Roof tiles, roof tile layout, and method of manufacture

Static structures (e.g. – buildings) – Processes – Fabrication of member – module – etc.

Reexamination Certificate

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Details

C052S749110, C425S094000, C425S099000, C425S104000, C425S132000, C425S133500, C425S296000, C425S299000

Reexamination Certificate

active

06604336

ABSTRACT:

BACKGROUND OF THE INVENTION
The present invention relates to roof tiles and more particularly to such tiles which interlock when laid in side by side overlapping relationship to form a roof tile layout.
Conventional interlocking fiat roof tiles have a generally rectangular shape with upper and lower surfaces, opposite side edges, top edges, and bottom edges. These tiles may be made from a variety of materials such as clay, polymer bound aggregates, and cementitious materials such as concrete. The cementitious mixture may include sand, or another aggregate, cement, coloring pigment, water, and one or more other additives to facilitate extrusion, prevent growth of fungus, etc. A variety of roof tile designs and manufacturing methods are illustrated in detail in U.S. Pat. No. 5,070,671 (Fifield et al.), U.S. Pat. No. 5,214,895 (Fifield), U.S. Pat No. 5,490,360 (Fifield et al.), U.S. Pat. No. 5,502,940 (Fifield), and U.S. Pat. No. 5,743,059 (Fifield), the disclosures of which are incorporated herein by reference.
Interlocking roof tiles are often arranged in successive rows of roof tile elements, with the bottom edge of each row overlapping the top edge of a lower row along the roof line. The roof tile layout formed in this manner defines an effective moisture barrier and an aesthetically pleasing appearance. In an effort to improve the aesthetic appearance of such a roof tile layout, some tile installers stagger the successive roof tiles in each row by positioning alternate roof tiles lower or higher on the roof than the directly adjacent roof tiles. This approach is problematic, however, because it is difficult to align the staggered tiles properly. Further, the interlocking and overlooking edges of the roof tiles become exposed when specific tiles are lowered or raised relative to the directly adjacent tiles.
Accordingly, there is a need for a roof tile layout and a system for manufacturing roof tiles that provide for a more effective means by which a staggered roof tile layout may be created. Further, there is a need for such a system and layout that enables efficient manufacture of such roof tiles and efficient and accurate installation of such a roof tile layout.
BRIEF SUMMARY OF THE INVENTION
This need is met by the present invention wherein two complementary roof tile designs, a process and apparatus for manufacturing the complementary roof tiles, and a roof tile layout including the complementary designs are provided.
In accordance with one embodiment of the present invention, a process of manufacturing roof tiles is provided comprising the steps of: (i) extruding a composite ribbon such that the composite ribbon defines an upper surface, a lower surface, and a pair of opposite ribbon side edges; (ii) conveying the composite ribbon from an upstream position to a downstream position along a composite ribbon path; (iii) demarcating the composite ribbon into an alternating succession of a first roof tile type and a second roof tile type by engaging the composite ribbon with an upstream cutting blade and a downstream cutting blade such that each roof tile type is demarcated at an upstream tile edge by one of the cutting blades and at a downstream tile edge by the other of the cutting blades, and such that a selected one of the roof tile types includes a pair of cut-out portions demarcated along one of the upstream and downstream tile edges, the pair of cut-out portions being positioned on opposite ones of the ribbon side edges; (iv) separating the succession of demarcated roof tile types into distinct roof tiles; and (v) curing the distinct roof tiles to form a set of cured roof tiles.
Preferably, the composite ribbon is demarcated such that (i) the first roof tile type includes a first set of nail holes spaced a first distance from one of the upstream and downstream tile edges and a second set of nail holes spaced a second distance from the first set of nail holes along the composite ribbon path; (ii) the second roof tile type includes the pair of cut-out portions and a first set of nail holes spaced the first distance from one of the upstream and downstream tile edges. The composite ribbon may be further demarcated such that the pair of cut-out portions extend the second distance from the other of the second roof tile type upstream and downstream tile edges along the composite ribbon path, whereby the spacing between the first and second sets of nail holes on the first roof tile type along the composite ribbon path matches the extent of the cut-out portions on the second roof tile type along the composite ribbon path. The composite ribbon may be demarcated such that the nail holes extend partially or completely through the composite ribbon between the upper surface and the lower surface. The demarcating step preferably comprises engaging the composite ribbon with the upstream cutting blade and the downstream cutting blade substantially simultaneously and conveying the cutting blade assembly in a direction parallel to the composite ribbon path as the demarcating step is executed.
The process of manufacturing roof tiles may further comprise the steps of (i)conveying a succession of partially cured roof tiles of alternating roof tile types and (ii) stacking said alternating roof tile types in succession to form a cubed product wherein each layer of the cubed product includes equal quantities of the two different roof tile types.
In accordance with another embodiment of the present invention, an apparatus for manufacturing roof tiles is provided comprising a composite ribbon extruder, a conveying mechanism, a cutting blade assembly, a pallet conveying path, and a roof tile curing station. The composite ribbon extruder is arranged to extrude a composite ribbon defining an upper surface, a lower surface, and a pair of opposite ribbon side edges. The conveying mechanism is arranged to move the composite ribbon from an upstream position to a downstream position along a composite ribbon path. The cutting blade assembly includes an upstream cutting blade and a downstream cutting blade arranged to demarcate the composite ribbon into an alternating succession of a first roof tile type and a second roof tile type by engaging the composite ribbon with the upstream cutting blade and the downstream cutting blade. Each roof tile type is demarcated at an upstream tile edge by one of the cutting blades and at a downstream tile edge by the other of the cutting blades. A selected one of the upstream and downstream cutting blades includes a pair of L-shaped cut-out extensions arranged to demarcate a pair of cut-out portions along one of the upstream and downstream tile edges on opposite ones of the ribbon side edges. The pallet conveying path is defined by a succession of demarcated roof tile types separated into distinct roof tiles by the conveying mechanism. The roof tile curing station is positioned along the pallet conveying path and is arranged to cure the distinct roof tiles to form a set of cured roof tiles.
Preferably, the cutting blade assembly further comprises first, second, and third sets of nail hole punches. The first set of nail hole punches is spaced a first distance from a selected one of the upstream cutting blade and the downstream cutting blade. The selected cutting blade includes the pair of L-shaped cut-out extensions. The second set of nail hole punches is spaced a second distance from the first set of nail hole punches along the composite ribbon path. The third set of nail hole punches is spaced the first distance from the other of the upstream cutting blade and the downstream cutting blade. The pair of L-shaped cut-out extensions preferably extend the second distance along the composite ribbon path from the other of the upstream cutting blade and the downstream cutting blade, whereby the spacing between the first and second sets of nail hole punches along the composite ribbon path matches the extent of the cut-out portion along the composite ribbon path. The first set of nail hole punches may be arranged such that the nail holes extend through the composite ribbon betwe

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