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 drainage and structural support of a cavity wall, the construct comprising: a matrix lath having a front side, a back side, a first plurality of filamentous elements arranged in a first direction, and a second plurality of filamentous elements arranged in a second direction substantially perpendicular to the first direction, wherein the first plurality of filamentous elements and the second plurality of filamentous elements together form a corrugated surface having peaks and valleys; and a water channel layer having a front side and back side, wherein the front side of the water channel layer is joined with the back side of the matrix lath, and wherein the water channel layer is formed from a matrix of randomly oriented, non-absorbent, fibrous elements that define a path for water passing through the water channel layer from a top to a bottom thereof.

2. The construct of claim 1 wherein the matrix lath comprises a thickness between the front side and the back side of inch or less.

3. The construct of claim 1, wherein the water channel layer comprises a thickness between the front side and the back side of inch or less.

4. The construct of claim 1, wherein the water channel layer comprises a thickness between the front side and the back side of inch or less.

5. The construct of claim 1 wherein water channel layer is joined with the matrix lath via an adhesive.

6. The construct of claim 1 wherein water channel layer is joined with the matrix lath via a plurality of fasteners.

7. The construct of claim 1 further comprising a scrim layer positioned between the matrix lath and the water channel layer.

8. The construct of claim 1, further comprising a plurality of spacers positioned between the matrix lath and the water channel layer.

9. The construct of claim 8 wherein the plurality of spacers is formed from a soft foamacious material.

10. The construct of claim 8, further comprising a scrim layer positioned between the matrix lath and the water channel layer, wherein the plurality of spacers is integrally formed with the scrim layer.

11. The construct of claim 10 wherein the plurality of spacers is positioned in a series of rows, wherein each row comprises two or more spacers laterally separated by a respective series of gaps, and wherein the series of gaps in a first row of spacers is vertically aligned with the spacers in a second row of spacers.

12. The construct of claim 11, wherein each gap in each respective series of gaps comprises a width that is less than a width of each spacer in the plurality of spacers.

13. A method of assembling a construct for drainage and structural support of a cavity wall, the method comprising: positioning a back side of a matrix lath in opposition to a front side of a water channel layer, wherein the matrix lath comprises a first plurality of filamentous elements arranged in a first direction and a second plurality of filamentous elements arranged in a second direction substantially perpendicular to the first direction, wherein the first plurality of filamentous elements and the second plurality of filamentous elements together form a corrugated surface having peaks and valleys, and wherein the water channel layer is formed from a matrix of randomly oriented, non-absorbent, fibrous elements that define a path for water passing through the water channel layer from a top to a bottom thereof; and joining the back side of the matrix lath with the front side of the water channel layer.

14. The method of claim 13, further comprising: before joining the back side of the matrix lath with the front side of the water channel layer, positioning a plurality of spacers between the matrix lath and the water channel layer.

15. The method of claim 14, wherein joining the back side of a matrix lath with the front side of a water channel layer comprises: bonding the back side of the matrix lath to a front side of each respective spacer in the plurality of spacers; and bonding the front side of the water channel layer to a back side of each respective spacer in the plurality of spacers.

16. The method of claim 15, wherein positioning the plurality of spacers between the matrix lath and the water channel layer comprises: positioning a first row of spacers, laterally separated by a first series of gaps; and positioning a second row of spacers, laterally separated by a first series of gaps, wherein the second row of spacers is vertically separated from the first row of spacers, and wherein the spacers in the second row of spacers are aligned with the gaps in the first series of gaps.

17. The method of claim 16, wherein the first row of spacers is positioned such that a width of each gap in the first series of gaps is less than a width of each spacer in the second row of spacers.

18. A method of installing a construct for drainage and structural support of a cavity wall, the method comprising: trimming a section of the construct for drainage and structural support of the cavity wall to a determined size, wherein the construct comprises: a matrix lath having a front side, a back side, a first plurality of filamentous elements arranged in a first direction, and a second plurality of filamentous elements arranged in a second direction substantially perpendicular to the first direction, wherein the first plurality of filamentous elements and the second plurality of filamentous elements together form a corrugated surface having peaks and valleys; and a water channel layer having a front side and back side, wherein the front side of the water channel layer is joined with the back side of the matrix lath, and wherein the water channel layer is formed from a matrix of randomly oriented, non-absorbent, fibrous elements that define a path for water passing through the water channel layer from a top to a bottom thereof; placing the section of the construct on a building wall; and fastening the section of the construct to the building wall.

19. The method of claim 18, wherein the construct further comprises a plurality of spacers positioned between the matrix lath and the water channel layer, and wherein fastening the section of the construct to the building wall comprises: driving a nail through the construct and into the building wall, wherein the nail is driven through one of the spacers in the plurality of spacers.

20. The method of claim 18, further comprising: applying a cementitious material to the corrugated surface of the matrix lath.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1A is a perspective view of a wall structure with a lath and water channeling construct made in accordance with the invention;

[0016] FIG. 1B is another perspective view of a wall structure with a lath and water channeling construct made in accordance with the invention;

[0017] FIG. 2 is a sectional view taken along line 2-2 of FIG. 1B;

[0018] FIG. 3 is a view of a corrugated lath material; and

[0019] FIG. 4 is a perspective view of a scrim material with stand-off elements.

DETAILED DESCRIPTION

[0020] 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.

[0021] 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 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.

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] 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.