US2139620A - Siding element and method of making the same - Google Patents

Description

Dec. 6, 1938. L. KIRSC'HBRAUN 2,139,620

SIDING ELEMENT AND METHOD OF MAKING THE SAME Filed Jan. 30, 1937 2 Sheets-Sheet l L 1 1L 1| 1% WW 1 1 v w --+--L 1 7L L720 M INVENTOR 7 1557-5? hescwae/wlv.

ATTORNEY Dec. 6, 1938. K|RSCHBRAUN 2,139,620

SIDING ELEMENT AND METHOD OF MAKING THE SAME Filed Jan. 30, 1937 2 Sheets-Sheet r1 .4.

5 3m Q71 /fl/fl' J W//// v A INVENTOR [Es TEE MESCl-IBf/i u/v fl! m ATTORNEY Patented 6,}

UNITED STATES SlDlNG ELEMENT AND METHOD OF MAK-' mo 'rna SAME Lester Kirschbraun, New York, N. r, assignmto The Patent and Licensing Corporation, New York, N. .Y., a corporation of Massachusetts Application January 30, 1937, Serial No.123,0Q2

.7 Claims.

This invention relates to improvements in brick simulating siding and similar elements and to a method of making the same. An object of the present invention is to provide an improved siding element employing a fibrous or similar insulating board as the base ma.-

terial. Siding elements constructed according to the invention present the appearance of a single course of bricks separated by transverse or'vertical mortar jointsand have means for lapping engagement with other similar elements, the lapping portions being arranged to provide simulation of horizontal mortar joints between elements of adjacent courses, and simulations of vertical l5 mortar joints between adjacent elements in each course.

Another object of the invention is to provide a method of producing a. multiplicity of siding elements of the character above described from a sheet of fibrous or similar insulating board, in

which the several steps of the method are performed on the sheet prior to its separation into separate siding elements.

A further object of the invention is to pro- 535 vide a method of processing a sheet of a fibrous or similar insulating board to produce a multiplicity of similar siding elements integrally connected to one another but readily detachable into separate elements.

By the practice of the present invention a single series of operations on a sheet of the base material such as Insulite or Masonite provides a plurality of siding elements which may be separated from one another at the point of manufacture or which may be handled and shipped in connected form and separated only at the place where they are to be employed for their. intended use. One of the features of invention resides in the provision of transverse mortar simulating joints for a plurality of elements by straight line cuts transversely across the sheet.

My improved siding element and method of making the same will be more clearly understood and further advantages thereof will become apparent from the detailed description which is to follow and from the accompanying drawings in which:

Figure 1 is a broken perspective view depicting a preferred form of the siding element of my invention;

FlgureZ is a plan view of a sheet of the base material from which my siding elements are formed showing the arrangement of grooves made in the sheet before it is subdivided into the 55 separate siding elements;

Figure 3 is a sectional view representing an enlarged section taken on the line 3-3 of Fig. 2 at one stage in the production of the siding elements.

Figure 4 is a sectional view representing an 5 enlarged section taken on the line 4-4 of Figure 2 at one stage in the production of the siding element. v

.Figure 5 is a view similar to Figure 4, but illustrating the manner of finally separating the sheet 10 into the completed elements; and

Figure 6 is a face view illustrating the appearance of several siding elementsv when laid upon a. wall or similar supporting structure.

Referring to the drawings, and particularly to 15 Figure 1 thereof, my new siding element per se is shown generally at l. The siding element is comprised of a fibrous insulating board, such as those known under the trade name of Insulite or-Masonite, as the base material. The siding 2o element presents, on its face to be exposed, the

appearance of a course of bricks with mortar joints therebetween. This appearance is imparted to the base material by a plurality of transverse grooves t which are of a depth preferably equal to one half the thickness of the base material. The grooves 33 are appropriately spaced so that the raised portions 2 between adjacent pairs of the grooves 3 and as well as between an outermost groove and one end t of the element, approximate in length the length of an ordinary building brick. One end 5 of the element is recessed as shown at t, the inner edge of the recess being Spaced from the nearest groove 3 a distance equal to the length of a brick to be simulated. The recess 5 is substantially the same depth as the grooves 3 but is substantially wider than the grooves and preferably is twice the width of the grooves 3. The face of the element in which are provided the grooves 3 and recess 6 40 also is provided with a recess 6 along one longi tudinal edge 8 thereof. The recess l is preferably of the same depth and width as the recess 6. The recesses 6 and i provide tongue receiving seats, as will be seen later, in addition to mortar 45 joint simulations between the elevated portions 2 of adjacent elements when a plurality of the ele- 'ments are laid upon a supporting structure in the manner shown in Figure 6. The element has formed on its other face, a recess 9 along the end 4- and a recess I I along the edge It. These recesses 9 and H are of a depth equal to substantially one-half the thickness of the base material and of a width equal to the difference between the width of a. groove 3 and of the recesses 6 or i.

partially into the interior of the element from the faces thereof, to leave the voids in the center or core of the element substantially free of the impregnating material and thus preserve the insulating quality of the fibrous board from which the elements are formed.

The entire upper surfacesof the element, and preferably including the walls and bottoms of the grooves 3 and recesses 6 and I, are covered with .ment.

a coating of asphaltic material It. The elevated bri'ck simulating areas 2 carry a facing of a crushed slate, or other comminuted grit I8, of any suitable color partially embedded in the coating. A grit of a contrasting color or kind may be similarly partially embedded in the coating on the side walls and/or bottoms of the grooves to enhance the mortar joint simulating effect of the grooves.

As shown in Figure 6, a siding element of the above described, construction is secured to a supporting structure with the edge carrying the tongues l4 lowermost. Similar elements are then laid in endwise relationship vn'th the first element to form a course, the tongue |3 of each element lying within and partially overlapping the recess 6 of the next endwise adjacent ele- Inasmuch as the width of the recess 6 is equal to the combined width of a groove 3 and the tongue l3, the end of the tongue l3 of each element, which is also the end of an elevated brick simulating area 2 of the element, will be spaced from'the end brick simulating area of an adjacent element a distance equal to the width of a groove 3 to provide the simulation of a transverse mortar joint at the adjoining ends of adjacentelements. A second course of the elements is laid with their tongues l4 lying within and partially overlapping the recesses I of the elements of the first laid course. Here also, due

to the fact that the recesses I are of a width 7 equal to the combined widths of a groove 3 and the tongues M, the ends of the tongues H, which also define longitudinal edges of the elevated areas 2 of the elementsof each course will be spaced from the brick simulating areas of each element of a preceding course a distance equal to the width of the grooves 3 to provide the simulation of a horizontal mortar joint between adjacent courses. Further courses of the elements are laid in a similar manner until the wall is entirely covered. The .several courses of elements are preferably so laid so that the transverse joints between elements of each course are staggered with relation to the transverse joints between elements of adjacent courses and also with the simulated transverse mortar joints staggered with relation to the simulated transverse mortar joints of adjacent courses.

A wall structure or the like covered with the siding elements of this invention, as illustrated in Figure 6, will closely simulate the appearance of a brick wall inasmuch as the brick simulating areas will all lie substantially in the same plane, the said plane being spaced outwardly in respect to the mortar line appearing portions therebetween. Due to the construction of the elements of such width as to simulate but a single course of bricks they may ,be readily fitted to conform with the requirements of window casings, etc.

In the process of producing the siding elements, according to a preferred method of my invention, a sheet 20 of suitable dimensions (see Fig. 2) of a base material such as Insulite or Masonite'of from approximately inch to inch in thickness is scored on one face to a depth substantially one-half the thickness of the sheet to provide recesses 2i and 22 extending along one longitudinal edge 23 and one end edge 24 respectivelyof the sheet. The widths of the recesses 2| and 22 are substantially greater than the width of a mortar joint as conventionally employed between bricks in a brick and mortar structure and are preferably of twice the width of such mortar joint.

The face of the sheet provided with the recesses 2| and 22 is also scored longitudinally at spaced intervals to provide grooves 30. The groove 30 nearest the edge 25 is spaced from said edge a distance equal to the width of the exposed portion of a building brick and the groove 30 closest to the edge 23 is spaced a similar distance from the inner edge of the recess 2|. The several grooves 30 are spaced at intervals substantially equal in width to the width of the exposed portion of a brick. Each groove 30 is made of a width and depth equal to the width and depth of the recess 2|.

The face of the sheet containing the recesses 2| and 22 is also scored transversely to provide spaced grooves 29, each row of grooves being in alignment transversely of the sheet. The

grooves 29 nearest the edge 26 of the sheet are spaced'therefrom a distance equal to the length of the exposed portion of a building brick and the grooves 29 nearest the edge 24 are spaced a similar distance from the inner edge of the recess 22. The several grooves 29 of each row are spaced apart by intervals substantially equal tothe length of the exposed portion of the bricks to be simulated. Each groove 29 is made of a width equal to that of a conventional mortar joint and of a depth equal to that of the recess 22.

The sheet is scored on its opposite face along the other side edge 25 and other end edge 23 to provide recesses 21 and 28 respectively (see Figures3 and 4). The recesses 21 and 28 are of a depth substantially equal to one-half the thickness of the sheet and are of a width equal to the difference between the width of the recess 2| (or 22) and the width of a conventional mortar joint.

The several grooves and recesses may readily be formed by means of a circular saw or other cutting device. After the completion of these grooving operations the sheet is impregnated with a suitable" material such as a low melting point asphalt (i. e., asphalt of a -180 F. melting point) or an asphalt emulsion. The saturating treatment may be such that the saturant will strike through the sheet from face to face but it is preferably so controlled that it will only partially permeate the sheet to provide in effect a surface impregnation. The impregnation of the sheet in such a manner will leave the center or core unimpregnated so. that the cells or interstitial void spaces thereof will remain unfilled by the saturating material to such an extent as might materially decrease the insulating value of the fibrous baseslightly offsetting the edge 5! of the material.

The impregnant may be appliedto the sheet by dipping the same in a bath of the saturant, permitting the saturant to drain from the sheet and storing the sheet in a heated atmosphere until the saturant strikes into the surface of the sheet. In an alternative method, an impregnant such as an asphalt cut-back may be sprayed or brushed in controlled quantities onto the surfaces of the sheet. The upper surfaceof the sheet is then coated and surfaced in any convenient manner. For example, the upper surface of the sheet (see Figure 5) may be coated with. a suitable asphaltic material such as a high melting-point asphalt or an emulsion of asphalt in water. The

coating M is extended to include the walls and preferably the bottoms of the grooves 29 and 30 and the recesses 2| and 22. A surfacing '42 of a suitably colored comminuted grit may be applied to he surfaces of the brick simulatingfields and, if desired, a grit of contrasting color and/or kind may be applied to the walls and bottoms of the grooves and recesses.

According to an alternative method the coating 4| is permitted to dry and thereafter all the grooves and recesses on the upper face of the sheet are masked with a templet. A second preferably thicker coating of asphalt or asphalt emulsion is applied overthe exposed portions of the sheet and the templet and prior to any substantial drying or setting of this coating there is applied to the coating a covering of comminuted grit material of any suitable color and kind, the comminuted grit. material being partially \embedded in the coating. Thereafter the templet is removed and the granular layer is rolled lightly .before the coating has completely dried or set and is again rolled after the setting'is completed.

The coating and surfacing materials may be applied in any other suitable manner in addition to the methods described above.

' After the coating and surfacing steps have been completed,the opposite (lower) face of the sheet is scored to provide longitudinally extending grooves as indicated at 45 which are so placed (as shown in Figure 5) that the longitudinal edge thereof furthest from the recess 2| is in substantial alignment with the longitudinal edge nearest the recess 2| of the corresponding groove 30 on the upper face. The depths of the grooves are preferably substantially but not quite equal to the thickness of the base-sheet less the depth of the grooves 30. At the completion of this grooving'operation the sheet will comprise a p'lurality of siding elements held together by thin .hinges 50 of the base material whereby they may be handled and packedin sheet form. The final separation of the sheets into individual siding elements may readily andconveniently take place at the place where they-are to be applied by.

I simply tearing them apart. Howeveiyif desiredthe sheets may be separated into the individual elements in the process of their manufacture by forming the grooves of sufficient depth to com pletely sever thematerial at the joining line of the grooves 30 and 45.

It may be preferable in' some cases to have the grooves 45 of such a depth that their depth combined with the depth of the grooves 30 is equal to or greater than the thickness of the sheet. In this case the integral connection of the several elements of the sheet is provided by /2 M being integrally joined together by thin hinges- Each siding element will have recesses inch in depth and 1 inch inwidth groove 45 in respect to the edge 52 of the groove 30.

-In the case where the impregnation of the sheet.

with a water-resistant material has been a surface impregnation only the grooves 45 will exsprayed onto the walls and bottoms of the grooves;

In the practice of the method of this invention accordingxto one specific example. thereof, an Insulite sheet inch by 14 inches by 43 inches may be employed as the starting material. Oneend edge and one side edge of one face of the sheet are provided with recesses,- as indicated at 2| and 22 in Figure 2, the recesses being M inch in depth and 1 inch in width. The other end edge and side edge are provided with recesses on the opposite face of the sheet, as indicated at 21 and 28, each inch in depth and /2 inch in width. The upper face of thesh'eet isthen divided into four elevated longitudinally extending zones of equal width by forming longitudinally extending grooves 30 each 4 inch in depth and l inchin width and the longitudinally extendingzones are in turn divided longitudinally into fields of equal length by four transversely extending grooves indicated at 29, each A and inch in width. After the completion of inch in depth 1 the coating andtheslatlng operations longitudlnal grooves are provided on the opposite face of will readily be observed that the sheet will now comprises four siding elements each provided with five brick simulating fields each 2 inches by 8 inches and with mortar simulating spaces inch in width therebetween, the four elements of the base material.

extending along one side edge and one end edge of one face thereof and recesses 3 inch in depth.

and V inch in width extending along the other side edge and end edge of the opposite face thereof. The siding elements of this specific example when laid upon a wall with the tongues of each element received in the corresponding recesses of adjacent elements -will sim ulate the appearance of a brick structure in which the bricks are each 2 -inches by 8 inches separated longitudinally and trans ersely by mortar lines V inch in width.

It is understood that the above specific example I of the carrying out of the method of this inven-- tion is for the purpose of illustration only and is not to be construed in a limiting sense.

'What I claim is:

1. A sheet of a fibrous insulating board grooved,

define a plurality of siding elements, each element comprising a row of brick simulating fields spaced longitudinally on one face thereof to from one another by transverse grooves, said elements being maintained in sheet form by thin readily severable portions extending adjacent one boundary of each of said longitudinal grooves.

2. A sheet of fibrous insulating boardgrooved longitudinally on one face thereof to define a plurality of siding elements, each element comprising a row of brick simulating fields thereon separated by mortar joint simulating spaces extending transversely along saidface of the sheet, the opposite face of the sheet being grooved longitudinally, each of the last named grooves having one side wall thereof substantially in cross-sectional alignment with one side wall of a longitudinal groove on the first-named face, whereby said elements are severable from the sheet along lines marking the intersection of said side walls with the bottom walls of said grooves.

3. A sheet of fibrous insulating board as defined in claim 2, in which the longitudinal grooves on the first named face are wider than those on the second named face.

4. As an article of manufacture a sheetof fibrous insulating board, spaced parallel grooves extending longitudinally along one face of the sheet, a recess extending along one longitudinal edge of the sheet, spacedparallel series of aligned grooves extending-transversely across said face of the sheet and connecting the longitudinally extending grooves, the longitudinally extending grooves and the transversely extending grooves defining therebetween a plurality of brick simulating fields, and a recess extending along one end of the sheet, the width of the recesses and the width of the longitudinally extending grooves being substantially greater than the width of the transversely extending grooves.

5. A method of forming a plurality of siding elements from a sheet .of a fibrous insulating material comprising forming on the upper surface of the sheet spaced parallel grooves extending longitudinally of the sheet and a series of spaced transversely extending grooves through each of the zones intervening between said longitudinal grooves, the grooves of each of said series being in alignment transversely of the sheet and connecting the longitudinally extending grodves, forming recesseson one longitudinal edge and one end edge of the sheet and separating the sheet along one boundary of each of said longitudinally extending grooves into a plurality of separate siding elements. 1

6. A method of forming a plurality of siding elements from asheet of a fibrous insulating material comprising forming on the upper surface of the sheet spaced parallel grooves extending longitudinally of the sheet and a series of spaced transversely extending grooves through each of the zones intervening between said longitudinal grooves, the grooves of each of said series being in alignment transversely of the sheet and connecting the longitudinally extending grooves, forming recesses on one longitudinal edge and one end edge of the sheet, impregnating the sheet with a water-resistant material in such a manner as to confine the impregnatingmaterial to portions of the sheet adjacent the surfaces thereof and separating the sheet along oneboundary of each of said longitudinally extending grooves into a plurality of separate siding elements.

7. A method of forming a plurality of siding elements from a sheet of a fibrous insulating material comprising forming on the upper surface of the sheet spaced parallel grooves extending longitudinally of the sheet and a series of spaced transversely extending grooves extending through each of the zones intervening between said longitudinal grooves, the grooves of each of said series being in alignment transversely of the sheet and last named grooves having one side wall thereof substantially in cross-sectional alignment with one side wall of a longitudinal groove on the firstnamed surface. I I

LESTER KIRSCHIBRAUN.

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