This invention is concerned with improvements in or relating to a novel tile panel, a novel support for use in a tile panel and a method of tiling a roof with such tile panels.

Conventional practice for tiling a roof varies worldwide. Such practice may be like the common practice in the United Kingdom where a pitched roof is constructed of rafters fixed at the eaves and ridge of the roof and supported intermediate their lengths by horizontal purlins, and to which rafters weather-proof insulation felt and tiling battens are then affixed prior to the laying of the tiles thereon. In the United States of America, on the other hand, roofs are gener¬ ally formed as a closed board construction to which felt and shingles are thereafter affixed in known manner. Practice in the European countries also includes pitched structures which are formed predominantly of brick and concrete slabs to which pitched structures individual tiles may thereafter be affixed.

The common thread in all of these methods of roof construction is the time-consuming practice of laying the roofing tiles one at a time.

By tiles, where used herein, it is meant planar or contoured interlocking roofing tiles of concrete or clay which tiles are generally rectangular in plan elevation having upwardly facing and downwardly facing longitudinal grooves or channels formed in opposed sidelock portions thereof respectively, the tiles each also comprising a headlock portion at an upper end thereof which is provided with hanging nibs or a transverse nib on an underside thereof. Such tiles are conventionally fixed to a roof structure and to other adjacent tiles to form a rigid structure using nails and clips or a combination of such means which again makes roofing a time-consuming and

costly business with the individual tiles thereof susceptible to fracture under load due to the rigid nature of the structure and the tile bodies.

Roofs constructed from metal or plastics panels of multi-unit tile format have been proposed and indeed in some countries, notably South Africa, metal sheets simulating conventional roofing tiles have found favour for the lower end of the market. However, for general application in the United Kingdom, USA and Spain where clay and concrete roofing tiles find favour, the use of panels of simulated tiles is only used for a very small section of the roofing industry.

The present invention seeks to overcome or mitigate the disad¬ vantages of prior art roofing methods and especially seeks to obviate the need for nailing and clipping of individual tiles on a roof.

The present invention thus conveniently provides a tile panel for roofing comprising a support having fixing means for secur¬ ing a plurality of tiles as hereinbefore defined on said support wherein the support further comprises resilient por¬ tions to enable, when in use, movement at right angles to a plane of the support of tiles secured thereto whereby, in use, such tiles are not susceptible to damage from loads impacting thereon.

In the tile panel of the previous paragraph, said fixing means may conveniently comprise:

i) a plurality of first tile engaging means adapted for engagement with sidelock portions of associated tiles in use; and, ii) a plurality of second tile engaging means adapted for engagement with headlock portions of associated tiles in use.

Preferably said second tile engaging means are each located at an associated resilient portion of said support whereby, in use, when a plurality of tiles is secured to said support, such tiles are not susceptible to loads impacting thereon as aforesaid.

In a tile panel according to either one of last two preceding paragraphs, said second tile engaging means may conveniently comprise mutually offset jaw-like members first ones of which jaw-like members are adapted to engage an upper surface of an associated tile, in use, and second ones of which jaw-like members are adapted to engage, in use, an undersurface of an associated tile and the second aw-like members may be recessed to enable, in use, the retention of a lateral rib formed on the underside of tiles secured to the support.

The support described hereinbefore may be constituted by a planar frame-like structure.

Conveniently the support may comprise a plurality of tile supporting surfaces one each of which is associated with and provides support, in use, for a tile.

Preferably support may further comprise interlocking means for engagement, in use, with interlocking means of supports of mutually adjacent tile panels.

In one convenient arrangement, the interlocking means com¬ prises bayonet-type lugs and bayonet-shaped recesses for enabling, in use, the interlocking of mutually adjacent tile panels.

The support may also conveniently comprise handles for facili¬ tating, in use, the handling of the tile panel.

In a tile panel according to any one of the last five preced¬ ing paragraphs the frame-like structure is a unitary moulding of plastics material and the tile engaging means, the tile supporting surfaces, interlocking means and the handles are formed as integral parts of the plastics moulding.

Tiles supported by the support in use may conveniently be in half-bond or full-bond relationship.

The present invention also conveniently provides a support adapted for use in a tile panel said support being provided by a frame-like structure comprising:

a) fixing means for securing, in use, a plurality of tiles as hereinbefore defined on said support;

b) resilient portions to enable, when in use, movement at a right angle to a plane of the support of tiles secured thereto whereby, in use, such tiles are not susceptible to damage from loads impacting thereon.

The present invention further provides a method of roofing comprising the steps of:

i) securing a supply of tile supports provided with snap-fit tile fixing means; ii) securing a supply of roof tiles; iii) assembling a series of tile panels by snap-fitting a plurality of tiles thereto; iv) offering a first of the assembled tile panels to a roof to be tiled using a plurality of such panels and fixing the panel in position; and, v) positioning successive tile panels seriatim to the roof by interengaging the successive panels with that or those previously affixed to the roof until the roof is covered,

wherein the tile supports each comprise resilient portions to enable, when in use, movement at right angles to a plane of the support of tiles secured thereto whereby, in use, such tiles are not susceptible to damage from loads impacting thereon.

Conveniently, the snap-fit tile fixing means of each support engages associated headlap or sidelock portions of the tiles assembled therewith.

The present invention still further conveniently provides a roof tiled with the tile panels by the method as hereinbefore described.

There now follows by way of example a detailed description of a novel tile support and a tile panel for use on an improved method of roofing which description is to be read with refer¬ ence to the accompanying drawings in which:

Figure 1 is an upper left-hand perspective view of a support;

Figure la and lc are enlarged fragmentary views of parts of Figure 1;

Figures lb and Id are enlarged fragmentary views of parts of Figure 1 but including features of tiles not shown on

Figure 1;

Figure 2 is a schematic side section view taken generally along the line II-II of Figure 1 but also including details of tiles not shown in Figure 1;

Figure 3 is an isometric perspective view as seen in the direction of the line III in Figure 1;

Figure 4 is an upper left-hand perspective view of a tile panel; and,

Figure 5 is an upper left-hand perspective view of several panels forming a roof.

Covering roofs or re-covering roofs with interlocking concrete or clay tiles has hitherto proven to be a labour intensive exercise mainly because the roofing and tiling practices which find favour in many parts of the world include the steps of battening the roof and fixing the tiles thereto one at a time utilising nails and/or clips or combinations of such means. There is now provided by the present invention a tile support 2, see Figure 1, to which a plurality of tiles T can readily be fitted to give a tile panel 4, see Figure 4, which panel 4 is readily affixed to a roof structure by a novel method to be described in full hereinafter.

The tile support 2 is a planar frame-like structure formed as a unitary moulding of plastics, e.g. polyethylene, and is intended to provide support for four tiles T of the tile panel 4 in half-bond relationship, see Figure 4.

The frame-like structure 6 thus consists of four tile modules 8, 10, 12 and 14 with the modules 8 and 10 being arranged in side-by-side relationship at a lower section of the structure 6 and the modules 12 and 14 being arranged in side-by-side relationship at an upper section of the structure 6, see Figure 1.

The modules 8 and 10 are offset by half a tile module from the modules 12 and 14 to facilitate the half-bond tiling of a roof to be described hereinafter.

The structure 6, see Figure 1, comprises a longitudinal lower wall 20, a longitudinal upper wall 22 and a longitudinal cen¬ tral wall 24. The three walls 20, 22 and 24 are parallel, or substantially so, one with the other and are interconnected by: (i) an outer right-hand end wall 26 extending between right-hand end portions 22a and 24a of the walls 22 and 24 respectively, (ii) an inner right-hand end wall 28 extending

between a right-hand end portion 20a of the wall 20 and the wall 24, (iii) an outer left-hand wall 30 extending between left-hand end portions 20b and 24b of the walls 20 and 24 respectively, and (iv) an inner left-hand end wall 32 extend¬ ing between a left-hand end portion 22b of the wall 22 and the wall 24. In the arrangement as just described, see Figure 1, it is evident that the walls 26, 28, 30 and 32 are parallel, or substantially so, one with the other.

The structure 6, see Figure 1, also comprises: (i) a left- hand internal wall 34 extending co-extensively with the wall 32 and between the walls 24 and 20, (ii) a right-hand internal wall 36 extending coextensively with the wall 28 and between the walls 22 and 24, (iii) a central bracing wall 38 extending between the walls 20 and 22, the walls 34, 36 and 38 are paral¬ lel, or substantially so, one with the other and also with the walls 26, 28, 30 and 32.

In addition the structure 6, see Figure 1, comprises a first diagonal wall 40 extending between a junction 42 of the walls 20 and 34 and a junction 44 of the walls 22 and 36, the struc¬ ture 6 also comprising a second diagonal wall 46 extending between the portions 20a and 22b of the walls 20 and 22 respec¬ tively. As can be seen from Figure 1, the walls 24, 38, 40 and 46 intersect at a central junction 48 of the structure 6.

Each tile module 8, 10, 12 and 14 of the support 2, comprises snap-fit tile fixing means by which when the support in use four tiles T may be secured to the structure 6 to provide a tile panel 4.

The snap-fit tile fixing means of each module is similar and comprises first tile engaging means for engagement with associ¬ ated sidelock portions of each tile T of the tile panel 4 and second tile engaging means for engagement with associated headlap portions of each tile T of the tile panel 4.

The first tile engaging means comprises a resilient upstanding hook 50 located at a junction 51 of the walls 20 and 30, see Figure 1, the hook 50 being associated with the tile module 8 of the support 2. Similar hooks 52, 54 and 56 associated with the tile modules 10, 12 and 14 respectively are located respectively at a mid-portion 58 of the wall 20, a junction 60 of the walls 24 and 32, and at a portion 62 of the wall 24 to the right of junction 48 when viewing Figure 1.

The second tile engaging means comprises two pairs of mutually offset jaw-like members 70 and 72 associated with tile module 8 and being located on a forwardly facing side of the wall 24, See Figures 1 and la. There are similar sets of jaw-like members 70a and 72a, 70b and 72b, 70c and 72c associated with the tile modules 10, 12 and 14 respectively which are located respectively on a forwardly facing side of the wall 24 and on a forwardly facing side of the wall 22, see also Figures 1 and la.

The member 70, see Figures la and 2, is adapted to engage, in use, an upper surface of a tile T located in the tile panel 4 at tile module 8. Likewise the members 70a, 70b and 70c are adapted to engage the upper surfaces of tiles T located respec¬ tively in the tile panel 4 at tile modules 10, 12 and 14.

The member 72, see Figures lb and 2, is recessed to captively engage in use, the ribbed undersurface of a tile T located in the tile panel 4 at the tile module 8. Likewise the members 72a, 72b and 72c are recessed to captively engage the ribbed undersurfaces of tiles T located respectively in the tile panel 4 at the tile modules 10, 12 and 14.

Because of the resilient nature of the members 70 and 72 and the ribbed feature of the tiles 7, it is apparent from Figures lb and 2 that the tiles T will be received between the jaw¬ like members 70 and 72 in a snap-fit operation.

The structure 6, see Figures 1 and 2, further comprises tile support surfaces 80, 82, 84 and 86 respectively associated with the tile modules 8, 10, 12 and 14. The surface 80 is provided in an inverted "L" shaped member 90 formed at a mid- section 34a of the wall 34, the surface 82 is provided on an inverted "L" shaped member 92 formed at a lower mid-section 46a of the wall 46, the surface 84 is provided on an inverted "L" shaped member 94 formed at an upper mid-section 46b of the wall 46 and the surface 86 is provided on an inverted "L" shaped member 96 formed at a mid-section 36a of the wall 36.

The purpose of the support surfaces 80 and 82, which are co-planar one with the other and the support surfaces 84 and 86 which are also co-planar one with the other will become clear hereinafter.

The support 2 is provided with interlocking means for engage¬ ment, in use, with interlocking means of supports of mutually adjacent tile panels 4. The interlocking means comprises bayonet-shaped lugs 100 and 102 extending forwardly of the walls 20 and a bayonet-shaped lug 104 extending forwardly of a right-hand end of the wall 24, see Figure 1. The interlock¬ ing means also comprises recesses 106 and 108 formed in an underside of the wall 22 and a recess 110 formed in an under¬ side of the wall 24 towards a left-hand end thereof. In use, the lugs 104 engaged in recesses 110 of mutually adjacent tile panels 4 and the lugs 100 and 102 engage in recesses 106 and 108 respectively of mutually adjacent tile panels 4.

The structure 6 is further provided with apertured bosses 112 and 114 extending rearwardly of the wall 22 and an apertured boss 116 extending rearwardly of a left-hand end of the wall 24, see Figure 1, the purpose of which bosses will become clear hereinafter.

For carrying the tile panels 4, the structure 6 is provided with two handles 118 and 120 formed with and extending rear¬ wardly of the wall 22, see Figure 1.

In order to avoid undue damage due to loads impacting upon the tiles in use, the walls 22 and 24 adjacent to and in either side of the jaw-like members 70 and 72, 70a and 72a, 70b and 72b, and 70c and 72c are of open frame structure having spaced apart upper and lower walls 120 and 122 respectively. Figure 3 shows the details of a right-hand pair of the jaw-like mem¬ bers 70 and 72 located on the spaced walls 120 and 122 associ¬ ated with wall 24 between the junctions 48 and 60.

The upper walls 120 each comprise a sinusoidal mid-portion 124 while the lower walls 122 each comprise an upwardly projecting hemispherical portion 126, see Figure 3.

The method of assembly of the novel tile panel of the present invention and the tiling of a roof will now be described with particular reference to Figures lb, lc, Id, 2, 4 and 5.

A roof is prepared for tiling using the novel tile panels 4 by applying boarding 130 and felt 132 in conventional manner; the boarding 130 extends over the whole of the roof structure (not shown) to provide a laying surface for fasteners, viz. nails, used to attach tile panels 4 thereto. The felt 132 overlies the boarding 130 to insulate the inner roof structure from the elements, see Figure 3.

A plurality of tile panels 4 are then assembled at ground level adjacent the roofed building to be covered. To this end, a first tile Tl is snap-fitted onto the tile support 2 at module 10 thereof with the two pairs of jaw-like members 70a and 72a snap-fitted over a headlap portion 140 of the tile Tl with an underside ribbed portion 142 of the tile Tl being received in the recessed portion of the jaw 72a as shown in

Figure 2. In addition, a sidelock portion 144 of the tile Tl is engaged by the hook 52, see Figure Id. When located as described an underside 146 of the tile rests on the support surface 82 of tile module 10.

A second tile T2 is then offered up to the tile module 8 and when snap-fitted into position, its headlap portion is engaged by the jaw-like members 70 and 72, its sidelock portion is engaged by the hook 50 and its underside rests on the support surface 80. In this position, juxtaposed sidelock portions of the tile Tl and T2 are interlocked one with the other, see Figures 4 and 5.

Third and fourth tiles T3 and T4 are then assembled overlying tile modules 14 and 12 in similar manner to complete the panel.

While successive panels 4 are constructed, the first tile panel 4 is carried up to the roof for which purpose the carry¬ ing handles 118 and 120 are provided. The panel 4 is then positioned where required and fixed to the boarding 130 by nails (not shown) which pass through the apertured bosses 112, 114 and 116 into the boarding 130. The successive panels 4 are thereafter positioned and fixed to complete the roof as shown in Figure 5 with the lugs 100, 102 and 104 being received in associated recesses 106, 108 and 110 of adjacent tile panels 4. Obviously special provision is made at the eaves of a roof for the securement of the lugs 100 and 102 of a row of tile panels 4 located thereat. In addition, down¬ wardly facing sidelock portions of corresponding tiles Tl and T3 are arranged in interlocking engagement with upwardly fac¬ ing sidelock portions of the tile T2 and T4 and of successive corresponding tiles T2 and T4.

When complete the roof is covered with tiles in half-bond relationship with opposite verge portions of a roof (not shown) completed using special half-tile panels (also not shown) .

The complete roof is constructed with ease and results in con¬ siderable economy in man-hours and fastenings used hitherto.

In use the roof constructed as aforesaid is extremely robust in that the tile panels 4 are inherently designed to enable the tiles assembled thereon to resist loads impacting there¬ upon. This is due to the local resiliency of the structure 6 adjacent the snap-fit jaw-like members 70 and 72.

Although the tile panels disclosed and described relate to planar tiles, in an alternative arrangement, contoured tiles may be used. Also, while the tile panels 4 and consequently the roof tiled therewith are in half-bond relationship, in an alternative arrangement the tile panels and consequently the roof tiled therewith may be in full-bond relationship.

In order to further facilitate the ease with which the tile panels may be constructed and a roof covered therewith, the tiles utilised may be of lightweight design or be made from lightweight compositions.

A further modification to the tile panels envisages the use of supports 2 which may be provided with two, three or more tile modules as required.

In a further modified arrangement provided by the present invention the hooks 50, 52, 54 and 56 and the jaw-like members 70 and 72 may be provided as clip-on or bolt-on features instead of being integrally moulded with the tile support 2.

In the example given herein the novel panels 4 are laid on boarding 130 and felt 132; however, in other arrangements whether when a building is being constructed or re-roofed, the panels 4 are readily adapted for use with boarded roofs as disclosed but with battens or indeed roofs consisting in the main of rafters whose pitch, i.e. the spacing apart thereof, is such that the panels 4 may be applied direct thereto.