Roof Tiles and Roof Tile Structures and Methods of Making Same

Abstract

A roof tile having a mesh covered foam core with a cement-based protective coating, a roof covering formed from such tiles and methods for making same.

What is claimed is: 
     
         1 . A roof tile, a plurality of which can provide a weather membrane for a roof structure comprising;
 a foam core member comprising a plurality of surfaces including an upper surface and a spaced-apart lower surface bounded by a first lateral edge surface and an opposing spaced-apart second lateral edge surface and a first end surface and a spaced-apart second end surface;   a coating of cement-based material over one or more of the foam core member surfaces including over the first end surface forming a first abutment member; and including over the second end surface forming a second abutment member;   wherein the first abutment member and the second abutment member are so shaped that when one tile in a course abuts an adjacent tile in the same course, the adjacent abutment members engage one another, forming an overlapping, flexible connection whereby adjacent roof tiles in a course are able to change position relative to one another.   
     
     
         2 . The roof tile of  claim 1  wherein the first and second abutment members are generally L-shaped. 
     
     
         3 . The roof tile of  claim 2  wherein the first L-shaped abutment member and the second L-shaped abutment member face in generally opposite directions. 
     
     
         4 . The roof tile of  claim 1  wherein all of the foam core member surfaces are coated with a cement-based material. 
     
     
         5 . The roof tile of  claim 1  wherein a plurality of foam core member surfaces are coated with a cement-based material and further wherein the thickness of the cement-based material is not the same for all coated surfaces. 
     
     
         6 . The roof tile of  claim 1  wherein the foam core member is generally flat and the upper surface is coated with a cement-based material textured and colored to simulate a cedar shingle. 
     
     
         7 . The roof tile of  claim 1  wherein the foam core member is generally flat and the upper surface is coated with a cement-based material that is textured and colored to simulate a slate shingle. 
     
     
         8 . The roof tile of  claim 1  wherein the upper surface is shaped to simulate a Spanish tile and coated with a cement-based material colored and textured to simulate a Spanish tile. 
     
     
         9 . The roof tile of  claim 1  wherein all of the surfaces are coated with a cement-based material. 
     
     
         10 . The roof tile of  claim 1  wherein all of the surfaces except the lower surface are coated with a cement-based material. 
     
     
         11 . The roof tile of  claim 1  certified to carry the UL Class A listing mark for Prepared Roof Covering Materials. 
     
     
         12 . The roof tile of  claim 1  certified Class A fire resistant under the UL 790 standard. 
     
     
         13 . The roof tile of  claim 1  further described as able to absorb the forces of a piercing fastener without cracking, breaking or otherwise compromising the structural integrity of the tile. 
     
     
         14 . The roof tile of  claim 1  wherein one or more surfaces have multiple layers of cement-based material applied to them. 
     
     
         15 . A roof tile, a plurality of which can provide a weather membrane for a roof structure comprising;
 a foam core member comprising a plurality of surfaces including an upper surface and a spaced-apart lower surface bounded by a first lateral edge surface and an opposing spaced-apart second lateral edge surface and a first end surface and a spaced-apart second end surface; and   a coating of cement-based material over one or more of the foam core member surfaces.   
     
     
         16 . The roof tile of  claim 15  wherein the foam core member is generally flat and the upper surface is coated with a cement-based material textured and colored to simulate a cedar shingle. 
     
     
         17 . The roof tile of  claim 15  wherein the foam core member is generally flat and the upper surface is coated with a cement-based material textured and colored to simulate a slate shingle. 
     
     
         18 . The roof tile of  claim 15  wherein the upper surface is shaped to simulate a Spanish tile and coated with a cement-based material colored and textured to simulate a Spanish tile. 
     
     
         19 . The roof tile of  claim 15  wherein all of the surfaces except the lower surface are coated with a cement-based material. 
     
     
         20 . The roof tile of  claim 15  wherein one or more surfaces have multiple layers of cement-based material applied to them.