US20240337104A1

US20240337104A1 - Roof tile apparatus and methods of making and use

Info

Publication number: US20240337104A1
Application number: US18/746,883
Authority: US
Inventors: Brian T. Casey
Original assignee: Individual
Current assignee: Individual
Priority date: 2021-03-26
Filing date: 2024-06-18
Publication date: 2024-10-10
Also published as: US20240384536A1

Abstract

Novel rigid tile, rigid tile apparatus, methods of making and use are disclosed. One embodiment includes a method of mounting rigid tile with a nail gun providing a protruding nail tip used as a nail passage or depression finder in the rigid tile. Another embodiment includes a metal rooftile having at least one fastener passage having pre-formed spacer section extending from the upper surface of the metal rooftile to space a fastener head or end from the upper surface of the metal rooftile. Yet another embodiment provides a unitary ganged set of rigid rooftiles. A tile bottom-side covering sealing bent T-trim can be utilized to cover open underside areas of a right rooftile. A novel installation method and rigid rooftile installation kit can utilize embodiments of the structures and methods stated above and, as desired, yet additional structure such as differently structured rigid rooftile components and trim components of differing shapes and sizes as desired.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation-In-Part of, and claims priority to, the applicant's prior U.S. Non-Provisional patent application entitled ROOFTILE APPARATUS AND METHODS OF MAKING AND USE, filed Mar. 28, 2022, Ser. No. 17/706,506, which claims priority to the applicant's prior U.S. Provisional Patent Application entitled STEELTILE APPARATUS AND METHODS OF USE, filed Mar. 26, 2021, Ser. No. 63/166,837; both of which prior applications are incorporated herein by reference, except that, in the event of any inconsistency between any such prior Applications and this Continuation-In-Part Application, this Continuation-In-Part Application shall govern.

FIELD OF TECHNOLOGY

This application is directed to the field of rooftile apparatus and methods of making and use, and in some embodiments to rigid, and in some embodiments particularly steel, rooftile apparatus and methods of making and use.

BRIEF DESCRIPTION OF THE DRAWINGS

The applicant's preferred and other embodiments are shown in the accompanying drawings in which:

FIG. 1 is plan view of a prior art pneumatic nail gun with 2.5 inch long nails mounted in the nail gun parallel to each other and with the nail tips extending along a mounting line A-A at an angle θ1 of 17 degrees to horizontal or from perpendicular to the laterally extending axis of each nail mounted in the nail gun;

FIG. 2 is a plan view of a prior art rack of nail 2.5 inch long gun nails for mounting in a prior art nail gun parallel to each other and with the nail tips extending along a mounting line B-B at an angle θ2 of 24 degrees to horizontal (as shown) or from perpendicular to the laterally extending axis, e.g., C-C, of each nail when mounted in the nail gun;

FIG. 3 is plan view of a prior art pneumatic nail gun with 2.5 inch long nails mounted in the nail gun parallel to each other and with the nail tips extending along a mounting line D-D at an angle θ3 of 34 degrees to horizontal (as shown) or from perpendicular to the laterally extending axis of each nail mounted in the nail gun;

FIG. 4 is a plan view of a prior art rack of nail 2.5 inch long gun nails for mounting in the prior art nail gun of FIG. 3 parallel to each other and with the nail tips extending along the mounting line B-B at an angle θ3 of 24 degrees to horizontal (as shown) or from perpendicular to the laterally extending axis, e.g., C-C, of each nail when mounted in the nail gun;

FIG. 5 is perspective view showing use of the prior art nail gun of FIG. 3 to use the protruding lead nail to commence locating pre-punched nail hole in a prior art roofing steeltile;

FIG. 6 is a partial perspective view showing use of the prior art nail gun of FIG. 5 to complete locating and commence penetrating a nail hole in the steeltile of FIG. 5 with the protruding lead nail in the nail rack of FIG. 5 ;

FIG. 7 is partial perspective view of a corner section of a steeltile having a fastener passage with an upper raised section abutting the underside of a nail head;

FIG. 8 is a partial cross-sectional view taken along section line 8-8 in FIG. 7 showing the raised section abutting the underside of the nail head of a nail with the nail shank fully penetrating through the fastener passage;

FIG. 9 is a alternative partial cross-sectional view taken along section line 8-8 in FIG. 7 showing the raised section having a flattened upper end section abutting the underside of the nail head of a nail with the nail shank fully penetrating through the fastener passage;

FIG. 10 is a lower front perspective view of a prior art rigid rooftile of FIG. 5 , such as a steeltile for example, having a widened, inter-connectable U-channel formed in a side (in this case the right side) of a steeltile.

FIG. 11 is right side perspective view of a prior art rooftile of FIG. 12 ;

FIG. 12 is upper side perspective view of a prior art rooftile of FIG. 12 ;

FIG. 13 is a left side perspective view of a prior art rooftile of FIG. 12 ;

FIG. 14 is a right bottom side perspective view of a prior art rooftile of FIG. 12 ;

FIG. 15 is a perspective view showing a plurality of prior art rooftiles of the type shown in FIG. 12 mounted on a roof with the rooftile U-channels providing interconnection between laterally adjacent rooftiles;

FIG. 16 is plan view of applicant's novel integral and unitary form of multiple (in this drawing, three) rooftiles stamped of one sheet of material, with a U-channel or trough extending from the rightmost of the multiple rooftiles;

FIG. 17 a right side cross-sectional view of use of the applicant's novel T-trim to underly the lowermost row of rooftile;

FIG. 18 is a right-side slightly exploded cross-sectional view of a rigid tile, such as an SierraSteeltile® steeltile, having applicant's novel T-trim mounted in an alternative fashion to abut the upper end of building fascia (or other outward building facing or structure downwardly extending from the roof deck);

FIG. 19 is an elevational view of roofing showing the rigid, square rooftile assembly step of developing a first snap line layout for a column of rigid tiles closest to a beginning roof gable, with the snap line extending upwardly on the roof and in a vertical plane perpendicular to the lower roof eave (called “vertical snaplines”);

FIG. 20 is an elevational view of roofing showing the next rooftile assembly step of developing further vertical snap lines at varying distances in order to terminate the final lowermost row of full sized rigid tiles at 6 inches, or 0 inches for full-tile finish, from the ending gable;

FIG. 21 is an elevational view of roofing showing the beginning of next rigid tile assembly step of developing horizontal snap lines at varying distances in order to terminate the final uppermost horizontal snap line with 10 inches of exposure extending from below the roof ridge;

FIG. 22 is an elevational view of roofing showing the completion of the rooftile assembly step of developing horizontal snap lines at varying distances in order to terminate the final uppermost horizontal snap line with 10 inches of exposure extending from below the roof ridge cap(s);

FIGS. 23 and 24 show the rooftile assembly step of installation of a first course of rigid tiles (that is, horizontally closest to the roof eave) and initiating an offset next row of rooftiles with six inch half-tile (along the half-tile's top edge), also having the applicant's widened U-channel on its right side;

FIG. 25 shows the rooftile assembly step of installation of step of installation of a second course of rigid tiles above and abutting the first course of rooftiles;

FIG. 26 shows an alternate method of installing rigid tiles in a pyramidal or slanted fashion;

FIG. 27 shows: the rooftile assembly step of completing all rigid tile courses to the roof ridge;

FIG. 28 shows the rooftile assembly step of initiating ridge cap installation at opposing gable ends;

FIG. 29 shows a gable end view of a double ridge cap installation at each gable end with each of the doubled ridge caps having an upper ridge slanted upwardly in the direction of the cap's associated gable (note that spacing shown between overlapping portions of rigid tiles and underlying roof underlayment will not exist and is solely shown for clarity of showing distinct structures);

FIG. 30 shows the rooftile assembly step of completing installation of identical single rigid ridge caps on the roof ridge with a final center interconnecting cap having rectangular opposing sides (only one rectangular side shown in FIG. 28 );

FIG. 31A is a perspective view of a prior art gable end protective closure mounted to a row of rigid tiles of the present specification;

FIG. 31B is an elevational, slightly exploded, view the end protective closure of FIG. 31A;

FIG. 32 is a photograph showing how rooftile layout planning can be performed in the field prior to actually mounting the rigid tile to a roof;

FIG. 33 is a perspective view of the prior art steeltile of FIG. 5 showing dimensions of the steeltile set forth in associated text infra;

FIG. 34 is a perspective view of an alternative prior art technique of providing a gable end protective closure with rake tiles;

FIG. 35 is a schematic elevational view of another alternative prior art technique of providing a gable end protective closure with both an L-closure and J-closure; and

FIG. 36 depicts the contents of a novel kit for assembly in the field of rigid rooftile, such as prior art steeltile for example.

DETAILED DESCRIPTION

This specification discloses multiple differing novel apparatus and methods of making and using them. Some embodiments of the differing novel apparatus and methods can be used together or can be otherwise mixed and matched as desired.

I. Rigid Rooftile Having Interconnecting Side Channel Structure:

A. Prior Art Rigid Rooftiles:

With reference now to FIG. 10 , a prior art rooftile 1010 has a central tile body section 1012 with a generally rectangular upper surface 1014 and a planar front side section 1016 extending perpendicularly downwardly from a laterally extending lower edge 1018 of the upper surface 1014. An upper stabilizer cavity 1020 extends (i) downwardly from the planar upper central surface section 1022 of the upper surface 1014 and (ii) laterally between the left side 1024 and right side 1026 of the generally rectangular upper surface 1014. The planar left side 1024 is parallel to the planar right side 1026, and the left side 1024 and right side 1026 extend perpendicularly downwardly from the generally rectangular upper surface 1014. The front ends 1028, 1030 of the planar left and right sides 1024, 1026, respectively, are adjacent the opposed left and right ends 1032, 1034, respectively, of the front side section 1016. Two spaced apart sets 1036, 1038 of three u-channel depressions, e.g., 1040, 1042, 1044, extend downwardly from the upper laterally extending edge 1046 of the planar upper central surface section 1022 toward and perpendicular to the upper stabilizer cavity 1020.
With reference now to FIG. 11 , an interconnectable U-channel 1110 extends along and integrally with the right side 1026 of the rooftile. 1010. The U-channel 1110 has a central planar, rectangular bottom side 1112 extending between the rooftile right side 1026 and a right upwardly extending planar side 1124 of the U-channel 1110. The rooftile right side 1026 lower edge 1030 is substantially taller than the right side 1026 upper edge or end 1126 extending perpendicularly upwardly from the bottom side 1112 to the upper surface 1012 of the rooftile 1010. Similarly, the lower upwardly extending end 1128 of the right side 1124 of the U-channel 1110 is more than two times taller than the opposed upper upwardly extending end 1130 of the U-channel 1110. The height of the right side 1124 of the U-channel 1110 is lower than the opposing height of the right side 1026 of the rooftile body section 1012 all along the length of these parallel right sides 1124, 1026. The lowermost edge 1132 of the U-channel 1110 is spaced upwardly from the bottom end 1030 of the right side 1026 of the rooftile central body section 1012. The (i) lowermost edge 1132 of the U-channel and (ii) bottom edge 1134 of the right side 1026 of the central body section 1012 extending from the lowermost edge 1132 and bottom end 1030 of the central body section 1012 right side 1026, cooperatively form an L-shape. The U-channel upper laterally extending edge 1136 is coplanar with the rooftile central body section's uppermost laterally extending edge 1138
Referring now to FIG. 12 , the central body section's uppermost laterally extending edge 1130 spans between and extends perpendicularly from (i) the upwardly extending end 1126 of the right side 1026 of the central body section 1012 and (ii) the upwardly extending end 1210 of the left side 1024 of the central body section 1012. The laterally extending edge 1130 and opposed upwardly extending ends 1130, 1210 cooperatively form an inverted U-shape. With reference to FIG. 13 , the left side 1024 of the rooftile 1010 has a front end 1028 more than two times taller (in one embodiment 3.3 times taller) than the height of the opposed upwardly extending end 1210. And, referring to FIG. 14 , the opposed front ends 1028, 1030 of the left and right sides 1024, 1026, respectively, are of the same height or, stated differently, equally tall. Similarly, the opposed laterally extending ends 1130, 1210 of the right and left sides 1026, 1024, respectively, are of the same height or, stated differently, equally tall.
With continuing reference to FIG. 14 , the stabilizer cavity 1020 has a lowermost laterally extending upper side 1410 that is as tall or, conversely, deep as the height of the opposed left and right sides 1024, 1026, respectively, at positions 1412, 1414 on the left and right sides 1024, 1026, respectively, along a line S-S parallel with the cavity's upper side 1410. The stabilizer cavity 1020 can thus support and structurally stabilize the upper central surface section 1022 of the central tile body section 1012. Further, the lower most edges 1416, 1418, 1420, 1422, 1424 of the rooftile's left side 1024, front side 1016, left side 1026, stabilizer cavity 1020, and U-channel bottom side 1112, respectively, are co-planar, cooperatively providing mounting, rooftile-structure-stabilizing, and moisture-seal-out structure as shown and explained further infra.
With reference now to prior art rooftile structure shown in FIG. 15 , a first row 1509 of rooftiles 1510, 1512, 1514 is mounted on a roof underlayment, with fasteners penetrating the fastener passages, e.g., 1516, and roof underlayment 1518, so that adjacent rooftiles, e.g., 1512, 1514 are sealingly interconnected. After a first rooftile 1510 is mounted, a second rooftile 1512 can be mounted with its left side 1520 abutting the bottom side 1522 of the first rooftile's U-channel 1624. This prior art mounting technique can be repeated in seriatim to create a first row 1509 of rooftiles. Similarly, a second row 1526 of rooftiles 1550, 1552, 1554 can be similarly mounted and arranged higher up on the roof underlayment 1518 but with the lower sections, e.g., 1528, of the second row 1526 rooftiles firmly and sealingly abutting the adjacent upper sections, e.g., 1530, of the lower first row 1509 of rooftiles. The rooftiles of FIGS. 11-15 are stamped from 22 gauge steel sheeting.
Further, one embodiment of a prior art rooftile is a steeltile having dimensions such as shown in FIG. 13 . The front side thickness FT is 0.7 inches; the frontside width is 11 nches; the topside height H is 15.25 inches; the topside width TW is 11.81 inches; the rear side thickness RT is 0.183 in inches. and the U-channel width CW is 1.5 inches. These dimensions may be altered in ranges of plus or minus 10, 20, 30, 40, 50, 60 percent, and of plus 70 to 1,000 percent and in differing ranges, including all subranges within these ranges, as further explained infra.
The rooftiles can have differently structure central tile body sections, such as non-rectangular, trapezoidal central tile body sections, as shown in FIG. 16 for example, similarly, as also shown in FIG. 16 , the U-channel may be shaped to have a trapezoidal peripheral shape, which can better mate with a trapezoidal central body section in adjacent rooftile.
Additional product specifications for the prior art embodiment of FIGS. 10-15 are:

- Base metal: 22 ga. (approximately 0.029″ thick) A606 aka “Weathering Steel”
- Exposure of steeltile face after installation: adjustable height along face of steeltile: 9″-10″; adjustable width along face of steeltile: 12″-12.5+″
- Weight per Square Installation of Steeltiles: 240 lbs.
- Units: 120 Steeltiles per Square
- Packaging: 5-50 pound boxes per Square

B. Novel Rooftiles:

The rigid rooftiles may have differing structure than shown in FIGS. 11-15 . For example, the U-channels can alternatively extend from the left sides rather than the right sides of the rooftiles. The U-channels may be formed differently, such as by separately formed components secured together in any suitable fashion, such with fasteners or adhesive. The U-channels may be of differing widths and lengths, and for example, a U-channel can be narrow enough to allow much less or very little spacing between adjacent rooftiles.
The rooftiles can have more rounded edges or other ornamental or other structures or materials stamped on, mounted to, painted on, or plated, anodized, or etched on or to them. For example, differing coloring of the rooftiles can be provided by differing colored metals or other materials providing a rigid rooftile or by painting, plating, laminating, anodizing, or etching the rooftile material.

II. Nail-Tip Steeltile Hole Locating and Attachment Method:

- Roofing consisting of steeltiles or other rigid tiles has been in widespread use for a very long time. These prior art techniques for mounting steeltiles or other very rigid rooftiles have typically involved manual use of standalone flathead nails by (i) locating a steeltile as desired above a wood roof underlayment, (ii) manually inserting a standalone metal nail into an upper end of a pre-drilled or pre-punched nail hole in the steeltile, (iii) using a hammer to manually nail the nail through nail hole and into the underlying wood roof underlayment. (Note, however, that in some embodiments, the rigid material may not need to be drilled or pre-punched) Most commonly this has involved using this technique twice to nail at least two pre-drilled holes in each steeltile. This technique is labor intensive and slow, and risky since it requires use of a hammer and possible mis-striking of the hammer on a user's hand or the nail head, often damaging, weakening, and requiring replacement of the damaged nail.

Another prior art technique uses a nail gun with the nails mounted in a coil within a circular canister on the nail gun. The tips of the nails are not visible to the user. In the case of steeltiles for example, they are often made of heavy, high strength steel, such as 22 gauge steel for example. If fasteners are shot with such a nail gun at a portion of flat, un-punched surface of the tile, the fasteners can ricochet and cause injury and deformation of the roofing tile, requiring replacement of the tile for appearance or structural defect reasons.
Many prior art nail guns and associated nail racks, such as shown in FIGS. 1-4 for example, have the nail racks with the nail tips aligned at an angle 17-24 degrees to a line perpendicular to a laterally extending axis of each nail in the rack. The incline of the tips of the nails provided by such prior art nail racks and nail gun render the leading tip of the lead nail in the nail rail rack blocked from the user's vision and from extending from the nail gun prior to shooting of the lead nail, and so these types of prior art nail guns present the same types of problems as coil-mount nail guns when used to mount rigid rooftiles such as steeltile discussed above.
With reference to FIG. 5 , a particular type of nail gun, e.g., 12, is selected and grasped by hand to mount a rigid tile, e.g., 14, to a roof (not shown in FIG. 5 ) over an underlying structure or area (not shown in FIG. 5 ). The nail gun, e.g., 12, is selected to provide a visible and protruding front nail tip, e.g., 16 in the nail gun, e.g., 12. In the embodiment of FIG. 5 , this can be provided by certain nail racks, e.g., 17, in the nail gun, e.g., 12. The rigid tile 14 can comprise or consist essentially of rigid material, such as for example metal, composite, ceramic, or cement.
In the embodiment of FIG. 5 , a rigid 22 gauge steeltile 14 is utilized, and the method then proceeds as follows:

- placing the steeltile 14 in the desired location, and if needed or desired, with one hand (not shown) securing the steeltile in that location, on roofing underlayment (not shown in FIG. 5 ) into which a nail can be shot and be held in place by the underlayment;
- with the nail gun 12 having the visible and protruding front nail tip 16, grasping and moving the nail gun 12 with other hand (not shown) to locate the visible and protruding nail tip 16 over a pre-formed nail mounting hole or passage 18 in the steeltile 14;
- while continuing to grasp and control the nail gun 12 with the other hand:
  - lowering and moving the nail gun and protruding nail tip 16 to, as shown in FIG. 6 , have the nail tip 16 locate and penetrate the nail mounting passage 18 in the steeltile, this may include first sliding the nail tip 16 over the upper surface 20 of the steeltile 14, allowing slight lowering pressure on the nail gun 12 and nail tip 16, to locate nail mounting passage 18 with the nail tip 16;
  - pulling the trigger 22 (see FIG. 5 ) of the nail gun 12 to shoot the lead nail 24 through the nail mounting passage 18 into the underlayment (not shown in FIG. 6 ) so that the upper nail flat head (see FIG. 4 ) securely abuts the portion of the upper surface 20 of the steeltile 14 surrounding the nail mounting passage 16;
- if needed or desired, repeating the moving, locating, lowering, moving, trigger pulling, and shooting processes set forth above in order to inject the next-up lead nail (previously 28 in FIG. 6 ) though another nail mounting passage such as 30 in FIG. 5 ;
- repeating the prior step and needed or desired for the given steeltile; and
- repeating the method set forth above in this paragraph as desired for mounting of one or more additional steeltiles (or other rigid tiles as desired).′

This novel method allows the installer of rigid pre-drilled roofing to use pneumatically driven fasteners with a nail gun and nail frame or magazine as shown to safely, more quickly, easily, efficiently, and/or reliably locate the tips of nails in pre-drilled nail holes, respectively, in the rigid tile, a then more reliably nail the nails through the pre-drilled holes respectively and thereby securely attach the rigid tile to the roof underlayment where desired.
With reference back to FIG. 4 . the nail frame 32 can be provided by one or more strips of paper, plastic, or other materials that allow mounting of each nail and associated nail tip with respect to an adjacent nail so the user can use the leading nail tip in the nail frame as a “finder” to “find” a pre-punched hole or depression in the tile. In this latter regard, the tile may have one or more such depressions that may also be utilized in the method in addition to, or as an alternative to, a nail mounting passage.
Similarly, other types of fasteners can be used. For example, with a suitable gun, an installer can use screws, framed and collated like the nails described above and that are arrange at an angled to provide visible protruding fastener tips to find and penetrate pre-drilled passages. Screws can provide a more secure tile mount, but screws can be more expensive and may require more effort to screw into the mating pre-drilled hole. The fasteners may be made of any of a variety of suitable materials, such as steel (such as stainless or other rust-reducing steel), other metal, or sufficiently rigid composite or plastic.
When a steeltile is made of a suitable weathering metal, the fastener can be of the type that will prevent possibly damaging or unaesthetically modifying the appearance of the fastener or associated metal tile. For example, in the case of a steeltile made of A606 weathering steel for example, a stainless steel fastener can be effectively utilized, including to reduce the likelihood of undesired and weakening ionic interaction between abutting A606 and stainless steel metals.
The fastener may be a rink-shank nail to present greater resistance to withdrawal of the nail from the roof underlayment. In addition, up to full head nails or other fasteners may be used. In some embodiments, full-head nails can more reliably secure a rigid tile in position and prevent moisture from leaking under the nail head abutting the top surface of the rigid tile surrounding the associated nail hole in the rigid tile.
III. Rigid Rooftile with Raised-Section Fastener Passage:
Prior art steeltiles typically have pre-drilled fastener passages with the upper end of the fastener passage coplanar with a topside planar section of the steeltile. When a nail is inserted into the fastener passage and hammered downward through the fastener passage into lower underlayment below the steeltile, the upper end of the fastener is at most coplanar with the lower side of the flat head of the nail. Often, however, the hammering of the nail into the nail passage can cause the flat head of the nail to deform and depress at least one or more portions of the upper end of the nail passage. Applicant believes he has discovered that this arrangement creates several problems. One problem is that water on the upper surface of the steeltile can leak under the nail head, into and through the fastener passage, and along the nail shank. This can cause undesired corrosion under and in the vicinity of the nail head, and this corrosion can cause structural damage to, and cause unsightly alteration of, the steeltile and associated nail head.
The applicant has developed, as shown in FIGS. 7, 8 and 9 , novel steeltile 710 structures providing one or more predetermined, pre-drilled or upwardly punched or otherwise preformed upwardly extending fastener mounting passages 712 in a steeltile 710, which can be pre-formed from a 22 gauge steel sheet. The embodiment shown in FIG. 8 , the upper end 808 of the fastener passage 712 is circular to surround the nail shank 810 when hammered into the fastener passage 712, and the circular upper end 812 of the fastener passage 712 then abuts the underside 814 of the nail head 816, which extends radially outwardly from the upper end 817 of the nail shank 810. In this mounted position of the nail shank 810 and associated nail head 816, the nail head 816 and abutting circular upper end 808 of the fastener passage 712 are spaced from and above the upper side 818 of the steeltile 710 extending radially outwardly from the upwardly extending fastener mounting passage 712.
In some embodiments, the upwardly extending fastener mounting passage 712 can provide a relatively strong, somewhat frusto-conical neck section 820, with a curved or arcuate, rather than strictly conical, side 821, that can resist being depressed downwardly with respect to steeltile upper side 818 when the nail 816 is hammered to firmly abut the circular upper end 712 of the frusto-conical neck section 820. Even if this frusto-conical neck or spacer section 820 is thereby depressed somewhat below the steeltile upper side 818, the frusto-conical neck section 820 can still provide substantial spacing between the nail head 816 and abutting upper end 712 of the frusto-conical neck section 820. This raised frusto-conical neck section 820 supporting and abutting the nail head 816 can thereby substantially reduce or even eliminate leakage of water or other fluid into or within the circular junction of the frusto-conical neck section 820 and abutting nail head 816.
With reference now to FIG. 9 , the steeltile 710 can alternatively have a frusto-conical neck or spacer section 910 having an upper plateau or planar nail-head supporting rim 912 extending radially inwardly from the frusto-conical body 914 of the frusto-conical neck section 910. The nail-head supporting rim 912 abuts the underside 814 of the nail head 816 and an interior circular nail passage 916 in the nail-head supporting rim 912 surrounds the nail shank 810 closely adjacent and possibly abutting the nail shank 810. This raised frusto-conical neck section 910 also having a nail-head supporting rim 912 abutting the nail head 816 and closely surrounding the nail shank 810 can thereby even more substantially (i) reduce or even eliminate leakage of water or other fluid into or within the junction of the supporting rim 912 and abutting nail head 816; and (ii) resist deformation, such as depression for example, of the frusto-conical neck section 910 and associate supporting rim 912 with respect the radially outwardly extending upper side 818 of steeltile 710.
With reference now to FIGS. 8 and 9 , the somewhat frusto- conical sections 820 and 910, respectively, can be differently structured. For example, these raised and spacing sections could be conical or tubular. Alternatively, the degree of curvature of the side wall of these spacing sections 820 and 910 can be different than as shown, and the junction of these spacing sections 820 and 910 and supporting rim 912 for the latter can be rounded or structured otherwise as well.

IV. Integrated Ganged Rigid Rooftiles:

Referring now to FIG. 16 , multiple rigid rooftiles 1610, 1612, 1614 can be formed of, such as stamped from, a single sheet of material or otherwise pre-manufactured to provide a unitary set of rooftiles that can be shipped or lifted and mounted, as applicable, as a single element, e.g., 1616. The number of such rigid tiles in a unitary can be from two to as many as are desired and are reasonably feasible for a given roofing project, manufacturing capability, lifting weight, etc.
Each adjacent pair of rooftiles, e.g., 1610, 1612, have a planer interconnecting section, e.g., 1613, spanning between the bottom a U-shaped channel 1617 intermediate and formed by adjacent upwardly extending planar sides, e.g., 1611, 1615, of the adjacent pair of rooftiles, e.g., 1610, 1612. A rigid adjacent-tile-mounting U-channel 1618 extending from a side 1620 of one unitary set of rooftiles 1619 can allow one rooftile or another set of mating rooftiles (not shown in FIG. 16 ) to be mounted to abut the one unitary set 1616 at its side 1620 having the U-channel 1618.
This type of multiple rooftile integrated structure can reduce installation time, the amount of sheet material required to manufacture the unitary set of rigid tiles, lighten the weight of total rigid tiles needed for a give roof installation, reduce the number fasteners required to securely mount rooftiles to the roof, reduce installation time, reduce rooftile shipping costs, and yield a stronger rooftile assembly. In the embodiment of FIG. 16 , which can be a steeltile, the number of fasteners that might be utilized is four, with two fastener passages 1622, 1624 in the central rooftile 1612 and two opposed outer fastener passages 1610, 1614 in the opposed outer two rooftiles.
The structure and shape of these types of rigid tiles may vary as described above in section IV.

V. T-Trim Sealing Underside of Rigid Rooftile:

Referring now to FIGS. 15 and 17 , one embodiment of a novel T-trim 1710 is formed of a single sheet of material 1302 bent to provide the T-trim cross-sectional configuration shown in FIG. 17 . The T-trim 1710 has (i) an upper planar roof mounting section 1712 that includes a lower rigid tile covering section 1714 and (ii) a planar building facia mounting section 1716 extending perpendicularly downwardly from the roof mounting section 1712. An optional fluid drip lip 1718 extends at an angel from the lower end 1717 of the facia mounting section 1716 to provide fluid run-off from T-trim 1710 fluid drip lip 1718 spaced from an adjacent building fascia 1720. The T-trim 1710 may be secured in position with respect to the adjacent underlying roofing 1721 by fasteners (not shown) penetrating the roof mounting section 1712 and adjacent underlying roofing 1721.
In the embodiment of FIG. 15 , a roofing underlayment sheet 1518 may underly the rows of steeltiles 1509, 1526 but terminates at the lowermost edge of the U-shapeugh sections, e.g., 1534, of the lowermost row of associated rooftiles 1509. An ice dam sheet 1536 may similarly underly the underlayment sheet 1518 to abut the upper planar surface 1538 of the upper planar roof mounting section 1544 of a smaller T-trim 1546 and upwardly extending portion 1540 of the roof deck 1542 not covered by the T-trim 1546 roof mounting section 1544.
Referring now to FIG. 18 , an alternative method of mounting a smaller T-trim 1810 has a planar upwardly extending roof mounting section 1812 extending upwardly along the top side 1814 of a primary membrane 1816, which in turn is mounted over the top side 1818 of the roof deck 1820. A nail fastener 1822 penetrates the roof mounting section 1821 and primary membrane 1816 to penetrate the roof deck 1820 below the primary membrane 1816. Optionally, a strip membrane counterflash strip 1824 can be mounted to cover the roof mounting section 1812, fastener head 1826 and upper primary membrane section 1826 extending upwardly from the roof mounting section 1812 along the roof deck 1820. The counterflash strip 1824 is cut to fit entirely within, as also shown in FIG. 14 , an open underside 1430 of the rooftile 1010 so that, as shown in FIG. 18 , the rooftile 1010 can be mounted to sealingly abut the upper surface 1828 of the T-trim 1810, thereby sealingly covering the open underside 1430 of the rooftile 1010 and preventing moisture and other things from penetrating the open underside 1430 of the rooftile 1010.
The T-trim may not provide exactly a T cross-section or end view. For example, the upstanding arm 1828 can be at an angle to the cross-arm 1830 differing from 90 degrees depending on the orientation needed to have the upstanding arm 1828 abut or be approximately parallel the fascia or other structure adjacent and downwardly extending from the roof 1814. For example, such an angle could be approximately 10-15 degrees if the fascia is vertical.

VI. Rigid Rooftile Installation Kit and Method of Use:

In prior art rigid rooftile installation, for example steeltile installation, the installer commonly would simply cut off the rooftile at the ending gable, leaving an open side of the rooftile at that cut side end. This technique is unsightly and also allows moisture, leaves, insects, etc., to enter within the open end of the rooftile.
Alternatively, the installer could cut a slightly enlarged rigid rooftile and bend the open side to close or box-in that side of the tile. This technique requires can be particularly difficult with heavy duty rooftile material, such as for example heavy and strong 22 gauge steel. Bending such materials appropriately can take substantial time and effort, and typically requires use of special tools.
Alternatively, the installer could use specially designed end caps such as shown in FIGS. 34 and 35 . These caps require additional material and installation time to provide covered rooftile sides at an end gable, and they are not as attractive or as durable as having the rigid tile provide the closed gable end, such as when the rigid tile is made of heavier duty material, such as 22 gauge steel in the case of steeltile made of such steel.
With reference now to FIG. 19 , a novel method of installing rigid rooftiles, including in some embodiments of the type identified in Section III above, commences by spacing rooftiles, e.g, 1908, for a lowermost row of rooftiles (not shown in FIG. 19 ) on a sloped roof 1909 having an underlayment 1910 intermediate an upper roof ridge 1909 and a lower roof cave 1908. The objective is to space the rooftiles, e.g., 1908, horizontally, in order to start the starting gable 1912 and finish the ending gable 1914 with pre-formed 6 inch wide half-tiles (not shown in FIG. 19 ) or 12 inch wide full-tiles, e.g., 1908, from a starter kit (not shown in FIG. 19 ). In doing so, mount a first lowermost rooftile 1908 in the lower corner 1916 formed by the starting gable 1912 intersection with the cave 1908. Next, develop a first snapline layout 1918 for a column of rigid tiles (not shown in FIG. 19 ) closest to a beginning roof gable, with the snap line 1918 spaced 12 inches horizontally from the starting gable 1912 and extending upwardly on the roof and in a vertical plane perpendicular to the lower roof eave (called “vertical snaplines”). Then measure the horizontal distance D-D from the snap line 1918 to the ending gable 1914. If the resulting distance measurement D-D is X number of feet plus 0 to less than 6 inches (“Y inches”), the installer uses Example A below. If the resulting measurement D-D is X number of feet plus greater than 6 but less than 12 inches (“Z inches”), the installer uses Example B below.
With reference now to FIG. 20 , in Example A, increase the snap-line spacing, e.g., E, F, G, between a number of rooftile column snap lines, e.g., 2010, 2012, 2014, to the right of the first snap-line 1918 from 12 inches by up to 0.50 inch until the total increase in spacing between snap lines, e.g., E, F, G, etc., equals Y inches. This arrangement will yield 12 inch spacings for the remaining snaplines (not shown in FIG. 20 ) for the remaining rooftiles (not shown in FIG. 20 ), with the last 12 inch rooftile in the row (not shown in FIG. 20 ) abutting the ending gable 1914.
In Example B, when the resulting distance measurement D-D is Z inches, the end rooftile (not shown in FIG. 20 ) abutting the ending gable 1914 will be a 6 inch wide rooftile (not shown in FIG. 20 ). For the amount of Z inches above 6 inches (“Z-6 inches”), the same technique will be applied as set forth in Example A above to consume the Z-6 inches and result in the ending rooftile being a 6 inch wide rooftile.
In other words, the objective is to provide sufficient distance between snaplines, e.g., E, F, G, so that the ending distance between the ending snapline and the ending gable 1914 is 12 or 6 inches (e.g., 6 inches for the depicted ending snapline 2016). Then, in the middle of the distance between primary snaplines, e.g., E, F, G, etc., across the roof 1910, snap intermediate snap lines, e.g, 2018, 2020, 2022, between primary snaplines.
With reference now to FIG. 21 , the next rooftile assembly step develops horizontal snap lines at possibly varying distances in order to terminate the final uppermost snap-line (not shown in FIG. 21 ) with 10 inches of roof exposure extending from below the top roof ridge caps (not shown in FIG. 21 ) or an angled wall flashing if the top edge of the roof abuts a vertical wall. First, mount a starting 6 inch rooftile 2110 (that is, having a 6 inch wide dimension S) with its lowermost edge 2112 approximately ⅓ the way down the face 2114 of lowermost rooftile 1908. Measure the distance V-V from the top of the 6 inch rooftile to the roof ridge
With reference to FIG. 22 , snap an upper horizontal snap line 2210 10 inches from the roof ridge 1909. Snap additional horizontal snap lines, e.g., 2212, 2214, 2216, at 9 to 10 spacing from each other.
Referring to FIGS. 23 and 24 install a first course of rigid tiles or steeltiles 2310 (that is, horizontally closest to the roof eave) by aligning the right upper tile tips, e.g., 2312, 2314 with their mating snap lines, e.g., 2010, 2012, respectively. Finish the first course 2310 with a full or half-tile as needed (a full-tile 2316 without a U-channel is shown in this example).
Referring now to FIG. 25 , continue installing a second row or course of rigid tiles 2510 by aligning the upper right tips, e.g., 2512, 2514, to rest along the redetermined intermediate snap lines, e.g., 2516, 2518. respectively. Then, finish the second course 2510 at the ending gable with a full or half-tile as needed (a half-tile 2516 without a U-channel is shown in this example).
With reference to FIG. 26 , an alternate method installs rigid tiles 2610 in a pyramidal or slanted grouping fashion. In this method, the installer (not shown) installs as many rooftiles as can be installed at a given position of the installer, who then moves on to the next installation position (not shown). As in the prior full row or course installation technique, the upper right tips of the rigid tiles, e.g., 2612, 2614, and 2616, are mated to align with the appropriate snapline, e.g., 2618, 2620, 2622, respectively.
Referring now to FIG. 27 , continue installing the rows of rigid tiles, e.g., 2710, 2712, 2714, 2718, with fasteners, e.g., 2722, 2724, 2726, until the co-aligned upper edge 2720 of a top row of rooftiles 2718 the aligns with the upper roof ridge 1909. Not fully shown in detail (see FIG. 29 ) is, as applicable, repeating the same technique installation of rows of rooftiles on the opposite side of the roof ending at the roof ridge 1909.
Referring to Figure FIG. 28 , next mount an initial beginning rigid ridge cap 2810 and ending ridge cap 2812 on the upper ends of underlying rigid tiles, e.g., 2814, 2816 and 2818, 2820, respectively, to align the outer ends 2822, 2824, of the opposed ridge caps 2810, 2812, respectively, with the opposed beginning and ending gables 1912, 1914, respectively.
Referring next to FIG. 29 , in an alternative embodiment, two ridge caps 2910, 2912 or more may be stacked and mounted at each gable end, e.g., 1912, with each of the doubled ridge caps 2910, 2912 having an upper ridge 2914, 2916, respectively, slanted upwardly in the direction of the cap's associated adjacent gable (see FIG. 28 ; and note that spacing shown between overlapping portions of rigid tiles and underlying roof underlayment will not exist and is solely shown for clarity of showing distinct structures).
With reference now to FIG. 30 , next, complete installing identical single ridge caps, e.g., 3010, 3012, along the roof ridge (not shown in FIG. 30 ) with a final center interconnecting cap 3014 having rectangular opposing sides, e.g. 3016 (only one rectangular side shown in FIG. 30 ) mounted to abut opposing ridge caps 3010, 3012 most closely adjacent the roof ridge center (not shown in FIG. 30 ) equidistant from the left side gable 1912 and right side gable 1914.
With reference now to FIGS. 31A and 31B, in some a rigid, pre-formed, protective J-closure 3110 can be mounted to cover the outermost ends, e.g., 3112, of rigid rooftiles, e.g., 3114, 3116, adjacent gable, e.g., 1914. Note that the FIG. 31B spacing between the components, e.g., 3110, 3112, is for schematic clarity; in practice the components, e.g., 3110, 3112, generally abut each other. In addition, note that the T-trim cover 3118 mounted to abut underlying structure fascia 3120 would be mounted, with nails for example, to the roof underlayment 3122 prior to installing the row of rooftiles, e.g., 3124, over the T-trim cover 3118. And, the associated J-closure 3110 also would be mounted, also with nails for example, over the T-trim cover 3118 and roof underlayment 3122 extending upwardly from the T-trim cover 3118, prior to installing the rooftiles, e.g., 3116, 3114, to be covered by the J-closure 3110. At the opposed starting gable (not shown in FIG. 31A), the same type of J-cover may be turned around to be similarly installed to rooftiles (not shown in FIG. 31A) adjacent the starting gable.
With reference to FIGS. 32 and 33 , rooftile layout planning of the type disclosed in this specification can be performed in the field prior to actually mounting the rooftiles to a roof. Alternatively, the rooftile layout can be performed remotely from the roof, such as at a on office, after roof measurements have been taken.
With reference now to FIG. 34 , an alternative protective gable end closure technique can use pre-formed inverted L-shaped rake tiles, e.g., 3410, 3412, to cover rigid rooftiles, e.g., 3414, 3416, and adjacent upper gable section 3418. shows an alternative prior art two-piece gable end protective closure with a two-piece channel the top closure piece. The rake tiles, e.g., 3410, 3412, may be secured in place with screw of other fasteners, e.g., 3420, 3422. It is to be understood the FIG. 34 is schematic and therefore reveals certain underlying structure that would be covered by the rake tiles 3410, 3412 and includes an area 3417 removed from an upper raketile 3412 that is not removed in practice and is structured as shown for the lower raketile 3410.
With reference now to FIG. 35 , another alternative protective gable end closure technique can use an inverted L-shaped gable cover 3510 mounted to the roof underlayment 3512 and a J-channel 3514 mounted above and abutting the L-shaped gable cover 3510. The L-shaped gable cover 3510 and J-channel 3514 can be mounted in place with nail or screw fasteners, or with other suitable fasteners or fastening material, prior to installing the rooftile 3516 to be covered by the J-channel 3514.
With reference now to FIG. 36 , the applicant's novel rigid (in this case, metal) rooftile installation kit, generally 3610, can include, for example, a number of types of components, in the case of the FIG. 36 embodiment, up to at least ten types of components shown in perspective view for the upper five types of components and in side view and perspective view for the lower five types of components. The installer can study the roof in advance in order for the kit assembler to determine which types of such components should be included for the given roof installation and the numbers to include for each type of included component.
The kit can utilizes specially made pre-formed components—which can be sold as a “Starter Kit”—that enables the roof installer to use factory- or pre-formed half-tiles, e.g., and full-tiles, e.g., 3616 (an ending gable full tile without the U-channel) for starting and ending gables (not shown in FIG. 36 ). This full-tiles 3614 having widened U-channels or toughs 3618 extending from a rooftile side 3620, allows the installer to adjust the location of rooftiles with respect to each other as explained and shown in association with FIGS. 19-28 , enabling the pre-formed rigid tiles and roof caps with closed (i.e., non-open) sides, e.g., 3614, 3612, 3616, 3622, to be used with such sides on the ends of a row of rooftiles. In addition, use of the novel half-tile 3612 plus a novel standalone U-channel trough 3624 can be used on the starting and other rooftiles, including as shown with starting rooftile 2114 in FIGS. 21 and 22 , for example. Conversely, the method also can optionally include use of standard full tiles 3614 without a U-channel or trough on a side, e.g., 3616, to be mounted at or adjacent an ending gable, eliminating the need to cut off an integrated trough if otherwise included such as in full a full tiles, e.g., 3614, having a U-channel 3618 on its right side 3620.
The kit can also include various types of trims, such as, for example, T-trim(s) 3626, L-shaped trim(s) 3628, U-channel trims 2630, angled or rake tile trim(s) 3632, roof trough trim(s) 3634.
This kits and its use can make installation much easier for the installer, much quicker, more attractive, and/or less subject to having any exposed open sides or bottom sides of the installed rooftiles, and/or with reduced problems from moisture, ice, insects, leaves, or other materials entering through such openings.
The components of the kit can be easy to make, such as by merely stamping metal, such as steel, aluminum, alloys, etc. The components of the kit can also all be made of the same type of metal or otherwise compatible materials that will not negatively react with other, such as by doing so and causing excessive corrosion.
It is to be understood that the above-identified methods of mounting rigid rooftile and associated ridge caps is specified for the particularly structured and dimensioned rooftile and ridge caps as shown in FIGS. 10-15 and 19-29 . The same basic technique can be used with adjusted for differently structured and dimensioned rooftiles, associated U-channels, and ridge caps. Similarly, the U-channels may be on the left sides of the rooftiles rather than the right sides. Of course, differing or additional rooftile and ridge cap securing mechanisms may be used.
It should be understood the apparatus, kits, and methods disclosed in this application can be mixed and matched with each other as desired for a given installation.
All dimensions and angles disclosed above can be varied for varying circumstances, uses, and objects. They may be varied by ranges of plus or minus 1% through up to 40% with the ranges in some embodiments varying by differing amounts for differing aspects of a given application. Some embodiments may vary in size from 40% greater to as large as desired, such as 1000% greater or even more, such as for larger roofs.
The foregoing detailed description has described some specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to explain the principles of the present systems and methods and their practical applications, to thereby enable others skilled in the art to best utilize the present systems, their components, and methods and various embodiments with various modifications as may be suited to the particular use contemplated.
Unless otherwise noted, the terms “a” or “an,” as used in the specification and claims, are to be construed as meaning “at least one of.” In addition, for ease of use, the words “including” and “having,” as used in the specification and claims, are interchangeable with and have the same meaning as the word “comprising.” In addition, the term “based on” as used in the specification and the claims is to be construed as meaning “based at least upon.” Also, as used herein, including in the claims, “or” as used in a list of items prefaced by “at least one of” indicates a disjunctive list such that, for example, a list of “at least one of A, B, or C” means A or B or C or AB or AC or BC or ABC (i.e., A and B and C).
Unless otherwise indicated, all numbers or expressions, such as those expressing dimensions, physical characteristics, alignment, and the like, used in the specification (other than the claims) are understood to be modified in all instances by the term “approximately.”
All disclosed ranges are to be understood to encompass and provide support for claims that recite any and all subranges or any and all individual values subsumed by each range. For example, a stated range of 1 to 10 should be considered to include and provide support for claims that recite any and all subranges or individual values that are between and/or inclusive of the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less (e.g., 5.5 to 10, 2.34 to 3.56, and so forth) or any values from 1 to 10 (e.g., 3, 5.8, 9.9994, and so forth).
All disclosed numerical values are to be understood as being variable from within minus 90% to plus 1000% and thus provide support for claims that recite such values or any and all ranges or subranges that can be formed by such values. For example, a stated numerical value of 8 should be understood to be capable of varying from 0.8 (minus 90%) to 80 (plus 1000%). The subject matter recited in the claims is not coextensive with and should not be interpreted to be coextensive with any embodiment, feature, or combination of features described or illustrated in this document. This is true even if only a single embodiment of the feature or combination of features is illustrated and described in this document.

Claims

What is claimed is:

1. A metal rooftile comprising in combination:

a metal rooftile body section having an upper side and a lower side;

at least one fastener passage penetrating the upper side of the metal rooftile body section and extending through the lower side of the metal rooftile body section, the fastener passage having a pre-formed spacer section extending from, and away from, the upper side of the metal rooftile body section, whereby a fastener may be forced through the fastener passage with the fastener head abutting and thereby being spaced from the upper side of the metal rooftile body section by the spacer section.

2. A rigid rooftile comprising in combination:

a rooftile body section having an upper tile section intermediate a first and second opposed side, each side extending downwardly from the trapezoidal upper tile section;

an upwardly extending U-channel extending from and along the first side of rooftile body section; and

wherein rooftile body section has:

an upper side and a lower side; and

at least one fastener passage penetrating the upper side of the rooftile body section and extending through the lower side of the rooftile body section, the fastener passage having a pre-formed spacer section extending from, and away from, the upper side of the rooftile body section, whereby a fastener may be forced through the fastener passage with the fastener head abutting and thereby being spaced from the upper side of the metal rooftile body section by the spacer section.

3. A unitary ganged set of rigid rooftiles comprising:

a unitary section having a plurality of rigid tiles rooftile body sections integrally formed within the unitary section, each rooftile body section having an upper tile section intermediate first and second opposed sides, each side extending downwardly from the upper tile section;

an upwardly extending U-channel extending from and along the first side of rooftile body section.

4. The metal rooftile of claim 1 wherein:

the rooftile body section has a trapezoidal upper tile section intermediate a first and second opposed body section side, each side extending downwardly from the trapezoidal upper tile section;

5. The metal rooftile of claim 4 wherein the upwardly extending U-channel has a trapezoidal central section intermediate a first and second opposed U-channel side.

6. The rigid rooftile of claim 2 wherein the upwardly extending U-channel has a trapezoidal central section intermediate first and second opposed U-channel sides.

7. The unitary ganged set of rigid rooftiles of claim of claim 3 wherein rooftile body section has:

an upper side and a lower side; and

8. The metal rooftile of claim 4 wherein each upper tile section also has:

an upper side and a lower side; and

9. The metal rooftile of claim 4 wherein each upper tile section has a trapezoidal periphery including the first and second opposed sides.

10. The unitary ganged set of rigid rooftiles of claim 7 wherein each upwardly extending U-channel has a trapezoidal central section intermediate a first and second opposed U-channel side.

11. The metal rooftile of claim 5 wherein each upper tile section has:

an upper side and a lower side; and

12. The rigid rooftile of claim 6 wherein each upper tile section has:

an upper side and a lower side; and

13. The rigid rooftile of claim 2 wherein the rigid rooftile comprises metal.

14. The rigid rooftile of claim 6 wherein the rigid rooftile comprises metal.

15. The rigid rooftile of claim 11 wherein the rigid rooftile comprises metal.

16. The rigid rooftile of claim 12 wherein the rigid rooftile is a metal rooftile.

17. The unitary ganged set of rigid tiles of claim 4 wherein each rigid rooftile is a metal rooftile.

18. The unitary ganged set of rigid rooftiles of claim 7 wherein each rigid rooftile is a metal rooftile.

19. The unitary ganged set of rigid rooftiles of claim 10 wherein each rigid rooftile is a metal rooftile.

20. The rigid rooftile of claim 2 wherein the rigid rooftile consists essentially of metal.