Lath and drainage

Abstract

An improved lath is disclosed having a water drainage layer provided in association with the lath. The water drainage layer serves to remove water that might otherwise build up between the lath and wall structure.

Claims

1. A construct for use in a wall structure, comprising: a lath member having a front side and a back side, the lath member composed of a matrix of fibers comprising a first diameter, wherein the matrix of fibers forms openings in the lath member sufficient to provide keying for cementitious material; and a water channel material having a front side and a back side defining a width therebetween, the width being generally filled in cross-section with non-absorbent, fibrous elements that span the width so as to define a path for water passing through the width from a top to a bottom thereof, wherein the fibrous elements comprise a second diameter smaller than the first diameter, wherein the water channel material comprises a porosity sufficient to permit water to pass therethrough, but insufficient for cementitious material to pass therethrough, and wherein the back side of the lath member is positioned on the front side of the water channel material.

2. The construct of claim 1, wherein the back side of the lath member is affixed to the front side of the water channel material such that the lath member and the water channel material are joined together as a unitary whole.

3. The construct of claim 1, wherein the lath member is self-furred.

4. The construct of claim 1, wherein the lath member is flat.

5. The construct of claim 1, wherein the matrix of fibers comprises a rigid material.

6. The construct of claim 1, further comprising a vapor barrier layer affixed to the back side of the water channel material.

7. The construct of claim 6, wherein the lath member, the water channel material, and the vapor barrier layer are joined together as a unitary whole.

8. A construct for use in a wall structure, comprising: a lath member having a front side and a back side, the lath member composed of a matrix of fibers, wherein the matrix of fibers forms openings in the lath member sufficient to provide keying for cementitious material; a water channel material composed of a plastic sheet having a front side and a back side, wherein the water channel material includes corrugations extending from the front side of the water channel material, wherein the corrugations define drainage channels from a top to a bottom of the water channel material, and wherein the back side of the lath member is positioned on the front side of the water channel material.

9. The construct of claim 8, wherein the back side of the lath member is affixed to the front side of the water channel material such that the lath member and the water channel material are joined together as a unitary whole.

10. The construct of claim 8, wherein the lath member is self-furred.

11. The construct of claim 8, wherein the lath member is flat.

12. The construct of claim 8, wherein the matrix of fibers comprises a rigid material.

13. The construct of claim 8, wherein the corrugations are thermoformed in the water channel material.

14. The construct of claim 8, further comprising a vapor barrier layer affixed to the back side of the water channel material.

15. The construct of claim 14, wherein the lath member, the water channel material, and the vapor barrier layer are joined together as a unitary whole.

16. A method of installing a lath and drainage construct comprising: trimming a section of the lath and drainage construct to a determined size, wherein the lath and drainage construct comprises: a lath member having a front side and a back side, the lath member composed of a matrix of fibers comprising a first diameter, wherein the matrix of fibers forms openings in the lath member sufficient to provide keying for cementitious material; and a water channel material having a front side and a back side defining a width therebetween, the width being generally filled in cross-section with non-absorbent, fibrous elements that span the width so as to define a path for water passing through the width from a top to a bottom thereof, wherein the fibrous elements comprise a second diameter smaller than the first diameter, wherein the water channel material comprises a porosity sufficient to permit water to pass therethrough, but insufficient for cementitious material to pass therethrough, and wherein the back side of the lath member is positioned on the front side of the water channel material; placing the section of the lath and drainage construct on a building wall; and affixing the section of the lath and drainage construct to the building wall.

17. The construct of claim 16, wherein the back side of the lath member is affixed to the front side of the water channel material such that the lath member and the water channel material are joined together as a unitary whole.

18. The method of claim 16, wherein affixing the section of the lath and drainage construct to the building wall comprises driving a plurality of penetrating fasteners through the section and into the building wall.

19. The method of claim 18, wherein the lath and drainage construct further comprises a plurality of spacers forming a space between the lath member and the water channel material, and wherein each fastener in the plurality of fasteners is driven through one of the plurality of spacers.

20. The method of claim 16, further comprising: applying cementitious material to the front side of the lath member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a perspective view of a wall structure with a lath and water channeling construct made in accordance with the invention;

(2) FIG. 1B is another perspective view of a wall structure with a lath and water channeling construct made in accordance with the invention;

(3) FIG. 2 is a sectional view taken along line 2-2 of FIG. 1B;

(4) FIG. 3 is a view of a corrugated lath material; and

(5) FIG. 4 is a perspective view of a scrim material with stand-off elements.

DETAILED DESCRIPTION

(6) Referring now to FIGS. 1B and 2 in particular, a construct in the form of a structural support for plaster, stucco and stone veneer is disclosed. A typical wall is shown, being formed of studs 10 to which a wallboard or wood sheathing 12 is attached in well-known manner.

(7) Outboard of the wallboard 12 (inboard being toward the studs 10), is a water channel material 14. In this embodiment, the water channel material is a fibrous mesh or matrix made up of thin plastic filaments or fibers. Such a material is sold by Mortar Net, Inc. under the name WALLNET. Here, the material is about ¼ inch to about ½ inch thick in width (width being measured normal to the substantially planer front side 15 and backside 16 of the water channel material 14). The water channel material thus generally fills the width defined between front side 15 and backside 16, forming a circuitous pathway for water that may then flow therebetween. The water channel material nonetheless can catch and hold debris that might fall thereon from above, without clogging the water channel thereby provided.

(8) If desired, a vapor barrier layer (not shown) may be provided inboard of the water channel material, against the wallboard. This could be a plastic sheet, or a spray-on vapor barrier.

(9) Next outboard from the water channel material 14 is an optional scrim 18. Scrim 18 is a non-woven sheet material in this embodiment which permits air and water to pass therethrough, but can provide some additional support and serve as a barrier to tiny insects.

(10) A lath material 20 is provided. There are many known types of lath, including metal and plastic being most commonly used. The lath serves as the main supporting structure for receiving and holding plaster or stucco, or some cementitious or other adhesive compound for holding stone veneer 22, for instance.

(11) In this embodiment, spacers 23 are used between the lath 20 and the scrim/water channel material. The spacers 23 may advantageously be glued or otherwise adhered to one or both of the layers on either side thereof. Spacers 23 are made of a soft foam material, which provides a self-sealing barrier for water when nails, screws or the like are driven through the spacers, so as to mount the lath 20 to the wallboard 12.

(12) It will be understood that some of the foregoing elements need not be employed in the exact order shown in FIGS. 1B and 2. The elements may be employed, for example, in the order shown in FIG. 1A.

(13) Note that one of the advantages of the present invention is that the construct of water channel material 14, spacers 23 and lath 20, with or without scrim 18, with or without vapor barrier, can be provided as a unitary whole. Especially advantageous is to make the construct as a roll stock material, so that a builder may simply unroll the amount desired and “cut to size,” more or less.

(14) FIG. 3 shows a type of material 25 that could be used as a lath material in this application. Here, it is a filamentous plastic having thin diameter elements 26 that run roughly parallel to one another, which are joined by other elements 27 that cross therebetween. The elements 26, 27 having sufficient rigidity to be formed into a somewhat corrugated surface having peaks and valleys. The material is open, so as to receive plaster, stucco, or other cementitious or adhesive material therein, and thereby serve the function of lath.

(15) FIG. 4 shows a variation on the scrim 18, which is here provided with integral stand-off elements or bosses. Scrim 18′ is as previously described, being a high loft non-woven thin material. This could also be some other material, whether non-woven or not. Attached to scrim 18′ are the bosses or bumps 24, which are affixed to one side of the scrim, as by bonding thereto. These bosses 24 may be made of a material that can readily receive a nail, screw or the like, and thereby attach the scrim in a manner whereby the fastener is self-sealed by the boss through which it passes. A rubber or rubber-like material may be used, or some softer thermoplastic, just to name two examples. The combination of scrim plus stand-off elements may have good advantage in field application.

(16) Thus, while the present invention has been described with respect to a certain embodiment, numerous changes and modifications will be apparent to those of skill in the art, and such changes and modifications are intended to be encompassed within the spirit of the invention, as defined by the claims.