Adhesive projection points for roofing elements

Abstract

A roofing element such as a concrete tile is provided that includes a body portion extending between a head end and a nose end. The body portion includes a lower surface, an upper surface, and a protrusion that is disposed substantially adjacent the nose end and extends downwardly from the lower surface. The protrusion is disposed on the lower surface such that when a nose end of a second roofing element is installed vertically above a head end of a first roofing element and overlapping by at least 3 inches, the protrusion of the second roofing element is positioned substantially above an aperture defined in the head end of the first roofing element. The protrusion reduces a distance between the aperture of the first roofing element and the nose end of the second roofing element, which increases the likelihood that the adhesive will securely join the first roofing element with the second roofing element.

1 . A roofing element for installing on a sloped roof, said roofing element comprising:
 a head end defining one or more apertures therethrough for receiving a fastener to secure said roofing element to said sloped roof;   a nose end opposite said head end;   a body portion extending between said head end and said nose end; and   said body portion comprising a lower surface, an upper surface opposite said lower surface, and a protrusion, said protrusion disposed substantially adjacent said nose end and extending downwardly from said lower surface,   wherein said protrusion is disposed on said lower surface such that when a nose end of a second roofing element is installed vertically adjacent a head end of a first roofing element and overlapping by at least a predetermined distance, said protrusion of said second roofing element is positioned substantially above said one or more apertures defined in said head end of said first roofing element, and   wherein said protrusion is configured to reduce a distance between said one or more apertures and said nose end lower surface such that an amount of adhesive needed to secure said nose end of said second roofing element to said head end of said first roofing element is reduced and a likelihood that the adhesive will contact and securely join said nose end of said second roofing element with said head end of said first roofing element is increased.   
     
     
         2 . The roofing element of  claim 1 , comprising a trim element. 
     
     
         3 . The roofing element of  claim 2 , comprising a ridge element, said ridge element configured for being installed along a ridge of said sloped roof. 
     
     
         4 . The roofing element of  claim 3 , wherein:
 said ridge element comprises a first wall, a second wall, and a third wall,   said first wall and said third wall extend substantially outwardly and downwardly from opposite edges of said second wall.   
     
     
         5 . The roofing element of  claim 3 , wherein a cross-section of said ridge element transverse to a longitudinal axis of said ridge element is substantially arcuate in shape. 
     
     
         6 . The roofing element of  claim 2 , comprising a rake element. 
     
     
         7 . The roofing element of  claim 6 , wherein said rake element comprises a first wall and a second wall, said first wall and said second wall being formed together along a common longitudinal edge of each of said first wall and said second wall at an angle substantially equal to 90°. 
     
     
         8 . The roofing element of  claim 1 , comprising a field tile. 
     
     
         9 . The roofing element of  claim 1 , wherein each of said roofing elements is formed of a concrete material. 
     
     
         10 . The roofing element of  claim 1 , wherein said body portion further comprises a front edge segment disposed adjacent said nose end, said front edge segment extending downwardly from said lower surface and being shaped to substantially conform to said upper surface adjacent said head end, said protrusion being disposed inward of said front edge segment toward said head end along a longitudinal axis of said roofing element. 
     
     
         11 . The roofing element of  claim 10 , wherein said front edge extends a first distance from said lower surface and said protrusion extends a second distance from said lower surface, wherein said first distance is greater than said second distance. 
     
     
         12 . The roofing element of  claim 1 , wherein said predetermined distance is three inches. 
     
     
         13 . The roofing element of  claim 12 , wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end. 
     
     
         14 . The roofing element of  claim 1 , wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end. 
     
     
         15 . The roofing element of  claim 1 , comprising a plurality of protrusions spaced from each other along a longitudinal direction of said roofing element. 
     
     
         16 . The roofing element of  claim 1 , comprising a plurality of protrusions spaced from each other along a lateral direction of said roofing element. 
     
     
         17 . The roofing element of  claim 1 , wherein said protrusion extends continuously from said nose end along a longitudinal direction of said roofing element. 
     
     
         18 . The roofing element of  claim 1 , wherein said protrusion protrudes from said lower surface at a location spaced away from said nose end and separated from said nose end by a portion of said lower surface that does not protrude from said lower surface. 
     
     
         19 . The roofing element of  claim 18 , wherein said protrusion extends on said lower surface along a lateral direction of said roofing element. 
     
     
         20 . A mold pallet for manufacturing a roofing element, for installing on a sloped roof, said mold pallet having an upper surface configured for molding a roofing element comprising:
 a head end defining one or more apertures therethrough for receiving a fastener to secure said roofing element to said sloped roof;   a nose end opposite said head end;   a body portion extending between said head end and said nose end; and   said body portion comprising a lower surface, an upper surface opposite said lower surface, and a protrusion, said protrusion disposed substantially adjacent said nose end and extending downwardly from said lower surface,   wherein said protrusion is disposed on said lower surface such that when a nose end of a second roofing element is installed vertically adjacent a head end of a first roofing element and overlapping by at least a predetermined distance, said protrusion of said second roofing element is positioned substantially above said one or more apertures defined in said head end of said first roofing element, and   wherein said protrusion is configured to reduce a distance between said one or more apertures and said nose end lower surface such that an amount of adhesive needed to secure said nose end of said second roofing element to said head end of said first roofing element is reduced and a likelihood that the adhesive will contact and securely join said nose end of said second roofing element with said head end of said first roofing element is increased.   
     
     
         21 . The roofing element of  claim 20 , wherein said predetermined distance is three inches. 
     
     
         22 . The roofing element of  claim 21 , wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end. 
     
     
         23 . The roofing element of  claim 20 , wherein said protrusion is disposed on said lower surface at a location at least (3-D) inches from said nose end, wherein D is a distance between said aperture and said head end. 
     
     
         24 . A method of manufacturing a roofing element, said method comprising the steps of:
 providing a roofing element having a head end, a nose end opposite said head end, an upper surface, and a lower surface opposite said upper surface, and   providing a protrusion disposed substantially adjacent said nose end and extending downwardly from said lower surface;   said protrusion being disposed on said lower surface such that when a first roofing element is installed on a sloped roof, by inserting a fastener through at least one aperture in said head end and into said sloped roof and a second roofing element is installed substantially vertically adjacent the first roofing element and overlapping by at least a predetermined distance, said protrusion of the second roofing element is positioned vertically above said fastener and said aperture of the first roofing element.   
     
     
         25 . The method of  claim 24 , further comprising the steps of:
 providing a front edge disposed adjacent said nose end and extending downwardly from said lower surface, said front edge being shaped to substantially conform to said upper surface adjacent said head end, and said protrusion being disposed inward of said front edge toward said head end along a longitudinal axis of said roofing element.   
     
     
         26 . The method of  claim 25 , wherein said front edge extends a first distance from said lower surface and said protrusion extends a second distance from said lower surface, wherein said first distance is greater than said second distance. 
     
     
         27 . The method of  claim 24 , said roofing element being provided by the steps of:
 providing a mold pallet, the mold pallet having an upper surface shaped for molding a lower surface of said head end, nose end and body portion, including a cavity in said upper surface shaped for forming said protrusion;   compressing green concrete into said mold pallet; and   curing said green concrete.   
     
     
         28 . The method of  claim 27 , wherein said green concrete is pressed into a series of said mold pallets, and further comprising the step of cutting said green concrete between said mold pallets.