Patent Publication Number: US-4096674-A

Title: False tenon structure

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to split log structures having the appearance of full log mortise and tenon structures, or other stacked member construction, and more particularly to a false tenon which is attachable to the corner structure of a conventional building having a facade thereon to present the appearance of a classic full log or other stacked member structure. 
     2. Description of Prior Art 
     Classically, log structures have been formed of full, round logs having notches in the ends thereof which interconnect at the corners thereof. The notches are therein referred to as mortises and the log extending through the notches, as well as the overhanging portion of the log extending past the corner portion, are referred to as tenons. While log structures, particularly full log structures, are quite popular for the appealing rustic appearance presented, in fact, modern building methods have been found to be superior in structural integrity, insulation and other such desirable characteristics. 
     The classical mortise and tenon structure was convenient for simplicity in the event of minimal tools and energy, but again more modern tongue and groove shapes now available with more sophisticated wood shaping equipment has provided for improved structure even when full logs are used. For instance, in U.S. Letters Pat. No. 2,005,921, there is disclosed a full log structure with longitudinal tongue and groove and more modern interconnection at the corners. However, though of no structural function, a false tenon is provided to maintain the classic mortise and tenon structure appearance. 
     An even more desirable structure is one in which a conventional wall, i.e., stud wall with, for instance, plywood sheathing is formed and half log or split log facade applied to the exterior and/or interior of the walls to provide a &#34;log structure&#34; appearance. This approach, in large part, combines the functional advantages of modern construction with the classical appearance of a rustic log structure. However, heretofore, half log or split log structures, either the stackable type, disclosed in, for instance, U.S. Letters Pat. Nos. 1,501,326 and 1,655,701, or the facade applied to conventional walls, as in U.S. Letters Pat. No. 4,012,876, have lacked the appearance of a true, classical mortise and tenon full log structure. The half log members, even when formed in a mortise and tenon fashion at the corners presented but a half log exposure. Other approaches, such as the vertical log in U.S. Letters Pat No. 1,665,701 have also been suggested. In general, the split log facade on a conventional wall appeared at the corners to be just that, i.e., a veneer or facade. 
     SUMMARY OF THE INVENTION 
     The present invention, which provides a heretofore unavailable improvement over previous split log structures, comprises an interface between the facade and false corner structure, and more particularly, false tenon which provides an accurate representation and appearance of a classical, full rounded log or other full structure. The structure of the instant invention primarily concerns a false tenon or overhang or overhang portion of a log in the form of a full member of a shape suggested by the facade or &#34;split&#34; members having at an end thereof a saddle, angular planar surfaces configured to abut against a conventional wall corner, and a projection, or tongue member, through which fasteners may be placed to secure the false tenon to a conventional wall. By forming the false tenon in left and right hand versions, i.e., mirror image versions, and stacking these false tenons vertically at the corner of a conventional wall, it is possible, by properly forming the ends of the split log facade, to provide a most realistic appearing, pseudoclassical full log, or other structure while maintaining all the advantages of modern construction. 
     Accordingly, it is an object of the present invention to provide a new and improved split log structure which realistically portrays a classical, full log mortise and tenon log structure. 
     Another object of the present invention is to provide a new and improved structure which, while appearing to be a full member structure, is in fact a facade structure. 
     Yet another object of the present invention is to provide a new and improved log structure which concurrently provides the advantages of modern construction with regard to cost, insulation, structural integrity while maintaining the appearance of full log, classical mortise and tenon struction. 
     Still another object of the present invention is to provide a new and improved structure which provides at the overlapping tenon portion, the appearance of a full member of a predetermined cross-section while, in the main portion of the structure, using a facade arrangement. 
     These and other objects and features of the present invention will become apparent from the following description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the drawing: 
     FIG. 1 is a perspective view of a portion of a classical, full log mortise and tenon log structure; 
     FIG. 2 is a sectional side view of a wall of conventional construction having thereon the split log facade of the present invention; 
     FIG. 3 is a perspective view of a full log false tenon in accord with the present invention; 
     FIG. 4 is a perspective view illustrating the end section of the split log facade with the removed portion shown in ghosted manner; and 
     FIG. 5 is a perspective, partially exploded view of the false tenon structure of the present invention illustrating also the interface of the split log facade therewith. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While the following discussion will primarily relate to the relationship between a split log facade and a full log false tenon to present the appearance of the classical full log mortise and tenon construction; it is to be understood that the apparent cross-section may vary substantially, i.e., square &#34;logs&#34; may be portrayed. In such an instance, the facade would be in the form of relatively thin rectangular members, while the false tenon would in fact be square. Other cross-sections can also be represented. 
     Similarly, though the facade is recited as being &#34;split&#34;, in fact planing or other forming steps are more generally employed to form a member having the split log characteristic. It is contemplated that materials other than wood, i.e., skinned polymeric foams can be employed to form the &#34;logs&#34;. 
     Turning now to the drawings, wherein the classical structure is specifically illustrated and wherein like components are designated by like numerals throughout the various figures, a classical log structure 10 is shown in FIG. 1. The most desirable appearance of the classical picture 10 is provided as a result of the interlocking at the bottom portion, of an initial half log 12, and thereafter a series of full logs 14 having at the end portions thereof mortise 16 defined with tenons 18 extending therethrough. As will be apparent, each log has both the mortise 16 and, a tenon portion 18. For purposes of this discussion, the portion of each log 14 extending beyond the intersection with interlocking logs will be referred to as the tenon 18, or overhang portion. 
     While the classical structure 10 of FIG. 1 presents an attractive and desirable rustic appearance, a more economical and functional structure is illustrated in FIG. 2. Conventional wall 20 is formed, typically, by studs 22, normally vertical but illustrated horizontally for simplicity, carrying thereon sheathing 24 of plywood, pressed board or other such material and having, as is conventional, insulation 25 disposed within the wall. On the exterior of sheathing 24, split logs 28 are fastened by, for instance, glues, nails, or other fasteners (not shown). It should be noted that split logs 28 or other facade shapes are generally of a nominal radius &#34;r&#34; or other cross-sections largely consistent between split logs 28, and of a thickness &#34;t&#34;, again substantially consistent between individual split logs 28. Bevels 30 may be provided at the interface of the planar portions of the split logs 28 and sheathing 24 to engage and retain chinking material 31 which may be a mortar, a caulking compound, or other filler. 
     As will be apparent, the surface appearance of conventional wall 20 is quite similar to the general appearance of the interface between logs 14 of classical structure 10. Facade members of other cross-sections can similarly present a desired appearance. However, at the intersections of walls 20, the appearance will differ radically from that desired in that split logs 28 do not present a true representation of tenons 18, or other full members. 
     As shown in FIG. 3, in the case of the classical log structure facade, false tenon 35 of the instant invention may be utilized to accurately reproduce the tenon appearance of classical wall 10. False tenon 35 is basically formed of a section of cylindrical log 38, having a radius &#34;r&#34; similar to that of nominal radius &#34;r&#34; of split logs 28. A partial cradle 40 is defined in the upper half of log 38. Partial cradle 40 is, generally, of a cylindrical configuration with the axis thereof parallel to the direction of the course of split logs 28 forming the subject corner, and roughly quarter cylindrical in extent. The bottom portion of partial cradle 40 is generally tangent to a horizontal plane through the center of log 38. If other than a round configuration is desired, cradle 40 would conform to the next adjacent tenon, i.e., of a complementary shape. 
     A first planar surface 42 is defined in a direction substantially parallel to the axis of cradle 40. Planar surface 42 extends from one edge of log 38, along the face defined and intersects with second planar surface 43, which extends in a direction parallel to the other course of split logs 28 defining the corner. Second planar surface 43 defines, in part, projection 46 which is of a maximum thickness &#34;t&#34; equivalent to the thickness of split log 28. Finally, projection 46 is further defined by curved surface 48, which is substantially cylindrical and having a radius &#34;r&#34; in the preferred instance, or again of the cross-sectional shape of the adjacent tenon for other than round tenons. Accordingly, the rather involved configuration of false tenon 35, in the case of a right angle corner, involves first and second planar surfaces 42 and 43 forming a right angle configuration with projection 46 arranged to receive glue or fasteners (not shown) for attachment to the corner of conventional wall 20. 
     Finally, it is necessary that split logs 28 be configured at the end portion thereof as shown in FIG. 4. More specifically, split log 28 has defined at the ends thereof symmetrical curved surfaces 50 substantially of radius &#34;r&#34; for round false tenons 35, or shaped to fit surface 48 and the exterior of false tenon 35 in general. 
     In practice, false tenons 35 are formed in right hand and left hand versions with the left hand version referred to as 35&#39;. The right hand and left hand versions are merely the configuration as shown in FIG. 3 and mirror images thereof. Thus false tenon 35 and false tenon 35&#39;  may be stacked, as shown in FIG. 5, with first and second planar surfaces 42 and 43 forming a continuous flat surface adapted for securing to the corner portion of conventional wall 20, and more specifically to the angular intersection of sheathing 24. Nails, or other fasteners (not shown), may be conveniently driven through projection 46 into the adjacent sheathing 24 to secure false tenons 35 and 35&#39; to the sheathing, or glue may be used for attachment. For convenience, tenons 35 and 35&#39; are stacked in a manner inverted from that shown in FIG. 5 to expose projection 46 for nailing. For purposes of illustration, the arrangement of FIG. 5 better displays the various planes, curves and interfaces, and also depicts an alternate, but not preferred, workable arrangement. 
     Surfaces 50 of split logs 28 intersect with the surface of tenon 35 adjacent planar surface 42 at one part, and curved surface 48 of tenon 35, as again is shown in FIG. 5. The perspective shown in FIG. 5 is that of a wall to which false tenons 35 and 35&#39; as well as split log 28 are secured. However, it will be recognized that from the opposite side, the members present an accurate representation of the structure of classical structure 10 shown in FIG. 1 with split logs 28 presenting the appearance of logs 14 along the length thereof, and false tenons 35 and 35&#39; interfacing with split logs 28 to provide a classic mortise and tenon appearance. 
     If the facade is intended to represent other than rounded logs, surfaces 40 and 48 and 50 are merely configured to interface with the desired cross-section. The false tenon of course is formed in the desired cross-section, i.e., square, round, rectangular, curvelinear, etc. 
     Summarily, the instant invention involves a means for providing the appearance of a stacked member structure, such as a log building, by attaching elongated members over a conventional building to form a facade and, by also utilizing the unique false tenon, presenting the image of a mortise and tenon overlapping, interlocking structure at the corners thereof. The false tenon, which is particularly adaptable to portraying classical full log structures, can be utilized with stacked members of varying cross-sectional configurations provided the cross-section is substantially constant throughout the various members. The facade and/or false tenon may be made from natural materials, i.e. wooden logs, or from synthetics such as polymers, foams, etc, representing the natural material. 
     Although but limited embodiments of the present invention have been illustrated and described, it is anticipated that numerous changes and modifications will be apparent to those skilled in the art, and that such changes may be made without departing from the invention as defined by the following claims.