Pan Tile Roof Structure With Fewer Exterior Tiles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional roofing systems are costly and labor-intensive due to the high number of hand-made or customized ceramic tiles required, which increases material and installation costs, and inefficient in terms of time and material usage.
Innovation Solution
A pan tile system with a machine-manufactured, fiber glass or plastic base and angled side segments that supports a reduced number of exterior tiles, allowing for efficient coverage of a roof surface with fewer tiles and reduced material usage, including the use of photovoltaic systems and heat dissipating assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional roofing systems use hand-made or customized ceramic tiles, then aesthetic quality and durability are improved, but material cost and installation cost increase significantly
Solution Approach 1:
The roofing system is divided into two distinct components: pan tiles that form the underlying structure and cover the roof deck, and barrel tiles that serve as the exterior aesthetic layer. This segmentation allows each component to be optimized independently - pan tiles can be machine-made from standard materials while barrel tiles maintain their traditional aesthetic appeal, thereby reducing overall material costs while preserving durability and aesthetic quality.
Solution Approach 2:
The pan tiles are designed to be made from standard, machine-manufacturable materials rather than expensive hand-made ceramic tiles. While individual pan tiles may not have the same longevity as traditional ceramic tiles, the overall system achieves comparable durability through the composite structure, significantly reducing material costs without sacrificing functional performance.
2Shape
If conventional roofing systems use hand-made or customized ceramic tiles, then aesthetic quality is improved, but installation time and labor cost increase
Solution Approach 1:
By separating the aesthetic function (barrel tiles) from the structural function (pan tiles), the system allows for more efficient installation. The pan tiles can be quickly installed as a base layer, and the barrel tiles can be efficiently placed on top, reducing overall installation time while maintaining aesthetic quality.
Solution Approach 2:
The system changes the material parameters of the pan tiles to be machine-manufacturable with consistent dimensions and properties, enabling faster installation. The barrel tiles retain their traditional characteristics for aesthetic purposes, while the overall installation process becomes more efficient due to the standardized base layer.
3Ease of manufacture
If conventional roofing systems use standard machine-made materials, then material cost is reduced, but aesthetic quality and customization capability deteriorate
Solution Approach 1:
The system segments the roofing components so that aesthetic requirements are concentrated in the barrel tiles, which can be traditional in appearance, while the pan tiles use standard machine-made materials. This allows the majority of the roof surface area to use cost-effective machine-made materials while the visible exterior maintains high aesthetic quality.
Solution Approach 2:
The pan tiles serve multiple functions: providing structural support, creating water drainage channels, and forming a stable base for the barrel tiles. By making the pan tiles machine-made and standardized, the system achieves cost efficiency while the barrel tiles maintain aesthetic quality, and the overall system remains versatile for different architectural styles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The pan tile system significantly reduces material and labor costs by requiring fewer tiles and less securing material, while also integrating solar energy and heat management features, enhancing efficiency and aesthetics.
Implementation Method 1
integrating solar energy
Implementation Method 2
heat dissipating assemblies
Data Source
AI summary
A plurality of pan tiles are disposed in confronting, supported relation on an underlying roof support and in underlying, at least partially supporting relation to plurality of overlapping, exteriorly exposed roof tile. Each pan tile includes a planar base and two oppositely disposed planar side segments extending outwardly from opposite peripheries of said base at a common, preferred obtuse angle. Leading and trailing ends of pan tiles have a greater and lesser transverse dimension respectively, wherein the side segments or oriented in a converging configuration extending from the leading end to the trailing end of the pan tile. Solar energy systems may also be incorporated in the pan tiles and a heat dissipating assembly and/or a stabilizing assembly may also be included.