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; and a water channel material having a front side and a back side with a width defined therebetween, the width of the water channel material including therein a structure that yields a path for water passing through the width of the water channel material under the influence of gravity when the water channel material is in use, wherein the water channel material comprises a plastic sheet defining a plane and having a front side and a back side, wherein the water channel material has corrugations, projections or a combination thereof extending from the plane of the water channel material.

2. The construct of claim 1, wherein the corrugations, the projections or the combination thereof define drainage channels from a top to a bottom of the water channel material.

3. The construct of claim 1, wherein the corrugations, the projections or the combination thereof are thermoformed in the water channel material.

4. The construct of claim 1, wherein the corrugations, the projections or the combination thereof extend from the back side of the water channel material.

5. The construct of claim 1, wherein the lath member has a front side and a back side and the back side of the lath member is coupled to the front side of the water channel material such that the lath member and the water channel material form a unitary continuous roll stock material.

6. The construct of claim 1, wherein the plastic sheet of the water channel material is non-fibrous.

7. The construct of claim 1, wherein the lath member comprises a matrix of fibers forming openings in the lath member configured to permit keying for cementitious material.

8. The construct of claim 1, wherein the water channel material and the lath member are joined together as an integrated whole as a continuous roll stock material.

9. The construct of claim 1, wherein the lath member comprises a material configured to receive cementitious matter such that the material of the lath member acts as a structural element for affixing the cementitious matter to the wall structure.

10. The construct of claim 1, wherein the lath member comprises a first plurality of filamentous plastic elements arranged parallel to one another that are joined by a second plurality of filamentous plastic elements that cross therebetween.

11. A construct for use in a wall structure, comprising: a lath member comprised of a first plurality of filamentous plastic elements arranged parallel to one another that are joined by a second plurality of filamentous plastic elements that cross therebetween thereby forming a matrix, the lath member having a front side and a back side; and a water channel material comprising a sheet of plastic having corrugations, projections or a combination thereof extending from a plane of the water channel material, the water channel material having a front side and a back side, wherein the front side of the water channel material is coupled to the back side of the lath member.

12. The construct of claim 11, wherein the front side of the water channel material is planar.

13. The construct of claim 11, wherein the corrugations, the projections or the combination thereof extend from the back side of the water channel material.

14. The construct of claim 11, wherein the corrugations, the projections or the combination thereof are configured to permit water to drain vertically downward therethrough.

15. The construct of claim 14, wherein the corrugations, the projections or the combination thereof define drainage channels from a top to a bottom of the water channel material.

16. The construct of claim 15, wherein the drainage channels include corrugations alternating with projections.

17. The construct of claim 11, wherein the corrugations, the projections or the combination thereof are thermoformed in the water channel material.

18. The construct of claim 11, wherein the matrix of the lath member has a plurality of openings configured to permit keying for cementitious material.

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 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.