Roof Tiles and Roof Tile Structures and Methods of Making Same

Abstract

A method of forming a roof tile having a mesh covered foam core with a cement-based protective coating.

What is claimed is: 
     
         1 . A method of making a roof tile of a size generally within industry standards comprising:
 forming a foam core member to have a first end section, a second end section and a plurality of surfaces sized and shaped such that a plurality of said tiles can rest onto each other in overlapping relationship;   applying a strengthening material to surfaces of said foam core member;   applying a cement-based protective coating over a plurality of said surfaces and said first and second end members of said foam core member.   
     
     
         2 . The method of  claim 1  wherein applying said cement-based protective coating forms a first L-shaped flange at said first end member and a second L-shaped flange at said second end member wherein said first L-shaped flange has a first flange engagement member having a first flange end and a first flange engagement surface, said first L-shaped flange further having a first flange abutment member adjacent to and generally perpendicular to said first flange engagement member, and having an abutment surface generally perpendicular to said engagement surface wherein said second L-shaped flange has a second flange engagement member having a second flange end and a second flange engagement surface, said second L-shaped flange further having a second flange abutment member adjacent to and generally perpendicular to said second flange engagement member, and having a second flange abutment surface generally perpendicular to said second flange engagement surface. 
     
     
         3 . The method of  claim 1  wherein the step of forming said foam core member further forms an arcuate section between said first end section and said second end section having an upper surface that, in one dimension, generally traces the arc of a first circle wherein the first circle has a center and a radius and an opposing lower surface that, in the same dimension, also traces the arc of a second circle wherein the second circle has generally the same radius as the first circle, but a center at a different location than the center of the first circle. 
     
     
         4 . The method of  claim 1  wherein applying a cement-based protective coating over a plurality of said surfaces comprises applying a first coating to a plurality of said surfaces, allowing said first coating to dry and then applying a second coating to a plurality of said surfaces. 
     
     
         5 . The method of  claim 4  wherein said second coating is applied to some but not all of the surfaces coated by said first coating. 
     
     
         6 . The method of  claim 1  wherein the cement-based protective coating is applied to a thickness of between 1/16 and 3/16 inches. 
     
     
         7 . A method of making a roof tile of a size generally within industry standards comprising:
 forming a foam core member to have a first end section, a second end section and a plurality of surfaces sized and shaped such that a plurality of said tiles can rest onto each other in overlapping relationship;   applying a strengthening material to surfaces of said foam core member;   applying a cement-based protective coating that encapsulates all of said foam core member.   
     
     
         8 . The method of  claim 7  wherein the cement-based protective coating is applied to a thickness of between 1/16 and 3/16 inches. 
     
     
         9 . The method of  claim 7  wherein applying a cement-based protective coating that encapsulates all of said foam core member comprises the steps of applying a first coating that encapsulates all of said foam core member, allowing said first coating to dry and then applying a second coating. 
     
     
         10 . The method of  claim 9  wherein said second coating is applied to some but not all of the surfaces covered by said first coating.