Concrete tile system and method of manufacture

Abstract

Tile panel assemblies and systems of manufacturing and installing said tile panels. The tile panels of the subject invention can be used as a covering for walls, roofs, siding, etc. on a variety of structures. In one embodiment, the tiles are manufactured of a lightweight concrete having sufficient strength to withstand extreme weather and wind conditions, as well as normal handling or foot traffic required for installation and maintenance. In a further embodiment, the tiles of the subject invention comprise insulation, preferably foam, affixed thereto. The tile panels are constructed so as to present an overlapping configuration and selectively interlocking systems that provide resistance to negative pressure wind uplifting and enhanced insulation properties. Also disclosed is a tile bracket apparatus that can secure the leading edge of a tile to prevent wind-uplift.

1 . A wind-resistant interlocking tile panel comprising: 
 a sheathing surface having a top side, a bottom side, a leading edge, and a trailing edge, wherein the leading edge of a first such tile panel is capable of overlapping a trailing edge of an adjacent second such tile panel when a portion of the bottom side at the leading edge of the first tile panel is positioned over a portion of the top side at the trailing edge of the second tile panel;    backing material connected to at least a portion of the bottom side of the sheathing surface; and    an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first tile panel is positioned to overlap the trailing edge of the second tile panel, a portion of the second tile panel engages the interlock channel of the first tile panel and backing material at the leading edge of the first tile panel abuts backing material at the trailing edge of the second tile panel.    
   
   
       2 . The tile panel according to  claim 1 , wherein at least a portion of the interlock channel is defined by the backing material.  
   
   
       3 . The tile panel according to  claim 1 , wherein the sheathing surface comprises a material selected from the group consisting of metals, clays, concretes, plastics, glass, woods, natural or petroleum-based products, and combinations of any of the foregoing.  
   
   
       4 . The tile panel according to  claim 1 , wherein the sheathing surface comprises a material selected from the group consisting of lightweight concrete, cellular concrete, and lightweight aggregate concrete.  
   
   
       5 . The tile panel according to  claim 1 , wherein the backing material is offset from the leading edge, so that some portion of the bottom side of the sheathing surface at the leading edge extends beyond the backing material.  
   
   
       6 . The tile panel according to  claim 1 , wherein the sheathing surface at the trailing edge of the second tile panel engages the interlock channel of the first tile panel.  
   
   
       7 . The tile panel according to  claim 1 , wherein the backing material is offset from the trailing edge, so that some portion of the bottom side of the sheathing surface at the trailing edge extends beyond the backing material.  
   
   
       8 . The tile panel according to  claim 7 , wherein the sheathing surface at the trailing edge of the second tile panel engages the interlock channel of the first tile panel.  
   
   
       9 . The tile panel according to  claim 5 , wherein the backing material is offset from the trailing edge, so that some portion of the bottom side of the sheathing surface at the trailing edge extends beyond the backing material.  
   
   
       10 . The tile panel according to  claim 9 , wherein the sheathing surface at the trailing edge of the second tile panel engages the interlock channel of the first tile panel.  
   
   
       11 . The tile panel according to  claim 1 , having a width, measured from the leading edge to the trailing edge, of approximately 1.5 feet and a length, measured from each side, of approximately 4 feet.  
   
   
       12 . The tile panel according to  claim 1 , further comprising one or more mounting holes.  
   
   
       13 . The tile panel according to  claim 12 , wherein said mounting holes are at an angle of approximately 40° to approximately 75°, relative to the support surface.  
   
   
       14 . The tile panel according to  claim 1 , wherein the sheathing surface is in a barrel-style formation.  
   
   
       15 . The tile panel according to  claim 1 , wherein the sheathing surface is in a flat-tile formation.  
   
   
       16 . The tile panel according to  claim 1 , wherein the backing material comprises plastics, woods, metals, lightweight concretes, ceramics, clays, foams, or combinations or composites thereof.  
   
   
       17 . The tile panel according to  claim 1 , wherein the backing material comprises a foam.  
   
   
       18 . The tile panel according to  claim 17 , wherein the foam is a rigid and closed-cell material.  
   
   
       19 . A wind-resistant interlocking crown tile panel comprising: 
 an elongated sheathing surface having a top side, a bottom side, a leading edge having a collar on the bottom side, and a trailing edge having a groove on the top side; and    backing material connected to at least a portion of the bottom side of the sheathing surface and filling at least a portion of the space around a locking track, the locking track extending lengthwise along the bottom side of the crown panel; the crown panel configured such that when the bottom side of the leading edge of a first such crown panel is overlapping the top side of the trailing edge of an adjacent second such crown panel, the collar of the first crown panel is positioned in the groove of the second crown panel.    
   
   
       20 . The crown tile panel according to  claim 19 , wherein the locking track is defined by the backing material.  
   
   
       21 . The crown tile panel according to  claim 19 , wherein the locking track is molded into the sheathing surface.  
   
   
       22 . The crown tile panel according to  claim 19 , wherein the locking track is at least partially defined by material that is different from the backing material, and that is incorporated into the crown panel.  
   
   
       23 . The crown tile panel according to  claim 19 , wherein a portion of the backing material extends forward at the leading edge so as to be received under the trailing edge of an adjacent second such crown panel when the collar of the first such crown panel is positioned in the groove of the second such crown panel.  
   
   
       24 . The crown tile panel according to  claim 19 , wherein a portion of the locking track extends slightly forward at its leading edge so as to be received under the trailing edge of an adjacent second such crown panel when the collar of the first such crown panel is positioned in the groove of the second such crown panel.  
   
   
       25 . A wind-resistant drip edge panel comprising: 
 a leading edge guard having a frontside and a backside;    at least one interlock flange connected to and extending away from the backside of the leading edge guard; and    a drip edge fixedly attached to and extending away from the frontside of the leading edge guard.    
   
   
       26 . The drip edge panel according to  claim 25 , further comprising a single interlock flange extending along at least a portion of the backside of the leading edge guard.  
   
   
       27 . The drip edge panel according to  claim 25 , further comprising a plurality of interlock flanges positioned along the backside of the leading edge guard.  
   
   
       28 . A wind-resistant interlocking hip tile panel comprising: 
 an elongated sheathing surface having a top side, a bottom side, a leading edge, and a trailing edge, wherein the leading edge of a first such hip tile panel is capable of overlapping a trailing edge of an adjacent second such hip tile panel when a portion of the bottom side at the leading edge of the first hip tile panel is positioned over a portion of the top side at the trailing edge of the second hip tile panel;    backing material connected to at least a portion of the bottom side of the sheathing surface and filling at least a portion of the space around a locking track, the locking track extending lengthwise along the bottom side of the hip panel; and    an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first hip tile panel is positioned to overlap the trailing edge of the second hip tile panel, a portion of the second hip tile panel engages the interlock channel of the first hip tile panel.    
   
   
       29 . The hip tile panel according to  claim 28 , wherein at least a portion of the interlock channel is defined by the backing material, the interlock channel configured such that when the leading edge of the first hip tile panel is positioned to overlap the trailing edge of the second hip tile panel, a portion of the second hip tile panel engages the interlock channel of the first tile panel and backing material at the leading edge of the first hip tile panel abuts backing material at the trailing edge of the second hip tile panel.  
   
   
       30 . The hip tile panel according to  claim 28 , wherein the backing material is offset from the leading edge, so that some portion of the bottom side of the sheathing surface at the leading edge extends beyond the backing material.  
   
   
       31 . The hip tile panel according to  claim 28 , wherein the sheathing surface at the trailing edge of the second hip tile panel engages the interlock channel of the first hip tile panel.  
   
   
       32 . The hip tile panel according to  claim 28 , wherein the backing material is offset from the trailing edge, so that some portion of the bottom side of the sheathing surface at the trailing edge extends beyond the backing material.  
   
   
       33 . The hip tile panel according to  claim 32 , wherein the sheathing surface at the trailing edge of the second hip tile panel engages the interlock channel of the first hip tile panel.  
   
   
       34 . The hip tile panel according to  claim 30 , wherein the backing material is offset from the trailing edge, so that some portion of the bottom side of the sheathing surface at the trailing edge extends beyond the backing material.  
   
   
       35 . The hip tile panel according to  claim 34 , wherein the sheathing surface at the trailing edge of the second hip tile panel engages the interlock channel of the first hip tile panel.  
   
   
       36 . The hip tile panel according to  claim 28 , wherein the locking track is defined by the backing material.  
   
   
       37 . The hip tile panel according to  claim 28 , wherein the locking track is molded into the sheathing surface.  
   
   
       38 . The hip tile panel according to  claim 28 , wherein the locking track is at least partially defined by material that is different from the backing material and that is incorporated into the crown panel.  
   
   
       39 . A wind-resistant interlocking gable tile panel comprising: 
 an elongated sheathing surface having a top side, a bottom side, an outside edge, an inside edge, a leading edge, and a trailing edge, wherein the leading edge of a first such gable tile panel is capable of overlapping a trailing edge of an adjacent second such gable tile panel when a portion of the bottom side at the leading edge of the first gable tile panel is positioned over a portion of the top side at the trailing edge of the second gable tile panel;    backing material connected to at least a portion of the bottom side of the sheathing surface and filling at least a portion of the space around a locking track, the locking track extending lengthwise along the bottom side of the gable panel;    an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first gable tile panel is positioned to overlap the trailing edge of the second gable tile panel, a portion of the second gable tile panel engages the interlock channel of the first gable tile panel; and    wherein the outside edge of the sheathing surface extends lower than the inside edge of the sheathing surface when the panel is viewed end-on with the locking channel in a lengthwise-horizontal perspective.    
   
   
       40 . An interlocking roof tile panel system comprising: 
 a plurality of tile panels, each comprising 
 a sheathing surface having a top side, a bottom side, a leading edge, and a trailing edge, wherein the leading edge of a first such tile panel is capable of overlapping a trailing edge of an adjacent second such tile panel when a portion of the bottom side at the leading edge of the first tile panel is positioned over a portion of the top side at the trailing edge of the second tile panel;  
 backing material connected to at least a portion of the bottom side of the sheathing surface;  
 an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first tile panel is positioned to overlap the trailing edge of the second tile panel, a portion of the second tile panel engages the interlock channel of the first tile panel and backing material at the leading edge of the first tile panel abuts backing material at the trailing edge of the second tile panel;  
   a plurality of drip edge panels, each comprising 
 a leading edge guard having a frontside and a backside;  
 at least one interlock flange connected to and extending away from the backside of the leading edge guard;  
 a drip edge fixedly attached to and extending away from the frontside of the leading edge guard;  
   a plurality of hip tile panels each comprising 
 an elongated sheathing surface having a top side, a bottom side, a leading edge, and a trailing edge, wherein the leading edge of a first such hip tile panel is capable of overlapping a trailing edge of an adjacent second such hip tile panel when a portion of the bottom side at the leading edge of the first hip tile panel is positioned over a portion of the top side at the trailing edge of the second hip tile panel;  
 backing material connected to at least a portion of the bottom side of the sheathing surface and filling at least a portion of the space around a locking track, the locking track extending lengthwise along the bottom side of the hip panel;  
 an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first hip tile panel is positioned to overlap the trailing edge of the second hip tile panel, a portion of the second hip tile panel engages the interlock channel of the first hip tile panel; and  
   a plurality of crown tile panels, each comprising 
 an elongated sheathing surface having a top side, a bottom side, a leading edge having a collar on the bottom side, and a trailing edge having a groove on the top side;  
 backing material connected to at least a portion of the bottom side of the sheathing surface and filling at least a portion of the space around a locking track, the locking track extending lengthwise along the bottom side of the crown panel; the crown panel configured such that when the bottom side of the leading edge of a first such crown panel is overlapping the top side of the trailing edge of an adjacent second such crown panel, the collar of the first crown panel is positioned in the groove of the second crown panel;  
   wherein the interlock flanges of the drip edge panels are complimentarily configured so as to engage an interlock channel along the leading edge of one or more tile panels.    
   
   
       41 . The roof tile panel system according to  claim 40 , further comprising: 
 a plurality of gable tile panels, each comprising 
 an elongated sheathing surface having a top side, a bottom side, an outside edge, an inside edge, a leading edge, and a trailing edge, wherein the leading edge of a first such gable tile panel is capable of overlapping a trailing edge of an adjacent second such gable tile panel when a portion of the bottom side at the leading edge of the first gable tile panel is positioned over a portion of the top side at the trailing edge of the second gable tile panel;  
 backing material connected to at least a portion of the bottom side of the sheathing surface and filling at least a portion of the space around a locking track, the locking track extending lengthwise along the bottom side of the gable panel;  
 an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first gable tile panel is positioned to overlap the trailing edge of the second gable tile panel, a portion of the second gable tile panel engages the interlock channel of the first gable tile panel; and  
 wherein the outside edge of the sheathing surface extends lower than the inside edge of the sheathing surface when the panel is viewed end-on with the locking channel in a lengthwise-horizontal perspective.  
   
   
   
       42 . A wind-resistant interlocking tile panel comprising: 
 a sheathing surface having a top side, a bottom side, a leading edge, a trailing edge, and a mounting hole proximal to the trailing edge, the trailing edge being above the mounting hole, wherein the leading edge of a first such tile panel is capable of overlapping a trailing edge and mounting hole of an adjacent second such tile panel when a portion of the bottom side at the leading edge of the first tile panel is positioned over a portion of the top side at the trailing edge of the second tile panel;    backing material connected to at least a portion of the bottom side of the sheathing surface; and    means for interlocking said leading edge with the trailing edge of an adjacent second tile panel wherein when the leading edge of the first tile panel is positioned to interlock with the trailing edge of the adjacent second tile panel, the means for interlocking is located above the mounting hole of the second tile panel.    
   
   
       43 . The tile panel according to  claim 42 , wherein the means for interlocking comprises a tenon extending from the leading edge and a mortise at the trailing edge of a tile panel, such that when the tenon of a first such tile panel is engaged with the mortise of an adjacent second such tile panel, a portion of the leading edge of the first tile panel will overlap the trailing edge of the second tile panel.  
   
   
       44 . The tile panel according to  claim 43 , wherein the means for interlocking further comprises a partial mortise at each comer of the trailing edge, such that when two of the tile panels are placed side by side, the trailing edge corners that abut one another form a mortise at the point where the trailing edges of the two panels meet.  
   
   
       45 . The tile panel according to  claim 42 , wherein the means for interlocking comprises a mortise at the leading edge and a tenon extending from the trailing edge, such that when the mortise of a first such tile panel is engaged with the tenon of an adjacent second such tile panel, a portion of the leading edge of the first tile panel will overlap the trailing edge of the second tile panel.  
   
   
       46 . The tile panel according to  claim 42 , wherein the means for interlocking comprises an interlock channel along the leading edge, the interlock channel configured such that when the leading edge of the first tile panel is positioned to overlap the trailing edge of the second tile panel, a portion of the second tile panel engages the interlock channel of the first tile panel.  
   
   
       47 . The tile panel according to  claim 46 , wherein at least a portion of the interlock channel is defined by the backing material.