Concrete tile system and method of manufacture

Abstract

Tile panel assemblies and systems of manufacturing and installing said tile panels. The tile panels of the subject invention can be used as a covering for walls, roofs, siding, etc. on a variety of structures. In one embodiment, the tiles are manufactured of a lightweight concrete having sufficient strength to withstand extreme weather and wind conditions, as well as normal handling or foot traffic required for installation and maintenance. In a further embodiment, the tiles of the subject invention comprise insulation, preferably foam, affixed thereto. The tile panels are constructed so as to present an overlapping configuration and selectively interlocking systems that provide resistance to negative pressure wind uplifting and enhanced insulation properties. Also disclosed is a tile bracket apparatus that can secure the leading edge of a tile to prevent wind-uplift.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S) [0001] The present application claims the benefit of U.S. Provisional application Ser. No. 60 / 724,831, filed Oct. 7, 2005, which is hereby incorporated by reference herein in its entirety, including any figures, tables, or drawings.BACKGROUND OF THE INVENTION [0002] The subject invention relates to a selectively interlocking tile covering system for homes, buildings, or other structures. Specifically, the subject invention relates to a four-sided interlocking tile panel covering system that utilizes an insulated lightweight concrete tile. The subject invention further relates to a method for manufacturing the concrete tiles and means for utilizing the tiles as a roof covering system. [0003] In many parts of the world, concrete or clay tiles are utilized on homes, buildings and an assortment of other structures. In their simplest design, overlapping tiles are positioned on an underlying support system. When used for roofing, the tiles are pla...

AI Technical Summary

Benefits of technology

[0007] In one embodiment, the tiles are manufactured of a lightweight concrete having sufficient strength to withstand extreme weather and wind conditions, as well as normal handling or foot traffic often required for installation and maintenance, especially when utilized as a roof covering. In a further embodiment, the subject invention provides a tile panel assembly wherein the tile panels may comprise insulation affixed thereto. The tile panels are constructed so as to present an overlapping configuration that can, preferably, interlock on all four sides to provide resistance to negative pressure wind uplifting. In a still further embodiment, the tile panels utilize a backing material to lend additional strength to the tile panels and, further, to reduce the amount of air space between the underlying roof structure and the panels. For example, a foam, or foam-like, material can be utilized to fill the space under the tiles and reduce air space. Reduction of the available air space can further reduce or eliminate the effects of wind uplift caused by negative pressure, i.e., the Bernoulli effect, and can additionally provide insulation properties to the tiles.

[0008] In certain embodiments, the backing material can also be formed to provide a four-sided interlocking tile system that holds and / or stabilizes tile panels against each other and the underlying roof structure(s), as well as reducing the amount of surrounding air space. However, in certain alternative embodiments, the sheathing surface can be formed, according to the subject invention, to provide a four-sided interlocking tile system also capable of holding and / or stabilizing tile panels against each other and the underlying roof structure(s).

[0013] The various embodiments of the subject invention are designed to secure at least the leading edges of installed tiles and, in preferred embodiments, the side and / or trailing edges as well, to prevent wind-uplift and / or the Bernoulli Effect from removing or breaking the tiles during high wind conditions. The more secure the edges of the tiles, and the less air space under the tiles, the less likely the tiles will be lifted off or broken off by high winds.

Problems solved by technology

Such installations are usually not overly secured and are easily destroyed under extreme environmental conditions.

Such tile systems are especially vulnerable during high wind conditions, for example during hurricanes.

It is not uncommon for high winds passing or crossing over the tiles to produce a negative pressure or Bernoulli effect, whereby air space under unsecured or ineffectively secured tiles is evacuated by high winds causing tiles to be more easily raised up from underlying roofing structure and displaced, or completely removed from a roof.

Tile roofing systems have been devised that are more secure, but such systems often require complicated means for manufacturing and installing tiles, see for example U.S. Pat. Nos. 5,743,059 and 6,604,336; or for securing them to the underlying roof structure, see for example U.S. Pat. Nos. 5,323,580; 5,522,187; and 5,921,045.

But, there have been few options available that provide direct roofing insulation that is cost-effective and easily installed.

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