Patent Publication Number: US-9416540-B2

Title: Dual-arch roof tile

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/909,791, filed Nov. 27, 2013, which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to roofing or siding tile systems for attachment to mounting surfaces. 
     BACKGROUND 
     Natural slate tiles may be used as roofing shingles or siding tiles. These tiles are often hand-split from larger sheets or blocks of slate and may require specialized tools and expert craftspeople. Slate shingles provide enhanced aesthetics as a roofing material. Other natural stone or manufactured stone materials may be used to create similar roofing tiles. 
     SUMMARY 
     An injection-molded tile for attachment to a mounting surface is provided. The tile is generally attached via at least one fastener. The tile includes a body having a face side opposite the mounting surface and an underside adjacent to the mounting surface. 
     A plurality of first-angle ribs and a plurality of second-angle ribs are formed on the underside of the body. The first-angle ribs are disposed at a first offset angle relative to a forward edge of the body, and the second-angle ribs are disposed at a second offset angle relative to the forward edge of the body. The first-angle ribs and second-angle ribs do not have shared vertices and the second offset angle is different from the first offset angle. 
     The injection-molded tile may be movable between an uninstalled position and an installed position. In the uninstalled position, the body defines a first offset along a longitudinal length between the body and the mounting surface. In the installed position, the body is biased against the mounting surface by the fastener to substantially close the first offset, such that the underside of the body abuts the mounting surface. 
     The above features and advantages, and other features and advantages, of the present subject matter are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the disclosed structures, methods, or both 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic isometric view of roof tiles usable to create a roofing system on a mounting surface; 
         FIG. 2  is a schematic side view showing a longitudinal span of one of the roof tiles shown in  FIG. 1 ; 
         FIG. 3  is a schematic front view showing a transverse span of one of the roof tiles shown in  FIG. 1 ; 
         FIG. 4A  is a schematic side view of the roof tile outline in an uninstalled position; 
         FIG. 4B  is a schematic side view of the roof tile outline in an installed position, in which a fastener biases the roof tile against the mounting surface; 
         FIG. 5  is a schematic bottom view of the roof tile, illustrating a rib structure having elongated, filleted diamonds; and 
         FIG. 6  is a schematic top view of the roof tile illustrating texture simulating natural slate. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings, like reference numbers correspond to like or similar components wherever possible throughout the several figures. There is shown in  FIG. 1  a roofing system  8  formed from at least one roof tile  10 . In  FIG. 1 , a plurality of the roof tiles  10  are arranged in a first course  10 A, a second course  10 B, and a third course  10 C to create the portion of the roofing system  8  shown. The roof tile  10  is schematically illustrated with a y-axis  12  and an x-axis  14 . In most installations, the y-axis  12  will be oriented with the slope of a mounting surface  16  and the x-axis  14  will be substantially perpendicular to the slope of the mounting surface  16 , such that the x-axis  14  is at a single elevation. 
     The mounting surface  16  may be a sloped or angled roof. The roof tile  10  may be attached to the mounting surface  16  with at least one fastener  18  (not shown in  FIG. 1 , viewable in  FIG. 4B ), which may be, for example and without limitation, a nail, a screw, or a staple. 
     Note that the roof tile  10  shown may also be used as siding along a vertical, or substantially-vertical, wall. The principles of operation and benefits described herein apply to both roof and siding applications. 
     While the present invention may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the invention. Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” et cetera, are used descriptively of the figures, and do not represent limitations on the scope of the invention, as defined by the appended claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the invention in any way. 
     Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description. 
     The roof tile  10  is formed from a body  20 , which is a substantially-continuous component and may be formed from different types of plastic or composite materials. The body defines a vertical or longitudinal length along the y-axis  12  and a horizontal or transverse width along the x-axis  14 . The y-axis  12  is generally oriented along the portion of the mounting surface  16  having vertical or elevational change. The span of the y-axis  12  may also be referred to as the longitudinal arch and the x-axis  14  may also be referred to as the transverse arch. 
     As will be described herein, the body  20  is movable between an uninstalled position (as illustrated in  FIGS. 2, 3, and 4A ) and an installed position (as illustrated in  FIG. 4B ). Generally, in the uninstalled position, the roof tile  10  has both transverse and longitudinal concavity-creating gaps or offsets from the mounting surface  16 . The body  20  is capable of elastic deformation between the uninstalled position and the installed position. 
     A forward edge  22  of the body  20  is on the downward side or lower portion of the roof tile  10 , relative to the mounting surface  16 . A rearward edge  24  is the upward side or higher portion of the roof tile  10 , relative to the mounting surface  16 . The rearward edge  24  may be chamfered toward the mounting surface  16 . 
     The roof tile  10  shown generally emulates slate or stone roofing tiles, even though it is formed from polymeric materials. However, the roof tile  10  may emulate other materials, such as wood shingles or clay tiles, without changing the functional and aesthetic benefits described and shown herein. 
     As shown in  FIG. 1 , the body  20  has a face side  25 —opposite the mounting surface  16 —with a textured surface  26  spreading from the forward edge  22  toward the rearward edge  24 , such that the roof tile  10  emulates the texture and grain found on natural slate. One or more non-linear edges  28 , such as the sides, further provide texture and improve the aesthetics of the roof tile  10 . The forward edge  22  may also be non-linear, which may further assist in emulating the look and feel of natural slate tiles. 
     Note that only one of the roof tiles  10  shown in  FIG. 1  is illustrated with the textured surface  26  and the non-linear edges  28 , while the remainder of the roof tiles  10  are shown with substantially smooth surfaces and linear or arced edges. The textured surface  26  and the non-linear edges  28  may not be illustrated in other figures. In many configurations of the roofing system, the roofing tiles  10  will have numerous different textures or patterns of the textured surface  26 . Therefore, several, if not all, of the roof tiles  10  will have different aesthetic looks. 
     One or more fastener points  32  are marked on the roof tile  10 , such as through indentations, molded features, or ink. The fastener points  32  help an installer identify locations through which the one or more fasteners  18  should be driven into the mounting surface  16 . 
     The body  20  further includes or defines a center mark  34  at the rearward edge  24 . The body  20  may also include or define one or more length marks  36 , which may be used in conjunction with chalk lines on the mounting surface  16  to vertically locate the roof tile  10  relative to other roof tiles  10 . 
     One typical installation method involves laying a first course  10 A of roof tiles  10  horizontally along the lower edge of the mounting surface  16 , such that the forward edge  22  is substantially parallel with the lower edge of the mounting surface  16 . Additional roof tiles  10  are arranged within the first course  10 A as illustrated in  FIG. 1 . Then, a second course  10 B of the roof tiles  10  are aligned above the first course  10 A, such that the forward edge  22  of the roof tiles  10  in the second course  10 B covers the fastener points  32  of the roof tiles  10  within the first course  10 A. Additional courses, such as a third course  10 C, may then be assembled to the mounting surface  16  above the previous course. 
     Generally, the subsequent course is horizontally offset by approximately one-half the width of the roof tiles  10 . Note that the non-textured portion effectively becomes part of the mounting surface  16  for the subsequent roof tiles  10 . In some installations, an underlayment layer may be placed between the mounting surface  16  and the roof tiles  10 . 
     As used herein, the term substantially refers to quantities, values, or dimensions that are within manufacturing variance or tolerance ranges of being exact or that are subject to human error during installation. Substantially equal dimensions, for example, may be planned as ideally equal but normal manufacturing tolerances may cause the resulting dimensions to vary by 10-20% for different pieces. 
     During installation of the roof tile  10 , the installer places the roof tile  10  onto the mounting surface  16 . At this point, the roof tile  10  is in the uninstalled position and both the longitudinal arch and the transverse arch are visible as camber away from the mounting surface  16 . The installer then flexes the body  20  against the mounting surface  16  to remove the camber and drives the fastener  18  through the body into the mounting surface  16 . Alternatively, the installer may simply drive the fastener  18  through the body  20  until the head of the fastener  18  is flush with the body  20  and the body  20  is flush with the mounting surface  16 . 
     Referring now to  FIG. 2  and to  FIG. 3 , and with continued reference to  FIG. 1 , there are shown two additional, schematic, views of the roof tile  10 .  FIG. 2  shows the roof tile  10  from the side to illustrate the y-axis  12  or the longitudinal span.  FIG. 2  shows the roof tile  10  from the front to illustrate the x-axis  14  or the transverse span. Both  FIG. 2  and  FIG. 3  show the roof tile  10  in its uninstalled position, such that the dual arches of the roof tile  10  are viewable. 
     As shown in  FIG. 2 , the body  20  has a forward thickness  42  at the forward edge  22  and a rearward thickness  44  at the rearward edge  24 . In the configuration illustrated in figures, the forward thickness  42  is greater than the rearward thickness  44 , such that the roof tile  10  is sloped or wedge-shaped. However, the forward thickness  42  and the rearward thickness  44  may be substantially equal or may have varying degrees of front-to-back drop. 
     In the uninstalled position, the body  20  has or defines a first offset  46  along the longitudinal length or vertical span of the roof tile  10 . The first offset  46  creates a gap or space between the body  20  and the mounting surface  16 , as shown in  FIG. 2 . 
     In the uninstalled position, the body  20  has or defines a second offset  48  along the transverse width or horizontal span of the roof tile  10 . The second offset  48  creates a gap or space between the body  20  and the mounting surface  16 , as shown in  FIG. 3 . Therefore, portions of an underside  50  of the roof tile  10  are not in contact with the mounting surface  16  while the roof tile  10  is in the uninstalled position. The underside  50  is the opposing side of the body  20  from the face side  25 , which includes all of the portions generally viewable in  FIG. 1 . 
     Referring now to  FIG. 4A  and to  FIG. 4B , and with continued reference to  FIGS. 1-3 , there are schematic outline views of the roof tile  10  to illustrate both the uninstalled and the installed positions.  FIG. 4A  schematically shows an outline of the roof tile  10  in the uninstalled position from a similar viewpoint to that shown in  FIG. 2 .  FIG. 4B  schematically shows the same viewpoint as  FIG. 4A , but illustrates the roof tile  10  in the installed position with the fastener  18  biasing or driving the body  20  against the mounting surface  16 . 
     Comparing  FIG. 4A  with  FIG. 4B , the fastener  18  is driven through the body  20 —at the fastener points  32 —to place the roof tile  10  into the installed position. The body  20  is biased against the mounting surface  16  by the fastener  18  to substantially close the first offset  46 . Furthermore, although not viewable in  FIG. 4B , the second offset  48  is also closed in the installed position. 
     Therefore, the body  20  abuts the mounting surface  16  and the underside  50  of the body  20  is substantially planar, as opposed to the dual arches of the uninstalled position. The roof tile  10  must be sufficiently flexible to allow the fastener  18  to bias the body  20  without fracturing any portions thereof. However, the roof tile  10  may be sufficiently rigid to retain some resistance to force applied to the body  20  and feel more like actual slate tile. 
     The uninstalled position may actually be further divided into an as-molded shape and a sagging shape. Generally,  FIGS. 1-3  illustrated the roof tile  10  in the as-molded shape. The molds (not shown) used to form the roof tile  10  define both longitudinal and transverse arches into the body  20 . 
     For example, the as-molded shape of the roof tile  10  may include arches defining the first offset  46  of up to approximately 0.375 inches and the second offset  48  of up to approximately 0.125 inches. The longitudinal length may be approximately 16 inches and the transverse width may be approximately 12 inches. Therefore, with the maximum respective offsets suggested above, the ratio (offset distance to span distance) of the longitudinal arch would be approximately 43 and the ratio of the transverse arch would be up to approximately 96. 
     However, when the roof tile  10  is removed from the mold, the weight of the body  20  may cause sagging by varying amounts, depending on: the materials used to form the roof tile  10 , the size of the first offset  46  and the second offset  48 , the longitudinal and transverse spans of the body  20 , and any deformation resulting from storage or transport of manufactured roof tiles  10 . The sagging shape may also be referred to as a resting shape or relaxed shape. 
     In the sagging position, for example, the body  20  may deflect enough to substantially close the second offset  48 , such that the transverse arch may not be viewable when the roof tile  10  is resting on the mounting surface  16  or a planar surface. However, the lack of arch is a result of deformation away from the arch defining the second offset  48  in the as-molded shape. 
     In the installed position, the fastener  18  is reacted by the body  20  at, or around, the fastener points  32 . However, the reaction forces between the mounting surface  16  and the body  20  are substantially at the corners of the body  20 , as illustrated by reaction arrows  52 . 
     Therefore, the roof tile  10  having the as-molded dual arches is pressing its corners against the mounting surface  16 . Contrarily, a tile that is molded completely flat would be pressing against the mounting surface  16  at or around the fasteners  18 . This may allow the corners of such a flat tile to curl away from the mounting surface slightly. 
     As illustrated in  FIG. 4B , wind shear (illustrated by arrow  54 ) may provide an upward force on the roof tile  10 , such as at the forward edge  22 . The upward force of wind creates a moment between the front edge  22  and the fastener  18 . However, the roof tile  10  counteracts this moment as a result of biasing the body  20  to close the first offset  46 . Contrarily, a flat tile would not have any counteract moment, and the front edge thereof may lift away from the mounting surface  16  in heavy winds. 
     Referring now to  FIG. 5 , and with continued reference to  FIGS. 1-4B , there is shown a bottom or underside view of the roof tile  10 . The non-linear edge  28  is viewable in  FIG. 5 . The non-linear edge  28  imparts additional visual texture to the roof tile  10  and further emulates natural slate tiles. 
     In some configurations of the roof tile  10 , the body  20  may include a plurality of ribs  60 , as best viewed in  FIGS. 5 and 5B . The ribs  60  may reduce the overall weight of the roof tile  10 , relative to a solid body, while maintaining engineered structural characteristics. The ribs  60  may define a portion of the underside  50 , such that moving the roof tile  10  from the installed to the uninstalled position includes closing the gap between the ribs  60  and the mounting surface  16 . 
     The roof tile  10  may include at least one longitudinal rib  62 , or cutting rib. The configuration shown in  FIGS. 5 and 5B  includes three longitudinal ribs  62 —one located substantially at the center and two further toward the edges of the roof tile  10 . The longitudinal ribs  62  allow the roof tile  10  to be cut vertically during installation and then installed to the mounting surface  16  without showing any of the gaps between the body  20  and the mounting surface  16 . For example, when offsetting the second course of roof tiles  10 , the installer may cut the first roof tile  10  in the second course in half by removing material to the left (as viewed in  FIG. 5 ) of the central longitudinal rib  62 . However, without the longitudinal rib  62 , caverns or gaps may be visible from the edge of the mounting surface  16  (i.e., from the side of the roof). 
     The other two longitudinal ribs  62  (nearer the left and right edges) may also assist in installation by providing cut lines for the last roof tile  10  in the course. The longitudinal ribs  62  create both beginning and ending cut lines that allow the roof tiles  10  to be offset, and to be installed on different width roofs, without exposing visible gaps at the ends of the mounting surface  16 . Note that the longitudinal ribs  62  are flush with the mounting surface  16  when the roof tile  10  is in the installed position. Additionally, the longitudinal ribs  62  extend from the front edge  22  toward the rear edge  24 , and extend vertically at least as far as any of the other ribs  60 . 
     The roof tile  10  includes a plurality of first-angle ribs  64 , which are angled relative to the y-axis  12  and to the x-axis  14 , and also relative to the forward edge  22 , as illustrated by a first offset angle  65 . The roof tile  10  also includes a plurality of second-angle ribs  66 , which are angled relative to the first-angle ribs  64 , the y-axis  12 , and the x-axis  14 , as illustrated by a second offset angle  67 . In the orientation of  FIG. 5 , the first-angle ribs  64  are generally angled from the upper left toward the lower right, and the second-angle ribs  66  generally angled from the upper right toward the lower left. 
     The first-angle ribs  64  and the second-angle ribs  66  cooperate to form or define an elongated diamond pattern. However, unlike some diamond patterns, the intersections of which form a continuous and repeating “X,” the first-angle ribs  64  and the second-angle ribs  66  do not have shared vertices. As used herein, a shared vertex refers to a single point at which two or more ribs intersect. For example, in the typical X-pattern, four ribs intersect at a shared vertex. 
     Furthermore, in the roof tile  10  shown, neither the first-angle ribs  64  nor the second-angle ribs  66  align with each other to form continuous lines. Adjacent first-angle ribs  64  are not collinear, such that there is an offset  69  between adjacent first-angle ribs  64 . Similarly, adjacent second-angle ribs  66  are not collinear and have an offset (unnumbered) there between. Therefore, there is a space of several elongated diamonds before any of the first-angle ribs  64  or the second-angle ribs  66  align. 
     The first-angle ribs  64  and the second-angle ribs  66  also join to form a plurality of filleted or radial intersections  68 . These radial intersections are arced or curved transitions between the first-angle ribs  64  and the second-angle ribs  66 , as opposed to abrupt points or sharp transitions. In the orientation shown in  FIGS. 5A and 5B , the radial intersections  68  are at the bottom of the elongated diamonds (with the exception of the uppermost diamonds). The radial intersections  68  prevent points at the vertices or intersections of the first-angle ribs  64  and the second-angle ribs  66 . Points or sharp intersections may provide tear initiation or tear propagation cites for the roof tiles  10 . 
     As illustrated in the figures, the ribs  60  substantially contact the mounting surface  16  when the roof tiles  10  are installed to the mounting surface  16 , although some slight offsets may exist. Therefore, there are substantially no continuous channels or passageways through which gases or liquids could flow upward or downward between the body  20  and the mounting surface  16 . The elongated diamond pattern formed by the first-angle ribs  64  and the second-angle ribs  66  breaks up all such pathways. 
     The ribs  60  shown provide improved strength characteristics in resisting wind loads. Furthermore, the ribs  60  may exhibit improved response to hail, or other storm impacts. As viewed in  FIG. 5 , the underside of the body  20  may also include a reinforcement rib  70  adjacent one or more of the fastener points  32 . The reinforcement rib  70  may help prevent the fastener  18  from being over-driven, fracturing the roof tile  10 , or both. 
     Referring now to  FIG. 6 , and with continued reference to  FIGS. 1-5B , there is shown a top or face view of the roof tile  10 . The roof tile  10  shown is formed from injection molding as a single, continuous, and unitary component. There are no seams or portions of the roof tile  10  where two separately made components are later joined or fastened. Other molding or manufacturing processes may be used to form the roof tile  10 . 
       FIG. 6  further illustrates the textured surface  26  and the non-linear edges  28  of the roof tile  10 . The approximate border or edge of the textured surface  26  is shown in dashed lines. Note that the textured surface extends substantially to the left and right edges of the roof tile  10 , such that no smooth surface should be visible in the keyways formed between installed roof tiles  10 . In the configuration shown, the textured surface  26  extends to within at least one inch of the left and right sides or edges of the roof tile  10 , and also to within at least one inch of the rearward edge  24 . 
     The injection molding process occurs in a mold as polymeric or composite materials are injected into the mold at an offset injection point  72 . In the configuration shown, a sprue injects the materials perpendicularly into what will become the face side  25  of the roof tile  10 . As illustrated in  FIG. 6 , the offset injection point  72  is above the fastener points  32 , such that it is also above the overlap line for the subsequent course of roof tiles  10 . 
     Furthermore, the offset injection point  72  is also offset to either the left or the right (as viewed in  FIG. 6 ) of the center mark  34  and the center line of the roof tile  10 . Therefore, the offset injection point  72  will not be visible once subsequent courses of roof tiles  10  are installed, as the keyway formed between subsequent roof tiles  10  will not expose the offset injection point  72  to view, which may be aesthetically displeasing. 
     The roof tile  10  also includes an injection area  74  surrounding the offset injection point  72 . The injection area  74  is textured, as opposed to smooth. This may be accomplished via post-injection processes, such as abrasion. Alternatively, the roof tile  10  may be formed in a mold with a textured injection nozzle, such that the texture is imparted during the injection molding process. 
     If the injection area  74  were smooth, portions of a non-textured area may be viewable through the keyways formed by subsequent courses of tiles, particularly if the injection point  72  is not sufficiently offset from the center of the roof tile  10 . Furthermore, the textured injection area  74  shown may improve the in-hand aesthetics—before the roof tiles  10  are actually installed to the mounting surface—of the roof tiles  10  by minimizing a visible remnant of the manufacturing process. 
     The detailed description and the drawings or figures are supportive and descriptive of the structures and methods disclosed herein. While some of the best modes and other embodiments for carrying out the claimed structures and methods have been described in detail, various alternative designs, configurations, and embodiments exist for practicing the appended claims.