Surface covering and assembly thereof

Feb. 11, 1941. a. s. vane 2,231,007

SURFACE COVERING AND ASSEMBLY THEREOF

Filed Oct. 11, 1937

<img file="US2231007A_D0001.tif" />

/fagusfasS. Time

ATTORNEY

Patented Feb. 11, 1941

2,231,007

UNITED STATES PATENT OFFICE

2,231,007

SURFACE COVERING AND ASSEMBLY THEREOF

Augustus S. Vane, Irvington, N. Y., assignor to Bakelite Building Products Co., Inc., New York, N. Y., a corporation of Delaware

Application October 11, 1937, Serial No. 168,376

Claims.

This invention relates to building materials, particularly to improvements in siding constructions.

An object of my invention is to provide a 5 composite siding unit comprising a substantially stiff base, preferably of considerable thickness and possessed of good insulating properties, and an outer cover member separable or permanently attached thereto, which may be of flexible 10 weather-resistant composition material, such as is generally used and well known to those skilled in the art.

The invention has as a further object, the creation of a novel joint between adjacent courses 16 of composite units whereby the adjacent units and cover pieces may be interlocked and only a single line of fasteners such as nails are required to mount the units to the supporting surface.

A further object of the invention is to provide a novel siding simulating clapboard siding, wherein the uniformity of the surface is broken by joints created by the cover pieces of my invention.

Also, the invention is directed to the use of composite units comprising a base of fibrous insulation material, which may also be treated to be weather-resistant, and a loose cover piece having a hook-like lower edge portion, which 30 cover piece has been treated over the surface to be exposed, as well as over the formed, portion with a rigidifying coating, for instance, a hydraulic cement.

With these and related purposes in view, I 35 show in the accompanying drawing such instances of adaptation as will disclose the broad underlying features of the invention without limiting myself to the specific details shown and described herein.

Figure 1 is a face view of assembled composite units of my invention.

Figure 2 is a sectional view taken at 2—2 of

Figure 1.Figure 3 is a cross sectional view of a modifl45 cation of the structure of Figure 2, and

Figure 4 is a cross sectional view of a further modification of my invention.

Referring to the figures of the drawing wherein similar numerals indicate similar parts of the 50 structure, 10 is a base of stiff or rigid characteristics, to be covered and preferably comprising a body of compressed or cemented vegetable and/or mineral fibrous material, for instance, bagasse, wood, substantially pure cellulose fiber, 55 paper, asbestos, mineral wool, animal hair, and (CL 20—5) others, usually used either alone or in combination, or adapted to be used in the making of products generally known to those skilled in the art, as wallboard or insulating board. One form of commercial product of this character which 5 I may use, is marketed under the name “Celotex”. The fibrous base may be of the same structure throughout dr may comprise a plurality of separate sheet-like plies bonded face to face by suitable cements to form an integral base struc- 10 ture.

The base may be rendered waterproof and/or fire-resistant by treatment with suitable agents, such as silicates or bitumens, for instance, asphalt, tar or pitch, but preferably with a syn- 15 thetic resin composition, comprising a phenol aldehyde resin or other known synthetic materials adapted to produce water insoluble impervious films after evaporation of suitable solvents combined therewith. Such treatment may extend 20 into one or more faces and edges of the base or throughout the base structure as by coating, saturating, or impregnating. Where the base is a laminated one, one or more plies only, preferably the outer ply, may be treated, particularly where 25 a structure with greatest porosity, with its advantages of heat and sound insulation, as well as lightness of mass, are desirable characteristics. The treatment may also be confined to certain sections of the base, particularly where said 30 bases are to back-up weather joints of further covering material of the invention. Furthermore, the base may be rendered weather-resistant by incorporating a water emulsion of bitumen or synthetic resin with the fibrous ma- 35 terial prior to forming the same into sheet form.

The base may also be of the well known asphalt composition roofing and may be a plurality of such layers bonded together to form a layer of substantial thickness. Also, it may be 40 ¹found desirable to employ a base of a hydraulic cement fiber composition made into sheet form by low or high pressure, but I prefer those made by low pressure and which are light in mass.

Bases of other cementitious and other fiber com- 45 positions are also contemplated, as well as bases of any of the aforesaid types where the ingredients comprising the same have been processed or treated with foams or gasifying substances to render them more porous and lighter in weight, 50 and to improve their Insulating characteristics.

In addition, I contemplate a base of bitumen mastic employing scrap materials as fillers. It will also be understood that the base 10 may be further treated with any of the materials previ- 55

2,231,007 ously described to convey to the same additional protective coatings or surfacings.

The base covering, preferably a detached and loose member, is generally referred to by the 5 numeral 12 and preferably comprises a waterresistant foundation layer and a surface layer comprising a rigidifying composition. The foundation layer may be a layer of composition roofing, comprising a flexible felted fibrous layer of 10 any of the fibrous materials heretofore mentioned, preferably impregnated or saturated with a low melting point asphalt and coated with a further bituminous or resinous layer, also of the types heretofore mentioned. Such material is 15 also generally surfaced with a layer of individual granules such as slate, brick, tile or cement, which are partially embedded into and bonded to the adhesive layer. Composition material of this type may be made in the manner described in the 20 Harshberger Patent No. 1,913,667, granted June 13, 1933.

The base 10 is preferably of tapered section, formed at its butt edge face with a groove 14 creating a lip or projection 16 at the rear face 25 of said portion, and a further lip or projection 18 at the outer face of said portion. It would be noted that the Up 16 is formed with an outwardly tapered section, the purpose of which will be hereinafter more readily discernible. More30 over, it will be observed that the lip 18 is of greater depth than the lip 16 in order to provide an adequate lap for adjacent courses of composite units. The upper edge portion of the base 10 is formed at its rear face with a recess or rabbet, 35 which is substantially complementary in shape to the lip 16. In assembly, the tongue or lip 16 interlocks with the recess 20, producing an automatic registration of adjacent bases and serving to hold the lower portion of the base 10 in posi40 tion against the supporting surface.

The cover member 12 has a body portion which is substantially the depth of the base 10 and the butt portion of said cover piece is formed with a hook-like extension 22, which fits over the lip 45 or projection 18 of the base 10. In this manner it will be seen that the lip 18 serves to hold the cover member in position. Preferably, the cover piece 12 includes an outer coating to lend rigidity to the face portion and to the bend 22. This ⁵⁰ coating will be particularly employed where composition roofing is used for the cover piece and preferably comprises a hydraulic cement, of which Portland and oxychloride cements are examples, but more preferably comprises a high ⁵⁵ aluminate cement composition. The cover piece 12 may also be rigidified by a coating layer of a synthetic resin which, when hardened, forms a stiff film or layer. Obviously, the rigidifying coatings referred to may extend over the whole 60 surface of the cover piece or may be limited to such portions as the rigidifying characteristics may be required. It will be noted that the depth of the retroverted portion of the hook 22 is slightly less in depth than the depth of the lip 18. 65 in assembly, a lower course of bases 10 are secured to the supporting surface, which may be boarding, as illustrated in Figure 2, although it will be understood that any foundation suitable for mounting my base elements may be employed. 70 The bases 10 may be of any desired length suitable for handling, but it will be understood that by reason of their stiffness they may be of considerable size. The bases in a course are laid with their ends substantially abutting. When the first 75 course of bases have been positioned and secured in place, cover pieces 12 are then hooked over the lip portions 18 and pushed upwardly as far as they can be made to go, the lower end of the lip acting as a stop for the cover piece. The cover piece 12 is then fastened as by nails 24 at the upper edge 5 thereof in a portion which will be covered by the next overlying course of units. Subsequently, the next course of bases will be positioned but it is now merely necessary to drop the tongue 16 thereof into the recess of the previous laid bases, 10 and such will hold the said base in position.' The cover piece 12 will then be located in the manner previously described and secured by the fasteners 24. It will, of course, be understood that this procedure may be altered, that is, the cover piece 1® may be assembled prior to application with the base fO as a permanent part thereof by tacking it upon the base 10 by suitable fasteners or an adhesive of the types heretofore mentioned, or the two may be handled as loose units but posi- ²⁰tioned simultaneously against the supporting surface.

In order to protect the joints between adjacent cover pieces, I provide joint or batten strips 26, which may be recessed into the base 10 at any suitable position. However, these strips may be dispensed with where the base itself has been treated to be weather-resistant, it being merely necessary to have the joints between adjacent cover pieces occur at a position other than the joint between adjacent bases in the same course. Moreover, while the batten strip 26 is illustrated as a thin member, it may be a piece having a section similar to the base 10.

It will be appreciated that a stormtight siding is obtainable by the disclosed structure, and that the composite units are readily applied and require a minimum of fastening. Obviously, the cover pieces, being separable members, are free to expand and contract at will, and in this manner any buckling thereof will be substantially avoided.

In Figures 3 and 4, I have shown additional features of my invention. Figure 3 illustrates the ₄₅joint between two adjacent courses of my composite units and discloses the lower part of one composite unit interlocked with the upper part of a similar composite unit. The base of this composite structure is generally referred to by the bo numeral 30 and the cover piece by the numeral 32. It will be seen that the butt portion of the base 30 is formed with a recess 34 at its rear face that is less than 90°, that is, with a recess or rabbet having converging sides. It will be noted that 55 the recess creates a lip or projection 36, also that the rear face of the lip 36 is substantially parallel to the front face thereof, and that the adjoining face of the recess slopes downwardly to form a further V-shaped projection 38. The upper edge 60 portion of the base 30 is formed with a sloping edge, creating a V-projection, complementary in shape to the projection 38. It will be understood that these composite units may be assembled in the same manner as described with respect to the 65 units of Figure 2, as by fasteners 40, and that this construction also only requires a single row of fasteners. The projection 38 produces a simple and ready interlock with the upper edge of the base of another unit and arranges itself slightly 70 easier by assembly than the interlock of Figure 2.

The interlock of Figure 2 produces a better-hold of the engaged units during application.

In Figure 4, composite units are illustrated omitting the interlocking feature of the previ- 75

2,231,007 ously described figures. The base in this figure is referred to by the numeral 42 and is also formed with a lower edge recess 46, which is, however, of greater than 90° between its faces. Thus, it will be noted that the upper edge of the recess is beveled in the opposite direction to that of the recess in Figure 3. The base 42 Includes a lip 48, over which the cover piece 44 is secured. The upper edge face of the base is provided with a bevel face 50 paralleling the upper edge of the recess 46. The composite units are assembled as previously described, except that in the instant construction no interlock occurs but the upper edge of the recess of one base is abutted against the face 50 of the bases in the adjacent Ipwer course and is fastened in position as by nails 51. Subsequently, the cover piece is attached and fastened adjacent the upper edge as by nails 52.

It will be understood that the bases and cover pieces of Figures 3 and 4 may be made of the same materials as those referred to with respect to the constructions of Figures 1 and 2, and that similarly, joint protection strips may be provided in their assembly. It should be noted that in each construction disclosed the adjacent bases in different courses register and abut with each other and thereby form a continuous insulation covering. It will also be appreciated that while the features of the invention have been described with respect to application to a flat boarding Surface, the same features may be employed by a modification of the bases to connection with a clapboard siding or shingle surface.

From a consideration of the foregoing description, it will be seen that I have produced, novel surface covering products and siding constructions thereof, as well as constructions adapted to rapid application. It will be understood that many changes to the foregoing exemplified features will suggest themselves to those skilled in the art without departing from the scope and spirit of my invention. Accordingly, I desire my invention to be construed as including all equivalents and as broadly as the claims, when taken in conjunction with the prior art, may allow.