IMPROVED MODULAR ROOF COVERING

Abstract

 The invention is a roof covering for roofs of buildings in general, comprising one or more covering modules (100, 200) in the form of roofing tiles or of a set of roofing tiles placed side by side and joined together, each covering module (100, 200) being made from EVA-PE through an injection moulding process, and at least one further module forming at least part of a ridge, or ridge module (400, 500, 600, 700), intended to be coupled with one or more of said covering modules (100, 200), and wherein also said further ridge module (400, 500, 600, 700) is made from EVA-PE through an injection process.

Description

[0001] The present patent concerns roof coverings, and more specifically it concerns a new improved modular roof covering for roofs of buildings in general.

[0002] Roof coverings for buildings in general are known. Roof coverings consisting of modular brick elements, such as roofing tiles, arranged close to one another and partially overlapping are known.

[0003] Brick elements of the known type are widely used and much appreciated, but they have some technical limitations: they have long installation times and high costs, they require routine maintenance and the replacement of the elements that break due to weather agents, they are heavy, and they have limited thermal and acoustic insulation performance.

[0004] The present applicants are also the holders of Italian patent No. 102019000003209 concerning a new type of element for roof coverings, generically configured as a roofing tile or as a set of roofing tiles joined and placed side by side, entirely made from EVA-PE by means of an injection moulding process. Each element also includes edges configured for coupling with other identical elements placed beside it. Each element also includes a series of ridges and channels that simulate a normal roof covering made up of roofing tiles.

[0005] The use of this special material has made it possible to manufacture high performance elements for roof coverings which, in particular, have the following advantages: they are lightweight, require shorter laying times than the known brick elements, can be easily and effectively installed, can be walked on, the material used is fireproof, resistant to wide temperature ranges, and has excellent thermal and acoustic insulation characteristics.

[0006] Furthermore, the material from which the element is made allows various colours to be used, unlike the known brick roofing elements.

[0007] The subject of the present patent is a new improved modular EVA-PE roof covering whose main object is to maximize the performance levels already achieved by the modular EVA-PE elements covered by the applicants' patent 102019000003209.

[0008] The new roof covering comprises:

• a plurality of covering modules in the form of roofing tiles or of a set of roofing tiles placed side by side and joined together, each modular element being made from EVA-PE through an injection process;
• at least one further module forming at least part of a ridge, intended to be coupled with one or more of said covering modules, and wherein also said further ridge module is made from EVA-PE through an injection process.

[0009] In the preferred solution, all the modules forming the roof covering, that is, not only the entire slopes but also the ridges, are made of EVA-PE, with the exception of the fixing means used to fix the modules to the roof structure, which are preferably made of metal or another material suitable for the purpose.

[0010] The special configuration of the elements that make up the roof covering, together with the material chosen, makes it possible to obtain a roof covering whose thermal and mechanical performance is synergistically enhanced.

[0011] By making not only the roofing tiles, but also the other elements in a material that was not considered suitable for use as a building material, it is possible to obtain a roof covering that has all the characteristics and performance features presently sought after for civil building roofs.

[0012] In fact, using covering modules in combination with ridge modules made of EVA-PE, and ensuring continuity in the material used, it is possible to maximize the performance of each individual module used and the overall performance of the roof covering obtained.

[0013] In fact, acoustic and thermal insulation properties are maximized. The resulting roof covering, furthermore, can be entirely walked on and can be entirely customized with colours and finishes as desired.

[0014] Since the elements are injection moulded, it is possible to provide them with coupling elements for mutual fixing, for example undercuts, and with shaped parts that prevent the backflow of water due to wind pressure, or with raised elements that favour under-roof ventilation.

[0015] The surface finish of the EVA-PE element can be very smooth or even slightly rough, similar to the finish of an element actually made of concrete but without open pores where mould or lichen can grow, since the latter are easily washed away by rainwater.

[0016] Since said EVA-PE element is resistant to temperatures ranging from -50 to +70 °C without appreciable thermal expansion, it maintains the linearity and engagement of the fixing parts with no risk of detachment.

[0017] The material used is based on polyolefins, in particular EVA (ethylene-vinyl acetate) and polyethylene, advantageously with the addition of anti-ageing, light protection agents in percentages not exceeding 1-2 % by weight with respect to the total weight of the mixture. It is also thanks to this material that it has been possible to obtain a building construction product that is above all lightweight, having a density included between 0.2 and 0.5 g/cm³, and preferably equal to 0.35 g/cm³, which ensures ease of installation and assembly.

[0018] The permissible temperature range without appreciable shrinkage or deformation is from -50 to +70 °C, which guarantees uniform laying and reliability of the laid roof covering that is exposed to weather agents.

[0019] Within the above-mentioned temperature range, the product can in any case be walked on, since its hardness is approximately 40-60 ShA (measured according to ASTM D2240) and its ultimate tensile strength (according to ASTM D638) is included between 2 and 4 MPa.

[0020] Above all, ultimate elongation (ASTM D638) can even reach 200-300% before the material can break.

[0021] As mentioned above, said foam material is also fire retardant and quite stable at normal installation temperatures for the specific application.

[0022] It was found that the best mixture to improve the behaviour of this material is made up of approximately 10-25% polyolefins and 90-75% polyethylene, and preferably 18% polyolefins (ethylene-vinyl acetate) and 82% polyethylene.

[0023] Advantageously, said mixture is enriched with an inflating agent in a percentage included between 2 and 5%, preferably equal to 3%, of the base mixture, inside which at a temperature of 200°C the small cells producing the expansion of the product develop.

[0024] Advantageously, said mixture is enriched with a crosslinking agent in a percentage between 0.7 and 2%, and preferably equal to 1% by weight of the base mixture, which helps create a chemical bond between the various molecules of said polyethylene-based mixture, so as to increase its mechanical strength and its temperature resistance. In fact, this material changes from the thermoplastic state into the elastic cross-linked (cured) state. Finally, it is a stable material, not noxious, expanded and cross-linked.

[0025] Thanks to the low weight of the material used to make the new roof covering, the latter is also particularly suitable for installation on wooden houses.

[0026] The material is also fully recyclable.

[0027] The characteristics of the new roof covering are better clarified in the following description, which makes reference to the drawings that are attached hereto by way of non-limiting example.

Figure 1 shows a three-dimensional view of a covering module (100) intended to be positioned in one of the central rows of the roof covering, while in Figure 2, showing the same covering module (100) shown in Figure 1, its underside is visible.

Figure 3 shows a three-dimensional view of the underside of a covering module (200) intended to form the first roof covering line.

Figure 4 shows a covering module (300) shaped in such a way as to include an air intake (310).

Figure 5 shows a three-dimensional view of a modular ridge element (400) made according to a first possible embodiment, while Figure 6 shows its underside.

Figure 7 shows a three-dimensional view of a modular ridge element (500) made according to another possible embodiment, while Figure 8 shows its underside.

Figure 9 shows a three-dimensional view of four (600, 600') ridge end units.

Figure 10 shows a three-dimensional view of a three-way ridge element (700), a bottom view of which is shown in Figure 11.

[0028] The covering module (100) as shown in Figure 1 has, for example, the shape of two rows of roofing tiles consisting of 4 tiles each, all oriented according to the same direction X.

[0029] The covering module (100), therefore, has a substantially rectangular shape in plan view.

[0030] Both the lateral edges (110, 120) parallel to said direction X and the lateral edges (130, 140) orthogonal to said direction X are configured to be coupled with other identical covering modules (100, 200) placed beside them.

[0031] In particular, said lateral edges (110, 120) parallel to said direction X are substantially linear and configured so that they are mutually complementary, for example with one or more male fixing elements (121) projecting downwards and intended to fit into one or more corresponding female fixing seats (111) on the opposite edge.

[0032] Said seat (111) and said fixing element (121) are preferably configured with undercuts to prevent any accidental detachment.

[0033] Said lateral edges (130, 140) orthogonal to said direction X, instead, are configured in a different manner.

[0034] In the covering module (100) shown in Figure 1, which is intended to form one of the central rows of the roof covering, the lateral edge (130) intended to be arranged in a lower position, or downstream lateral edge (130), includes a rib (131) extending downwards.

[0035] The opposite lateral edge (140), or upstream lateral edge, that is, the one intended to be arranged in a higher position, comprises a rib (141) extending upwards. In proximity to said upstream lateral edge (140) there is also a second rib (142) substantially parallel to said first rib (141). Between said two ribs (141, 142) there are protruding elements (143), for example positioned on the ridges of the roofing tiles.

[0036] Said ribs (141, 142) and said protruding elements (143) are configured to be coupled with the corresponding downstream lateral edges (130) of covering modules placed beside them.

[0037] Said downward-oriented rib (131) of said downstream lateral edges (130), in fact, is coupled with said second rib (142) of the upstream lateral edge (140) of an adjacent covering module. Said ribs (141, 142, 131) also have the function of preventing rainwater from flowing back and penetrating between two adjacent modules.

[0038] On the underside of said covering modules (100) there are also additional ribs (150) arranged according to said direction X and extending downwards from the bottom of the channels between the roofing tiles.

[0039] Said ribs (150) are corrugated or in any case they are not linear, so that they feature raised parts suited to allow ventilation.

[0040] Said ribs (150) have a hook-shaped end (151) suited to be coupled with correspondingly hook-shaped fixing elements which are intended to be positioned on the roof and to which the covering modules (100, 200) are to be constrained.

[0041] Furthermore, said hook-shaped end (151) is dimensioned so that it comes into contact with said first rib (141) of the opposite downstream lateral edge (140), thus acting as a guide for the correct mutual positioning of the covering modules (100). In proximity to said downstream lateral edge (130) there are also holes or parts suited to be drilled (132) for the insertion of means for fixing it to adjacent covering modules.

[0042] Said holes or parts suited to be drilled (132) are positioned at the level of said protruding elements (143) of the lateral edge (140) upstream of an adjacent covering module (100).

[0043] The solution shown in Figure 3A comprises a covering module (200) intended to form the first row of the roof covering. Said covering module (200), for example, is essentially identical to said covering module of the more central rows, except for the holes or parts suited to be drilled on the downstream lateral edge (230), which may also not be provided.

[0044] On the underside of said covering module (200) there is also at least one further partition or rib (270) arranged crosswise with respect to said direction X according to which the roofing tiles are oriented. Said rib (270), which substantially occupies the entirety or part of the width of the covering module (200), serves as an anti-bird element, that is, it serves to prevent animals, for example birds, from entering.

[0045] In particular, said rib (270) occupies the concave space corresponding to the ridge of the roofing tiles.

[0046] The lower edge (271) of said rib (270) is preferably shaped, for example notched or serrated or generically corrugated to allow for ventilation in any case.

[0047] In the solution shown in Figure 4, the covering module (300) comprises an air intake (310) made, for example, at the level of a ridge of one of the roofing tiles. Said air intake (310) is obtained by means of one or more openings (311) that are made in a sort of cap (312) raised with respect to the ridge of a roofing tile and are oriented downstream.

[0048] Figure 5 shows an example of a ridge module (400) configured as a "canopy", that is, comprising a central part (410) configured as a ridge consisting of one or more roofing tiles aligned along a direction Y, and two lateral parts (420) arranged symmetrically with respect to said direction of alignment Y and inclined downwards, in accordance with the pitch of a roof.

[0049] The edge (421) of said lateral parts (420) is configured with recesses (422) whose shape corresponds to the shape of the roofing tiles.

[0050] The two opposite lateral edges (430, 440), orthogonal to the direction of alignment Y, are correspondingly configured for coupling with other ridge modules (400) placed beside them.

[0051] More specifically, one of said lateral edges (430) comprises a raised rib (431), while the opposite edge (440) comprises a seat (441) suited to be coupled with said rib (431) of an opposite ridge module.

[0052] On said central part (410) and on said lateral parts (420) there are holes (450) or parts suited to be drilled for the insertion of fixing means intended to fix the ridge module to the roof structure, to other roof covering modules and to other ridge modules.

[0053] Figure 7 shows a possible embodiment of a grooved ridge module (500) having a convex body elongated in a direction Y and comprising a plurality of ribs (510) positioned crosswise with respect to said direction Y of extension of the module and protruding from its upper surface.

[0054] Also in this case, the grooved ridge module (500) comprises two opposite lateral edges (520, 530), arranged crosswise with respect to said direction Y, configured for coupling ridge modules (500) placed side by side.

[0055] For example, one of said lateral edges (520) includes a protruding rib (521), while the opposite lateral edge (530) includes a seat (531) for the insertion of the rib (521) present on the opposite edge of an adjacent element.

[0056] Figure 9 shows how, according to the invention, the new roof covering can be provided with ridge end units (600, 600') configured in various manners and suited to be coupled with said ridge modules (400, 500).

[0057] Said end units (600, 600') are substantially in the shape of a semi-dome, with an arched part (610) designed to be coupled with a lateral edge (440, 530) of a ridge module (400, 500), and a closed part (620) designed to serve as a closed ridge end unit.

[0058] Figure 10 shows a three-way ridge element (700) comprising three arched branches (710, 720, 730) converging towards a central part (740). The edges (711, 721, 731) of said branches (710, 720, 730) are configured to be coupled with the corresponding lateral edges of ridge modules and comprise, for example, seats (750) into which the protruding ribs (431, 521) of the lateral edges (430, 520) of the ridge modules (400, 500) are intended to fit.

[0059] Therefore, with reference to the above description and the attached drawings, the following claims are made.

Claims

1. Roof covering for the roofs of buildings in general, characterized in that it comprises:

- one or more covering modules (100, 200) in the form of roofing tiles or of a set of roofing tiles placed side by side and joined, each covering module (100, 200) being made from EVA-PE through an injection moulding process;

- at least one further module forming at least part of a ridge, or ridge module (400, 500, 600, 700), intended to be coupled with one or more of said covering modules (100, 200), and wherein also said further ridge module (400, 500, 600, 700) is made from EVA-PE through an injection moulding process.

2. Roof covering according to claim 1, characterized in that it is entirely made up of said covering modules (100, 200) and said ridge modules (400, 500, 600, 700) made of EVA-PE.

3. Roof covering according to claim 1 or 2, characterized in that it comprises one or more coupling profiles suited to be fixed to the structure of the roof to be covered, and wherein said covering modules (100, 200) and said ridge modules (400, 500, 600, 700) comprise parts (151) shaped for coupling with said profiles and/or holes or parts suited to be drilled (132, 450, ...) for the insertion of fixing means for mutual coupling.

4. Covering module (100, 200) for roof coverings according to one or more of claims from 1 to 3, characterized in that it has the shape of one or more rows of roofing tiles, all oriented according to the same direction X, and wherein both the lateral edges (110, 120) parallel to said direction X and the lateral edges (130, 140) orthogonal to said direction X are configured in such a way that they can be coupled with other identical covering modules (100, 200) placed beside them.

5. Covering module (100, 200) for roof coverings according to claim 4, characterized in that said lateral edges (110, 120) parallel to said direction X are configured in a mutually complementary manner, with one or more male fixing elements (121) intended to fit into a corresponding female fixing seat (111) on the opposite edge, and wherein said seat (111) and said fixing element (121) are preferably configured with undercuts to prevent any accidental detachment.

6. Covering module (100, 200) for roof coverings according to claim 4, characterized in that:

- said lateral edge (140) orthogonal to said direction X and intended to be arranged in a higher position, or upstream lateral edge, comprises a first rib (141) extending upwards and a second rib (142) substantially parallel to said first rib (141), and wherein between said two ribs (141, 142) there are protruding elements (143), for example positioned on the ridges of the roofing tiles;

- said lateral edge (130) orthogonal to said direction X and intended to be arranged in a lower position, or downstream lateral edge (130), comprises a rib (131) directed downwards and intended to be coupled with said second rib (142) of the upstream lateral edge (140) of an adjacent covering module (100).

7. Covering module (100, 200) for roof coverings according to the preceding claim, characterized in that on the lower surface of said covering modules (100) there are also further supporting ribs (150) arranged in said direction X and extending downwards from the bottom of the channels between the roofing tiles, and wherein said supporting ribs (150) have a hook-shaped-shaped end (151) for coupling with said coupling profiles, and wherein, furthermore, said hook-shaped-shaped end (151) is dimensioned in such a way that it comes into contact with said first rib (141) of the opposite downstream lateral edge (140), thereby serving as a guide for the correct mutual positioning of the covering modules (100).

8. Covering module (100) for roof coverings according to claim 6, characterized in that holes or parts suited to be drilled (132) for the insertion of fixing means suited to join it to adjacent covering modules (100, 200) are also provided in proximity to said downstream lateral edge (130), and wherein said holes or parts suited to be drilled (132) are positioned at said protruding elements (143) of the lateral edge (140) upstream of an adjacent covering module (100).

9. Covering module (100) for roof coverings according to claim 4, characterized in that on the lower surface of said covering module (200) there is also at least one further partition or rib (270) arranged crosswise to said direction X according to which the roofing tiles are oriented, and wherein said rib (270) occupies the concave space corresponding to the ridge of the roofing tiles, and wherein the lower edge (271) of said rib (270) is preferably shaped, for example notched or serrated or generically corrugated.

10. Covering module (300) for roof coverings according to claim 4, characterized in that it comprises an air intake (310) made at the level of a ridge of one of the roofing tiles, and wherein said air intake (310) is obtained through one or more openings (311) made in a sort of cap (312) that is raised with respect to the ridge of a roofing tile and oriented downstream.

11. Ridge module (400, 500) for roof coverings according to one or more of claims from 1 to 3, characterized in that it comprises a central part (410) configured as a ridge and mainly oriented according to a direction Y, and wherein the two opposite lateral edges (430, 440), orthogonal to said direction of alignment Y, are configured in a corresponding manner for coupling with other adjacent ridge modules (400, 500).

12. Ridge module (400) according to claim 11, characterized in that one of said lateral edges (430, 520) comprises a raised rib (431, 521) while the opposite edge (440, 530) comprises a seat (441, 531) for coupling with said rib (431, 521) of an opposite ridge module (400, 500).

13. Ridge module (400) according to claim 11, characterized in that it comprises said central part (410) configured as a ridge consisting of one or more roofing tiles aligned along a direction Y, and two lateral parts (420) that are symmetrical with respect to said direction of alignment Y and inclined downwards in accordance with the pitch of a roof, and wherein the edge (421) of said lateral parts (420) is preferably configured with recesses (422) corresponding to the shape of the roofing tiles.

14. Ridge end unit (600, 600') for roof coverings according to one or more of claims from 1 to 3, characterized in that it substantially has the shape of a semi-dome, with an arched part (610) suited to be coupled with a lateral edge (440, 530) of a ridge module (400, 500) according to one or more of claims from 11 to 13, and a closed part (620) serving as a closed end unit of the ridge.

15. Three-way ridge element (700) for roof coverings according to one or more of claims from 1 to 3, comprising three arched branches (710, 720, 730) converging towards a central part (740), and wherein the edges (711, 721, 731) of said branches (710, 720, 730) are configured for coupling with the corresponding lateral edges of ridge modules (400, 500) according to one or more of claims from 11 to 13 and comprise, for example, seats (750) in which the protruding ribs (431, 521) of the lateral edges (430, 520) of the ridge modules (400, 500) are intended to fit.

Drawing