Glazed porcelain roof tile
10316518 ยท 2019-06-11
Assignee
Inventors
- Rahul Patki (Richardson, TX, US)
- Terry Adams (Dallas, TX, US)
- Raul Rodriguez (Dallas, TX, US)
- Claudio Caselli (Dallas, TX, US)
Cpc classification
E04D1/2918
FIXED CONSTRUCTIONS
E04D1/16
FIXED CONSTRUCTIONS
B44C5/04
PERFORMING OPERATIONS; TRANSPORTING
B28B11/001
PERFORMING OPERATIONS; TRANSPORTING
E04D1/265
FIXED CONSTRUCTIONS
E04D1/28
FIXED CONSTRUCTIONS
International classification
E04D1/16
FIXED CONSTRUCTIONS
E04D1/28
FIXED CONSTRUCTIONS
Abstract
Roof tile for forming a roof covering, wherein the roof tile (1) comprises a ceramic body (8); wherein said ceramic body (8) is made of porcelain; and wherein the roof tile (1) further comprises a glaze coating (9), which is situated above said ceramic body (8).
Claims
1. A roof tile for forming a roof covering, the roof tile comprising: a ceramic body made of porcelain; a glaze coating situated above the ceramic body, and a second layer situated below said ceramic body, wherein said second layer is made of one or more materials selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and an elastomer, and wherein the glaze coating comprises (i) a dcor comprising a print and (ii) a transparent or translucent glaze layer arranged over the print, and wherein the roof tile has a water absorption rate of less than 0.5% measured according to the norm ASTM C373, and wherein the dcor represents or forms an image of a plurality of roof tiles providing a reduced risk of water penetration.
2. The roof tile according to claim 1, wherein the roof tile has a hail impact rating of class 3 or higher measured according to the norm FM 4473.
3. The roof tile according to claim 1, wherein the roof tile comprises a reinforcement layer, which is situated below said ceramic body, said reinforcement layer being formed by a mesh.
4. The roof tile according to claim 3, wherein said reinforcement layer is embedded in said second layer.
5. The roof tile according to claim 1, wherein the thickness of said roof tile is located between 5 mm and 20 mm.
6. The roof tile according to claim 1, wherein the width of the roof tile is larger than its length.
7. The roof tile according to claim 1, wherein the roof tile is at least 350 mm wide.
8. The roof tile according to claim 1, wherein the roof tile is provided with at least one attachment hole, said at least one attachment hole being present in at least said ceramic body.
9. The roof tile of claim 1, wherein the dcor is digitally printed.
10. The roof tile of claim 1, wherein the print resembles a natural product.
11. The roof tile of claim 1, wherein the dcor comprises a plurality of images separated by a depression in the ceramic tile.
12. A roof tile for forming a roof covering, the roof tile comprising: a ceramic body made of porcelain; a reinforcement layer situated below said ceramic body; at least one attachment hole present in at least said ceramic body; a glaze coating, situated above the ceramic body, and a second layer situated below said ceramic body, wherein said second layer is made of one or more materials selected from the group consisting of a thermoplastic polymer, a thermosetting polymer, and an elastomer, and wherein the glaze coating comprises (i) a dcor comprising a print and (ii) a transparent or translucent glaze layer arranged over the print, and wherein the roof tile has a water absorption rate of less than 0.5% measured according to the norm ASTM C373, and wherein the thickness of said roof tile is located between 5 mm and 20 mm, and wherein the roof tile is at least 350 mm wide.
13. The roof tile according to claim 12, wherein the roof tile is at least 500 mm wide.
14. The roof file according to claim 12, wherein said reinforcement layer is embedded in said second layer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) With the objective of better showing the characteristics of the invention, hereafter, as example without any limiting character, some preferred embodiments are described, with reference to the accompanying drawings.
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DETAILED DESCRIPTION
(21)
(22) The roof tile 1 is mainly rectangular and, in the represented example, rectangular and oblong. It has an upper surface 2 and a lower surface 3, whereby, in the installed condition of the roof tile 1, the upper surface 2 is directed upwards, whereas the lower surface 3 is directed downwards. The upper surface 2 forms the decorative surface of the roof tile 1.
(23) Furthermore, the roof tile 1 has an upper edge 4 and a lower edge 5, whereby, in the installed condition of the roof tile 1, the upper edge 4 is directed towards the top of the roof, whereas the lower edge 5 is directed towards the bottom of the roof. Also, the roof tile 1 has two opposite side edges 6-7.
(24) The roof tile 1 comprises a ceramic body 8, which is made of porcelain, and a glaze coating 9, which is situated above said ceramic body 8.
(25) The glaze coating 9 comprises a dcor, which here simulates wood. In particular, the dcor shows wood nerves 10 and wood pores 11.
(26) In the represented example, the front face of the roof tile 1 represents or forms an image of a plurality of roof tiles 1A-1B-1C-1D. The borders or transitions between the roof tiles 1A-1B-1C-1D are formed by depressions 12, which form part of the relief at the upper surface 2 of the roof tile 1.
(27) Although, in the represented example, the front face of the roof tile 1 represents or forms an image of four roof tiles 1A-1B-1C-1D, it is not excluded that less than four roof tiles are represented, such as two or three roof tiles, nor is it excluded that more than four roof tiles are represented.
(28) The thickness T of the roof tile 1 is preferably located between 5 and 20 mm, more preferably between 8 and 15 mm, and still more preferably the thickness T of the roof tile 1 is approximately 11 mm.
(29) The width W of the roof tile 1 is larger than its length L. The width W of the roof tile 1 may be at least 350 mm and preferably at least 500 mm.
(30) The roof tile 1 is provided with at least one attachment hole 13. Here, the roof tile 1 is provided with a plurality of attachment holes 13. The attachment holes 13 are present in at least the ceramic body 8 of the roof tile 1. They are situated closer to the upper edge 4 of the roof tile 1 than to the lower edge 5 of the roof tile 1. In particular, the attachment holes 13 are situated at a distance D from the upper edge 4, measured in the length direction of the roof tile 1, which is smaller than 0.25 times the length L of the roof tile 1. The minimal width or diameter of the attachment holes 13 is smaller than the thickness T of the roof tile 1.
(31) In a not represented embodiment, the lower surface 3 of the roof tile 1 may be provided with a relief, such as a chamfer or taper present at one of the edges 4-7 of the roof tile 1, at the lower surface 3. Preferably, the chamfer or taper is present at least at the lower edge 5 of the roof tile 1. Such chamfer at the lower edge 5 offers the advantage of the roof tile 1, according to a view on the lower edge 5, looking relatively thin, e.g. looking like a thin slate roof element, while being provided with better weather and frost resistance than roof elements that are actually made of such materials like slate.
(32)
(33) In the represented example, the glaze coating 9 is situated directly above the ceramic body 8.
(34) The ceramic body 8 forms at least 50%, more preferably at least 75% and still more preferably at least 90% of the thickness T of the roof tile 1.
(35) The glaze coating 9 comprises a dcor, said dcor comprising a print 14, a glaze layer 15 of uniform color, which is situated below the print 14, and a transparent or translucent glaze layer 16, which is arranged over said print 14.
(36) The print 14 is at least partially formed by lines 17 simulating the wood nerves 10.
(37) The upper surface 2 of the roof tile 1 is provided with a relief, which, in the represented example, is formed by a plurality of excavations 18 present in said upper surface 2.
(38) In the represented example, by the relief, the texture of the roof tile 1, at the upper surface 2 thereof, simulates the texture of wood. In particular, the relief simulates the texture of the wood nerves 10 and the wood pores 11. For example, the relief is at least partially formed by lines 19 simulating the wood nerves 11.
(39) Here, the relief is also used to represent the borders or transitions between the roof tiles 1A-1B-1C-1D, which, as aforementioned, are formed by the depressions 12 in the upper surface 2 of the roof tile 1.
(40) In the example, the relief is performed in register with the print 14. For example, the lines 19 of the relief follow the course of the lines 17 of the print 14.
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(44) In such case, the print 14 may be provided directly on the upper surface 20 of the ceramic body 8 or, in an alternative, the print 14 may be provided on a primer or ground coat present at the upper surface 20 of the ceramic body 8. A primer or ground coat may be used for improving the adherence of the print 14 to the ceramic body 8. A primer or ground coat may also be used to create an even or substantially even surface, upon which the print 14 can be provided, which is especially useful in case the upper surface 20 of the ceramic body is irregular.
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(46) The roof tile 1 comprises a reinforcement layer 21, which is situated below the ceramic body 8.
(47) In the represented example, the reinforcement layer 21 is situated directly below the ceramic body 8, whereby it is not excluded that an adhesive layer such as glue is present in between the reinforcement layer 21 and the ceramic body 8.
(48) Here, the reinforcement layer 21 is formed by a mesh, preferably a fiberglass mesh.
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(50) The roof tiles 1 are attached or fastened to a framework 23 by means of nails 24, which are put in the attachment holes 13.
(51) The roof tiles 1 are installed in subsequent rows, of which only a few are represented in
(52) For example, the roof tiles 1 of row 25C and 25B respectively overlap the roof tiles 1 of previous row 25B and 25A.
(53) The overlap 26 between the roof tiles 1 of the respective rows is less than 20%. Or, in other words, the roof tiles 1 of row 25C and 25B respectively overlap the roof tiles 1 of previous row 25B and 25A, whereby the overlap 26 is such that less than 20% of the upper surface 2 of the roof tiles 1 of row 25A and 25B is covered by the roof tiles 1 of row 25B and 25C respectively.
(54) A denotes the inclination of the roof with respect to the horizontal.
(55) It is noted that the structure of the glaze coating 9 is not represented in detail in
(56)
(57) The roof tile 1 comprises a layer 27, which is situated below the ceramic body 8.
(58) Said layer 27 is preferably made of a material different from ceramic or porcelain. In particular, it preferred that said layer 27 is made of one or more of the materials selected from the group consisting of: a thermoplastic polymer, such as polyvinylchloride, polyethylene, polypropylene and/or polyethylene terephthalate, a thermosetting polymer, such as polyurethane, and/or an elastomer, such as rubber or a thermoplastic elastomer.
(59) The layer 27 has a part 28 which extends beyond the ceramic body 8, and which is provided with attachment holes 13. In the represented example, the part 28 extends beyond the upper edge 29 of the ceramic body 8.
(60) The attachment holes 13 are situated closer to the upper edge 4 of the roof tile 1 than to the lower edge 5 of the roof tile 1. In particular, the attachment holes 13 are situated at a distance D from the upper edge 4 of the roof tile 1, as measured in the length direction of the roof tile 1, which is smaller than 0.25 times the length L of the roof tile 1.
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(62) The layer 27 is situated directly below the ceramic body 8, whereby it is not excluded that an adhesive layer such as glue is present between said layer 27 and the ceramic body 8. The layer 27 and the ceramic body 8 may be laminated or press laminated together, for example by means of glue such as epoxy glue.
(63) The ceramic body 8 forms between 25% and 75% of the thickness T of the roof tile 1 and preferably between 40% and 60% of the thickness T of the roof tile 1. The layer 27 forms between 25% and 75% of the thickness T of the roof tile 1 and preferably between 40% and 60% of the thickness T of the roof tile 1.
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(65) The layer 27 and the ceramic body 8 are offset with respect to each other in the length direction of the roof tile 1. In particular, part 28 of the layer 27 extends beyond the upper edge 29 of the ceramic body 8, whereas part 30 of the ceramic body 8 extends beyond the slower edge 31 of said layer 27.
(66) It is noted that the structure of the glaze coating 9 is not represented in detail in
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(68) The roof tiles 1 are attached or fastened to a framework 23 by means of nails 24, which are put in the attachment holes 13, which are situated in the layer 27, in particular in part 28 of said layer 27.
(69) The roof tiles 1 are installed in subsequent rows, of which only a few are represented in
(70) The overlap 26 between the roof tiles 1 of the respective rows is less than 20%. Or, in other words, the roof tiles 1 of row 25C and 25B respectively overlap the roof tiles 1 of previous row 25B and 25A, whereby the overlap 26 is such that less than 20% of the upper surface 2 of the roof tiles 1 of row 25A and 25B is covered by the roof tiles 1 of row 25B and 25C respectively.
(71) In the represented example, the upper surface 2 of the roof tiles 1 denotes the upper surface 2 of the glaze coating 9. In other words, the upper surface 2 is formed by the decorative surface of the roof tiles 1.
(72) A denotes the inclination of the roof with respect to the horizontal.
(73) It is noted that the structure of the glaze coating 9 is not represented in detail in
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(75) The roof tile 1 comprises a layer 32, which is situated below the ceramic body 8.
(76) Said layer 32 is preferably made of a material different from ceramic or porcelain. In particular, it preferred that said layer 32 is made of one or more of the materials selected from the group consisting of: a thermoplastic polymer, such as polyvinylchloride, polyethylene, polypropylene and/or polyethylene terephthalate, a thermosetting polymer, such as polyurethane, and/or an elastomer, such as rubber or a thermoplastic elastomer.
(77) The layer 32 has a part 33 which extends beyond the ceramic body 8, and which is provided with attachment holes 13. In the represented example, the part 33 extends beyond the upper edge 29 of the ceramic body 8.
(78) The attachment holes 13 are situated closer to the upper edge 4 of the roof tile 1 than to the lower edge 5 of the roof tile 1. In particular, the attachment holes 13 are situated at a distance D from the upper edge 4 of the roof tile 1, as measured in the length direction of the roof tile 1, which is smaller than 0.25 times the length L of the roof tile 1.
(79) The layer 32, at least at two opposite edges 34-35, is provided with coupling parts 36-37, which allow that two of such roof tiles 1 can be coupled to each other.
(80) In the represented example, the opposite edge 34-35, at which the coupling parts 36-37 are provided, concern the upper and lower edge of the layer 32.
(81) In a not represented embodiment of the invention, instead of the edges 34-35, the opposite side edges 38-39 may be provided with coupling parts. Or, in another not represented embodiment of the invention, both pairs of edges 34-35 and 38-39 may be provided with coupling parts.
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(83) The layer 32 is situated directly below the ceramic body 8, whereby it is not excluded that an adhesive layer such as glue is present between said layer 32 and the ceramic body 8. The layer 32 and the ceramic body 8 may be laminated or press laminated together, for example by means of glue such as epoxy glue.
(84) The ceramic body 8 forms between 25% and 75% of the thickness T of the roof tile 1 and preferably between 40% and 60% of the thickness T of the roof tile 1. The layer 32 forms between 25% and 75% of the thickness T of the roof tile 1 and preferably between 40% and 60% of the thickness T of the roof tile 1.
(85) The layer 32 and the ceramic body 8 are offset with respect to each other in the length direction of the roof tile 1. In particular, part 33 of the layer 32 extends beyond the upper edge 29 of the ceramic body 8, whereas part 40 of the ceramic body 8 extends beyond the lower edge 35 of said layer 32.
(86) In the represented example, the upper edge 34, with its associated coupling part 36, is situated completely beyond the ceramic body 8, whereas the ceramic body 8 extends completely beyond the lower edge 35.
(87) The upper surface 41 and the lower surface 42 of said layer 32 converge towards each other. In particular, they converge towards each other in the direction towards the upper edge 34 of said layer 32.
(88) In the represented example, the coupling parts 36-37 are formed in the material of the layer 32. They are provided with a locking system, which, in the coupled condition of two of such roof tiles 1, is only active in the direction V perpendicular to the plane of the roof covering, which means that the moving apart of two of such coupled roof tiles 1 in said direction V is counteracted and preferably prevented. The locking system comprises locking surfaces 43-44, which, in the coupled condition, cooperate with each other to counteract the moving apart of the coupled roof tiles 1 in said direction V.
(89) The coupling parts 36-37 are configured such that they allow to couple two of such roof tiles 1 by means of a substantially downward movement M1 of one roof tile 1 with respect to the other roof tile 1.
(90)
(91) In the represented example, the coupling parts 36-37 are provided with a locking system, which, in the coupled condition of two of such roof tiles 1, is active in the direction H parallel to the plane of the roof covering and perpendicular to the coupled edges 34-35 as well as in the direction V perpendicular to the plane of the roof covering, which means that the moving apart of two of such coupled roof tiles 1 in said directions H and V is counteracted and preferably prevented.
(92) Here, the coupling parts 36-37 provide for a click-type or snap-type coupling. This means that a click or snap action occurs upon coupling two of such roof tiles at the respective edges 34-35.
(93) The coupling parts 36-37 are configured such that they allow to couple two of such roof tiles 1 by means of a downward movement M2 of one roof tile 1 with respect to the other roof tile 1. In the example, they are of the so-called push-lock or push-down type, known per se from the field of flooring.
(94)
(95) The roof tiles 1 are attached or fastened to a framework 23 by means of nails 24, which are put in the attachment holes 13, which are situated in the layer 32, in particular in part 33 of said layer 32.
(96) The roof tiles 1 are installed in subsequent rows, of which only a few are represented in
(97) The overlap 26 between the roof tiles 1 of the respective rows is less than 20%. Or, in other words, the roof tiles 1 of row 25C and 25B respectively overlap the roof tiles 1 of previous row 25B and 25A, whereby the overlap 26 is such that less than 20% of the upper surface 2 of the roof tiles 1 of row 25A and 25B is covered by the roof tiles 1 of row 25B and 25C respectively.
(98) In the represented example, the upper surface 2 of the roof tiles 1 denotes the upper surface 2 of the glaze coating 9. In other words, the upper surface 2 is formed by the decorative surface of the roof tiles 1.
(99) The coupling parts 36-37 allow coupling the roof tiles 1 lying adjacent to each other in subsequent rows 25A-25B-25C of the roof covering 22.
(100) The upper surface 41 and the lower surface 42 of said layer 32 converge towards each other. Here, they converge towards each other in the direction towards the upper edge 34 of said layer 32.
(101) In the represented example, the upper surface 41 of the layer 32 is substantially parallel to the lower surface 45 of the ceramic body 8, whereas the lower surface 42 of said layer 32 is configured such that, in the installed condition of the roof tile 1, it is substantially parallel to the slope of the roof. Here, the lower surface 42 of said layer 32 is arranged such that, in the installed condition of the roof tiles 1 in subsequent rows 25A-25B-25C, the lower surfaces 42 of the respective layers 32 of these roof tiles 1 form a generally flat surface. In other words, the transition from the lower surface 42 of the layer 32 of the roof tile 1 in row 25A and 25B to the lower surface 42 of the layer 32 of the roof tile 1 in respectively row 25B and 25C is flush or substantially flush.
(102) A denotes the inclination of the roof with respect to the horizontal.
(103) It is noted that the structure of the glaze coating 9 is not represented in detail in
(104)
(105) The roof tile 1 comprises a layer 46, which is situated below the ceramic body 8. The layer 46 is similar to the layer 32 represented in
(106) The layer 46 has a part 47, which extends beyond the side edge 48, whereas the ceramic body 8 has a part 49, which extends beyond the side edge 38 of said layer 46.
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(108) In the represented example, instead of being mainly rectangular, the roof tile 1 has an irregular shape. In particular, the front face of the roof tile 1 represents a plurality of staggered roof tiles 1A-1B-1C-1D.
(109) In such case, the length of the roof tile 1 is to be interpreted as the average length of the roof tile 1.
(110)
(111) In particular, the step S1 of providing a body composition 50, which here is formed by body powder, and the step S2 of pressing the body composition 50 are represented.
(112) For forming the attachment holes 13, before the step of firing, recesses 51 are formed in the ceramic body 8 in the form of blind holes or through holes. Here, recesses 51 are formed in the form of blind holes.
(113) In the represented example, the blind holes are formed in said step S2 of pressing. In particular, the body composition 50 is pressed between an upper press element 52 and a lower press element 53, which are provided with means for forming said blind holes. Here, said means are formed by protrusions 54 present at the upper press element 52, the length of which being smaller than the thickness of the ceramic body 8.
(114) The step S2 of pressing is preferably performed with the upper surface 20 of the ceramic body 8 facing upwards or, in other words, with the upper surface 20 of the ceramic body 8 facing towards the upper press element 52.
(115) The blind holes that are formed prior to firing the pressed body composition 55 preferably constitute at least 50%, more preferably at least 75%, and still more preferably at least 90% of the length of said attachment holes 13.
(116) The through holes can be made from the blind holes before the step of firing or after the step of firing, which through holes then correspond to said attachment holes 13. For example, the through holes may be made by means of stamping, before or after the step of firing. As alternative, the through holes may be made upon installing the roof tile, e.g. by punching/hammering a nail or turning a screw into the blind hole, which then removes the remaining part.
(117)
(118) The present invention is in no way limited to the hereinabove described embodiments, but such roof tiles and methods may be realized according to different variants without leaving the scope of the present invention.