US2205080A - Method of making interlocking roofing tile - Google Patents

Description

June 18, 1940. D. BROWN ET AL METHUD OF MAKING INTERLOCKING ROOFING TILE 2 Sheets-Sheet 1 June 18, 1940. D. BROWN Er A1. 2,205,080

METHOD OF MAKING INTERLOCKING ROOFING TILE Original Filedl Aug. 4, 1956 2 Sheets-Sheet 2 UNITED STATES y I '12,205,080y i METHOD orv MAKING mTEnLocmG f nooFINdTim; naviserown and Joseph B. Peebles, Los Angeles,

and Bruner Moore Burchiiel, Glendale, Calif.;

said Peebles and said Burchliel assignors to said Brown 'i f Original application August l4, 1936, Serial No. 94,184. -Divided and this application January- 31, 1938, Serial No. v187,902.

3 claims. v(ci. 2s-15'6i This application is a division of our patent tion at one edge there is a partial rib, this being application for Interlocking roofing tile and about half the depth of the other ribs. On the method and apparatus for making, Ser. No, other margin a channel is formed facing up- 94,l84, led August 4, 1936, matured to Patent wardly and this has a longitudinal rim on its 5 No. 2,177,607, issued October 24, 1939. As it is outerv edge, such rim terminating in a. plane 5 necessary to describe certain parts of the maof the underside of the main body of the rib. chine or equipment in relation to the method of A further feature in the method of making the making the tile and the tile as an article, we tile is passing this ribbon through an automatic use some of the drawings of the parent applircutting machine which has a travelling carriage,

l0 cation -such carriage moving with the same speed as the l0 Our invention relates to a method of making ribbon after a predetermined amount of such rooiing tile having a longitudinal edge interlockribbon has been fed on to the carriage and then ing between adjacent tile, such interlock being the cutting of the ribbon to form both ends of of a type in which the drainage or seepage of the tile and the sealed end is done in one operwater at the longitudinal tile joints is carried ation, this operation also cutting oli a short 15 downward in part of the interlocking construcwaste strip. The cutting is done during a lontion and thus drains' on to the lower tiles of a gitudinal motion ofthe cutters and the press for roof. Another feature of our invention is in sealing the end so that the longitudinal speed providing a sealed end closure for a tile with of these cutters equals the longitudinal Speed 0f ribs on its underside, such closure thus when the ribbon of clay. Thus, in the action of cut- 20 interfitted by an overlapwith other tiles preting the ribbon into tile lengths, a notch is cut vents seepage of water upward in the grooves out of one corner at the end of the interlocking formed between the ribs on the underside of the channel, the lower end of each tile is sealed `or tile and also permits a lesser overlap of the tiles. rounded oiI, this also forming a short waste Another feature involving the sealed end and Strip, the Opposite end iS Cut by a Shear Gilt tranS- 25 the interlocking channel of adjacent tiles is in verse to the clay ribbon and at the Same time having the channel terminate slightly short of nail holes are punched adjacent the upper edge 0f the sealed end so that an adjacent tile has its the tile sealed end extend over and below the end of the Oui invention iS illustrated in connection `with channel used for interlocking the adjacent tile. the accompanying drawings, in which: 30

A characteristic therefore of our invention, is Fig. 1 iS a plan 0f a DOTtOn Of the machine that each individual tile has a series of longishowing the Dart O the Carriage taken in the tudinal ribs on its underside thus forming direCtiOn 0f the aIrOW 0f Fig- 2I emitting hOW- grooves between the ribs. At the margin or ever, the hydraulic Operating mechanism.

longitudinal side of each tile a longitudinal chan- Fig. 2 iS a Vertical lngitlldinal Section 0n the 35 nel is formed and the edge of the adjacent tile line 2--2 of Fig. 1 taken in the direction of the has a downturned partial rib which interts with arrows showing part of the Oscillating hydraulic the said channel. In addition the lower end of motor in elevation and a portion of the cutters each tile is rounded over forming a seal across and dies for forming the shingle, these being in the ribs. This gives a convex curve to the lower an elevated position. 40 end of eachtile considered on a longitudinal scc- Fig. 3 is a partial longitudinal section similar tion and thus forms with the ribs flat underto Fig. 2 but showingthe cutters and dies in surface portions to t on the nat top of an under their lowermost position when severing and dietile.v 'I'he sealed lower end of each tile where pressing the shingle end.

it is turned downwardly engages over the end of Fig. 4 isa perspective View of one of the tiles 45 the marginal channel of the adjacent tile, such showing the upper surface and the channel at channel being slightly shorter than the total one side.

length of the tile. Fig. 5 is a perspective reverse view of the tile i A further object and feature of our invention showing the full ribs, the half rib on one edge is in the ymethod 0f manufacturing tile in a conand the underside of the channel. 50 tinuous and in effect, automatic manner. In Fig. 6 is a plan of an assembly of tiles in a this a ribbon ofclay is forced through a suitable y roofing. extruding machine whichforms the ribbon with Fig. 7 is a transverse section of two adjacent continuous longitudinal ribs onv its underside, tiles on theline .'l-l of Fig. 6 in the direction these ribs being all of the same depth. In addiof the arrows. 55

Our invention as it relates to the tile is illustrated particularly in Figs. 4 through 7 in which the individual tile is indicated by the numeral II. This is formed from a continuously molded ribbon of clay which has a web I2 with a series oi internal ribs I3 formed on the lower side. The formation of the ribs thus forms wide longitudinal grooves I4. At one marginal edge a partial and designated half rib or rim I5 is formed, there being a narrow groove I6 between such marginal half rib or rim and the next adjacent full rib I3. It will thus be seen that the upper surface of the ribbon presents a smooth surface of the web of the tile except that on one margin there is formed a longitudinal channel I1, this being on the side opposite that having the half rib or rim I5. This channel has a marginal half rib or rim I8. The base or underside I 9 of the channel is on the same plane as the bottom edge 20 of the main ribs I3 so that the half rim or rib I8 is approximately the same in vertical measurement as the half rib or rim I5 on the opposite side of the ribbon. The inner face 2| of the channel I1 is thus in effect a p0rtion of the side face of a rib. It will be understood that as the ribbon of clay is extruded ina continuous operation that the web, the various interior ribs, the marginal rim I5 on one side and the channel structure I1 on the opposite side are formed in a continuous manner and that the individual tiles are made by cutting into proper lengths. In this cutting a transverse cut is made which forms the upper end 25 of an individual tile, this serving the web, the various internal ribs, the marginal rim I5 and the channel structure I1. This cut is at right angles to the plane of the ribbon. 'I'he lower end of the tile is formed with a sealed end 26. This is made by die-pressing the web portion downwardly forming connected cross blocks 21 between the ribs and also partially widening or spreading the ends of the ribs I3 adjacent their lower end as indicated at 28. The characteristic of the sealed end 26 is that it has a convex rounded curvature 29 merging with the top surface of the web I2 and this convex curve or nose merges into a sloping end edge 30 which forms an obtuse angle with the plane of the web of the tile. The sealed end has a transverse under'edge 3| which is in the same plane as the bottom I9 of the channel and of the lower edges 20 of the main ribs I3.

In the same operation in which the sealed end is die-pressed in shape, a notch 35 is formed at the lower end of the channel structure I1.v 'I'his is done by making a transverse cut which severs the half rib or rim I8 of the channel, the bottom of the channel leaving an end face 36. 'I'his action also makes an end cut 31 in a portion of the lateral rib 38. There is also a longitudinal cut 39 made in this rib from the sealed end 26. This leaves a right angular corner 40 at the transverse cut of the channel I1 at its end face 36 and the side face 39 cut in the rib 38.

To intert with this the rim I5 joins with the sealed end 26 on a junction line 4I which is positioned slightly above the lower edge 3i of the sealed end as shown in Fig. 5. It will be noted that in forming the ribs, the center ribs I3 have a small llet 42 where they join the web I2. 'Ihc rib 38 adjacent the channel I1 has a larger fillet or sloping side wall 43.` Also the rib 44 which is adjacent the groove I6 also has a large fillet 45 or sloping inner edge. This construction at the ribs 38 and 44 strengthens the connection of the channel structure I1 on one side of the tile and the groove structure I6 with the rim I6 on the opposite side of the tile.

'I'he tiles are provided with the usual nail hole perforations 46 spaced inwardly from the edge 25. In this construction of a sealed tile however, the nail holes may be made much closer to the upper end of the tile than in the usual tile as it is not necessary to have such an overlap of the tiles when laid up on a roof.

In setting up the tiles they interflt as shown in Fig. 7 in which it will be seen that the rim I6 on one side oi' a tile fits in the channel I1 on the edge portion of an adjacent tile. It will be noted that the rim I8 on the outside of the channel I1, being of half the rib height, substantially engages the underside of the web I2 whereas the edge of the rim I5 substantially engages the bottom of the channel I1. The outside of the rim I5 is in close engagement with the longitudinal edge surface 2| of the channel I1 and the rim I8 is in close engagement with the rib 44 of an adjacent tile.

The corner portion of the sealed end 26 of the tile at its junction with the rib I5 fits in the notch 35 formed by cutting the channel I1 a shorter length than the main body of the tile so this gives a seal across the end of the channel I1. Therefore any water seeping between adjacent tiles and ilowing down this channel is directed downwardly onto the tiles immediately below in a roof structure.

Our invention, so far as the machine assembly is concerned, has the following main features in which an extruding machine extrudes through a die forming a ribbon of clay 52. This is received by a transfer table 53 mounted on a substantial frame structure 54. This frame structure forms a mounting and track for the carriage designated by the assembly numeral 55. The carriage is mounted on wheels in the usual manner to facilitate its reciprocating movement. The shingles after being formed are conveyed from the machine by an out-feeding conveyor, this travelling at a higher rate of speed than the ribbon of clay to lead the cut tiles quickly away from the machine.

Certain characteristics of the carriage 55 is that this has a carriage bed 51 with marginal guides 68 and 59 (note Fig. 1), these being formed of angle-irons and between such angle-irons there are longitudinal straps 60 which fit the grooves between the main rib. 'Ihere is also a side strap 6I with a longitudinal recessed edge 62 which accommodates the marginal rim I5. These straps and the angles have a somewhat pointed end 63 to facilitate feeding the ribbon of clay over these straps. 'Ihe straps have a slightly beveled end 64 remote from the end 63. The machine is provided with a cutting and die-pressing assembly 65. This has an upper frame 66 supported on four vertically reciprocating rods 61, these being connected to longitudinal angles 66 forming part of the top frame 66, this frame being adjustable on these rods. 'I'he rods pass downwardly through tubular guides 69 forming part of the carriage bed or secured thereto in any suitable manner. The lower ends of these rods are connected to a lower frame 10. This frame has longitudinal angles 1I and cross or transverse angles 12. l

The cutters include a transverse severing blade 15 which is illustrated as secured to a transverse angle-iron 16 extending between the longitudinal angles 68 of the top frame 66 and is adjustable longitudinally to regulate the length of the tile. Punches 11 are also secured to the angle-iron 16 to punch the nail holes.

The die 80 for forming the sealed end on the .tile has a sloping blade 8| depending from a cross strap 82 located between the longitudinal angles 68. This blade slopes at an angle upwardly and towards the severing blade and forms the main portion of the end seal 26, giving the slope to the end 30 and bythe downward ilow of clay I adjacent the top surface of the web forms the convex curve 29. This die has a longitudinally extending blade section 82 and an outwardly extending shearing blade 83 which forms the notch 35. 'I'he longitudinal shearing part 82' cuts the longitudinal cut-39 of the notch and the .out-

wardly extending shearing blade 83 gives the transverse cut 36v and 31at vthe Vend of the channel structure I1. Forming the notch causes a slight waste inthe clay ribbon forming the tile.

The cutter assembly with the blade and the end seal forming die is vertically reciprocated by an oscillating engine 85. This engine has a crank shaft 86 extending therethrough with a crank 81 on each end. From each crank there depends a connecting rod 88 which is pivotally connected at 89 to a cross or transverse angle 12 which angles form in effect a cross head. The engine has two similar end heads 98 which have a supporting base 9| bolted to a cross channel 92 which forms part of the machine carriage. Between thesev heads there is a ring 93 cylindrical on-its inside surface, this ring fitting against shoulders of the end heads and the assembly being attached by bolts.

The two supply pipes have elbows |22 and there are two longitudinal pipes |23 and |24 (note Fig. 2) which are supported in the carriage and from'each of these there is a ilexible hose leading to couplings of a control valve. This valve may be of the usual character and has an inlet connection from a hydraulic pump and return to the pump or a reservoir, thus by a suitable control of the oscillating engine 85 as described in the parent application above noted, such engine is operated to oscillate the shaft 86 and hence raise and lower the cutting and die pressing assembly 65.

The mechanism for' initiating the movement of the carriage with the ribbon of clay and the return of the carriage at the end Aofits stroke may be arranged somewhat in the manner of the patent application to Davis Brown for Automatic brick and tile cutter, Ser. No. 44,727, lled October 12, 1935, matured to Patent No. 2,058,663, issued October 27, 1936.

In this cutting action the transverse cutter blade l5 isbrought down at predetermined periods during which time a ribbon of clay has been fed, thus giving a series of cuts, two of which are indicated at |85 in Fig. 3. At the same time the diecutter makes a severance cut |86 as v well as die-pressing the end of the tile. Thus riage.

-and 31.

The cuttingv edge of this sloping blade is horizontal and thus parallel to' the bed of the car- However the sloping part of this blade does not extend the full width of the clay ribbon from which the tile'is formed and cut but at the left hand end considered facing in a forward direction of the movement of the ribbon, there is a -longitudinally extending blade section 82 which is vertical as clearly shown in Fig. 2. At thel rear end of this latter blade lthere is the shearing blade 83 which is also vertical as shown in Figs. 1 and 2.v Thus in the operation as shown in connection with Fig. 3, the shearing blade 15 cuts through the ribbon of clay, making a ver- -tical cut and. completely severing the' web and the various ribs. The action of .the die and in particular the sloping blade 8| in its downward movement engages the ribbon back of the right 'The characteristics of the action of the longitudinal blade 82' and the cross blade 83 is at the same time to form a longitudinal cut in the clay forming the surface 39 shown in Fig. 4

and to make the cut crosswise at the right angular corner 40, leaving. exposed the surfaces 36 This cutsout the notch designated as 35, Fig. 4. In this action the cutting edges at the bottom of the die, that is, the cutting edge of the sloping blade 8| and of the blades 82' and 83, are all on the same level and thus cut through the web, the ribs and the channel structure giving the formation at the end of the tile shown in Figs. 4 and 5 and developing a slight waste strip |81 which includes the portion cut out to form the notch 35.

Various changes may be made in the details 4of the construction without departing from the an upper surface for exposure to the weather and a pluralityA of downwardly extending ribs with spaces between the ribs and the web comprising while the ribbon is moving in a forwarddirection at the rate of extrusion, in asingle operation severing the ribbon to form a tile length and at the same time deforming one end of the web and a portion of the ribs adjacent thereto to formv an end seal integral with the web and the ribs and bringing the lower edge of the seal into alignment with the lower edge of the ribs whereby the said seal forms an end closure for the space between the ribs and the web when the tile is set up on a roof.

2. In the method of making roong tile as claimed in claim 1, at the same time of severing the ribbon into a tile length forming a waste piece supporting the web with a moving support on the underside between the ribs except at the end which is deformed and in the deforming of the end of the ribbon and ribs pressing the under portion of the web and the side portions of the ribs into contact with the moving support.

3. The method of making rooiing tile in which a ribbon of clay is continuously extruded to form a web with an upper surface for exposure to the weather and a plurality of ribs iormed integral 75 10 the said seal forms an end closure for the said space when the tile is set up on a roof, supporting the web of the portion of the ribbon to be severed into a tile during its movement except at the end in which the seal is formed whereby a portion of the web is distorted downwardly and the end portion of the ribs distorted laterally to form the end seal.

DAVIS BROWN.

JOSEPH B. PEEBLES. BRUNER MOORE BURCHFIEL.

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