Method for producing a roof tile having a water barrier and roof tile having a water barrier shaped thereon

Abstract

A method for producing a roof tile having a water barrier, wherein the water barrier is shaped onto a roof tile blank, which is supplied onto a lower mould, of a shaping unit, with a shaped piece and a shaping stamp that can move in relation to same. The shaped piece is placed on an upper side of a top end of the roof tile blank, and the shaping stamp is pressed against the top end of the roof tile blank, such that material of the roof tile blank is pressed into a shaping mould of the shaped piece. The roof tile blank is also arranged below the shaping unit and the shaping unit is vertically lowered onto the roof tile blank. The invention also relates to a roof tile produced according to this method having a water barrier shaped thereon.

Claims

1. A method for producing a roof tile having a water barrier, wherein the water barrier is shaped on a roof tile blank, comprising: feeding the roof tile blank on a lower mold, to a shaping unit, with a shaped piece and a shaping stamp which is movable relative to said shaped piece, placing the shaped piece onto a top surface of a head end of the roof tile blank and moving the shaping stamp parallel to the lower mold and to the shaped piece, pressing the shaping stamp against the head end of the roof tile blank such that material of the roof tile blank is pressed into a shaping recess of the shaped piece, the roof tile blank being arranged below the shaping unit and the shaping unit being lowered vertically onto the roof tile blank, the method further comprising: providing less than an entire top surface of the roof tile blank with a separator prior to the realization of the water barrier, guiding a bottom surface of the shaping stamp to a height with a bottom surface of the roof tile blank, and pressing the shaping stamp at a penetration depth E of between 10 and 20 mm into the head end of the roof tile blank, wherein the separator is applied onto the top surface of the head end of the roof tile blank as a 2 to 5 cm wide strip.

2. The method for producing a roof tile having a water barrier as claimed in claim 1, wherein the water barrier is realized with a height H of between 5 and 20 mm.

3. The method for producing a roof tile having a water barrier as claimed in claim 1, wherein the water barrier is molded in a thickness S of between 5 and 15 mm.

4. The method for producing a roof tile having a water barrier as claimed in claim 1, wherein the water barrier is realized with a setting angle of between 60 and 90.

5. A roof tile having a water barrier shaped thereon which is produced using a method comprising: feeding a roof tile blank on a lower mold, to a shaping unit, with a shaped piece and a shaping stamp which is movable relative to said shaped piece, placing the shaped piece onto a top surface of a head end of the roof tile blank and moving the shaping stamp parallel to the lower mold and to the shaped piece, pressing the shaping stamp against the head end of the roof tile blank such that material of the roof tile blank is pressed into a shaping recess of the shaped piece, the roof tile blank being arranged below the shaping unit and the shaping unit being lowered vertically onto the roof tile blank, providing the top surface of the roof tile blank with a separator prior to the realization of the water barrier, guiding a bottom surface of the shaping stamp to a height with a bottom surface of the roof tile blank, pressing the shaping stamp at a penetration depth E of between 10 and 20 mm into the head end of the roof tile blank, realizing the water barrier and the roof tile in one piece and the water barrier comprising a planar rear side, and indenting the water barrier at a depth T of between 10 and 20 mm with respect to the head end of the roof tile blank with and at least one suspension lug being realized on the bottom surface of the roof tile blank at a minimum distance M from the head end of the roof tile blank, wherein the minimum distance M corresponds to at least the sum of the depth T of the setback and the thickness S of the water barrier (M >T+S).

6. The roof tile having a water barrier shaped thereon as claimed in claim 5, wherein the water barrier comprises an increased density.

7. The roof tile having a water barrier shaped thereon as claimed in claim 5, wherein the water barrier comprises a setting angle of between 60 and 90.

8. The roof tile having a water barrier shaped thereon as claimed in claim 5, wherein the water barrier comprises a thickness S of between 5 and 15 mm.

9. The roof tile having a water barrier shaped thereon as claimed in claim 5, wherein the water barrier comprises a height H of between 5 and 20 mm.

10. The method for producing a roof tile having a water barrier as claim in claim 4, wherein said setting angle is 75.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features, details and advantages of the invention are produced from the wording of the claims and from the following description of exemplary embodiments by way of the drawings, in which:

(2) FIG. 1 shows a view of a roof tile according to the invention

(3) FIG. 2 shows a cross-sectional view of a roof tile blank prior to the shaping thereon of a water barrier

(4) FIG. 3 shows a cross-sectional view of a roof tile blank during the shaping thereon of a water barrier

(5) FIG. 4 shows a cross-sectional view of a roof tile according to the invention with a water barrier shaped thereon.

DESCRIPTION OF PREFERRED EMBODIMENTS

(6) FIG. 1 shows a top view of a roof tile 1 according to the invention. The roof tile 1 comprises a water notch 2 and a cover notch 3 on its longitudinal edges as well as a center rim 4 located in between. A watercourse 5, 6 is realized between each of the notches 2, 3 and the center rim 4. A water barrier 8, 9 is realized in each region of the watercourse 5, 6 on a head end 7 of the roof tile 1. In this case, the water barrier 8, 9 extends at least over the region of the watercourse 5, 6. One single water barrier, however, can also extend over the entire length of the head edge 7 of the roof tile 1.

(7) The method for producing a roof tile having a water barrier and the roof tile produced according to said method are explained below by way of FIGS. 2 to 4.

(8) FIGS. 2 to 4 show a longitudinal section B-B of the roof tile 1 or preliminary steps of the roof tile 1 from FIG. 1 in the region of the head edge 7, the longitudinal section running through the watercourse 5.

(9) The shaping of the water barrier 8, 9 is effected at the head end 7 in the region of the watercourse 5 of a roof tile blank 10. The water barrier 8, 9 of the finished roof tile 1 is created from said roof tile blank 10 as a result of being shaped thereon. The roof tile blank 10 produced from fresh concrete 11 rests with its bottom surface 12 on a lower mold 13. After stopping and aligning the roof tile blank 10 below a shaping unit 14, which is formed from a shaped piece 15 with a mold recess 16 and a shaping stamp 17, said shaping unit is lowered vertically. In this case, the lateral one opening of the mold recess 16 is arranged opposite the wedge-shaped shaping stamp 17. As a result of lowering the shaping unit 14, the shaped piece 15 with the mold recess 16, the inner contour of which corresponds to the shape of the water barrier to be produced, rests on a top surface 18 of the roof tile blank 10 close to the head edge 7. The mold recess 16 comprises an L-shaped cross section with rounded corners. In order to prevent the fresh concrete 11 from sticking and consequently a layer build-up in the mold recess 16, prior to placing the shaped piece 15 close to the head edge 7, a separating layer 19 is applied to the top surface 18 of the roof tile blank 10. Said separating layer 19 can preferably consist of a strewn layer of loose, dry sand particles 20 and prevents the fresh concrete 11 sticking in the mold recess 16. The fresh concrete 11 for shaping the water barrier 8 is obtained by the shaping stamp 17, provided with a wedge angle , penetrating into the roof tile blank 10 from the head end 7. In a preferred embodiment, the shaping stamp 17 is moved parallel to the lower mold 13 in a reversing manner, the bottom surface 21 of the shaping stamp 17 being guided at a height with the bottom surface 12 of the roof tile blank. The penetration position is designated by means of the reference P.

(10) When the shaping stamp 17 is advanced further, as shown in FIG. 3, the fresh concrete 11 detaches itself from the lower mold 13 and slides upward along the inclined wedge surface into the mold recess 16, where it is compacted to form the water barrier 8. In this connection, the particles of the separation layer 19, for example sand particles 20, abut against the wall of the mold recess 16 and in this way ensure easy detachment of the formed water barrier 8 from the mold recess 16. After the shaping operation, the sand particles 20 are pressed into the top surface 18 of the roof tile blank 10 or of the water barrier 8 such that they do not appear visually or only appear in a minimum manner. On account of the feed movement of the shaping stamp 17, the head end 7 of the roof tile blank 10 is recessed in relation to a plane E1 in the region of the watercourse 5 or the water barrier 8 arranged there. The plane E1 is formed by the original head end 7. Said setback 22 comprises a depth T, which corresponds to the insertion depth E of the shaping stamp 17, in a plane 2 (E2) which runs through the separation layer between the roof tile blank 10 and the lower mold 13.

(11) For the forming of a high-quality water barrier 8, 9, it is significant that a sufficient volume V (see cross-hatching in FIG. 3) of fresh concrete 11 is available, as a result of which as high a compaction of fresh concrete 11 as possible is able to be obtained. In this case, the water tightness of the water barrier 8, 9 is all the better, the higher the compaction of the fresh concrete 11 in the mold recess 16.

(12) The size of the volume V of fresh concrete 11 available and the compaction thereof is determined substantially by the following tool and method parameters: the wedge angle of the shaping stamp 17 the penetration depth E of the shaping stamp 17 the penetration position P of the shaping stamp 17

(13) It is favored that the wedge angle of the shaping stamp 17 comprises at least 60 and should not exceed 90. The wedge angle is preferably approximately 75. If the wedge angle is chosen too small, the shaping stamp 17 has to carry out a very long feed movement so that an upward movement of the fresh concrete 11, which is sufficient to fill the mold recess 16 and for compaction, is generated with a small wedge action. In this case, a very deep setback 22 is created at the head end 7 of the roof tile blank 10 on account of the necessary large penetration depth E of the shaping stamp 17, as a result of which the suspension lugs 23 on the bottom surface 12 of the roof tile blank 10 have had to be arranged spaced at a large distance from the plane E1 of the head end 7. The larger said distance M (see FIG. 4), the smaller the possible coverage length of the roof tile 1 when suspended on the roof battens. The disadvantage of a reduction in the coverage length is that more rows of roof tiles running parallel to the eaves have to be laid in the ridge-eave direction. This increases the load on the roof substructure, the material and the operating costs.

(14) The wedge angle of the shaping stamp 17 and the penetration depth E of the shaping stamp 17 are therefore to be coordinated with one another such that a setback 22 with as small a depth T as possible is created on the roof tile 1 so that, on the one hand, the coverage length of the roof tile 1 is not reduced by an unfavorable positioning of suspension lugs 23 and, on the other hand, nevertheless as large a volume V as possible of fresh concrete 11 is obtained. For obtaining the volume V of fresh concrete 11, it is additionally important to place the penetration position P of the shaping stamp 17 into the separation plane (=E2) between the bottom surface 12 of the roof tile blank 10 and a top surface 24 of the lower mold 13. In this case, no more grout is created at the head end 7 in the region of the watercourse 5, but simply the setback 22. The concrete volume squandered previously to realize the grout is pressed completely into the water barrier 8. As a result, the water barrier 8 can be dimensioned thicker and there is better compaction of the fresh concrete 11 in the region of the water barrier 8.

(15) In summary, the shaping of the water barrier 8, 9 is effected in four operating steps: First of all, the roof tile blank 10 is placed in an accurate position beneath the shaping unit 14, the shaped piece 15 being situated close to the head end 7 of the roof tile blank 10. The shaping unit 14 is movable vertically in the direction of the top surface 18 of the roof tile blank 10 and in the opposite direction. In a first operating step, the shaping unit 14 is lowered in the direction of the top surface 18 of the roof tile blank 10, the shaped piece 15 abutting against the top surface 18 of the roof tile blank 10 and the side opening of the mold recess 16 being arranged on the head end 7. In this connection, at the same time the shaping stamp 17 is lowered such that the tip thereof is positioned in front of the lower mold 13 and at the height of the separation plane between the top surface 24 of the lower mold 13 and the bottom surface 12 of the roof tile blank 10. In the second operating step, the shaping stamp 17 carries out a movement which is effected parallel to the lower mold 13 and directed to the head end of the roof tile blank 30, where the shaping stamp 17 provided with the wedge angle penetrates into the fresh concrete 11 and presses said fresh concrete into the mold recess 16 of the shaped piece 15. In this connection, the shaping stamp 17 penetrates into the mold recess 16 by the penetration depth E. The pressed fresh concrete 11 fills the mold recess 16 completely such that a roof tile blank 10 is created with a water barrier 8, 9 shaped monolithically thereon. In the third operating step, the shaping stamp 17 is then returned back to its starting position, and in the fourth operating step, the shaping unit 14 is pulled back from the top surface of the roof tile blank 18 such that the shaped piece 15 is removed from the top surface of the roof tile blank 10 and the mold recess 16 releases the water barriers 8, 9 shaped monolithically thereon. Further steps connected to the production method can serve for surface coating, hardening and packaging.

(16) The roof tile blank 10 produced by way of the method according to the invention or the roof tile 1 with the realized water barrier 8 is shown in FIG. 4. The shaping parameters preferred in the method can be seen on the finished roof tile 1. Thus, the water barrier 5 comprises a setting angle , with reference to the plane E2, which corresponds to the wedge angle of the shaping stamp 17. In addition, the depth T of the setback 22 corresponds to the penetration depth E of the shaping stamp 17, which should be at least 10 mm and should not exceed 22 mm. The shape of the mold recess 16 provides the shape of the water barrier 8, in particular the height H (H=5 to 20 mm) and the thickness S (S=5 to 15 mm), the thickness S of the water barrier 8 corresponds to the width of a root 25 proceeding from the top surface 18 of the roof tile 1.

(17) In order to ensure the stackability of the roof tiles 1, the water barrier 8 on the top surface 18 of a roof tile 1 lower in the stack should not be positioned in the same position as the suspension lug 23 on the bottom surface 12 of a roof tile 1 above in the stack, for otherwise the stack of roof tiles 1 would become lopsided and tip.

(18) So that, consequently, the collision between the water barrier 8 and the suspension lug 23 is prevented during stacking, the suspension lugs 23 should maintain a minimum distance M from the head end 7 of the roof tile 1, which is produced as follows: Mdepth T of the setback 22+ thickness S of the root 25 of the water barrier 8, 9.

(19) The invention is not restricted to one of the previously described embodiments, but is convertible in diverse ways.

(20) All the features and advantages emanating from the claims, the description and the drawing, including structural details, spatial arrangements and method steps, can be essential to the invention both on their own per se and in the most varied combinations.

LIST OF REFERENCES

(21) 1 Roof tile 2 Water notch 3 Cover notch 4 Center rim 5 Watercourse 6 Watercourse 7 Head end 8 Water barrier 9 Water barrier 10 Roof tile blank 11 Fresh concrete 12 Bottom surface 13 Lower mold 14 Shaping unit 15 Shaped piece 16 Mold recess 17 Shaping stamp 18 Top surface 19 Separation layer 20 Sand particle 21 Bottom surface of the shaping stamp 17 22 Setback 23 Suspension lug 24 Top surface of the lower mold 13 25 Root of the water barrier 8, 9 26 Projection height of the suspension lug 23 A-A Cutting plane through the roof tile 1 B-B Cutting plane through the roof tile 1 E Penetration depth of the shaping stamp 17 E1 Plane of the original head edge 7 E2 Separation plane between the lower mold 7 and the roof tile blank 10 H Height of the water barrier 8, 9 and of the mold recess 16 M Minimum distance of the suspension lug 23 P Penetration position of the shaping stamp 17 S Thickness of the root of the water barrier 8, 9 and of the mold recess 16 T Depth of the setback 22 V Volume of fresh concrete 11 Wedge angle of the shaping stamp 17 Setting angle of the roof tile blank 10/roof tile 1