Abstract:
Roof tile systems for structures are provided. A representative system ( 100 ) includes a solar panel tile ( 102 ) having a top side ( 121 ) for facing away from a structure, a bottom side ( 122 ) for facing lower side ( 126 ) for facing the downslope direction, the solar panel ( 150 ), the solar panel tile ( 102 ) having a first rib ( 131, 132, 133, 134 ) extending across the cavity ( 128 ); and a solar panel ( 150 ) mounted within the cavity ( 128 ) and supported by the first rib ( 131, 132, 133, 134 ) such that the solar panel tile ( 102 ) being a first of multiple solar panel tiles ( 102 ), with the multiple tiles being operative to engage in a side-by- side arrangement to form at least a partial course of tiles of the system ( 100 ).

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This utility application claims priority to U.S. Provisional Application 61/421,862, filed Dec. 10, 2010, the contents of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND 
     1. Technical Field 
     This disclosure relates to tiled roofing systems. 
     2. Description of the Related Art 
     Conventional tiled roofing systems are known that have met with varying degrees of success. However, these systems do little to address many modern needs associated with responsible energy usage and acquisition. 
     SUMMARY 
     Roof tiles and related systems are provided. In this regard, an exemplary embodiment of a roof tile system comprises: a solar panel tile having a top side for facing away from a structure, a bottom side for facing the structure, a left side, a right side, an upper side for facing the upslope direction and a lower side for facing the downslope direction, the solar panel tile defining a cavity sized and shaped for mounting therein a solar panel, the solar panel tile having a first rib extending across the cavity; and a solar panel mounted within the cavity and supported by the first rib such that the solar panel is flush mounted with respect to the top side of the solar panel tile; the solar panel tile being a first of multiple solar panel tiles, with the multiple tiles being operative to engage in a side-by-side arrangement to form at least a partial course of tiles of the system. 
     Another exemplary embodiment of a roof tile system comprises: a left edge tile having a top side for facing away from a structure, a bottom side for facing the structure, a left side, a right side, an upper side for facing an upslope direction and a lower side for facing a downslope direction, the left edge tile further having a left side extended portion spanning along a length of the left side of the left edge tile and extending from the top side, passed the bottom side and to a distance beyond the bottom side of the left edge tile; a field tile having a top side for facing away from a structure, a bottom side for facing the structure, a left side, a right side, an upper side for facing the upslope direction and a lower side for facing the downslope direction; a solar panel tile having a top side for facing away from a structure, a bottom side for facing the structure, a left side, a right side, an upper side for facing the upslope direction and a lower side for facing the downslope direction, the solar panel tile defining a cavity sized and shaped for mounting therein a solar panel; and a right edge tile having a top side for facing away from a structure, a bottom side for facing the structure, a left side, a right side, an upper side for facing the upslope direction and a lower side for facing the downslope direction, the right edge tile further having a right side extended portion spanning along a length of the right side of the right edge tile and extending from the top side, passed the bottom side and to a distance beyond the bottom side of the right edge tile; the left edge tile, the field tile, the solar panel tile and the right edge tile being operative to engage in a side-by-side arrangement to form at least a partial course of tiles of the system in which at least one of the tiles at least partially overlaps an adjacent one of the tiles. 
     Other systems, methods, features and/or advantages of this disclosure will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and/or advantages be included within this description and be within the scope of the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIG. 1  is a perspective view of an exemplary embodiment of a roof system. 
         FIG. 2  is a perspective, top view of an exemplary embodiment of a solar panel tile. 
         FIG. 3  is a perspective, bottom view of the solar panel tile of  FIG. 2 . 
         FIG. 4  is a partially-exploded view of the solar panel tile of  FIG. 2 . 
         FIG. 5  is a perspective, top view of an exemplary embodiment of a field tile. 
         FIG. 6  is a perspective, bottom view of the field tile of  FIG. 5 . 
         FIG. 7  is a perspective, top view of an exemplary embodiment of a right edge tile. 
         FIG. 8  is a perspective, bottom view of the right edge tile of  FIG. 7 . 
         FIG. 9  is a perspective, top view of an exemplary embodiment of a partial tile. 
         FIG. 10  is a perspective, bottom view of the partial tile of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION 
     Roof tiles and related systems are provided, several exemplary embodiments of which will be described in detail. In some embodiments, a roof tile system incorporates several different tile configurations that can be combined in various arrangements. Such tile configurations can include field tiles and solar panel tiles (which, as the name implies, mount solar panels). Additionally, right edge tiles and left edge tiles that are designed for trimming out the right and left sides, respectively, of an assembly of tiles can be provided. Notably, in some embodiments, the tiles are formed of durable weather-resistant materials and can be colored and/or textured to reduce surface temperature, which can have a detrimental effect on solar panels. 
     Referring in more detail to the drawings,  FIG. 1  is a perspective view of an exemplary embodiment of a roof system. As shown in  FIG. 1 , roof tile system  100  incorporates five types of tiles: a solar panel tile (e.g., tile  102 ), a field tile (e.g., tile  104 ), a right edge tile (e.g., tile  106 ), a left edge tile (e.g., tile  108 ) and a partial tile (e.g., tile  110 ). The tiles are arranged in a multi-course configuration, with each course being formed of tiles in a side-by-side configuration. In this embodiment, a portion of each lower course is overlapped by a portion of an upper course of tiles, and as to adjacent tiles within a course, each tile positioned to the right is overlapped by a portion of the corresponding tile positioned to its left. 
     An exemplary embodiment of a solar panel tile is shown in  FIGS. 2 and 3 , in which  FIG. 2  is a top view of solar panel tile  102  and  FIG. 3  is a bottom view. As shown, tile  102  includes a top side  121  for facing away from a support structure, a bottom side  122  for facing the structure, a left side  123 , a right side  124 , an upper side  125  for facing the upslope direction and a lower side  126  for facing the downslope direction. Prominently, tile  102  also defines a cavity  128  that is sized and shaped for mounting therein a solar panel (not shown in  FIGS. 2 and 3 ). In the embodiment shown, the cavity is an open cavity located at a central portion of the top side of the tile, with several ribs spanning across the open cavity. Specifically, two main ribs  131 ,  132  span the cavity widthwise, and two main ribs  133 ,  134  span the cavity lengthwise. Additionally, intersections of the main ribs include platforms, of which four are included in this embodiment (e.g., platform  135 ), that are sized and shaped to receive respective daubs of adhesive for bonding the solar panel to the tile. Further, a minor rib  136  spans between ribs  133 ,  134  to add rigidity and to facilitate routing of wiring associated with the solar panel. This support will help limit the bending of the solar panel in general and in case of dynamic loads. 
     Screw holes ( 137 ,  138 ) are provided to facilitate mounting of the tiles to a batten structure. In some embodiments, one or more of the screw holes can be configured an elongated slot to facilitate tile expansion and contraction. 
     Also shown in  FIGS. 2 and 3  is a vent opening  140  positioned along the lower side of the solar panel tile. The vent opening facilitates air flow into a cooling channel  142  formed beneath the solar panel. That is, the tile is designed for cooling and ventilation that gives a superior functioning of the solar panels. Notably, excessive heat reduces the efficiency of solar panels. This opening allows the wind and the air to penetrate under the solar roof tile and between the battens to cool down the solar panel element. A continuous flow of air will be created in this way that cools the solar panel temperature in order to enhance generation of electric power. 
     Additionally, the solar panel tile includes a pair of locking pins ( 144 ,  145 ) that protrude outwardly from the upper side of the tile. The locking pins are sized and shaped to mate with corresponding locking members positioned on the bottom side of tile of an overlying course of tiles. Notably, the tile  102  carries the locking members ( 146 ,  147 ) for engaging the corresponding locking pins of an adjacent tile. Each of the locking members has an aperture (e.g., aperture  148 ) formed therein for receiving a corresponding locking pin. In some embodiments, the aperture is configured as a laterally-oriented, elongated slot. In such an embodiment, the locking pin can exhibit lateral play within the slot which accommodates lateral movement of the associated tile. 
     Notably, on a side of the tile (e.g., on the right side) is a curved element  149  that is configured to cover an edge of an adjacent roof tile. As such, in an assembled configuration, adjacent tiles overlap each other in the sideways direction. This overlap protects the underlying roof structure from the natural elements such as rain, wind and sun. 
     As shown in  FIG. 4 , a solar panel  150  is mounted within the cavity and supported by the ribs. In this embodiment, the solar panel is flush mounted with respect to the top side of the solar panel tile when mounted. Also shown in  FIG. 4  are raised drip barriers  152 ,  154  that are used to direct water about the surface of the tile to reduce the opportunity for water to flow under a neighboring tile. Once assembled, the drip barriers are positioned under the curved element of an adjacent tile. 
     In some embodiments, the width and length of a representative tile is determined by the size of a broken up solar cell. Broken up cells are high performing cells that produce more electric power than full cells. 
     An exemplary method for securing a solar panel to a tile involves using bonding material (e.g., polymer or silicone bonding glue). For instance, before placing bonding material, a plasma treatment is applied to the cavity and bonding surfaces to activate the molecules. This process allows the molecules to react better with the bonding material. 
     In one such process, within 2 minutes after applying plasma, a bonding paste of approximately 150 grams per solar roof tile is injected on the bonding surfaces of the opening to hold the solar panel. The bonding material is 2 components and is water resistant and also resists extreme temperatures of −40 Celsius (−38 Fahrenheit) freezing and heats up to +85 Celsius (+185 Fahrenheit) this according to German normalization for solar roof tiles. German normalization is the world standard for solar panels and solar roof tiles. In other embodiments, various other amounts and/or types of bonding material (e.g., a single component material) can be used. 
     Preferably, the bonding is able to expand and shrink under these extreme temperatures. The bonding also preferably resists dynamic concentrated pressures of hail and a human stepping on the solar roof tile and solar panel. 
     The solar panels are made to resist the natural elements and occasional pressures. The top layer of the solar panel is preferably made of laminated glass that allows light penetration in the best condition to produce electric power. 
       FIGS. 5 and 6  depict an exemplary embodiment of a field tile  104 , with  FIG. 5  being a top view of the tile and  FIG. 6  being a bottom view. As shown, tile  104  includes a top side  221  for facing away from a support structure, a bottom side  222  for facing the structure, a left side  223 , a right side  224 , an upper side  225  for facing the upslope direction and a lower side  226  for facing the downslope direction. Tile  104  also includes a vent opening  230  positioned along the lower side of the tile to facilitate air flow into a cooling channel  232  formed beneath the tile. 
     Additionally, tile  104  includes a pair of locking pins ( 234 ,  235 ) that protrude outwardly from the upper side of the tile. The locking pins are sized and shaped to mate with corresponding locking members positioned on the bottom side of tile of an overlying course of tiles. In some embodiments, the pins are T-shaped and long enough to allow vertical movement of the roof tiles. Thus, each roof tile can move up or down or top to bottom under limited measurements. This may be needed when calculating a roof to determine the number of roof tiles needed from top to bottom. By moving the roof tiles more outward or inward on the pins, cutting of roof tiles can be limited because the tiles are still secured to one another across a range of variable widths and lengths. 
     Notably, the tile  104  carries the locking members ( 236 ,  237 ) for engaging the corresponding locking pins of an adjacent tile. Each of the locking members has an aperture (e.g., aperture  238 ) formed therein for receiving a corresponding locking pin. In some embodiments, the aperture is configured as a laterally-oriented, elongated slot. In such an embodiment, the locking pin can exhibit lateral play within the slot which accommodates lateral movement of the associated tile. 
     In some embodiments, the characteristics of the pin are also to allow roof tiles to be placed under an angle of 5%. Practical example: the bottom 3 roof tiles are tilted up 5% on the end of a roof structure sometimes done on ranch homes. The T-shaped pin can be partially cut off on the bottom so the roof tiles can end up in an angle and still hold the roof resistant against the wind. It should be noted that the two types of roof tiles previously described, the solar panel tile and the field tile, can use the same technique of roof tile pins and apertures as locking systems. 
     As best shown in  FIG. 6 , a tile can incorporate a roof tile tape ( 240 ) that can be used as an aid to cut roof tiles to desired dimensions. 
       FIG. 7  is a perspective, top view of an exemplary embodiment of a right edge tile  106 , with  FIG. 8  showing the bottom view of the tile. As shown, tile  106  includes a top side  321  for facing away from a support structure, a bottom side  322  for facing the structure, a left side  323 , a right side  324 , an upper side  325  for facing the upslope direction and a lower side  326  for facing the downslope direction. Tile  106  also includes a vent opening  330  positioned along the lower side of the tile to facilitate air flow into a cooling channel  332  formed beneath the tile. Notably, tile  106  also includes a right side extended portion  333  spanning along a length of the right side of the right edge tile, with the right side exhibiting a cylindrical shape along the top side of the tile. This extended portion extends from the top side, passed the bottom side and to a distance beyond the bottom side of the right edge tile. So configured the right edge tile is adapted to end a course of tiles by being the last tile of the course on the right hand side, with the extended portion acting to finish the course by partially covering the side of the batten structure to which the tile is attached in some embodiments. 
     Additionally, tile  106  includes a pair of locking pins ( 334 ,  335 ) that protrude outwardly from the upper side of the tile. The locking pins are sized and shaped to mate with corresponding locking members positioned on the bottom side of tile of an overlying course of tiles. In some embodiments, the pins are T-shaped and long enough to allow vertical movement of the roof tiles. Thus, each roof tile can move up or down or top to bottom under limited measurements. This may be needed when calculating a roof to determine the number of roof tiles needed from top to bottom. By moving the roof tiles more outward or inward on the pins, cutting of roof tiles can be limited because the tiles are still secured to one another across a range of variable widths and lengths. 
     Notably, the tile  106  carries the locking members ( 336 ,  337 ) for engaging the corresponding locking pins of an adjacent tile. Each of the locking members has an aperture (e.g., aperture  338 ) formed therein for receiving a corresponding locking pin. In some embodiments, the aperture is configured as a laterally-oriented, elongated slot. In such an embodiment, the locking pin can exhibit lateral play within the slot which accommodates lateral movement of the associated tile. 
     A left edge tile (e.g., tile  108 ) can be configured as a mirror image of tile  106  in some embodiments. 
       FIG. 9  is a perspective, top view of an exemplary embodiment of a partial tile, with  FIG. 10  showing the bottom view of the tile. As shown, tile  110  includes a top side  421  for facing away from a support structure, a bottom side  422  for facing the structure, a left side  423 , a right side  424 , an upper side  425  for facing the upslope direction and a lower side  426  for facing the downslope direction. Tile  106  also includes a vent opening  430 . 
     Additionally, tile  110  includes a pair of locking pins ( 434 ,  435 ) that protrude outwardly from the upper side of the tile and locking members ( 436 ,  437 ) for engaging the corresponding locking pins of an adjacent tile. 
     In some embodiments, the partial tile has a width that is half the width of a field tile. Notably, availability of partial tiles can reduce cut that need to be made onsite for assembling a roof tile system. 
     Roof tiles can be formed of various materials and by various techniques. In some embodiments, high pressured injection technologies with colored polypropylene mixed and strengthened with glass fibers are used. Additionally, the surface of a tile can be is flat with a microscopic structured surface. This can be configured to reduce sun reflection and prevent excessive surface temperatures. A UV resistant factor can also be included with or without a color master badge. 
     It should be emphasized that the above-described embodiments are merely possible examples of implementations set forth for a clear understanding of the principles of this disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the accompanying claims.