Roof tile fastener
An apparatus for attaching one or more roof tiles to a roof ridge is disclosed. The apparatus includes a channel positioned parallel to the roof ridge, the channel having a central planar strip parallel to the roof ridge and flat sides that extend upwards at an acute angle from the central planar strip. The channel accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel, and the channel accepts a screw for fastening the roof tile to the apparatus. The apparatus further includes a planar element connected to a distal end of, and coextensive with, each flat side, wherein each planar element extends towards either side of the roof ridge, and wherein each planar element includes a coextensive flat end extending outwards substantially parallel to one side of the roof ridge.
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Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENTNot Applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISCNot Applicable.
FIELD OF THE INVENTIONThe invention disclosed broadly relates to the field of commercial construction, and more particularly relates to the commercial construction of roofs.
BACKGROUND OF THE INVENTIONThe use of barrel roof tiles on residential housing has increased over the years, especially in areas having substantial amounts of precipitation. A barrel roof tile comprises a hollow, semi-cylindrical tile, usually fabricated from a type of clay. Barrel roof tiles are laid on a slopping roof plane in alternating columns of convex and concave tiles. Each tile is typically ‘hung’ from the framework of the roof by fixing it with a fastener such as a nail. The tiles are usually hung in parallel rows, with each row overlapping the row below it to exclude rainwater and to cover the nails that hold the row below. It can be particularly difficult, however, to attach barrel roof tiles to the ridge of a roof, wherein two roof planes meet at a protruding apex, because there is no appropriate location for fastening the roof tile.
One approach to this problem is described by U.S. Pat. No. 6,647,675, which discloses a hip and ridge attachment device that is attached to the ridge of a roof, on top of which the roof tile is fastened using an adhesive. The device used in this approach includes a V-form along the top of the device so as to accept the adhesive necessary to bond the top of the device to the underside of a barrel roof tile. Adhesive, however, is expensive and its application requires the use of resources. Further, excessive adhesive can be messy and difficult to clean up.
Therefore, a need exists to overcome the problems with the prior art as discussed above, and particularly for a more efficient way to fasten roof tiles onto a roof ridge while reducing the amount of adhesive used.
SUMMARY OF THE INVENTIONBriefly, according to an embodiment of the present invention, an apparatus for attaching one or more roof tiles to a roof ridge is disclosed. The apparatus includes a channel positioned parallel to the roof ridge, the channel having a central planar strip parallel to the roof ridge and flat sides that extend upwards at an acute angle from the central planar strip. The channel accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel, and the channel accepts a screw for fastening the roof tile to the apparatus. The apparatus further includes a planar element connected to a distal end of, and coextensive with, each flat side, wherein each planar element extends towards either side of the roof ridge, and wherein each planar element includes a coextensive flat end extending outwards substantially parallel to one side of the roof ridge. In one alternative, the channel is about 2 inches wide and from about 1/16 inch to about 2/16 inch deep and accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel.
in another embodiment of the present invention, an apparatus for attaching one or more roof tiles to a roof ridge is disclosed. The apparatus includes a central planar strip positioned parallel to the roof ridge and a first planar strip longitudinally parallel to the central planar strip and extending upwards at an acute angle from a first side of the central planar strip. The apparatus further includes a second planar strip longitudinally parallel to the central planar strip and extending upwards at an acute angle from a second side of the central planar strip. A channel is formed by the central planar strip and the first and second planar strips, wherein the channel accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel, and wherein the channel accepts a screw for fastening the roof tile to the apparatus. The apparatus further includes a first planar element connected to a distal end of, and coextensive with, the first planar strip, wherein the first planar element extends towards a first side of the roof ridge and includes a coextensive flat end extending outwards substantially parallel to the first side of the roof ridge. The apparatus further includes a second planar element connected to a distal end of, and coextensive with, the second planar strip, wherein the second planar element extends towards a second side of the roof ridge and includes a coextensive flat end extending outwards substantially parallel to the second side of the roof ridge.
The foregoing and other features and advantages of the present invention will be apparent from the following more particular description of the preferred embodiments of the invention, as illustrated in the accompanying drawings.
The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and also the advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings. Additionally, the left-most digit of a reference number identifies the drawing in which the reference number first appears.
The present invention provides an apparatus for attaching one or more roof tiles to a roof ridge while reducing the amount of adhesive used to attach a barrel roof tile to the apparatus. The apparatus includes a channel positioned parallel to the roof ridge, the channel having a central planar strip parallel to the roof ridge and flat sides that extend upwards at an acute angle from the central planar strip. The channel of the apparatus is about 2 inches wide and from about 1/16 inch to about 2/16 inch deep, thereby creating a shallow conduit for holding adhesive to which the underside of barrel roof tiles are attached. Although the present invention reduces the amount of adhesive used to attach a barrel roof tile to the apparatus, the present invention allows for an amount of adhesive necessary to bond the roof tile to the apparatus within desired strengths.
In one alternative, the channel 124 is about 2 inches wide and from about 1/16 inch to about 2/16 inch deep. The channel 124 accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel 124. In another alternative, central planar strip 108 of the channel 124 is about ¼ inch in width and each flat side 106, 116 is about ⅞ inch in width.
The apparatus 100 further includes planar element 104, which is connected to a distal end of, and coextensive with, flat side 106, wherein planar element 104, extends towards side 140 of the roof ridge 144. The apparatus 100 further includes planar element 114, which is connected to a distal end of, and coextensive with, flat side 116, wherein planar element 114, extends towards side 142 of the roof ridge 144. The angle 132 between element 106 and element 104, as well as between element 116 and element 114, is substantially perpendicular or from about 85 to 90 degrees. In one alternative, the length of planar elements 104, 114 is about 3 and ¾ inches.
The apparatus 100 further includes a coextensive flat end 102 (connected to the distal end of planar element 104) extending outwards substantially parallel to side 140 of the roof ridge 144. The apparatus 100 further includes a coextensive flat end 112 (connected to the distal end of planar element 114) extending outwards substantially parallel to side 142 of the roof ridge 144. The angle 130 between element 102 and element 104, as well as between element 112 and element 114, is about 60 degrees. In one alternative, the length of flat ends 102, 112 is about 1 and ¼ inches. Upon fastening of the apparatus 100 to the roof ridge 144, the underside 120 of flat end 102 contacts side 140 of roof ridge 144 and the underside 122 of flat end 112 contacts side 142 of roof ridge 144.
The roof tile attachment apparatus 100 can be manufactured from a variety of materials using a variety of methods. In one embodiment of the present invention, the roof tile attachment apparatus 100 can be manufactured from hot-forged alloy steel that is oil quenched and tempered for maximum strength and durability. Alternatively, the roof tile attachment apparatus 100 can be manufactured from 26 gauge Type G-90 galvanized metal. Additionally, the roof tile attachment apparatus 100 may include nickel-chrome plating that resists rust.
In another embodiment of the present invention, the roof tile attachment device 100 can be manufactured from aluminum or an aluminum alloy. Aluminum can be either non-treated, clear or color anodized. The aluminum alloys are categorized into two types, non-heat-treatable and heat-treatable.
Type 1100 non-heat-treatable aluminum alloys are commercially pure, low-strength alloys having corrosion resistance and satisfactory anodizing and coating finishes. Type 3003 non-heat-treatable aluminum alloys are the most widely used general-purpose alloys because of their corrosion resistance, moderate strength, formability, and weldability. Type 5005 non-heat-treatable aluminum alloys are comparable to Type 3003 in strength and formability, and have good finishing characteristics, making it much better for anodizing. They also exhibit corrosion resistance and weldability, but rates below Type 1100 and Type 3003 alloys for machining.
Type 5052 non-heat-treatable aluminum alloys are versatile high-strength alloys with good forming characteristics and excellent corrosion resistance. Although easily welded, they are not recommended for brazing and soldering applications. Type 2024 heat-treatable aluminum alloys are high-strength alloys with nearly twice the strength of Type 5052 and fair corrosion resistance. Type 6061 heat-treatable aluminum alloys are high-strength alloys that are corrosion resistant and have good finishing, and welding characteristics. Type 7075 heat-treatable aluminum alloys were developed for aircraft applications, and re one of the highest strength, commercially available alloys. They have fair corrosion resistance and machinability.
The roof tile attachment apparatus 100 can further be manufactured using a variety of methods for casting metals. Metal casting involves the shaping of free-flowing liquid metals through the use of dies, molds, or patterns. Castings are generally roughly finished due to the nature of their production. In many cases, additional finishing is required to remove burrs and other artifacts of the casting process. Metal castings are used to design a wide range of components and finished products. Common metal casting processes include sand casting, die casting, permanent mold casting, investment casting, centrifugal casting, and lost foam casting.
Die-casting includes a number of processes in which reusable dies or molds are used to produce casting. The die contains an impression of the finished product together with its running, feeding and venting systems. The die is capable of a regular cycle and of (quickly) dissipating the heat of the metal poured into it. Once the liquid metal has cooled sufficiently, the mold is opened and the casting can be removed and finished. In permanent mold casting, molten metal is poured into cast iron molds, coated with a ceramic mold wash. Cores can be metal, sand, sand shell, or other materials. When completed, the molds are opened and the castings are ejected.
Investment casting involves molding patterns by the injection of a special wax into a metal die. The patterns are assembled into a cluster around a wax runner system. The ‘tree’ of patterns is then coated with eight to ten layers of a refractory material. The assembly is heated to remove the wax. The hot mold is cast, and when cool, the mold material is removed by impact, vibration, grit blasting, high pressure water blasting or chemical dissolution leaving the castings, which are then removed from the runner system.
Centrifugal casting is used to produce castings that are cylindrical in shape. In centrifugal casting, a permanent mold is rotated about its axis at high speeds as the molten metal is poured. The molten metal is centrifugally thrown towards the inside mold wall, where it solidifies. The casting is usually a fine grain casting with a very fine-grained outer diameter, which is resistant to atmospheric corrosion. Lost foam casting is metal casting that uses foam filled patterns to produce castings. Foam is injected into a pattern, filling all areas, leaving no cavities. When molten metal is injected into the pattern, the foam is burned off allowing the casting to take shape.
The roof tile attachment apparatus 100 can further be manufactured using metal injection molding (MIM) method for preparing metals. MIM is a powder metallurgy process used for manufacturing metal parts. Although metal injection molding uses powder metal, it is nothing like conventional powder metal processing. The metal powders used in MIM are ten to one hundred times smaller than in powder metal processes. Also, the end product of metal injection molding is much higher in density (greater than 95% theoretical density). Unlike powder metal, products manufactured by MIM can be case or through hardened, painted, and drilled and tapped.
The roof tile attachment apparatus 100 can further be manufactured using a variety of metals, such as ferrous metals and alloys. Ferrous metals and alloys are iron-based materials that are used in a wide variety of industrial applications. Examples include carbon steels, alloy steels, stainless steels, tool steels, cast iron, cast steel, maraging steel, and specialty or proprietary iron-based alloys.
There are many types of ferrous metals and alloys. Carbon steels are ferrous alloys that contain carbon and small levels of other alloying elements such as manganese or aluminum. Alloy steels contain low to high levels of elements such as chromium, molybdenum, vanadium and nickel. Stainless steels are highly corrosion resistant, ferrous alloys that contain chromium and/or nickel additions. There are three basic types of products: austenitic stainless steels, ferritic and martensitic stainless steels, and specialty stainless steels and iron super-alloys. Tool steels are wear resistant, but difficult to fabricate in their hardened form. Specific grades are available for cold-working, hot-working, and high speed applications. Cast iron is a ferrous alloy with high amounts of carbon. This category includes ductile iron, gray iron and white cast iron grades. Cast steel alloy grades are made by pouring molten iron into a mold.
The roof tile attachment apparatus 100 can further be manufactured using nickel and nickel alloys. Nickel and nickel alloys are non-ferrous metals with high strength and toughness, excellent corrosion resistance, and superior elevated temperature properties. Commercially pure, unalloyed or very low alloy nickel does not contain or contains only very small amounts of alloying elements. By contrast, nickel alloys contain significant amounts of added elements or constituents. Clad or bimetal stock consists of two different alloys that are bonded integrally together. Metal matrix composites have a composite or reinforced metal or alloy matrix filled with a second component, which may be in particulate, chopped fiber, continuous filament, or fabric form. Other unlisted, specialty or proprietary nickel and nickel alloys are also available. These materials are often based on a unique alloy system, use a novel processing technology, or have properties tailored for specific applications.
In one embodiment of the present invention, the roof tile attachment apparatus 100 can be manufactured from steel using the hot rolling method. The metallurgical process of hot rolling, used mainly to produce sheet metal or simple cross sections from billets, describes the method of when industrial metal is passed or deformed between a set of work rolls and the temperature of the metal is generally above its recrystallization temperature, as opposed to cold rolling, which takes place below this temperature. This permits large deformations of the metal to be achieved with a low number of rolling cycles.
Because the metal is worked before crystal structures have formed, this process does not itself affect its microstructural properties. Hot rolling is primarily concerned with manipulating material shape and geometry rather than mechanical properties. This is achieved by heating a component or material to its upper critical temperature and then applying controlled load which forms the material to a desired specification or size.
Mechanical properties of the material in its final as-rolled form is a function of: the material chemistry, reheat temperature, rate of temperature decrease during deformation, rate of deformation, heat of deformation, total reduction, recovery time, recrystallisation time, and subsequent rate of cooling after deformation.
In another embodiment of the present invention, the roof tile attachment device 100 may be hot-dipped galvanized steel. Hot-dip galvanizing is a form of galvanization. It is the process of coating iron or steel with a thin zinc layer, by passing the steel through a molten bath of zinc at a temperature of around 460° C. When exposed to the atmosphere, pure zinc reacts with oxygen to form zinc oxide, which further reacts with carbon dioxide to form zinc carbonate, a dull gray, fairly strong material that stops further corrosion in many circumstances, protecting the steel below from the elements. Galvanized steel is widely used in applications where rust resistance is needed, and can be identified by the crystalization patterning on the surface (often called a “spangle”).
The process of hot-dip galvanizing results in a metallurgical bond between zinc and steel with a series of distinct iron-zinc alloys. The resulting coated steel can be used in much the same way as uncoated. Galvanized steel can be welded; however, one must exercise caution around the resulting zinc fumes. Galvanized steel is suitable for high-temperature applications of up to 200° C. Use at temperatures above this level will result in peeling of the zinc at the intermetallic layer. Galvanized sheet steel is commonly used in automotive manufacture to enhance corrosion performance of exterior body panels of some models.
Steel strip can be hot-dip galvanized in a continuous line. Hot-dip galvanized steel strip (also sometimes loosely referred to as galvanized iron) is extensively used for applications requiring the strength of steel and resistance to corrosion. Applications include: roofing and walling, consumer appliances and automotive body parts. One common use is in metal pails.
Individual metal articles, such as steel girders or wrought iron gates, can be hot-dip galvanized by a process called batch galvanizing. Other modern techniques have largely replaced hot-dip for these sorts of roles. This includes electrogalvanizing, which deposits the layer of zinc from an aqueous electrolyte by electroplating, forming a thinner and much stronger bond.
Zinc coatings prevent corrosion of the protected metal by forming a barrier, and by acting as a sacrificial anode if this barrier is damaged. When exposed to the atmosphere, zinc reacts with oxygen to form zinc oxide, which further reacts with water molecules in the air to form zinc hydroxide. Finally zinc hyroxide reacts with carbon dioxide in the atmosphere to yield a thin, impermiable, tenacious and quite insoluble dull gray layer of zinc carbonate which adheres extremely well to the underlying zinc, so protecting it from further corrosion, in a way similar to the protection afforded to aluminium and stainless steels by their oxide layers.
Hot dip galvanizing deposits a thick, robust layer that may be more than is necessary for the protection of the underlying metal in some applications. This is the case in automobile bodies, where additional rust proofing paint will be applied. Here, a thinner form of galvanizing is applied by electroplating, called “electro-galvanization”. However, the protection this process provides is insufficient for products that will be constantly exposed to corrosive materials such as salt water. Nevertheless, most nails made today are electro-galvanized.
Galvanic protection (also known as sacrificial-anode or cathodic protection) can be achieved by connecting zinc both electronically (often by direct bonding to the protected metal) and ionically (by submerging both into the same body of electrolyte, such as a drop of rain). In such a configuration the zinc is absorbed into the electrolyte in preference to the metal that it protects, and maintains that metal's structure by inducing an electric current. In the usual example, ingots of zinc are used to protect a boat's hull and propellers, with the ocean as the common electrolyte.
As noted previously, both mechanisms are often at work in practical applications. For example, the traditional measure of a coating's effectiveness is resistance to a salt spray. Thin coatings cannot remain intact indefinitely when subject to surface abrasion, and the galvanic protection offered by zinc can be sharply contrasted to more noble metals. As an example, a scratched or incomplete coating of chromium actually exacerbates corrosion of the underlying steel, since it is less electrochemically active than the substrate.
Upon fastening of the apparatus 100 to the roof ridge 144, the underside 120 of flat end 102 contacts side 140 of roof ridge 144 and the underside 122 of flat end 112 contacts side 142 of roof ridge 144. In one embodiment of the present invention, the roof tile attachment apparatus 100 is attached to the roof ridge 144 through the use of a fastener, such as a 1 and ¼ inch rink shank nail.
Shown to the side, on side 140 of roof ridge 144, is a set of barrel roof tiles 210. Barrel roof tiles are semi-cylindrical tiles are typically made by forming clay around a log and laid in alternating columns of convex and concave tiles. Barrel roof tiles are ‘hung’ from the framework of a roof by fixing them with nails. The tiles are usually hung in parallel rows, with each row overlapping the row below it to exclude rainwater and to cover the nails that hold the row below.
In an embodiment of the present invention, the barrel roof tile 308 includes an orifice 322 located at one end of the barrel roof tile 308—the end facing the apex of the roof. The orifice 322 extends through the material of the barrel roof tile 308. A fastener 320, such as a 2.5 inch galvanized aluminum #8 screw, may be used to fasten the barrel roof tile 308 to the ridge 144. The fastener 320 extends through the barrel roof tile 308 and screws into the apparatus 100 at location 324 so as to fasten the tile 308 to the ridge 144. This fastening feature acts in addition to the adhesive 302, which serves to fasten the barrel roof tile 308 to the ridge 144. The additional use of the screw 320 may comply with certain state building code requirements, such as Section 120-3.10 of the Florida Building Code, which requires that “ridge tiles are mechanically fastened.”
Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments. Furthermore, it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention.
Claims
1. An apparatus for attaching one or more roof tiles to a roof ridge, comprising:
- a channel positioned parallel to the roof ridge, the channel having a central planar strip parallel to the roof ridge and flat sides that extend upwards at an acute angle from the central planar strip, wherein the channel accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel, and wherein the channel accepts a screw for fastening the roof tile to the apparatus; and
- a planar element connected to a distal end of, and coextensive with, each flat side, wherein each planar element extends towards either side of the roof ridge and wherein each planar element includes a coextensive flat end extending outwards substantially parallel to one side of the roof ridge.
2. The apparatus of claim 1, wherein each flat side extends upwards at about 10 degrees from the central planar strip.
3. The apparatus of claim 2, wherein each planar element extends downwards substantially perpendicular from each flat side towards either side of the roof ridge.
4. The apparatus of claim 3, wherein each flat end extends outwards at about 60 degrees from each planar element.
5. The apparatus of claim 4, wherein the length of the apparatus is about 10 feet.
6. The apparatus of claim 5, wherein the height of the apparatus is from about 3 inches to about 5 inches.
7. The apparatus of claim 1, wherein each flat end accepts nails for attaching the apparatus to either side of the roof ridge.
8. The apparatus of claim 7, wherein the channel is about 2-inches wide.
9. The apparatus of claim 7, wherein the channel is from about 1/16 inch to about 2/16 inch deep.
10. The apparatus of claim 1, wherein the apparatus is made of a material selected from a group consisting of: steel, plastic, and aluminum.
11. An apparatus for attaching one or more roof tiles to a roof ridge, comprising:
- a central planar strip positioned parallel to the roof ridge;
- a first planar strip longitudinally parallel to the central planar strip and extending upwards at an acute angle from a first side of the central planar strip;
- a second planar strip longitudinally parallel to the central planar strip and extending upwards at an acute angle from a second side of the central planar strip, wherein a channel formed by the central planar strip and the first and second planar strips accepts adhesive for contact with a roof tile placed longitudinally on top of, and parallel to, the channel, and wherein the channel accepts a screw for fastening the roof tile to the apparatus;
- a first planar element connected to a distal end of, and coextensive with, the first planar strip, wherein the first planar element extends towards a first side of the roof ridge and includes a coextensive flat end extending outwards substantially parallel to the first side of the roof ridge; and
- a second planar element connected to a distal end of, and coextensive with, the second planar strip, wherein the second planar element extends towards a second side of the roof ridge and includes a coextensive flat end extending outwards substantially parallel to the second side of the roof ridge.
12. The apparatus of claim 11, wherein the first and second planar strips extend upwards at about 10 degrees from the central planar strip.
13. The apparatus of claim 12, wherein the first and second planar elements extend downwards substantially perpendicular from the first and second planar strips, respectively, towards either side of the roof ridge.
14. The apparatus of claim 13, wherein each flat end extends outwards at about 60 degrees from the first and second planar elements, respectively.
15. The apparatus of claim 14, wherein the length of the apparatus is about 10 feet.
16. The apparatus of claim 15, wherein the height of the apparatus is from about 3 inches to about 5 inches.
17. The apparatus of claim 11, wherein each flat end accepts nails for attaching the apparatus to either side of the roof ridge.
18. The apparatus of claim 17, wherein the channel is about 2-inches wide.
19. The apparatus of claim 17, wherein the channel is from about 1/16 inch to about 2/16 inch deep.
20. The apparatus of claim 11, wherein the apparatus is made of a material selected from a group consisting of: steel, plastic, and aluminum.
Type: Application
Filed: Apr 12, 2007
Publication Date: Oct 16, 2008
Applicant:
Inventor: Agustin Exposito (Davie, FL)
Application Number: 11/786,517
International Classification: E04D 1/30 (20060101);
