US1794449A - Building product and process for making the same - Google Patents

Description

March 3, 1931. 4 R. E. BRAKE v 1,794,449

BUILDING PRODUCT AND PROCESS FOR MAKING THE SAME i Filed Oct. 8I 1925 ATTORNEYS Patented Mar. 3, 1931 ff-UNITED* .Slfa12S. PATENT OFFICE f RALPH BRAKE-or JAMAICA, NEWYoRm-Assrenoa, BY MESNE Ass'IGNMEN'rsro Anaconnn -sMIEsconstruir7 -oENEW vom, n; Y., ak CORPORATION or DELAWARE v BUIEnING PEOEUCTAND PaocEss son MAKING kTHE SAME i Application alea octobers, 192e. .seriaiua 140.247.'

l This invention relates tothe manufacture of composite building elements suitable for roofing and otherpurposes and comprising a 'non-metallic bas'e material anda sheathing of Weather-resistant metal appliedl to the surface thereof. 'More particularly, the invention relates to an electrolyti'c process for' the application ofmetalito bases of this type 1n the manufacture. of such'composite products. 10 This process is of primary utility in the application ofcopper, .'Whchis the metal principally used inbuilding elements of this kind, owing to the resistance which copper oli'ers to corrosion, and its attractive appearance, but the utility of the invention islby no means limited zto the application of copper, nor to the use of any specific base material.

Owing to the high cost of Wooden shingles, and'their low lire resistance, numerous prepared v,roofin'gs are now in extensive use, these products being made of roofing felt, asbestos board, magnesite compositions and the like.

rlhe felt product now enjoys the Widest popularity and it is made o1n a felt of suitable Weight arid thickness which is ordinarily saturated `With bituminous products, such as asphalt, andthen coated with a layer of asphalt which is capable ofwithstanding solar heat. 'Sometimes the felt has an additional coating of granular material such as crushed slate, which improves its Wearing qualities and increases its resistance to fire. Roofing products of this kind are in general satisfactory but their appearance on the roofvis somewhat monotonous and When not properly made, the edges of the overlapping elements have a tendency '.in .time to Warp and curl,

making the roof unsightly and possibly subject to leakage. u A

to It has been proposed heretofore to use materials ofthis type in a composite product which includes an additional layer of metal applied to that area of the element Which is exposed to the Weather. A layer of copper thus applied 'wives the ro'ofthe appearance of being coveredwith copper sheathing and such a roofis of handsome appearance, and of high -ire resistanceand long life. The difficulty involved in making such a roofing is to secure a good bond between the -base and metal, for

imperfect product and adds thetWo expand and/contract at different rates and exposure to the Weather is likelyto cause ghe metal sheathing to come vloosefrom the ase. 1

One proposa-lin an eHort to overcome lthis suggests the application of the metal to a base which has a roughand irregular surface due to the application of a layer of granularma-d `terial, such as crushed slate., 'The slate may be embedded partially in the aspha-ltcoating layer on the base land the slate granules which are of substantial size project beyond the base and form crests andxdepressions. When the metal is applied electrolytically over such a surface, the metal enters the depressions and conforms to the irregularities of the surface, so that a firm mechanical bond is established.' In addition, the different parts of the metal sheet expand and contract in dilerent planes so that the expansioneffect is not cumulative throughout the sheet in a horizontal plane.

`While the grit surfaced base coated' With metal is thus far superior to a plain surrfacedv product, attempts to apply the meta-l electrolytically have met -with'numerous obstacles.' Anelectroconductive material. must be applied to the base' in order to permit the electrodeposition of kthe metal and graphite, which is the simplest andA cheapest material to use, can be in a thin continuous film over all parte of irregular base sur face only- WithV considerable diiiculty., and by the use of an adhesive. any failure to pra duce a film which enters all the depressions and extends over all the crests results in an argcly to the cost of lproduction owing increased electrical resist-ance of the film.

This dilliculty has been overcome' by sub-5' stituting for the granular material ordinarily used for roong purposes, an electroconductive-inaterial of granular form, as distinguished from the electroconductive powder or graphite ordinarilyl used.y rlhis material may be crushed petroleum coke, or the'like, and the individual pieces are about the same size as the particles of slate ordinarily used. IThe electroconductive material is affixed to the base by being partially embedded in the coating layer of asphalt over'the felt in the lso 'j It is the-object of usual way, and since the granules are of considerable sizeand are conductive, they 'provide the irregular surface on the base and also the conductive surface neededfor the ele'ctrodeposition.` v 4 In the use of the electroconductive granular material above mentioned I have found thatthe granules of the irregularlayer must be in close contact throughoutthe surface of the base in onder that a substantially' continuous conductive surface may be provided on,v

which the metal is deposited, and any vfailure in this respect results in the production of a plating which has gaps and also the cost of `the operation is high because of the low conductivity of the discontinuous cathode surface y this invention to pro vide a process of producing` building elements of the composite type electrolytically which may be carried onmore easily than those heretofore employed and which produces better results because the process'yields a' higher 'percentage of perfect elements. This process involves the application' of an electroconductive granular material to the surface of the base so that the'latter has the desired conductive surface and the irregular contour, but this granular materialv is select-ed and graded "so that 'a layer of it applied to the base is substantially continuous i I with respect to its conductivity. This result 'vis obtained by preparing av granular material in which the granules are of different sizes, selected so that in a mass of granules the voids are considerably less than those present in an ungraded grit. When such a material is applied to the surface of the base in the usual way, a layer results in -which each particle `is in close` contact with those adjacent, due

to the intermixture of large and small granu les, the smaller granules filling the spaces between the larger ones andl insuring this contact, while the large granules project from the base and produce the irregularity desired. The metal is plated over this granular surface in the usual way.

Instead of using a graded grit'made of granules of different sizes in suitable proportions, I may secure the desired continu- 1ity in the conductive -lm by using an u'ngraded grit of particles of different sizes just as it comes fromthe Crushers, where the grit masses have been reduced to particles of a given maximum size suitable in a product of this type. But when such a grit is emy ployed, I first embed .the grit and then apply manner, and no considerable care in its apa thin film of graphite. The graphitemay be brushed on or applied in any convenient plication is required. The graphite thus applied finds lodgment in the crevices between vthe grit particles, covers any asphalt exposed lbetween adjacent particles andsome of the graphite adheres to the exposed surfaces of the grit to provide with the grit a continuous electroconductive layer. When ordinary grit and anadhesive are used, the graphite or other conductor must be spread with extreme care and it is almost impossible to make it adhere to the 'projecting points of the granules, but in the new process,- this extreme care is not necessary for the graphite is intended only to bridge the spaces between the adjacent conductive particles and lodges readily between them. Accordingly, thel graphite which acts chiefly to augment the conductivity of the granular layer, may be lapplied'with great rapidity and by an attendant of only ordinary skill.

The invention includes not only a process of producing building products of the composite type but also the improved product resulting from the use of thisprocess. This product hasimportant advantages over those previously produced in that a hrm bond between base and metal is secured, lthe metal layeris continuous throughout, and the product may be made morev cheaply, owing to the lower number of imperfect elements in a given run.

For a better understanding of the inven- -ion I'EGIGDC@ may be had to the accompany-l ing drawing, 1n which,

Fig. 1 is a plan View of a rectangular building element made in accordance with the yinvention', the layer of material on the base being broken awayfor purposes of illustration,

loo

Fig. 2 is a vertical s ectionalview on an enlarged scale, A K

Fig. 3 is a view similar to Fig. 2, but with the granular material shown soniewhat enlarged, this material being graded as to size, Fig. 4 is a'view similar to Fig. 3, with the granular material ungraded and with` graphite or similar conductive powder also used,

Fig. 5 is a granular layer ready to be plated.

plan view of'a portion of the.

` ReferringV to the drawings, Fig. l shows l a building element in approximately the `shape of an ordinary shingle, the element comprising a base '1.0, a coating layer 11 thereon, a layer of granular materialy 12 a'py standing solar heat without running'. This 'coating layer adds to. the waterproof qualivv `employ is referably of a'car'bonaceous char-V acter andKV have found. that calcin'ed petroleum coke, metallurgical coke, coke 'obtained' from coal tar pitch," andlcarbon obtained by thejcalcining of anthracite coalare satis-` factory 'for -thei purpose. These materials possess lthe necessary velectrical conductivity,

are readilyobtainable, and easily crushed.

` I have fouhd'that the Siae ofthe particlesV ofconducting material tor beused to provide the cathode surface fon' the lelements 'over which metal is to be plated is of 7importance for vithe conductive material used is made up of particles which arefvery fine, lit is difficult to produce a layer of vsuch particles ofuniform thickness, in which all the particles areun contactfunless excesslve quantities `of the vmateria-l are used. Then, when the layer is subjected to'pressure to cause the particles to be-aiixed, many of the particles beeoine submerged and are thus quite useless. Unless r contact `is made betweengadjacent particles, so that the layer is continuous asto its conductivity,- the .metal platingl is notv continuous and it isnot uniformlythick.v V'Also,1as

theconductivity of a non-continuous layer is low, the `cost for plating current becomes high. jAlso, if material madeup ofnne particles `is usedto the extent ynecessary. to produce a continuous conductive film, some of the particleswill not become firmly affi-xed tothe base and thus the bond between thedmetal coating yandthe base will be weakene c If the particles employed are of too large a -size so that anappreciable portion of each particle is submerged in the plastic coating on the jbase, there is a likelihood .of laclr of contact, although the bond between such metal as can bedeposited, and the base, is quite good.

Accordingly, it will be seen the size of the granules has an importantbearing on the excellence of the finished product and its manufacture, and I have found that best results are obtained when the granular material is linade up of particles of predetermined sizes, lso graded as to size and proportioned as to amounts as to produce a mixture of fine and coarse, particles which may be applied in` a thin layer on the face of a sheet in such manner that'the finer particles largely iill the lspaces between the coarse particles so that eachuparticle contacts with those adjacent to it. By the use of such a mixture there are secured maximum contact and optimum'conductivity in the granular layer.

In the grading of the granular material, I.

composition is satisfactory have found that almat'erial of-'the felloWi-ng1V` 'Percent Retained jon a 14 mesh screen TA lO. ,A Retainedon a20 mesh screenrp 5.y Retained'on a.35 mesh screen e r l 220,y Retainedon a-48 mesh screen 50.. Retained ona mesh .screen r 25 2 i This' material is substantially ifreey fron? f1 f dust, which would interfere Agreatly withv its a' application and also -With the adherencey of4 the mixture, and in a layer applied' to ay sheet; the particles are in contact with eachother to,

such an extent that goodfconductivity is Jwf.8o

obtained.- -Y

'In Figs. 2 and 3,A abui'lding-product isshown made with 'granular material: as abovev prepared, the illustrations being-'necessarily somewhat diagrammatic. The base- `lO -y of' felt or othermaterial is coatedwith thelayer of plastic material 11,then the graded-gran-` ular material is spreadthereoverand'iallixed by the application of pressure whichcauses a firm adherence yor partial submergence of` the grit. The'metal deposit v13 isv produced by ordinary electrolytic methods'and it willi bev seen that the metal'layer conforms to the irregular contour of the granular. surface,`

eac-h of the'particles of which-is a4 cathode f" surface on which metal collects.` --The granulesinclude those' of coarse size Asuch asl/ly and finer particles, such asie and 16, 'thesener particles lying between the coarse ones.' The larger particles vproducethe major ir# regularities of'the 'surface which aiiord means for securing the mechanical `bond-be- -tween base and metal, while thelineriparticles provide the contact between the larger;I i

particles so that the plating is vcontinuous and may be made at a.v low current cost. f f

.In some instances it may be desirable to'. .avoid the careful grading and proportioning of the granular material to produce. a mix# ture of the proper characteristics,- and 'this can be.. done by having themateriall crushed to approximate maximum and l vminimum sizes, then .embedding this materialy in the coating on the base and iinally supplementing the contact between the adjacent particles by an application of fine conductive material, This such as graphite or carbon flour. should be done preferably while the asphaltic coating is hot so that any exposedparts ofv the coating will be covered by the graphite and act as an adhesive therefor.

The application of the graphite may be conveniently eii'ected by sprinkling it on the sheet, then brushing or vvibrating the sheet so that the graphite will settle into the interstices between adjacent granules, and then removing the excess. This last operation prevents the loose graphite from intervening between the plating andthe embedded granules, thusdetriinentally affecting the bond.

In Fig; 4 there is shown a building element produced accordance with the method just described. The base lOvhas the coating layer 11 in which are'embedded the granules of the d conducting layer 12 over which is deposited the metal layer 13. It will b e noted that the granules do not have the grading as to' size and4 proportioning vasto amount present in the case `of the granules shown in Fig. 3, but the open spaceswhich would ordinarily occur between adjacent granules are now filled with graphite as at 17. In some instances, thel graphite will contact with .exposed portions of the base coating as at 18 while in 'others the powder will be wedged into the crevices, between adjacent granules. In eithercase, the conductivity of the granular layer is greatly improved s that the metal may be deposited very readily in the form of a continuous sheet of substantially uniform thickness which i's tightlyy bound to the base;

Fig. 5 is a plan-view of a"small portion of `the surface. ready for the plating operation,

this surface being -madeof .particles graded' as to size and with' the particles of different contour, there is1 a substantially continuous contact'between each particle and those which are adjacent to it. Y Furthermore, the area of such contacting surfaces throughout the sheet A is quite' large, owing to the use' of the fine particles which lie in the interstices between the larger ones. This results in a layer of good electrical conductivity and there is thus produced a continuous layer of metal of substantially uniform thickness, and owing to vthe high conductivity of the cathode surface,

the cost of plating current. used in the plating operation is kept at a minimum.

`The application of metal may be carried on by any'convenient electrolytic process and may result in a plating over the entire surface of the. base or over predetermined areasthereof only. For thislatter purpose,

V the conductive material may be limited to those areas where metal 'is to appear, as at 21, the remainder 22 of the base being coated with a non-conductive material, or'the entire base may becoated with conductive granular material and the deposit limited to selected areas by the use of a stencil or mask during the plating operation. j

While I prefer to employ a non-metallic `conductive granular material, such as coke,

.it is possible 4to secure good results witha metallic material such as granules or filings of copper, lead and other metals.

By employing thefconductive grit graded as to size'and proportioned as to amount and 4 lwith or without the graphite 'to secure an.

irregular conducting surface of the desired character, a superior product is secured.

The presence of the fine particles .of the grit between thelarger particles, or the l-odgment of thegraphite between adjacent grit particlesiu the coating, tend to insure the production of a layer which is substantially continuous with respect to conductivity and as. the linterstices are thus partially filled either with fine grit or graphite, as described,

thedepressions in thesurface are partially filled, so that the depressions in the irregular surface are not so deep as would ordinarily occur. This has the effect of slightly smoothing out theirregular surface, but does not interfere with the obtaining ofthe mechanical bond. It does,h owever, result in securing a metal' film "which is of substantially uniform thickness, because it is found that in an ordinary granular layer vthe metal which enters the deep depressions between adjacent particles is not so thick as the metal which lies on the crests. This is because the crests lie closer to the anode in the platingcell and the metal has a natural tendency to collect on these crests for that reason., Whilethe more,- under these conditions, a better cover- .v

age is secured because there is less'. superficial area to be plated in the latter case than in the caseof al layer in which the interstitial lspaces are not partially filled. It is evident of course .that these interstitial spaces must not be completely filled, as this would interfere with the strength of the mechanical bond, but it has been found possible to secure a satisfactory bond under the conditions I above suggest.

khere 1s a A production of the new material because a low percentage of imperfect elements is produced due to thesuperior conductivityA of the cathodesurface. Furthermore, there is also a saving of energy because in a surface in which the particles are not in contact it is possible, by4 continuing the fplating operation, even-- tually to secure a lm which is continuous throughout the base, but this requires that the metal plating should be built uv so as to bridge the points not in contact, an inmany instances this continuous film of metal can only bevsecured by carrying on vthe plating operation to a point such that the thickness of the film at soniepoints on the base is 'much' greater than is desired.

Owing to the fact that the new material includesl the rough irregular surface on which further saving in the cost of arcate-e the metal is plated, the product is of attractive appearance because the metal coating is given a texture and the product is of long life, due to the complete protection aorded theA base by the metal plating.

l claim:

l. A process for producing building elements suitable for roofing and similar pur poses, Which comprises crushing and grading clectro-conductive granular material to produce a mixture containing selected amounts of particles of different sizes While substan tially eliminating dust, applying a layer of sucli graded granular material to the surface of a base, said layer having high electrical conductivity and giving the base an irregular surface, applying a conductive powder thereover, the powder largely occupying the interstices between adjacent granules, and electrodepositing a layer of metal over the conductive surface soformed.

2. A building product suitable for roofing and other purposes, Which com rises a base, a layer of material affixed to t e surface of the base, this material being graded selected amounts of particles of dierent sizes, ex-

' cluding dust to produce a layer in which each particle is in good electrical contact With the particles adjacent to it, certain of these par-v ticles being of a size sufficient to give the layer lan irregular surface, and a coating of metal over the said layer and conforming to the irregularities thereof. y.

3. A process for producing building elements suitable for roofing and similar purposes which comprises affixing to the surface of a base a layer formed of a graded mixture of granules of electrosconductive material in Which mixture all of the granules will pass through a screen of 14 mesh and a substantial proportion Will be retained on a screen of 48 mesh, dust being substantially absent from the mixture,.and.electro-depositing a film of metal over the granular layer.

4. A process for producing building elements suitable for roofing and similar purposes, which comprises grading electro-conductive granular material to produce a mixture including a substantial proportion of granules of substantial size and a pro ortion of iner granules, particles of dust fineness being eliminated in the grading operation, aflixing this mixture to the surface of a base to provide a layer of irregular surface contour due to the presence of the larger granules and of high electrical conductivity due to the finer granules lodged between and electrically connecting the larger granules, and electro-depositing a coating of metal over 0 the granular layer.

In testimony whereof I aliix my signature. RALPH E. DRAKE.

Images