Lath stapling system

Abstract

A cost-effective and expeditious method for attaching a water channel layer to lath pre-installation, for subsequent application to an inner wall structure, increasing the efficiency and decreasing the cost of building construction, and also encompasses the stock material made thereby. In one form, there is a stapling frame equipped to be placed in juxtaposition to a water channel layer atop a layer of lath on and adjacent surface. A plurality of staplers mounted to the frame then combine the water channel layer and lath to form an integrated stock material that can then be used in a wall structure.

Claims

1. A method for attaching a water channel layer to a lath, comprising: placing the water channel layer atop the lath such that a first side of each and an adjacent second side of each are flush, wherein the lath extends past the water channel layer for a predetermined distance at a third side and an adjacent fourth side, and wherein the lath is formed from a matrix of fibers forming openings in the lath member sufficient to provide keying for cementitious material; lowering a stapling; mechanism vertically from an original vertical resting position to a top surface of the water channel layer; inserting one or more staples, each staple comprising a head and two ends, at one or more predetermined positions on the top surface of the water channel layer such that the head of each staple is on the top surface of the water channel layer and the ends of each staple are clinched so as to engage the lath; and raising the stapling mechanism vertically to its original vertical resting position.

2. The method of claim 1, wherein the stapling mechanism is positioned to simultaneously apply one or more staples evenly spaced along a length of the water channel layer and lath at a predetermined distance inward from the first side of the water channel layer, and to apply one or more staples evenly spaced along a width of the water channel layer and lath at the predetermined distance inward from the second side of the water channel layer.

3. The method of claim 1, wherein the one or more staples are outwardly clinched such that the ends of each staple are returned approximately to the top surface of the water channel layer while engaging the lath.

4. The method of claim 1, wherein the stapling mechanism is cooperatively engaged with a pneumatic pressure mechanism such that the one or more staples are applied to the water channel layer and lath using pneumatic pressure.

5. A method for attaching a water channel layer to a lath to form a stock material, comprising: placing a water channel layer in facial engagement with a lath, wherein the water channel layer and the lath are overlaid, wherein a surface area of water channel layer is less than a surface area of the lath, wherein a region of lath extends beyond at least one long edge and one short edge of the water channel layer, and wherein the lath is formed from a matrix of fibers forming openings in the lath member sufficient to provide keying for cementitious material; positioning the water channel layer and the lath within a stapling mechanism having a frame and a plurality of staplers mounted to the frame in a preset arrangement, wherein the frame is movably mounted to the stapling mechanism so as to position the staplers for stapling; inserting a plurality of staples, each staple comprising a head and two ends, into a top surface of the water channel material to thereby join the overlaid water channel layer and lath into an integrated unit; and moving the frame away from the integrated unit.

6. The method of claim 5, wherein the plurality of staplers is mounted to the frame so as to simultaneously apply staples evenly spaced along a length of the water channel layer and lath at a predetermined distance inward from a first side of the water channel layer, and to apply staples evenly spaced along a width of the water channel layer and lath at the predetermined distance inward from a second side of the water channel layer.

7. The method of claim 5, wherein each staple in the plurality staples is outwardly clinched such that the ends of the staple are returned approximately to the top surface of the water channel layer while engaging the lath.

8. The method of claim 5, further comprising: removing the integrated unit from the stapling mechanism; and depositing the integrated unit onto a roll.

9. The method of claim 5, wherein the frame comprises a plurality of apertures, and wherein inserting the plurality of staples into the top surface of the water channel material comprises inserting the plurality of staples through the plurality of apertures in the frame.

10. The method of claim 5, further comprising horizontally sliding the frame over the overlaid water channel layer and lath before inserting the plurality of staples.

11. The method of claim 1, wherein the predetermined distance is 1.5 inches at the third side and the adjacent fourth side.

12. The method of claim 5, wherein placing the water channel layer in facial engagement with the lath comprises placing the water channel layer such that the region of lath extends a predetermined distance beyond the at least one long edge and one short edge of the water channel layer, and wherein the at least one long edge and one short edge of the water channel layer are adjacent edges.

13. The method of claim 12, wherein the predetermined distance is about 1.5 inches.

14. A method for attaching a water channel layer to a lath to form a stock material, comprising: placing a water channel layer in facial engagement with a lath, wherein the water channel layer and the lath are overlaid; positioning the water channel layer and the lath within a stapling mechanism having a frame and a plurality of staplers mounted to the frame in a preset arrangement, wherein the frame is movably mounted to the stapling mechanism so as to position the staplers for stapling; inserting a plurality of staples, each staple comprising a head and two ends, into a top surface of the water channel material to thereby join the overlaid water channel layer and lath into an integrated unit, wherein the frame comprises a plurality of apertures, and wherein inserting the plurality of staples into the top surface of the water channel material comprises inserting the plurality of staples through the plurality of apertures in the frame; and moving the frame away from the integrated unit.

15. The method of claim 14, wherein the plurality of staplers is mounted to the frame so as to simultaneously apply staples evenly spaced along a length of the water channel layer and lath at a predetermined distance inward from a first side of the water channel layer, and to apply staples evenly spaced along a width of the water channel layer and lath at the predetermined distance inward from a second side of the water channel layer.

16. The method of claim 14, wherein each staple in the plurality staples is outwardly clinched such that the ends of the staple are returned approximately to the top surface of the water channel layer while engaging the lath.

17. The method of claim 14, further comprising: removing the integrated unit from the stapling mechanism; and depositing the integrated unit onto a roll.

18. The method of claim 14, further comprising horizontally sliding the frame over the overlaid water channel layer and lath before inserting the plurality of staples.

19. The method of claim 14, wherein a surface area of the water channel layer is less than a surface area of the lath, wherein a region of lath extends beyond at least one long edge and one short edge of the water channel layer.

20. The method of claim 14, wherein placing the water channel layer in facial engagement with the lath comprises placing the water channel layer such that the region of lath extends a predetermined distance beyond the at least one long edge and one short edge of the water channel layer, and wherein the at least one long edge and one short edge of the water channel layer are adjacent edges.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a wall structure with lath and water channel layers made by an example stapling system, as applied to a frame construction.

(2) FIG. 2A is a partial corner view of a lath and water channel layer as attached by an example stapling system.

(3) FIG. 2B shows a lath and water channel layer attached with a staple according to an example embodiment.

(4) FIG. 3 is a perspective view of a stapling system according to an example embodiment, deployed to operate on lath and water channel layers atop a flat surface.

(5) FIG. 4 is a perspective view of a stapling system according to another example embodiment, deployed to slide into position to operate on a lath and water channel layer atop a flat surface.

(6) FIG. 5 is a lath and water channel layer combined into an integrated unit via staples, according to an example embodiment.

DETAILED DESCRIPTION

(7) Referring now to FIG. 1 in particular, a wall structure with lath and water channel layers previously stapled together by the method discussed herein is depicted. The inner wall is typical, but not limited, to that shown here as using a CMU wall structure. Additionally, the elements shown need not be employed in the exact order shown in FIG. 1. The systems and methods discussed herein are directed to combining the water channel layer and lath to yield a stock material for later installation with whatever wall structure is desired, regardless of whether water channel layer 120 surface or lath 115 surface is selected as the outboard surface. A wood (stud) wall structure and others may be used, of course.

(8) Outboard of an exterior-grade sheathing 100 is a weather resistive barrier 105, which may be a heavy-duty plastic sheeting, operating as a moisture barrier. Outboard of the weather resistive barrier 105 is the lath-and-water channel layer combination 110. The lath-and-water channel layer combination 110 is in this illustrative embodiment applied to the sheathing in a conventional manner such that the lath 115 is outboard to the water channel layer 120 and affixed to the sheathing.

(9) The water channel layer 120 material may be, as noted previously, a fibrous diameter entangled randomly oriented plastic or other durable fiber, formed in a thinner width, such as 3/16 or WALLNET product, made or sold under that name by Mortar Net, Inc. The lath 115 may be any commonly used which is readily combinable with the water channel material by stapling, as hereinafter discussed. There are many known types of lath, including metal and plastic being most commonly used. Fiberglass lath, typically supplied in continuous rolls, may be 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 thin stone veneer or stucco finish coat 140, and may be outboard to the water channel layer 120 as shown here, or inboard to the water channel layer 120.

(10) FIG. 1 shows the lath 115 peeled back to illustrate the water channel layer 120. The surface area of the water channel layer 120 may preferably be less than that of the lath 115 such that a region of lath 115 is exposed along at least one long edge and one short edge of the water channel layer 120. Consequently, one segment of the lath-and-water channel layer combination 110 may be enabled for ready overlap 125 of an adjacent segment of lath-and-water channel layer constructs, creating code-compliant lath and continuous water channel layer in one. This can also be seen in FIG. 5.

(11) Outboard to the lath-and-water channel layer combination 110 is base coat 130. Outboard to the base coat 130 is a scratch coat 135. Finally, outboard to the scratch coat 135 is thin stone veneer or stucco finish coat 140. It will be understood that some of the foregoing elements need not be employed in the exact order shown in FIG. 1.

(12) FIG. 2A shows a partial corner vie of an example lath-and-water channel layer combination 200. The corner view shows that the surface area of the water channel layer 205 may preferably be less than that of the lath 210, such that a region of lath exposed along at least one long edge and one short edge of the water channel layer 205. A staple 215 has been applied to the water channel layer 205, which is also shown in FIG. 2B. The head 215a of the staple 215 is on the top surface 205a of the water channel layer 205 and the two ends 215b, 215c of the applied staple 215 are clinched such as to engage the opposite side of the lath 210 (i.e., the side not in facial contact with the layer 205). Further, in the example shown in FIG. 2B, the ends 215b, 215c of the staple 215 are clinched outwardly such that each end returns approximately to the top surface 205a of the water channel later 205 while engaging the lath 210. As noted above the lath-and-water channel layer combination 200 may be installed such that the water channel layer 205 or the lath 210 is the outboard surface.

(13) FIG. 3 shows a perspective view of the stapling system deployed to operate on lath 305 and water channel layer 310 atop a flat surface 315. The frame 300, which is equipped with one or more staplers 320 positioned at predetermined positions, is cooperatively affixed to a vertical deployment mechanism 325 providing for movement of the frame 300 towards and away from the flat surface 315. The staplers 320 may be simultaneously engaged to perform the stapling operation, although they need not be. The staplers here are pneumatically operated by cooperatively engaging the staplers 320 with pneumatic mechanism 330. The stapling system may optionally be engaged for use with fiberglass lath, which is typically supplied in continuous rolls, such that the water channel layer would be delivered to the flat surface 315 in a roll to roll process rather than sheets. The staplers and the pneumatic system along with a suitable controller are well known in the art. The arrangement of the components in this system is new.

(14) FIG. 4 shows a perspective view of an alternative embodiment of a stapling system deployed to operate on lath 405 and water channel layer 410 atop a flat surface 415. The stapling frame 420 is a surface equipped with one or more staplers 425 engaged to deliver staples through apertures 445 in the surface of the stapling frame 420. The stapling frame 420 is equipped on its ends 440 to slide horizontally via a sliding mechanism 430 over the adjacent flat surface 415, and over a rectangular portion of water channel layer 410 atop a rectangular portion of lath 405 on such adjacent flat surface 415. The staplers 425 may then be simultaneously engaged to deliver staples through the apertures 445 in the surface of the stapling frame 420 such that the heads of the applied staples are on the top surface of the water channel layer 410 and the ends of the applied staples are clinched such as to engage the lath 405. The stapling frame 420 may then slide horizontally to its original starting position so that the attached rectangular portions of water channel layer 410 and lath 405 may be removed and new, separate rectangular portions of water channel layer 410 and lath 405 may be inserted atop the flat surface 415. The staplers may optionally be pneumatically operated by cooperatively engaging the staplers 425 with pneumatic mechanism 435.

(15) In one alternative to the foregoing, a more open frame could be used for mounting the staplers, as described with the first embodiment. In another alternative to the foregoing, the stapling system may be engaged for use with fiberglass lath, which is typically supplied in continuous rolls, such that the water channel layer would be delivered to the flat surface 415 in a roll to roll process rather than sheets.

(16) FIG. 5 shows a lath 505 and water channel layer 510 combined into an integrated unit via staples 515. The staples 515 are generally evenly spaced along the width of the integrated unit, as shown by the spacing 525 between each staple 515. Further, the staples 515 begin at predetermined distance 520 from inward from the long edge of the water channel layer 510. Similarly, the staples 515 are generally evenly spaced along the length of the integrated unit, as shown by the spacing 535 between each staple 515. Further, the staples 515 begin at predetermined distance 530 from inward from the short edge of the water channel layer 510.

(17) While the present invention has been described with respect to certain embodiments, 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.