Patent Application
20070251178
1. Field of the Invention
The present invention relates to roofing tiles.
2. Description of Related Art
The art of roofing tiles extends back over centuries involving a variety of media, such as fired clay, slate, and wood shingles. In general, tiles can be formed with a variety of shapes. For example, rectangular tiles arranged in overlapping rows are a common roofing style. Some styles include curves or angles on exposed segments and supporting areas that give the tile a three-dimensional look on a flat roof. These tiles can be formed of fired clay, cement, and metal.
Some tiles are configured with a diamond shape in which the lower axis of the diamond extends in a direction generally perpendicular to the roof line. Diamond shaped tiles involve somewhat more complex arrangements for securing and overlapping the tiles than do straightforward rectangular tiles. One such type of rectangular tile includes a generally diamond shaped flat main surface having upwardly turned flanges along its upper two diamond edges and downwardly turned flanges along its lower two diamond edges. The flanges of this tile extend in a perpendicular relation to the main surface. Considering two vertically spaced upper and lower rows of tiles according to such arrangement, the downwardly facing flanges along the lower edges of the tiles in the upper row hook over the upwardly facing flanges along the upper edges of the tile in the lower row, and connector pins are driven into the underlying roof laths through appropriately positioned openings through the tiles.
While tiles of the prior art type, as previously described, are generally satisfactory, certain disadvantages are associated with such a structure. The use of flanges which contact the surfaces of different tiles essentially at right angles tends to give a rather “blocky” or abrupt appearance to the assembled groups of tiles rather than a smooth flowing transition. The essentially perpendicular flange relationships would tend to interfere with laminar flow of wind over the roof, which create eddies and turbulence with increased wind resistance. In general, wind resistance is undesirable in a roofing system due to increases in wind noise and, in severe wind conditions over time, can contribute to the earlier loosening of tiles and reduced roof life. Reducing the wind resistance of a tile system and providing a good means of attachment to the roof deck provide better protection from high winds.
In addition, this prior art type of tile fails to compensate for structural variations of the tiles due to imprecise manufacturing techniques involved in tile making. These structural variations of the tiles can lead to difficulties in fitting tiles together due to interference fits and instances of roofers installing tiles imprecisely on the roof laths such that they are to some degree misaligned. Sometimes, the roof deck may not be perfectly flat which contributes to the alignment problem.
Another problem that can arise with tiles of this character is in connection with water that tends to run down the exposed surfaces of the tiles. Water can run under the flanges and flow in the channels defined by the space between adjacent flanges of the tiles. While such water movement cannot be entirely avoided, there should be ways to reduce the opportunity for such channeled water to pass through the roof tiles onto the underlying structure.
The present invention relates to roofing tiles intended to provide a repeating, diamond shaped, three-dimensional, streamline impression, having improved resistance to wind effects and capable of accommodating variations in the dimensions or positioning of individual tiles. The present invention further relates to an assembly of roofing tiles for a similar function and purpose.
In one aspect, the tile and tile assembly of the present invention give a roof an attractive repeating diamond pattern with a three-dimensional surface in which the edges of overlapping tiles slope together in a streamlining manner. Such a surface is intended to be visually attractive and contribute to a more laminar flow of wind over the roof to thereby reduce wind resistance and providing improved resistance to high wind tile blow off and to thereby avoid excessive noise along with enhancing the life of the roof against loosening from the effects of wind. Moreover, the tile assembly is adapted to accommodate tile imperfections and misalignments during installation and reduce opportunities for leakage of water through the roof.
In one embodiment, the tile assembly includes a set of four tiles that are adapted to connect in a repeating manner. A plurality of tile assemblies can be connected to each other in a surrounding manner to provide the roof. Each four tile assembly includes left and right center tiles, side by side with each other. Each tile has a generally diamond shaped main surface with vertically spaced upper and lower apices and a laterally spaced lateral apices. Two upper flanges extend along the upper edges of each center tile extending upwardly and outwardly at an obtuse angle from the main surface and are joined in an upper flange apex. Each center tile includes two lower flanges that extend along the lower edges of the main surface downwardly and outwardly at an obtuse angle. The tile assembly includes upper and lower tiles, of the same configuration. The upper tile fits over the adjacent upper flanges of the two center tiles while the lower tile fits beneath the adjacent lower flange of the two center tiles.
This arrangement provides a tile assembly in which the overlapping tile edges have a streamlined appearance in which the transitions between surfaces of tiles, which are at different elevations relative to each other, are blended smoothly by the intervening overlapping flanges. Thus, air flowing over relatively lower and higher tile surfaces is encouraged to flow in a more nearly laminar condition over the transitions so that eddies and other turbulence-inducing phenomena are reduced.
In another embodiment, at the lateral apex of each tile, the edges of the upper and lower flanges and of the main surface blend together to form an inflection edge extending in a plane perpendicular to the main surface. Each flange has an outer edge parallel to the main surface of the tile and a transition edge extending from the outer edge to the adjacent lateral axis of the tile. The inflection edge includes the transition edges of the upper and lower flanges, which extend above and below the main surface and the adjacent portion of the main surface. The two center tiles have inflection edges next to each other. The inflection edges reduce the disadvantageous effects of manufacturing variances or slight misalignment on the lath 190 by the installer to be easily fitted together in the installing process.
The arrangement by which the lower flange apex of the upper tile overlaps and covers the inflection edges of the center tiles makes it difficult for water to enter and pass the line of intersection of the two edges. Further, at the opposite end of each center tile, the upturned flanges at the upper end of the bottom tile are adapted to serve as a drain pan beneath the inflection edges of the two center tiles to collect water that passes through. The water can be directed over the outer surface of the bottom tile. In one aspect, the lower flange apex of the upper tile does not necessarily overlap the entire inflection edges intersection due to the streamlined lower flanges that are directly exposed to water. Reducing the gap between the inflection edge intersection and redirecting water back out onto the main surface is accomplished through the use of a lower rain gusset. The lower rain gusset fits under the lower portions of the inflection edges of two adjacent center tiles to provide additional protection against the ingress of water through the intersection of the inflection edges. To facilitate the redirection of water out from the gusset to the exposed main tile surface, an open area at the junction of the lower inflection edges at the main tile surface of the bottom tile allows water to be directed out by the gusset. This can be accomplished by rounding the end of the lower inflection edges. The gusset keeps the inflection edges of the center tiles close together and in alignment.
In still another embodiment, the upper flange of each tile, in the inflection edge region, is notched to accommodate the passage of a two headed nail so as to simplify the installation of the tiles. The two headed nails each have a shaft and a head which extends oppositely in two directions to overlap the edges of two adjacent tiles. When the connector is driven into place in the lath, its head region overlaps and grips the tile in its notched regions to hold it in place. The notch, which is oversize in relation to the size of the nail shift permit the connector to have some freedom of installation. This freedom, aided by the inflection edge itself which accommodates some misalignment of the adjacent edges of two center tiles, provides for an installation which is forgiving of structural variations in the manufacturing tolerances of tiles and accommodates some carelessness on the part of the installer in positioning the connectors when driven into the underlying layer or lath.
In one aspect, the two headed nail may include features, such as a lining to absorb shocks and to hold the upper abutting flanges together. An alternative embodiment of the flange may have an extension which interlocks with a catch underneath and a part of the top tile to further improve the wind blow off resistance and to keep the tiles aligned.
One further embodiment of the invention resides in a supplemental upper rain gusset which can be used, as an alternative embodiment. The rain gusset fits over the upper portions of the inflection edges of two adjacent center tiles to provide additional protection against ingress of water through the adjacent inflection edges to the roof.
In yet another embodiment, which can further improve wind resistance of the tile system and which provides a different appearance, the tile or tile assembly may include a narrowed tile. In comparison to the previous embodiments, the inflection edges of the narrowed tile are parallel to, but closer to the center of the tile than the previous embodiments. The main surface segment of the inflection edge allows the bottom edge flange apex to rest fully on the inflection edge. This design feature provides more wind resistance because the tip of the bottom edge flange apex is not protruding out over the lower infection edge juncture of the two center tiles. This embodiment is more applicable to thick tiles because thick tiles have a significantly more protruding bottom edge flange apex. In one aspect, this feature of the tiles allows for narrowing one or more lateral sides of the tiles to allow fitting tiles into a narrower space.
As a result of these features of the present invention, a roof built up of tile assemblies according to the invention provides a visually attractive, diamond shaped pattern having a three dimensional streamline look which is intended to have reduced resistance to wind and to be effective in moving rain off the roof with reduced intrusion of water through the roof.
Water which may be trapped behind flanges and run between channels by gravity can flow to the upper inflection edge intersection. The upper flanges here act as a dam and direct water back out toward the main surface of the lower tile. Some of this water may flow through the intersection instead of over the inflection edge junction area where it can be caught by the upper apex of the bottom tile. If the water is damned up to a sufficient degree, the underlying upper flange apex may not be directly under to act as a catch basin and this water could travel to the under roof. To protect this potential, methods of extending the upper flange apex up the roof as compared to the upper inflection edges are provided.
Other features and advantages of the invention will be apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, various features of embodiments of the invention.
Reference will now be made to the drawings wherein like numerals refer to like parts throughout.
As shown in
In one aspect, although at different relative elevations in a direction perpendicular to the plane of the roof, tiles 102, 104, 106, 108 in tile assembly 110 Blend together in a streamline contour that fosters laminar wind flow over the tiles to reduce wind resistance as compared to a tile arrangement in which overlapping flanges are substantially perpendicular to the tile surfaces 130.
To enable each tile 102, 104, 106, 108 to connect to adjacent tiles to the left, right, above, and below, each tile 102, 104, 106, 108 is provided with two upper flanges 140 and two lower flanges 142. Upper flanges 140 extend along the upper edges of main surface 130 between upper apex 132 and the lateral apices 136, 138 in an integral manner. Upper flanges 140 incline upwardly and outwardly from main surface 130 at a generally obtuse angle and join together at the upper end of each tile 102, 104, 106, 108 to form an upper flange apex 144. Lower flanges 142 incline downwardly and outwardly from the lower two edges of the main surface 130 at a similar obtuse angle, but in a downward direction. Lower flanges 142 join to form a lower flange apex 146. Upper and lower flanges 140, 142 are generally similar in height perpendicular to main surface 130 and in shape.
Each flange 140, 142 extends laterally for a first distance of approximately, for example, one-twelfth to one-half of the transverse width of main surface 130 measured in a direction perpendicular to each flange 140, 142. Each flange 140, 142 includes an outer edge 148, which is spaced from and extends generally parallel to main surface 130, and a transition edge 152, which extends between outer edges 148 and main surface 130 at lateral apices 136, 138. In one aspect, flanges 140, 142 include a radial contour as they extend out and upward or out and downward, respectively, from main surface 130 of each tile 102, 104, 106, 108.
When tiles 102, 104, 106, 108 are connected together to form tile assembly 110, the inclination of the overlapping flange of one tile to main surface 130 for the next overlapped tile provides a smooth, streamline transition due to the obtuse angles chosen. In one embodiment, the obtuse angle at which each flange extends in relation to main surface 130 into which it blends is approximately 135 degrees. However, it should be appreciated that other obtuse inclinations may be utilized without departing from the scope of the present invention. For example, obtuse inclinations within a range of approximately 110 to about 165 could be utilized. Within this range of obtuse angles and inclinations, flanges 140, 142 of adjacent tiles may overlap, as shown in
Each tile 102, 104, 106, 108 may be formed from various types of materials, such as, for example, rigid materials including fired clay or cement for a thick type or style of tile and metal or steel for a thin type or style of tile. However, each tile 102, 104, 106, 108 may be formed of other materials such as, without limitation, fiberglass reinforced plastic, cement, metal, or various types of composite materials. In one aspect, an insulating foam backed tile alternate embodiment makes the tile thicker except at the flange overlaps.
As shown in
In one embodiment, each tile 102, 104, 106, 108 of tile assembly 110 can be secured to the underlying laths 190, as shown in
When each fastening nail 170 is driven into position, the double head portions overlie and grip against the edges of upper flanges 140 to securely hold tiles 102, 104, 106, 108 against the lath. Once attached, tiles 102, 104, 106, 108 are less likely to move laterally from nail shaft 174 due to the secure attachment of another nail 170 received in an opposing notch 172 on the laterally opposite upper flange 140. Nail head 176 of nail 170 may have a softer material, such as, for example, rubber, nylon, or plastic, attached as a washer underneath to absorb shocks from weight loads for brittle tiles. Nail head 176 of nail 170 may also have a washer like attachment under head 176 that matches the contour of upper inflection edges 150 and, thus, further serves to retain tiles 102, 104, 106, 108 in position. In one aspect, nail head 176 of nail 170 may be formed of a semi-flexible material, such as, for example, brass, aluminum, or various types of soft alloys. This connector arrangement, coupled with the previously described advantage of inflection edges 150, enables tiles 102, 104, 106, 108 to be installed with some accommodation for variation in tile dimension due to the manufacturing process or misalignment by its installer. The fastener, along with securing and aligning tiles, also improves high wind blow-off resistance.
Another embodiment may incorporate an extension on the double head nail 170 or washer underneath nail head 176 of nail 170 to serve as a hold.
In general, it may be necessary that roof 120 be efficient at shedding water while resisting passage of water through roof 120 between tiles 102, 104, 106, 108 of tile assembly 110. In one aspect, referring to
In use and operation, the installer can proceed along roof 120, securing tiles 102, 104, 106, 108 of tile assembly 110 to the laths 190 of roof 120 in a continuous sequence of overlapping and underlapping tiles, whereby each tile 102, 104, 106, 108 can form at least part of tile assembly 110. Thus, roof 120 can include numerous groupings of four tile assemblies 110 disposed in the form of a diamond shaped pattern. In one aspect, each tile 100 on the assembled roof 120 includes tiles 102, 104, 106, 108 as a group with additional groups of tiles surrounding it. In one aspect, the overall effect is to provide an attractive, diamond pattern roof 120 having a streamline appearance, which is aesthetically attractive, and which contributes to reduced wind resistance. The relationship of overlapping flanges 140, 142 is also intended to provide for efficient drainage of water from the surface of roof 120 and to reduce intrusion of water through it. Also, inclusion of inflection edges 150 and oversized nail installation apertures 172 permit installation despite structural variations of tiles 102, 104, 106, 108 in the manufacturing process and inaccuracies of alignment by the installer.
In one aspect, width of narrowed tile 300 can be formed, without changing the tile angles as previously described in reference to tile 100 of
In one aspect, the closeness of abutting lower inflection edges 150 of center tiles 102, 104 and the use of lower and upper gusset 180, 182 reduces rain penetration. In high rain and wind conditions, when the tiles 102, 104, 106, 108 are structurally imperfect, placed improperly on the roof, or the roof deck is uneven, rain water may penetrate and travel behind lower flanges 142 of center tiles 102, 104. This water can flow to the upper inflection edge intersection of lower tiles 108. In this instance, the trapped water can flow back out onto the exposed outer tile surfaces or pass through the upper infection edge intersection and be caught by upper flange apex 140 of lower tile 108. Should this process of penetrated water that runs behind lower flanges 142 occur at a large number of tile upper inflection edges intersections, the amount of trapped water at the upper flange inflection edge intersection can increase due to combining with water at upper inflection edges on lower rows of tiles. There can be an large enough amount of trapped water, depending on tile thickness and roof angle, that can overwhelm the basin characteristic of the upper flange apex 144 of the lower tile 108. In general, the thinner the tile and the flatter the roof, the more susceptible a given tile design will be. However, the present invention overcomes these problems by providing gussets 182, 180 and the following features.
To reduce the vulnerability of upper flange apex 144 to being overwhelmed by water as previously described above, the distance between the middle of each tile 102, 104, 106, 108 and upper flange apex 144 can be formed longer than the distance between the mid-tile and the lower flange apex 146. Upper flange apex 144 in the following described extended basin tile is at a higher position up the roof line relative to the abutting upper flange inflection edges 150 of the center tiles 102, 104 positioned above when compared with a tile embodiment without the extended basin. This method of extending the upper flange apex 144 may take, for example, four different forms, all of which do not effect the aesthetics, finished appearance, wind resistance, or wind characteristics of the tile system.
In one aspect, the tiles edges can be joined together with the main surfaces in a tight fitting configuration with very little space between edges and between edges and main surfaces. The overlapping and underlapping flanges provide a double row of structural support. This supportive structure and the tight fit of the tile assembly provide a roof system which can withstand weight loads.
In another aspect, the tile assembly 110, as described herein, can make use of thick materials such as clay and cement, and also thin materials such as metal and composites. It should be appreciated by those skilled in the art that tiles 100, 102, 104, 106, 108 for tile assembly 110 can include multiple materials for more choice in selecting roof materials and features, such as weight of a tile system, and weight of a tile system with a snow load. Moreover, thin and thick tiles 100, 102, 104, 106, 108 in tile assembly 110 could be positioned next to each other on the same roof 120.
In still another aspect, this tight fitting feature may provide additional protection for roof 120 in the form of resistance to fire embers due to the tight fitting assembly of tiles 102, 104, 106, 108 of tile assembly 110. The underlapping and overlapping flange structural support feature provides resistance to weight loads in snow conditions and in roof maintenance. The weight load resistance can be further enhanced with use of the lath 190 when mounting the tiles and tile assembly.
In one embodiment, insulation may be molded to fit under a number of tiles to make up an assembly of tiles, with or without an embedded lath, with assembly being attached to the subroof. The assemblies may fit together closely to provide an insulated roof with an associated installation labor savings.
In one embodiment, the tiles may have solar cells embedded into them or coated onto them through various manufacturing techniques. In these tiles, the lead conductors would be in place to connect from the solar cells to the inflection edges. The inflection edge conductors would make contact to electrical connectors which in turn, bring the electrical power onto the lath. The lath would be embedded with conductors which in turn connect the tiles to the power using devices.
While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. In some instances, for aesthetic reasons, these modifications can take the form of tiles which change shape to make a pattern that involves multiple tiles. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.
The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
