwed to the roof structure so as not to cause breakage of the ceramic body. In a preferred embodiment, said extending portion is free from any attachment hole and during installation the nail or screw is forced through the support layer. In this case, as it will be explained also below, the support layer is made of a material and/or has a thickness that can be easily perforated by the nail or screw. Moreover, by attaching the nail in the support layer it is also possible to reduce the overlapping between the ceramic bodies of adjacent roof tiles, thereby reducing the load in the roof structure.
According to a preferred embodiment, said upper edge corresponds to the length, i.e., the longest edge, of the roof tile. The inventors have found that by attaching the roof tile to the roof structure close to the longest edge, the roof covering may be composed of a relatively small amount of roof tiles, thereby minimizing the number of joints present in the roof covering, in particular between roof tiles in the same row, and consequently lowers the risk of water penetration.
According to an alternative embodiment, the roof tile is provided with at least one attachment hole. Such attachment hole is used to attach or fasten the roof tile to a roof structure or framework of the roof, said framework for instance being formed by battens. The attachment hole may be preferably a through hole. As advantage, the attachment hole allows a safe and secure installation of the roof tile, for example by using nails, screws or wires. Moreover, the attachment hole allows a simple and efficient way to install the roof tile.
The attachment hole can be situated closer to the upper edge of the roof tile than to the lower edge of the roof tile. Preferably, the attachment hole can be situated at a distance from the upper edge of the roof tile, as measured in the width direction of the roof tile, which is smaller than 0.25 times the width of the roof tile. As advantage, the extent of overlap between adjacent roof tiles in subsequent rows of the roof covering may be minimized.
In this alternative embodiment, the roof tile can be provided with a multiplicity of attachment holes, for example more than 2, preferably less than 6. The inventors have found that three attachment holes provide for a good balance between the desired wind lift-up resistance and speed of installation. The attachment holes of said plurality of attachment holes can be aligned parallel to the upper edge of the roof tile.
If the roof tile comprises attachment holes, it is preferable that they are provided in the portion of the support layer that extends beyond an upper edge of the ceramic body. In this way the risk of breaking the tile during installation with nails and/or screws is reduced.
In a special embodiment, the roof tile can comprise an anchorage element for the anchorage of the roof tile to the structure or framework of the roof. Said anchorage element can comprise one or more attachment holes or can be suitable for being perforated so that the attachment hole is created during the installation. The anchorage element is adapted to provide a fixing of the roof tile in a position that is distanced from the upper edge to help keep the lower edge of the roof tile as close as possible to the structure or framework. In this way it is possible to reduce the risk of wind lift-up and of tilting of the roof tile around its upper edge. In particular due to the anchorage element that keeps down the roof tile, it may be possible to significantly improve the waterproofness of the roof covering. In fact, the inventors have surprisingly found that with the addition of the anchorage element the waterproofness can be enhanced at such a level that it can justify the absence of any underlayment below the roof tiles thereby also speeding up the installation of the roof covering.
In a preferred configuration of said special embodiment, the anchorage element can be in form of a tilting arm that can tilt around one of its ends in order to adjust its inclination with respect the plane of the roof tiles. In this way the anchorage element can be tilted to adjust its position on the structure or framework so to allow the anchoring of roof tiles having different inclinations. In fact, it is to be noted that the roof tiles are normally installed with overlap in the roof covering so that each roof tile will stay in the roof covering with an inclination that differs from that of the roof structure or framework. Preferably said anchorage element is positioned closer to the lower edge of the roof tile than to the upper edge thereof. In a preferred configuration of said special embodiment said anchorage element can be disposed at a side edge of the roof tile, in this way the anchoring element can be easily accessible by the operator and can be hidden by an adjacent roof tile after the installation.
In a preferred configuration of said special embodiment, the anchorage element can be provided in or on the support layer. Preferably, said anchorage element can be disposed close to the coupling element, in particular the first coupling element. In particular, in a preferred configuration the anchorage element can be disposed in such a way that the coupling element, preferably the first coupling element, can be disposed in or on the support layer in such a way that the coupling element is disposed between the edge of the decorative layer and the anchoring element. The inventors have surprisingly found that this disposition may lead to an improved synergy between the coupling element and the anchoring element for achieving a higher waterproofness of the floor covering. In fact, in this way the coupling element is closer to the edge of the decorative layer so to avoid infiltration of the water and the anchoring element keeps the roof tile in position so that the coupling at the coupling elements is tighter and more precise and its waterproof effect is further improved.
In an alternative embodiment, the attachment hole may be present at least in the ceramic body of the roof tile. Accordingly, for example when using nails or screws, pressure is exerted onto the ceramic body for attaching it to the roof framework. Due to the ceramic body being made of porcelain, the risk of any damage or breakage of the roof tile, resulting from that pressure, may be reduced. In this case the attachment can comprise a first portion in the ceramic body and a second portion in the support layer.
In another alternative embodiment, said support layer may be offset with respect to the decorative layer in the length direction of the roof tile and/or in the width direction of the roof tile. In this further alternative embodiment, the support layer comprises portions that extend beyond one side edge and/or beyond the upper edge (or the lower edge) of the decorative layer, whereas the decorative layer comprises portions that extend beyond the opposite side edge and/or beyond the lower edge (or the upper edge) of the support layer. In the coupled condition the extending portion of the decorative layer is intended to overlap the extending portion of the support layer. Preferably, in this further alternative embodiment the coupling elements are in the form of the adhesive strip. Alternatively, in this alternative embodiment, the roof tile can be free from coupling elements, in this case the support layer can be nailed to a supporting structure, but the extending portion may provide for sufficient impermeability.
Preferably, said support layer is made of a material different from ceramic or porcelain. The support layer may provide additional functionalities to the roof tile. As an advantage, it may be tailored, irrespective of the properties of the ceramic body. Still another advantage is that such support layer may hold together pieces or parts of the roof tile, which are damaged or broken off due to e.g., heavy wind or a hailstorm. Said support layer may thus function as a safety layer to prevent shards from falling from the roof.
In a preferred embodiment the support layer can act as a reinforcing layer or can comprise a reinforcing element or can be attached to the decorative layer through a reinforcing element. Said reinforcing element is preferably adapted to improve the toughness, or impact resistance, of the ceramic body by reducing the thickness of the decorative layer, thereby obtaining good hail resistance performance while reducing the weight of the roof tile and of the roof covering. In a preferred embodiment, the support layer can be in form of a sheet that covers all or at least the majority of the lower surface of the decorative layer. In a special embodiment the support layer may be in the form of one or more strips disposed close to one or more edges of the decorative layer.
According to preferred embodiments, the reinforcing layer may comprise a metal sheet, for example a steel or aluminum sheet attached to the lower surface of the decorative layer. Preferably, the ceramic body is compressed by the metal sheet. In this way, since the ceramic body is in a compressive state, the impact resistance is strongly improved, because the compression blocks the propagation of cracks. Moreover, even in case of a break, the compressive state helps in disguising the visual effect of superficial cracks. To achieve this goal, the metal sheet is first stretched, for example by means of a mechanical or, preferably, thermal stretching, and then is bonded to the ceramic body while the metal sheet is still in the stretched state. Subsequently, the stretch is released, by interrupting the mechanical solicitation or by cooling the metal sheet itself, thereby establishing a compressive state in the ceramic body. For example, the metal sheet has a coefficient of thermal expansion higher than the coefficient of thermal expansion of the ceramic body. Due to this solution, the reinforcing element can be heated to a stretched state, and then it is bonded to the ceramic body while it is still in the stretched state and subsequently it is cooled down to retract and put the ceramic body in compression.
Preferably the metal sheet can comprise an anticorrosion alloy, like stainless steel, or comprise an anticorrosion coating, for example of zinc, chrome, paint, glaze or a plastic film.
The metal sheet can be attached to the decorative layer with an adhesive layer. Said adhesive layer can comprise one or more glues. The resin can be a thermosetting adhesive or thermoplastic adhesive. Examples of thermosetting adhesive are epoxy, polyurethane, unsaturated polyester, vinyl ester, cyanoacrylate, reactive hot melt. Examples of thermoplastic adhesive are hot melt, polyester thermoplastic, acrylic resin, vinyl etc. in the preferred embodiment the adhesive is a reactive hot melt polyurethane glue. Anyway, it is preferred that the adhesive is provided in an amount below 150 g/sqm, preferably below 50 g/sqm.
It is noted that in some embodiments, said adhesive for fixing the support layer to the decorative layer can be the same as the adhesive strip. Preferably, said adhesive for fixing the support layer to the decorative layer can be different from the adhesive strip.
In an alternative embodiment, said support layer may be made of one materials selected from the group consisting of: a thermoplastic polymer, such as polyvinylchloride, polyethylene, polypropylene and/or polyethylene terephthalate; a thermosetting polymer, such as polyurethane; and/or an elastomer, such as rubber or a thermoplastic elastomer. In case polyethylene is used as a material for said layer, high-density polyethylene or HDPE is preferred, although the use of low-density polyethylene or LDPE is not excluded. Another preferred material for the support layer is PVC, in particular rigid PVC. The support layer may also comprise a high amount of filler materials, preferably mineral fillers such as calcium carbonate, talc, chalk, e.g., more than 30 wt % or more than 60% wt of such filler materials. The content of filler should be preferably limited to below 75 wt %, preferably below 65 wt % in order to avoid excessively increasing the brittleness of the support layer. Thereto, the support layer may preferably be made of SPC (solid polymer composite) that relates to a polymeric board, preferably in PVC, comprising solid particle filler, like limestone. If said support layer is made of a polymer, the layer may comprise one or more plasticizers. The one or more plasticizers may be present in an amount of less than 20 phr and, in this case, preferably in an amount between 5 phr and 15 phr. In this case, the support layer is of the so-called rigid type. In an alternative, the one or more plasticizers may be present in an amount of minimal 15 phr and, in this case, preferably in an amount of minimal 20 phr. In this case, the support layer is of the so-called soft type. It is to be noted that a rigid polymeric support layer is preferable to a flexible or soft polymeric support layer since it provides two main advantages. The first advantage is that due to its rigidity the support layer interacts with a reinforcing element, if any, thereby enhancing the reinforcing effect thereof. The second advantage is that a rigid support shows a limited thermal expansion coefficient that is closer to that of the ceramic body, thereby providing a higher stability to the ceramic body.
Preferably, the support layer is made a material having a flexural modulus greater than 1.5 GPa, preferably greater than 3 GPa, more preferably greater than 5 GPa, for example, approximately 8 GPa. Said flexural modulus is preferably less than 15, more preferably less than 10 GPa. The support layer may also comprise a flexural strength between 20 and 90 MPa, for example between 30 and 50 MPa. In fact, inventors have found that the rigidity of the support layer helps absorbing the impact energy thereby improving the impact strength.
In a particular embodiment, said support layer may be foamed.
According to a further alternative embodiment the support layer may be made of an inorganic material. For example, the support layer may be made of cement, for example a Portland cement board, preferably a fiber cement board. The support layer may be also made of a mineral board, like mica, magnesium oxide or other mineral boards.
Preferably the thickness of the support layer is less than 10 mm, even more preferably less than 4 mm. In the preferred embodiment of the invention wherein the support layer comprises a metal sheet, it can show a thickness less than 1 mm, preferably less than 0.7 mm even more preferably less than 0.5 mm. The metal sheet may have a thickness greater than 0.1 mm, preferably greater than 0.2 mm.
In a particular embodiment, the upper and lower surface of said support layer may converge towards each other. Advantageously, the risk of breakage or damage of the roof tile, e.g., when walking over it, may be significantly reduced. For example, the upper surface of said support layer may be substantially parallel to the lower surface of the ceramic body, whereas the lower surface of said support layer may be configured such that, in the installed condition of the roof tile, it is substantially parallel to the slope of the roof. In particular, they may converge towards each other in the direction towards the upper edge of said layer. In a particularly preferred embodiment, the lower surface of said support layer is arranged such that, in the installed condition of two of such roof tiles in subsequent rows of the roof covering, the lower surfaces of the respective layers of these two roof tiles form a generally flat surface. In other words, the transition from the lower surface of the support layer of one roof tile of these two roof tiles to the lower surface of the support layer of the other roof tile is flush or substantially flush. It is noted that in case of such converging surfaces the thickness of said support layer varies. In this case, where reference is made to the thickness of said support layer, this thickness should be interpreted as the average thickness of said support layer. The same applies to the thickness of the roof tile.
Alternatively, the support layer can comprise a supporting element that protrudes from the lower surface of the support layer, or that protrudes from the plane of the support layer. Said supporting element is configured to rest on the roof structure adjusting the inclination of the roof tile in the roof covering so that the risk of breakage or damage of the roof tile, e.g., when walking over it, may be significantly reduced. Said supporting element is preferably disposed closer to the upper edge of the roof tile than to the lower edge. Preferably said supporting element is disposed below the decorative layer. In a preferred embodiment, the supporting element runs substantially along the entire length of the roof tile. The supporting element is preferred over a support layer with converging surfaces in an attempt to reducing cost and weight. Further, the support element is more adapted than the converging surfaces solution for a support layer with low thickness like, for example, in the case of the support layer made of a metal sheet.
As mentioned above, the support layer can be fixed to the decorative layer through a reinforcing element. In a preferred embodiment, the reinforcing element comprises a resin, for example can consist of a resin. The resin can be a thermosetting resin or a thermoplastic resin. Examples of thermosetting resins are epoxy, polyurethane, unsaturated polyester, vinyl ester, cyanoacrylate. Examples of thermoplastic resins are hot melt, reactive hot melt, polyester thermoplastic, acrylic resin, vinyl etc. Preferably the resin is a rigid resin. In fact, the inventors have found that a rigid resin, rather than flexible resin, shows a higher absorption of the energy rather than flexible resin. In particular, according to a preferred embodiment of the invention the reinforcing element comprises an epoxy resin. In some embodiments of the invention, the resin is a bicomponent resin, i.e., a thermosetting resin obtained by curing a mixture of two components, namely a resin and a hardener, at a low temperature (for example at room temperature). When the two components of the resin are mixed together the curing reaction starts so that it is not necessary to activate the cure by providing external energy, like heat, UV or EB radiation. Said external energy could be optionally provided in order to accelerate the curing process.
Moreover, according to a preferred embodiment, the resin material permeates a lower surface of the decorative layer, in particular of the ceramic body, and in particular an open porosity thereof. The inventors have found that, due to this solution, the impact resistance of the roof tile is highly increased. Moreover, in this way it is possible to improve the impact resistance of the roof tile without the necessity to add further rigid or resilient reinforcing elements like a rubber layer, fiberglass or metal sheets. In fact, the resin permeating the pores of the decorative layer substantially improves the transmission and dissipation of the impact stress through the roof tile so that a lesser portion of said energy is absorbed by the decorative layer improving the impact resistance thereof. Since it is not necessary to add rigid reinforcing elements, the resulting roof tile is lighter and thinner. Moreover, the resin hinders the propagation of cracks in the decorative layer. Furthermore, in case of superficial cracks of the ceramic body, the reinforcing layer keeps the ceramic body itself coherent, and preferably compacted, thereby disguising the visual appearance of the superficial cracks.
According to a preferred aspect of the invention the resin comprises a viscosity at 20° C. less tha 1000 mPas, preferably less than 800 mPas, more preferably less than 600 mPas, for example approximately 400 mPas. Within the scope of the invention, the term “viscosity” means the viscosity of the uncured resin, for example the viscosity of the mixture of the two components before the completion of the curing, i.e., during the so-called pot life. In fact, the inventors have found that if the resin is sufficiently fluid, during its application onto the back of the decorative layer, it can permeate the pores thereof. In practice, when the resin permeates the pores of the ceramic body it substantially forms a “composite polymer-ceramic layer” that significantly improves the impact strength of the decorative layer. Moreover, due to the reinforcing layer described herein, it is possible improve the impact resistance and fatigue behavior of a relatively thin ceramic body, thereby reducing the weight of the roof tile and improving the maneuverability. According to a preferred embodiment, the resin is in a substantially liquid state during the manufacturing process of the roof tile. It is also possible that the resin is in a pasty or gel state during the manufacturing process, for example showing a thixotropic behavior, in order to reach a sufficient fluidity to permeate the pores of the decorative layer under predetermined process conditions, for example during a pressing step.
In some embodiments the resin may also show a shrinkage, after curing, between 0.5 and 15% for example between 1 and 10%. The inventors have surprisingly found that a resin showing this characteristic during its curing retires significantly. Since during curing the resin is the only component of the roof tile that shrinks, it compresses the decorative layer disposed above thereby reinforcing the ceramic body itself. This effect can be further enhanced if the resin permeates the lower surface of the decorative layer. In fact, if the resin of the intermediate layer permeates the lower surface of the decorative layer the strong bonding within the two layers helps the compressive action of the resin. Moreover, this reinforcing mechanism due to the compressive action of the resin may join the reinforcing action due to the filling of the pores and the improved stress transfer mechanism.
This compressive effect is evident by measuring the bowing of the roof tile, i.e., the planarity deviation thereof. Usually, the planarity deviation of the ceramic body is reflected in the bowing of the whole roof tile. The inventors have found that after curing of the resin the roof tile shows a planarity deviation which is higher than the planarity deviation of the sole decorative layer before application of the resin. This means that the ceramic body is compressed and reinforced. Therefore, according to a preferred embodiment, after gluing the ceramic body a planarity deviation less than 1.5 mm, preferably less than 1 mm, more preferably less than 0.8 mm. Within the context of the present application, the term “planarity deviation” is defined as the height difference between the extremal portion and the central portion of an edge of the decorative layer. In particular within the scope of the present invention the planarity deviation is measured by placing the extremes of one edge of the decorative layer, on a horizontal plane and measuring the distance between the middle of the edge from that horizontal plane. According to an embodiment of the invention, upon this compressive effect the planarity deviation of the roof tile after gluing is at least 1%, preferably at least 5%, for example at least 10% higher than the planarity deviation of the ceramic body before gluing.
The inventors have also found that preferably the resin may be free from fillers, like mineral fillers. In fact, the inventors have found that while the presence of fillers can improve mechanical properties of the resin, however the fillers also increase the viscosity of the resin thereby preventing the permeation of the decorative layer. In case of presence of said fillers, it is preferable that they are limited to less than 10% wt of the resin.
The resin preferably comprises a tensile strength between 50 and 90 MPa, more preferably between 60 and 80 MPa, for example 75 MPa. It is noted that the resin preferably comprises a compressive strength between 90 and 130 MPa, more preferably between 100 and 120 MPa, for example 110 MPa. The inventors have found that such strength is sufficient to provide a rigid matrix for the composite polymer-ceramic layer that allows dissipation of the impact energy. It is also noted that the resin may preferably show a hardness value of at least 50 measured on a Shore D scale. Preferably the resin may comprise a Young modulus comprised above 0.5 GPa, more preferably above 1 GPa. It may also be preferable that the Young modulus is below 3 GPa, more preferably below 2 GPa. For example, the Young modulus can be comprised between 1 GPa and 1.5 GPa, preferably around 1.3 GPa.
Preferably the resin covers at least a portion of the lower surface of the decorative layer, for example the majority, i.e., at least 50 percent, of the lower surface of said decorative layer. More preferably the resin covers 80 percent or more of the lower surface of the decorative layer, for example it covers 100 percent of the lower surface of the decorative layer so that the effect of distribution and dissipation of the impact energy is obtained for an impact occurring in any point of the decorative layer. The resin is preferably provided onto the lower surface of the decorative layer in an amount greater than 50 g/sqm, more preferably greater than 100 g/sqm, even more preferably greater than 150 g/sqm, for example 220 g/sqm so that the resin is in an amount that is sufficient to fully permeate the open pores of the lower surface of the decorative layer. It is also preferable that the resin is provided in an amount less than 300 g/sqm, more preferably less than 250 g/sqm.
It is also preferable that the resin is provided in an amount sufficient to overflow from said open porosity in order to act as a glue for the support layer. In other words, it is preferable that the resin partially permeates the open porosity of the decorative layer and partially coats the lower surface thereof for forming an intermediate layer between the decorative layer and the support layer and improving the transfer of energy. Said effect of transfer of energy is further improved if the support layer is directly fixed to the intermediate layer and, in particular, to said portion of the resin that coats the lower surface of the decorative layer, so that the intermediate layer acts as an adhesive layer that bonds together the decorative layer and the support.
Although according to a preferred embodiment, the reinforcing element is free from any filler or rigid element, it is possible that according to alternative embodiments the reinforcing element can comprise a rigid element for example at least partially embedded into the resin material. The rigid element may comprise fibers like glass fibers carbon fibers, polymeric fibers, for example aramid or polyamide fibers, or ceramic fibers, for example boron or silicate fibers. The fibers may be woven or non-woven fibers, for example with fibers disposed at different orientations, and may be in in form of a mat, fleece or cloth. Fillers can also comprise minerals such as calcium carbonate, talc, silica, mica, wollastonite, ash and others. If a rigid element is used, the reinforcing effect of the reinforcing layer can be caused by the sole presence of the rigid element or by a combination of the effects provided by the rigid element and the resin.
According to a preferred embodiment of the present invention the ceramic body is made of porcelain since porcelain provides for a better frost and mechanical resistance with respect to other ceramic material.
Although a ceramic body made of porcelain is preferred, that the system may alternatively comprise a roof tile having a body of a red ceramic material, clay ceramic or any other material used for roof covering, especially brittle material like, for example, natural stone or slate.
According to a preferred aspect of the invention the ceramic body may comprise, at least in correspondence of its lower surface, an open porosity adapted to allow the resin to permeate the ceramic body itself. Thus, according to a preferred embodiment of the invention, the ceramic body may comprise an apparent porosity between 0.10% and 10% determined according to ASTM C373, more preferably between 2% and 8%, for example 6%. Since, the pores of the material, especially the closed pores may represent weak points of the material itself, it is preferable that the ceramic body comprises an apparent porosity lower than 15%, preferably lower than 10% measured according to ASTM C373. Furthermore, the ceramic body may preferably have a volume of the open pores comprised between 0.01 cc (cubic centimeter) and 1 cc, more preferably between 0.10 cc and 0.90 cc, for example 0.60 cc. The abovementioned ranges and values of apparent porosity provide the optimum balance between intrinsic mechanical properties of the ceramic body and the resin permeability thereof, thereby providing the best bonding between the resin without affecting the intrinsic mechanical properties of the ceramic body. In this way the pores are big enough to be filled by the resin while at the same time they are sufficiently small to avoid compromising the mechanical properties of the ceramic body.
Preferably the roof tile further comprises a glaze coating, which is situated above said ceramic body, i.e., at least on the upper surface of the ceramic body. The glaze coating is not necessarily situated directly above the ceramic body, however, this is preferably the case. The glaze coating contributes to the overall weather and frost resistance of the roof tile, since water can mainly only be absorbed via the edges of the roof tile. Another advantage is that the roof tile, due to the presence of the glaze coating, may be provided with a variety of textures, designs and colors. Other advantages that may be obtained by the presence of the glaze coating are the prevention or at least the minimization of moss growth, easy cleanability and/or UV-resistance.
Further, according to an embodiment of the invention, the glaze coating may cover at least one edge of the roof tile, for example three edges of the roof tile. In particular, since the roof tiles are destined to be installed partially overlapping each-other, there will be always one edge, namely an upper edge, that in use will be placed below another roof tile and that consequently will not be exposed to weather and water. On the contrary the other three edges will be exposed to weather and water. By providing a glaze coating on said exposed edges the overall weather and frost resistance of the roof tile is improved. Preferably said exposed and glaze edges may be rounded or chamfered edges, for example they may be bullnose edges.
In a preferred embodiment, the glaze coating comprises a glaze layer of uniform color, which, in case of said glaze coating comprising a print, is situated below said print. Advantageously, the glaze layer of uniform color may hide imperfections in the upper surface of the ceramic body. Although the glaze layer of uniform color is preferably of a white, beige or grey color, the glaze layer may be of another color as well. In the latter case, the ink lay-up, which is needed for obtaining the desired colors in the aforementioned print, can advantageously be lowered.
Preferably, the glaze coating comprises a transparent or translucent glaze layer, which, in case of a glaze coating comprising a print, is arranged over said print. By having such glaze layer, the advantage may be obtained that the print can be protected from wear. Other advantages that may be obtained by the use of such transparent or translucent glaze layer are the minimization of moss growth, easy cleanability and/or UV-resistance. It is noted that the aforementioned glaze coating may be a so-called wet or dry glaze. In a particular embodiment, the color or appearance of the ceramic body substantially matches the color or appearance of the front face of the roof tile. Advantageously, no major color or appearance differences are visible between for example the edges of the ceramic body and the front face of the roof tile.
In a preferred embodiment, said glaze coating comprises a décor, which may simulate a natural product such as stone, natural slate or wood. In the latter case, the décor may show wood grains or wood nerves. The roof tile may have the look of a natural product such as natural slate or wood, while being provided with better weather and frost resistance than roof elements that are actually made of such materials. In a particular embodiment, said décor comprises a print. In other words, the décor, or at least part of the décor, is provided by means of a printer or printing machine. Various techniques may be used to provide said print, such as screen printing, rotary serigraphy or digital printing, the latter technique being the preferred one. In case of digital printing, an inkjet printer may be used, which may be of the single pass type. In particular, a device similar to the one disclosed in EP 1 038 689 A1 may be used, wherein each roof tile is printed separately with a single pass of the roof tile underneath the fixed print heads of the device. With such device, the possibility is offered to print in certain areas of the upper surface of the roof tile. For example, the device may be used to print multiple images, each of these images being present in respective areas of the upper surface of the roof tile. These images may be separated from each other by means of intermediate lines, transitions or edges, which are not necessarily provided by means of printing, although this is not excluded.
Preferably, the front face of the roof tile represents or forms an image of a plurality of roof tiles. In such case, the roof covering may have the appearance of a conventional one, however, with the advantage of being composed of fewer roof tiles. Because the roof covering is composed of fewer roof tiles, the overall risk of water penetration is reduced. Indeed, the number of joints present between the roof tiles in the roof covering, in which water might penetrate, may be minimized. For forming such kind of front face, a décor with multiple images may be applied, e.g., with each image representing a single roof tile. These multiple images may be provided by respectively printing in certain areas of the upper surface of the roof tile, as previously described. Thereto, a device such as the device known from EP 1 038 689 A1 may be applied. In such front face, the borders or transitions between adjacent images of roof tiles may be represented by means of a print or of a relief.
When the glaze coating is provided with a print, it is advantageous that the ceramic body substantially matches the general color or appearance of that print. Indeed, in that way, any substantial contrast between the edges of the ceramic body and the print may be excluded. For accomplishing that goal, the ceramic body may be provided with one or more color pigments. The pigments may then be chosen such that they provide the ceramic body with a color or appearance that substantially matches the color or appearance of the front face of the roof tile. It is noted that, in general, the ceramic body may be provided with one or more color pigments, irrespective of the ceramic body substantially matching the color or appearance of the front face of the roof tile.
According to an alternative embodiment wherein the roof tile comprises a ceramic body, the roof tile may be free from said glaze coating and the body may comprise a body décor. For accomplishing that goal, the ceramic body may be provided with one or more color pigments. The pigments may then be provided into the body randomly or according to a predetermined pattern or drawing. In this way the body décor may represent a natural product such as natural slate or wood. The body décor may also represent multiple images substantially in the same manner described above with reference to the glaze coating.
In an embodiment, the upper surface of the roof tile is provided with a relief, which preferably is formed by a plurality of excavations present in said upper surface of the roof tile. Due to the relief, the texture of the roof tile, at the upper surface thereof, may simulate the texture of a natural product such as stone, natural slate or wood. In the latter case, the relief may for example simulate the texture of wood grains or wood pores.
The relief or at least part of the relief may also concern one or more chamfers present at the upper surface of the roof tile, which may be provided at one or more edges of the roof tile. For example, the relief or at least part thereof may concern a chamfered perimeter of the roof tile, for example in the form of a bullnose edge. In case of a décor with multiple images, the relief may also be used to represent lines or transitions between these images. For example, these lines or transitions may be represented in the form of depressions in the upper surface of the roof tile, situated between the images. Various processes may be applied for providing the relief. Preferably, the relief is formed in the upper surface of the ceramic body, in which case the relief manifests itself through the glaze coating up to the upper surface of the roof tile. Alternatively, the relief or at least part of the relief may be formed in the glaze coating, such that it is situated substantially or completely above the ceramic body. In case of said glaze coating being provided with a print, said relief may be performed “in register” with said print, which means that the relief is in alignment with the print. By having the relief “in register” with the print, the natural look or appearance of natural products such as wood or natural slate is better simulated. For example, in case the print is a wood pattern with lines simulating wood grains, the relief may be formed by lines following the course of said lines of the printed wood pattern or by a plurality of successive dashes having a configuration following the lines of the printed wood pattern.
For having the relief being performed “in register” with the print, the techniques known from WO 2015/092745 A1 may be used.
In a particular embodiment, the lower surface of the roof tile, and in particular of the ceramic body, is flat. Particularly, said lower surface is free from any structure or comprises a relief structure having a deepness or an height less than 1 mm, preferably less than 0.5 mm, more preferably less than 0.2 mm. Due to this feature the adhesion between the ceramic body and the reinforcing layer is significantly increased.
Preferably, the thickness of the roof tile is below 10 mm, for example less than 8 mm, more preferably less than 6 mm. The thickness is preferably greater than 1 mm, preferably greater than 3 mm. In fact, due to the reinforcing layer, it is possible to reduce the thickness of the ceramic body and thus reducing weight of the roof tile itself.
In a preferred embodiment, the ceramic body forms at least 50%, more preferably at least 75%, and still more preferably at least 90% of the thickness of the roof tile. In that way, the roof tile has optimal advantage of the beneficial characteristics of porcelain.
Preferably the roof tile, may have a weight expressed in kg/sqm less than 20 kg/sqm, more preferably less than 15 kg/sqm, even more preferably less than 10 kg/sqm.
The inventors have found that the roof tile may be made relatively wide. For example, the length of the roof tile may be larger than its width. For example, the roof tile may be at least 350 mm wide and preferably at least 500 mm long. Because the roof tile may be made relatively long, the roof or roof covering may advantageously be composed of a relatively small amount of roof tiles, thereby minimizing the number of joints present in the roof covering and consequently the risk of water penetration. Within the scope of the present application the width of a roof tile is that dimension that in use is intended to be disposed horizontally, i.e., parallel to the roof ridge, whereas the length is that dimension that in use is intended to be disposed inclined according to the slope of the roof. Due to the presence of the reinforcing layer, the thickness of the ceramic body as well as the weight thereof can be reduced, and it is possible to further increase the dimensions of the roof tile, in particular the width and/or length, preferably length in such a way to further reduce the number of joints between the tiles.
It is noted that the fact that the roof tile comprises an anchoring element forms an inventive aspect that is independent from other features of the roof tiles, in particular from the presence of the coupling elements. Thereto the present invention, in accordance with its second independent aspect, the invention provides a roof tile comprising a decorative layer, having at least a ceramic body, and a support layer disposed below the decorative layer, wherein the roof tile comprises an upper edge, a lower edge which is opposite to the upper edge and two opposite side edges, said side edges being transverse to the upper edge, wherein said roof tile comprises at least one anchoring element for anchoring the roof tile to a structure or framework. Preferably the anchoring element comprises an attachment hole or is suitable to be perforated by an attachment element like a nail or a screw. It is particularly preferred that the anchoring element comprises a tilting arm that is able to tilt around one of its ends in order to adjust its inclination relative to the plane of the roof tile. It is also particularly preferred that the roof tile comprises a support layer and that the anchoring element is provided in or on said support layer. It is noted that the roof tile according to this second independent aspect can comprise one or more of the features described in relation to the first aspect.
In some embodiments, the roof tile can comprise a reinforcement hole adapted for preventing the tearing of the anchoring element apart from the support layer. Said reinforcement hole can be preferably formed in the extending portion of the support layer that extends beyond a side edge of the decorative layer, preferably close to the anchoring element not on the anchoring element itself.
In a preferred embodiment the reinforcement hole can be disposed close to the second end of the arm and in particular to an extremity of said second arm that is distal from a side edge of the support layer. Preferably, said extremity and said attachment hole, especially the center thereof, are aligned along a substantially rectilinear line that is incident but not perpendicular to the side edge of the support layer. Said line substantially defines a preferred tearing line that, being non-perpendicular to the edge, is longer than a tearing line perpendicular to said side edge, that would be the preferred tearing line without the reinforcement hole. Because of this longer tearing line, the energy required for tearing the anchoring element is higher and the anchoring element is consequently reinforced.
In some embodiments multiple reinforcing holes can be aligned along said line.
In some embodiments said reinforcement hole can be in the form of a mark of indication sign, like a drawing or indentation, instead of a real hole.
Said attachment hole can be a preferred solution for thinner support layer where risk of tearing is higher, for example for support layer made of a metal sheet with a thickness of less than 0.30 mm.
In a special and preferred embodiment, the roof tile may comprise:
The inventors have found that the combination of the anchoring element and the coupling element may provide for an optimal waterproofness of the roof covering while at the same time speeding up the installation operation. The inventors have also found that this combination is so effective in improving the waterproofness of the roof covering that it is possible to reduce the dimension of the roof tile itself, thereby increasing the number of joints between the roof tiles without affecting the waterproofness of the performances of the tile. Due to said reduction of dimension the maneuverability and the weight of the roof tile is improved as well as the speed of the installation operation. Preferably, the roof tile in this special embodiment may have a length between 150 and 500 mm, more preferably between 200 and 400 mm, even more preferably between 250 mm and 350 mm. In this special embodiment the length can also be equal or lower to the width of the roof tile.
In this special embodiment the roof tile can further comprises a support layer disposed below the decorative layer, preferably said support layer comprising at least an extending portion that extends beyond one of the edges of the decorative layer, preferably one of the side edges. Said first coupling element and said anchoring element can be provided in or on said support layer, in particular on said extending portion.
In this special embodiment, the roof tile can comprise on or more attachment hole, preferably provided in the support layer, in particular in an extending portion thereof that extends beyond the upper edge of the decorative layer.
It is to be noted that a roof covering comprising a plurality of roof tile is an independent aspect of the invention. Said roof tile can comprise one or more of the features described in relation to the first or second aspect.
With the intention of better showing the characteristics of the invention, in the following, as an example without any limitative character, several preferred forms of embodiments are described with reference to the accompanying drawings, wherein:
The roof tile 1 is mainly rectangular and, in the represented example, rectangular and oblong. Furthermore, the roof tile 1 has an upper edge 2 and a lower edge 3, whereby, in the installed condition of the roof tile 1, the upper edge 2 is directed towards the top of the roof, whereas the lower edge 3 is directed towards the bottom of the roof. Also, the roof tile 1 has two opposite side edges 4-5. The length L of the roof tile 1 is larger than its width W. The length L of the roof tile 1 may be at least 250 mm and preferably at least 500 mm. It is to be noted that the length L of the roof tile 1 correspond to an upper edge 2 and the lower edge 3, and defines that dimension that is destined to be placed horizontally in use. Consequently, the width W correspond to the side edges 4-5.
The roof tile 1 comprises a decorative layer 6 and a support layer 7 disposed below the decorative layer 6. The decorative layer 6 comprises a ceramic body 8, preferably made of porcelain, and has an upper surface 9 provided with a décor 10. In the illustrated example, said décor 10 represent a wood pattern. It is noted that the décor 10 can represent stone, slate pattern or any other kind of desired image. It is to be noted that the décor 10 is printed, more preferably digitally inkjet printed, using ceramic pigments. Advantageously, the décor 10 represents or forms an image of a plurality of roof tiles 1A-1B-1C-1D. In the example the borders or transitions 11 between the roof tiles 1A-1B-1C-1D are simulated by printed décor. Alternatively, said transition can be formed by excavations, which form part of the relief at the upper surface 2 of the roof tile 1.
In the example shown in
Furthermore, the roof tile 1 comprises first coupling elements 15, for coupling with coupling elements of an adjacent roof tiles, which are provided at the side edges 4-5 of the roof tiles 1 itself. Preferably, said firsts coupling elements 15 are provided in extending portions 16 of the support layer which extend beyond side edges 17 of the decorative layer. Said firsts coupling elements 15 extend substantially along the whole side edge 5 of the roof tile 1. In the example both the side edges 4 and 5 of the roof tile are provided with said firsts coupling elements 15.
As shown in
The upper surface 9 of the decorative layer 6 is provided with a relief, which, in the represented example, is formed by a plurality of excavations 23 present in said upper surface 9. According to the present embodiment the relief is formed in the ceramic body 8 and manifest itself through the glaze coating 20, although according to non-shown embodiments the relief may be at least partially formed directly in the glaze coating 20.
The thickness T of the decorative layer 6 is less than 12 mm, for example less than 8 mm, more preferably less than 6 mm. The thickness T is greater than 1 mm, preferably greater than 3 mm.
The support layer 7 is in the form of a metal sheet 23. Preferably, the metal sheet (or plate) 23 is made of steel. The metal sheet 23 compresses the ceramic body 8 starting from the lower surface thereof. In this way, since the ceramic body 8 is in a compressive state, a major improvement in the impact resistance is obtained. In order to achieve this goal, the metal sheet 23 is firstly tensioned (stretched or elongated) by means of a mechanical or thermal stretching action and is then arranged underneath the ceramic body 8 while it is still in the elongated state. Then the stretched condition is released, by interrupting the mechanical stress or cooling the metal sheet 23, so as to cause compression of the ceramic body 8.
According to a first preferred embodiment, the metal sheet 23 has a thermal expansion coefficient greater than the thermal expansion coefficient of the ceramic body 8. Due to this solution the metal plate 22 may be stretched by means of heating so as to expand in a substantially uniform manner in every direction. After the metal sheet 23 has been arranged underneath the ceramic body 8 it may be cooled down so as to contract and cause compression of the ceramic body 8.
The metal sheet 23 has a thickness less than 1 mm, preferably less than 0.5 mm, even more preferably less than 0.3 mm. The metal sheet 23 has a thickness A greater than 0.05 mm, preferably greater than 0.1 mm.
The metal plate 22 is attached to the lower surface of the ceramic body 8 by means of an adhesive. Said adhesive is preferably a reactive hotmelt polyurethane glue.
Preferably the metal sheet 23 is made of stainless steel, galvanized steel or comprises a coating that protects the sheet against corrosion.
As shown in
In this way in a coupled condition, the decorative layers can be closer each other thereby reducing a gap between said decorative layers and improving waterproofness of the roof covering. In this way it is also possible that the portion of the lower surface of the decorative layer that partially overlap the coupling element, in the coupling condition, can form a locking surface that limit or prevent a mutual movement of the roof tile in a direction that is perpendicular to the plane of the roof covering.
As shown in
The second locking element 28 is in form of an upwards concave groove open on the upper surface 9 of the decorative layer 6 to receive the third locking element 24 of an overlapping tile by a downward movement.
In this alternative, reinforcing element 26 comprises, preferably consists of, a resin material, for example a thermosetting resin or thermoplastic resin. Examples of thermosetting resins are epoxy, polyurethane, cyanoacrylate, unsaturated polyester, vinyl ester or acrylic resin. It is to be noted that in this example the reinforcing element 26 is constituted by the resin. Examples of thermoplastic resins are reactive hot melt, hot melt, polyester thermoplastic, vinyl etc. Preferably the resin is a rigid resin. In particular, according to a preferred embodiment of the invention the reinforcing element 26 comprises an epoxy resin. It is also preferred that the epoxy is a bicomponent resin, i.e., a thermosetting resin obtained by curing a mixture of two components, namely a resin and a hardener at a low temperature (for example at room temperature).
The resin preferably comprises a tensile strength between 50 and 90 MPa, more preferably between 60 and 80 MPa, for example 75 MPa. Moreover, the resin preferably comprises a compressive strength between 90 and 130 MPa, more preferably between 100 and 120 MPa, for example 110 MPa. It is also preferable that the resin shows a hardness value of at least 50 measured on a Shore D scale.
As illustrated the reinforcing element 26 covers the 100 percent of the lower surface of the ceramic body 8. The resin is preferably provided onto the lower surface of the ceramic body 8 in an amount greater than 150 g/sqm, more preferably greater than 200 g/sqm, for example 220 g/sqm.
As illustrated in
Thus, according to this second embodiment of the invention, the ceramic body 8 comprises an apparent porosity between 0.1% and 10% determined according to ASTM C373, more preferably between 2% and 8%, for example 6%. Furthermore, the ceramic body 8 may preferably have a volume of the open pores 27 comprised between 0.01 cc (cubic centimeter) and 1 cc, more preferably between 0.10 cc and 0.90 cc, for example 0.60 cc.
Preferably, in order to properly flow into said open pores 27 the resin of the reinforcing element 26 comprises a viscosity at 20° C. less than 1000 mPas, preferably less than 800 mPas, more preferably less than 600 mPas, for example approximately 400 mPas. Within the scope of the invention “viscosity” means the viscosity of the uncured resin, for example the viscosity of the mixture of the two components before the completion of the curing, i.e., during the so-called pot life.
In the alternative of
In the alternative of
Preferably the rigid PVC may comprise a flexural modulus between 1.5 and 3.5 GPa, for example, approximately 2.6 GPa. The support layer 30 may also comprise a flexural strength between 60 and 90 MPa, for example approximately 76 MPa.
In this alternative of a first preferred embodiment the support layer 7 can comprise a thickness less than 10 mm, even more preferably less than 4 mm.
It is to be noted that in this alternative of the first preferred embodiment the resin of the reinforcing element 26 acts as an adhesive that bonds together the ceramic body 8 and the support layer 7.
It is to be noted that the support layer 7 of this variant of the first preferred embodiment can be made of cement-based board or mineral based board like magnesium oxide board. Moreover, the support layer 7 in the variant can be a metal sheet as in the example of
The roof tiles 1 are attached or fastened to a framework (or roof structure) 29 by means of nails 30, which are put in the attachment holes 12.
The roof tiles 1 are installed in subsequent rows, of which only a few are represented in
The overlap O between the roof tiles 1 of the respective rows is less than 50%, preferably less 35%. Or, in other words, the roof tiles 1 of row 31C and 31B respectively overlap the roof tiles 1 of previous row 31B and 31A, whereby the overlap O is such that less than 35% of the roof tiles 1 of row 31A and 31B is covered by the roof tiles 1 of row 31B and 31C respectively.
Due to the coupling elements 15, 18, 19, 24 the impermeability of the roof covering is improved so that it is not necessary to place any underlayment below the roof tiles 1, thereby accelerating the installation of the roof covering 28.
Said couplings are show in
As shown in
As shown in
As shown in
It is noted that the limitation of said movement is particularly useful during installation before the roof tiles 1 are nailed to the framework 29.
In the second preferred embodiment of the invention illustrated in
The roof tile 1 shown in
Instead of being tilted the anchoring element 40 can also be deformable or can be configured in alternative ways so that the first end 42 of the arm 41 can be disposed on a plane that is different from the plane of the roof tile.
The anchorage element 40 comprises an attachment hole 12 having the same features described in relation to the previous figures. In the example, the attachment hole 12 is disposed on the arm 41 in a portion proximal to the first edge 42.
In the example, the anchoring element 40 is disposed beside the coupling element 15 so that the coupling element 15 itself is disposed between the anchoring element 40 and the edge 17 of the decorative layer 6.
Preferably the anchoring element 40 is disposed in closer to the lower edge of the roof tile 1 than to the upper edge, for example it occupies a part of the side edge of the roof tile 1 closer to the lower edge thereof.
As shown in
In this example of
The drawings are merely schematic in order to better explain the invention and they are not drawn in scale.
Further, as is clear from the content of the description, the present invention relates to one or more of the items as listed below, numbered from 1 to 64:
1.—A roof tile comprising a decorative layer, having at least a ceramic body, and a support layer disposed below the decorative layer, wherein the roof tile comprises an upper edge, a lower edge which is opposite to the upper edge and two opposite side edges, said side edges being transversal to the upper edge, wherein said roof tile comprises at least a first coupling element configured for being coupled to an adjacent roof tile in a roof covering and wherein said first coupling elements is provided at least at one side edge of the roof tile.
2.—The roof tile according to item 1, wherein said first coupling elements are at least partially formed in the support layer.
3.—The roof tile according to any of the preceding items, wherein the support layer comprises at least a portion extending beyond at least an edge of the decorative layer.
4.—The roof tile according to item 3, wherein said first coupling elements are at least partially formed in one or more of said extending portions.
5.—The roof tile according to any of the preceding items, wherein said first coupling elements are provided at opposite side edges, wherein said first coupling elements at opposite side edges have substantially the same shape, preferably are the same.
6.—The roof tile roof tile according to any of the preceding items, wherein said first coupling elements are configured to limit, preferably prevent, mutual movement between the roof tiles in a direction that is substantially parallel and/or perpendicular to the plane of the roof covering.
7.—The roof tile according to any of the preceding items, wherein said first coupling element is in the form of an adhesive strip.
8.—The roof tile according to item 7, wherein said adhesive strip comprises a pressure sensitive adhesive.
9.—The roof tile according to item 7 or 8, wherein said adhesive strip comprises natural rubber PSA, synthetic rubber PSA, acrylic PSA, silicone PSA, blends of different polymers.
10.—The roof tile according to any of items 7 to 9, wherein said adhesive strip is covered by a peelable sheet.
11.—The roof tile according to any of items 1 to 6, wherein the first coupling element is configured for forming a mechanical coupling with the coupling element of an adjacent roof tile.
12.—The roof tile according to any of the preceding items, wherein said first coupling elements comprise an upward concave shape.
13.—The roof tile according to any of the preceding items, further comprising at least a second coupling element that is at least partially provided on, preferably formed in, the decorative layer
14.—The roof tile according to item 13, wherein the second coupling element in the decorative layer is at least partially provided on, preferably formed in, an upper surface of the decorative layer.
15.—Roof tile according to item 13 or 14, wherein said second coupling element is disposed at a predetermined distance from an upper edge of the decorative layer.
16.—Roof tile according to any of items 13 to 15, wherein said predetermined distance is less than ½ of the distance between the upper edge and the opposite lower edge, preferably less than ⅓.
17.—Roof tile according to any of items 13 to 16, wherein said second coupling element in the decorative layer is in the form of a groove.
18.—Roof tile according to any of items 13 to 16, wherein said second coupling element is in the form of an adhesive strip, preferably according to any of the items from 7 to 10.
19.—Roof tile according to item 17 or 18, wherein said groove or strip of the second coupling element runs parallel to an edge of the decorative layer.
20.—Roof tile according to any of the preceding items, wherein it comprises a third coupling element, preferably configured for coupling with the second coupling element according to any of items 13 to 19 of an adjacent roof tile in the roof covering.
21.—Roof tile according to item 20, wherein said third coupling element is provided in the support layer.
22.—Roof tile according to item 20 or 21, wherein said third coupling element is in the form of a downward projection that protrudes form a lower surface of the roof tile.
23.—The roof tile according to items 20 to 21, wherein said first coupling element is in form of an adhesive strip, preferably according to any of items 7 to 10.
24.—The roof tile according to any of the preceding items, further comprising a supporting element that protrudes from the lower surface of the support layer, or that protrudes from the plane of the support layer.
25.—The roof tile according to item 24, wherein the supporting element is disposed closer to the upper edge of the roof tile than to the lower edge thereof.
26.—The roof tile according to item 24 or 25, wherein said supporting element is disposed below the decorative layer.
27.—The roof tile according to any of items 24 to 26, wherein the supporting element runs substantially along the entire length of the roof tile.
28.—The roof tile according to any of the preceding items, wherein the decorative layer is compressed by the support layer.
29.—The roof tile according to any of the preceding items, wherein the support layer comprises a metal sheet, preferably made of steel.
30.—The roof tile according to item 29, wherein the metal sheet has a thickness less than 1 mm, preferably less than 0.7 mm, even more preferably less than 0.5 mm; for example the he metal sheet may have a thickness greater than 0.1 mm, preferably greater than 0.2 mm.
31.—The roof tile according to any of the preceding items, wherein the support layer is made of a thermoplastic material, preferably PVC or PP.
32.—The roof tile according to any of the preceding items, wherein the support layer comprises a filler, preferably a mineral filler.
33.—The roof tile according to any of the preceding items, wherein the support layer has a thickness less than 10 mm, even more preferably less than 4 mm.
34.—The roof tile according to any of the preceding items, wherein the support layer is attached to the decorative layer via a reinforcing element that preferably acts as the adhesive bonding together the decorative layer and the support layer.
35.—The roof tile according to item 34, wherein the reinforcing element comprises, preferably consists of, a resin, preferably permeating an open porosity of the ceramic body.
36.—The roof tile according to any of the preceding items, wherein the support layer comprises an extending portion that extends beyond an upper edge of the decorative layer.
37.—The roof tile according to any of the preceding items, comprising one or more attachment holes, preferably provided in the extending portion of item 36.
38.—The roof tile according to item 37, wherein the attachment holes are aligned along the upper edge of the roof tile.
39.—The roof tile according to any of the preceding items, wherein the upper edge defines the length of the roof tile, preferably wherein the length is longer than the width.
40.—The roof tile according to any of the preceding items, wherein the decorative layer comprises a glaze coating of the ceramic body.
41.—The roof tile according to any of the preceding items, wherein the ceramic body is made of porcelain.
42.—The roof tile according to any of the preceding items, wherein the decorative layer comprises a décor, preferably a digitally printed décor.
43.—The roof tile according to item 42, wherein said décor imitates a plurality of roof tiles.
44.—A roof covering comprising a plurality of roof tiles according to any of the preceding items.
45.—The roof tile according to any of the preceding items, wherein said roof tile comprises at least one anchoring element for anchoring the roof tile to a structure or framework.
46.—A roof tile comprising a decorative layer, having at least a ceramic body, and a support layer disposed below the decorative layer, wherein the roof tile comprises an upper edge, a lower edge which is opposite to the upper edge and two opposite side edges, said side edges being transverse to the upper edge, wherein said roof tile comprises at least one anchoring element for anchoring the roof tile to a structure or framework.
47.—Roof tile according to item 46, wherein the anchoring element comprises an attachment hole or is suitable to be perforated by an attachment element like a nail or a screw.
48.—Roof tile according to item 46 or 47, wherein the anchoring element comprises a tilting arm that is able to tilt around one of its ends in order to adjust its inclination relative to the plane of the roof tile.
49.—Roof tile according to any of items 46 to 48, wherein the roof tile comprises a support layer and that the anchoring element is provided in or on said support layer.
50.—Roof tile according to item 49, wherein the support layer comprises at least a portion extending beyond at least an edge of the decorative layer.
51.—Roof tile according to any of items 46 to 50, wherein said roof tile comprises at least a first coupling element configured for being coupled to an adjacent roof tile in a roof covering.
52.—Roof tile according to item 51, wherein said first coupling elements is provided at least at one side edge of the roof tile.
53.—Roof tile according to item 51 or 52, wherein said first coupling element is in form of an adhesive strip.
54.—Roof tile according to item 53, wherein said adhesive strip comprises a pressure sensitive adhesive.
55.—Roof tile according to item 53 or 54, wherein said adhesive strip comprises natural rubber PSA, synthetic rubber PSA, acrylic PSA, silicone PSA, or blends of different polymers.
56.—Roof tile according to any of items 53 to 55, wherein said adhesive strip is covered by a peelable sheet.
57.—Roof tile according to any of items 51 to 56, wherein said first coupling element is disposed between an edge of the decorative layer and said anchoring element.
58.—Roof tile according to any of items 46 to 57, comprising at least one reinforcement hole in the support layer.
59.—Roof tile according to item 58, wherein said reinforcement hole, preferably the center thereof, is aligned with an extremity of an end of the anchoring element that is distal from a side edge of the support layer, said line being substantially rectilinear and incident but not perpendicular to said side edge.
60.—A roof tile that comprises:
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/015571 | 2/8/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17471238 | Sep 2021 | US |
| Child | 18263900 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17171245 | Feb 2021 | US |
| Child | 17471238 | US |
