Stucco Crack Reduction at Corners

Abstract

Stucco cracks at doors and windows are reduced or eliminated by use of a corner element fastened at a corner juncture before stucco coats are applied. The disclosed corner element spreads out or evenly dissipates differential movement or buckling often occurring at exterior corner junctures. The corner element may comprise various concentric circle attributes useful in stopping or reducing cracks in stucco and related building materials. The corner element embodiments may be secured at widow and door corner areas and then integrated with traditional stucco applications.

Claims

1. A system to reduce stucco cracks, the system comprising: a corner element having a top side, bottom side, a circular outer edge defined by a perimeter distal edge and two frame leg sections.

2. The system of claim 1 further comprising: a door and window integration area comprising the two frame leg sections and a center receiving area located between the two frame leg sections.

3. The system of claim 2 further comprising a flat outer perimeter area defined between the perimeter distal edge and a first transition edge, the first transition edge in the shape of a concentric circle.

4. The system of claim 3 further comprising a mid-concentric transition section defined between the first transition edge and a second transition edge, the second transition edge in the shape of a concentric circle.

5. The system of claim 4 wherein the mid-concentric transition section is radially arched in shape having a higher elevation at the second transition edge as compared to the first transition edge.

6. The system of claim 5 further comprising a crown section defined as the area within the second transition edge.

7. The system of claim 6 wherein the crown section comprises a center void (101) and wherein the crown section defines a plurality of eyebrow assemblies (130) wherein each eyebrow assembly defines a horizontal void (132) and wherein each eyebrow assembly comprises an arched bridge (134) centrally disposed over the horizontal void, with the arched bridge defining a vertically defined void (136).

8. The system of claim 7 wherein the crown section comprises a plurality of pegs originating from the bottom side.

9. The system of claim 8 wherein the bottom edges of the legs extend to a plane level with the bottom side of the flat outer perimeter area.

10. The system of claim 8 wherein the perimeter distal edge defines a plurality of outer notches.

11. The system of claim 10 wherein the flat outer perimeter area defines a plurality of circle voids.

12. The system of claim 11 wherein the mid-concentric transition section defines a plurality of circle voids.

13. The system of claim 12 wherein crown section defines a plurality of circular void areas.

14. The system of claim 13 wherein the top side of the crown section defines a plurality of dimples.

15. The system of claim 14 wherein the center void is further defined by a flat side, the flat side adjacent to the center receiving area.

16. A method of reducing stucco cracks, the method comprising: a) attaching a corner element at a corner point of a door or window; and b) applying a coat of stucco material over the corner element.

17. The method of claim 16 including the step of filling the voids of the corner element with the stucco coat.

18. The method of claim 17 including the step of securing the corner element by use of a plurality of fasteners set through the corner element.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1 depicts a front perspective view of a corner element

[0031] FIG. 2 depicts a back perspective view of a corner element

[0032] FIG. 3 depicts a front side view of a corner element

[0033] FIG. 4 depicts a back side view of a corner element

[0034] FIG. 5 depicts a left side view of a corner element

[0035] FIG. 6 depicts a right side view of a corner element

[0036] FIG. 7 depicts a top side view of a corner element

[0037] FIG. 8 depicts a bottom side view of a corner element

[0038] FIG. 9 depicts a corner element in position before the installation of metal lath

[0039] FIG. 10 depicts an expansion joint of the prior art

[0040] FIG. 11 depicts a corner crack of the prior art

[0041] FIG. 12 depicts a bottom perspective view of a corner element

[0042] FIG. 13 depicts a bottom perspective view of a corner element with two pegs

[0043] FIG. 14 depicts four corner elements attached next to a widow

[0044] FIG. 15 depicts four corner elements under chicken wire

[0045] FIG. 16 depicts one corner element under chicken wire

[0046] FIG. 17 depicts four corner elements within a scratch coat

[0047] FIG. 18 depicts a perspective view of an alternative embodiment

[0048] FIG. 19 depicts a perspective view of an alternative embodiment

[0049] FIG. 20 depicts a side view of an alternative embodiment

[0050] FIG. 21 depicts a side view of an alternative embodiment

[0051] FIG. 22 depicts a top view of an alternative embodiment

[0052] FIG. 23 depicts a bottom view of an alternative embodiment

[0053] FIG. 24 depicts a top perspective view of a third embodiment

[0054] FIG. 25 depicts a bottom perspective view of a third embodiment

[0055] FIG. 26 depicts a front view of a third embodiment

[0056] FIG. 27 depicts a back side view of a third embodiment

[0057] FIG. 28 depicts a bottom plan view of a third embodiment

[0058] FIG. 29 depicts a top plan view of a third embodiment

[0059] FIG. 30 depicts an enlarged view of eyebrow void assemblies

REFERENCE NUMERALS IN THE DRAWINGS

[0060] 100 a corner element in general

[0061] 101 a center void found in a center area of a corner element 100

[0062] 102 a circular void area defined by a corner element

[0063] 103 a circle void defined by a corner element and sometimes found between circular void areas 102

[0064] 104 perimeter edge of a corner element 100

[0065] 105 outer notch defined by the perimeter edge 104

[0066] 106 optional flat side of center void, the flat side sometimes adjacent to the center receiving area 180

[0067] 110 corner element having no pegs

[0068] 112 corner element having two pegs

[0069] 120 arc section of a center void 101

[0070] 122 straight edge or nearly straight edge of center void 101

[0071] 130 eyebrow void assembly

[0072] 132 center or horizontal void of eyebrow assembly

[0073] 134 raised arc or arched bridge of eyebrow void assembly

[0074] 136 vertically defined void or eyebrow assembly, defined by the raised arc or arched bridge

[0075] 152 flat outer perimeter area

[0076] 153 a plurality of circle voids defined within the flat outer perimeter area 152

[0077] 160 a first transition edge between flat perimeter area 153 and mid concentric transition section 165

[0078] 165 mid-concentric transition section

[0079] 166 a plurality of circle voids defined within the mid concentric transition section 165

[0080] 167 a second transition edge between mid-concentric transition section 165 and crown section 171

[0081] 171 crown section defined within the second transition edge 167

[0082] 172 dimples defined within the top side of the crown section

[0083] 180 a center receiving area of a corner element 100

[0084] 181 frame leg sections of a corner element 100

[0085] 185 door and window integration area

[0086] 190 peg found on bottom side of crown section 171

[0087] 200 lath wire, also known as chicken wire

[0088] 300 a window or door frame

[0089] 301 a horizontal member of a window or door frame

[0090] 302 a vertical member of a window or door frame

[0091] 303 a corner point comprising a vertical member 302 and a horizontal member 301 of a window or door frame 300

[0092] 304 a joint line between a vertical member 302 and a horizontal member 301 of a window or door frame 300

[0093] 400 an expansion joint of the prior art

[0094] 401 a window

[0095] 500 a stucco crack of the prior art

[0096] 600 exterior stucco surface

[0097] 650 scratch coat, part of stucco system

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0098] The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways as defined and covered by the claims and their equivalents. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout.

[0099] Unless otherwise noted in this specification or in the claims, all of the terms used in the specification and the claims will have the meanings normally ascribed to these terms by workers in the art.

[0100] Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in a sense of including, but not limited to. Words using the singular or plural number also include the plural or singular number, respectively. Additionally, the words herein, above, below, and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application.

[0101] The above detailed description of embodiments of the invention is not intended to be exhaustive or to limit the invention to the precise form disclosed above. While specific embodiments of, and examples for, the invention are described above for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. For example, while steps are presented in a given order, alternative embodiments may perform routines having steps in a different order. The teachings of the invention provided herein can be applied to other systems, not only the systems described herein. The various embodiments described herein can be combined to provide further embodiments. These and other changes can be made to the invention in light of the detailed description.

[0102] All the above references and U.S. patents and applications are incorporated herein by reference. Aspects of the invention can be modified, if necessary, to employ the systems, functions and concepts of the various patents and applications described above to provide yet further embodiments of the invention.

[0103] Referring to FIG. 1, a corner element 100 may comprise a perimeter edge 104 which may define a distal boundary of a flat outer perimeter area 152. For purposes of clarity, components closer to the center void 101 are sometimes considered medial while components closer to perimeter edge 104 are sometimes considered distal.

[0104] A flat outer perimeter area 152 assists in placing the corner element securely to a substrate such as plywood or waterproofing membrane. The flat nature of the flat outer perimeter area 152 also assists in balancing with the bottom pegs 190 found under the crown section 171. The flat outer perimeter area may be relatively flat and comprise a plurality of circle voids 153. The flat shape or flat elevation of the flat outer perimeter area may also be helpful in applying frictional force against a substrate. Nails, staples or other fasteners may be applied through the flat outer perimeter area or other parts of the disclosed corner element.

[0105] The circle voids 153 of the flat outer perimeter area 152 may be of any shape and assist in the even integration with stucco. The flat outer perimeter area 152 may be used to secure the corner element to a substrate. Nails or other fasteners may be used to secure the corner element to the exterior of a building. The perimeter edge 104 assists in blending the stucco to the surrounding components. The perimeter edge may define a plurality of outer notches 105 which assist in adding surface area to the corner element for greater contact with applied stucco.

[0106] A first transition edge 160 may separate the flat outer perimeter area 152 from the mid concentric transition section 165. The mid concentric transition section 165 may take the form of a circular section concentric to the flat outer perimeter area. The mid concentric transition section 165 may gain elevation or cause the corner element to be higher in the medial sections or center sections as compared to the distal sections or outer sections. This raise in height is helpful in integrating the corner element within the center of a stucco application. The elevation may also be helpful in preventing the corner element from being moved during differential building movement.

[0107] The mid concentric transition section 165 may comprise a plurality of circular voids 166 of any shape. The circular voids 166 may have a somewhat vertical or near vertical orientation and thus assist with integration with stucco at various elevations or stucco depths. The angled circular voids 166 may also assist in more evenly displacing differential building movement within or along the corner element. The angle of the mid concentric transition section 165 allows for three dimensional flexing to further dissipate differential building movement.

[0108] Areas medial or more center from the mid concentric transition section may be considered a crown section 171 as marked more clearly on FIG. 5. A crown section may comprise a top side further comprising dimples 172 which may take the form of indentations. The dimples 172 allow for keying of the stucco to the corner element which helps in keeping the corner element firmly in place within applied stucco. Also, the dimples 172 increase the surface area of the exposed corner element, assisting in securing the corner element in the stucco. Moreover, the dimples help to keep the stucco from sliding off the corner element during the stucco drying process. The crown section 171 may comprise or define a plurality of circular void areas 102 which helps to allow wet stucco or mud to flow between the top and bottom sides of the corner element. The circular void areas 102 may be circular or concentric in shape. The circular shapes of the circular void areas helps the corner element to flex along a greater area which in turn helps to maximize the even disbursement of uneven building movements at corners. Center void 101 may act as a focal point to radiate or absorb differential building movement in a radial fashion to the distal areas of the corner element. A center receiving area 180 flanked by two frame leg sections 181 assist in placing the corner element in a corner area of construction. The area spanning the two frame leg sections 181 and the center receiving area 180 is sometimes referred to as the door and window integration area 185.

[0109] FIG. 2 depicts a plurality of pegs attached to the bottom side of the crown section of the corner element.

[0110] FIG. 3 depicts a flat outer perimeter 152 from a side perspective.

[0111] FIG. 4 depicts a flat outer perimeter 152 from a side perspective.

[0112] FIG. 5 depicts a crown section 171 from a side perspective.

[0113] FIG. 6 depicts a mid-concentric transition section from a side perspective.

[0114] FIG. 7 depicts a top side view of a corner element 100. A corner element may have a perimeter edge 104 that may define a plurality of outer notches 105. A flat outer perimeter area 152 may be found between the perimeter edge 104 and the first transition edge 160. The flat outer perimeter area may comprise or define a plurality of voids, such as circle voids 153. The flat outer perimeter area may have a top side and bottom side, and the bottom side may be considered to have a zero or neutral elevation.

[0115] A mid-concentric transition section 165 may be considered to have a positive or increased elevation, having an elevation greater than the flat outer perimeter area 152. The mid-concentric transition section 165 may be found or defined between the first transition edge 160 and a second transition edge 167. The mid-concentric transition section may define a plurality of voids, such as circle voids 166.

[0116] Areas medial from the second transition edge 167 may comprise a crown section 171. A crown section may be flat near the center void 101 so as to sit in a mid-depth of applied stucco. A crown section 171 may comprise or define a plurality of circular void areas 102 which may take the shape of voids concentric to the center void 101. Areas of the crown section 171 may comprise dimples 172.

[0117] FIG. 7 further depicts a plurality of circular void areas 102 defined by or defined within a corner element 100. Circular void areas 102 aid in the reduction of stucco cracks by a number of physical factors. In some embodiments, circular void areas 102 sometimes take the shape of partial concentric circles with a center point found within a center void 101. The concentric configuration of circular voids 102 results in areas of stucco attachment and support perpendicular to the typical stucco cracks originating at doors and windows. The concentric configuration of the circular voids 102 more evenly dissipates movement of stucco and thus greatly reduces resulting cracks. The concentric configuration of the circular voids 102 results in a stucco base coat or scratch coat entering the circular voids and integrating into the corner element.

[0118] In order to retain a correct combination of rigidity and flexibility, circular voids 102 are defined on either end by corner element material. For added flexibility and absorption of stucco movement, circle voids 103 are sometimes placed between circular voids 102.

[0119] FIG. 8 depicts a plurality of pegs 190 and a center void 101. The center void 101 is shown with an optional flat side 106, the flat side toward the center receiving area 180. The flat side 106 may help to laterally dissipate building movement to either side of the frame legs.

[0120] FIG. 9 depicts a window or door frame 300 is adjacent to or in contact with the corner element 100. The window or door frame may comprise a horizontal member 301, a vertical member 302 and a joint line 304, the joint line defined by the connection line shared by the horizontal member 301 and the vertical member 302. At the outer edge of the joint line 304, a corner point 303 is formed. The corner element 100 is illustrated as attached over lath wire 200.

[0121] FIG. 10 depicts a building comprising a window 401 with a vertical expansion joint 400 of the prior art. The vertical expansion joint 400 of the prior art detracts from the esthetic appeal of using stucco as an exterior covering.

[0122] FIG. 11 depicts a stucco crack 500 originating at a corner point 303 of a window or door frame 300. The stucco crack 500 is seen upon the exterior stucco surface 600.

[0123] FIG. 12 depicts a corner element 110 not having pegs. Disclosed embodiments contemplate zero, one or a plurality of pegs. In some applications, pegs help to set the corner element into the stucco system. Pegs may also provide vertical support as the corner element is fastened, screwed, stapled or nailed into a substraight such as plywood or other building sheathing.

[0124] FIG. 13 depicts a corner element having two pegs 190.

[0125] FIG. 14 depicts a window 300 with four corner elements 100 attached near the window corners.

[0126] FIG. 15 depicts a continuation of FIG. 14 with chicken wire or lath wire 200 placed over the corner elements 100.

[0127] FIG. 16 is an expanded view of FIG. 15 wherein chicken wire or lath wire 200 is attached on top of a corner element 100 and the corner element has been attached near, touching or adjacent to a window 300 and in particular a window corner.

[0128] FIG. 17 is a modified view of scratch coat 650 applied over and covering chicken wire or lath wire and covering the four corner elements. The view is modified in that the scratch coat 650 is embedded into the voids of the corner elements, obscuring the view of the corner elements. In a more realistic rendering, the corner elements would be difficult to see due to the application of the scratch coat 650.

[0129] Advantages in preventing or reducing stucco cracks are also found by the relatively lower elevation of the flat corner perimeter area 152. By use of a lower elevation of the outer or distal surface a more direct attachment may be obtained with an underlying substrate.

[0130] Advantages in preventing or reducing stucco cracks are also found by having a raised top surface or crown section 171, sometimes having a relatively higher elevation and thickness as compared to the flat outer perimeter area 152. The higher elevation of the raised crown section allows for added material to define and support the center void 101, the circular void areas 102 and the circle voids 103. The added depth by use of a raised crown section may also assist in giving the corner element an ability to flex in areas between areas used for attachment to a substrate.

[0131] A corner element may also comprise artful integration with a door or window corner section by use of a door or window integration area 185. The integration area 185 may comprise two frame leg sections 181 with each frame leg section starting at a perimeter edge 104 and terminating at or near a center receiving area 180. A center receiving area 180 may be centered upon a center void 101. A center receiving area 180 is sometimes curved so as to further disburse stucco movement at a window or door corner. The center receiving area 180 may flex left, right, up or down to further dissipate the buckling forces commonly encountered by stucco at door and window corners. Also the door and window integration area 185 provides advantages in that it may also flex left, right, up or down to further dissipate the buckling forces commonly encountered by stucco at door and window corners.

[0132] The center receiving area 180 is sometimes configured to be adjacent or relatively near the center void 101 or center area of the corner element. Such a configuration provides rotational support and retardation of movement in directions perpendicular to common stucco cracks at doors and windows. Such a common stucco crack 500 is seen in FIG. 9.

[0133] In the best mode known to date, a corner element 100 is comprised of high density polyethylene. Such material is semi-rigid, allowing for an optimal degree of flexibility to evenly disperse stucco movement. The material is strong enough to provide further stucco support and reinforcement when the corner element is embedded in plaster. In the best mode known to date, the corner element height is .sup.ths of an inch in width such that the corner element is embedded in approximately the center of a .sup.ths of an inch stucco application.

[0134] Further advantages of the disclosed embodiments include the use of smooth rolled edges and circular lines which redistribute stress or stucco movement or compression evenly over the corner element and related components. A configuration of concentric circular voids in the shape of slots originates from the center with each concentric circular void distal from the center point, resulting in concentric circular voids or concentric slots positioned at right angles to the corner section of a door or window.

[0135] FIGS. 18 to 23 depict an alternative embodiment or a second embodiment having the same or similar attributes and advantages of the other disclosed embodiments.

[0136] FIG. 24 depicts a third embodiment having a plurality of eyebrow void assemblies 130, the eyebrow void assemblies comprising a horizontally disposed center or horizontal void. A raised arc 134 may be centrally disposed over a horizontal void, with the raised arc 134 defining a vertically defined void 136.

[0137] The disclosed eyebrow assembly represents a significant breakthrough in the art, as the stucco cracks are eliminated or greatly reduced as the raised arc 134 is able to adhere within the stucco significantly better as compared to the first and second embodiments herein. The raised arc 134 placed over a horizontal void 132 allows the corner element to embed in the stucco in three dimensions, producing improved results over the prior art and over the first two embodiments disclosed herein. The eyebrow assemblies may be located or defined anywhere upon or within a corner element.

[0138] In the depicted third embodiment, starting at FIG. 24, the eyebrow assemblies are illustrated to be disposed in the upper elevations of the element and sometimes above a second transition edge 167, as shown in FIG. 29. Eyebrow assemblies are found or defined within or above a crown section 171, as marked on FIG. 28. FIG. 28 depicts a center or horizontal void 132 of an eyebrow assembly. The horizontal void 132 overcomes shortfalls in the art by providing a stucco retention area at a right angle to the stucco retention area comprising the vertically defined void 136 of the raised arc 134 or raised arch.

[0139] FIG. 30 depicts a perspective view of several eyebrow assemblies 130 which may comprise an arched bridge 134 or raised arc, with the arched bridge defining a vertically defined void 136. The unique shape and configuration of the eyebrow assembly overcomes shortfalls in the art as the vertically defined void 136 retains dried stucco and allows the overall corner element to stay retained in the stucco and thus better deflect or disperse differential stucco movement to reduce stucco cracks.

[0140] These and other changes can be made to the invention in light of the above detailed description. In general, the terms used in the following claims, should not be construed to limit the invention to the specific embodiments disclosed in the specification, unless the above detailed description explicitly defines such terms. Accordingly, the actual scope of the invention encompasses the disclosed embodiments and all equivalent ways of practicing or implementing the invention under the claims.

[0141] While certain aspects of the invention are presented below in certain claim forms, the inventors contemplate the various aspects of the invention in any number of claim forms. Disclosed embodiments may include the following items.

[0142] Items

[0143] Item 1. A system to reduce stucco cracks, the system comprising:

[0144] a corner element 100 having a top side, bottom side, a circular outer edge defined by a perimeter distal edge 104 and two frame leg sections 181.

[0145] Item 2. The system of 1 further comprising:

[0146] a door and window integration area 185 comprising the two frame leg sections and a center receiving area 180 located between the two frame leg sections.

[0147] Item 3. The system of item 2 further comprising a flat outer perimeter area 152 defined between the perimeter distal edge and a first transition edge 160, the first transition edge in the shape of a concentric circle.

[0148] Item 4. The system of item 3 further comprising a mid-concentric transition section defined between the first transition edge and a second transition edge 167, the second transition edge in the shape of a concentric circle.

[0149] Item 5. The system of item 4 wherein the mid-concentric transition section is radially arched in shape having a higher elevation at the second transition edge as compared to the first transition edge.

[0150] Item 6. The system of item 5 further comprising a crown section 171 defined as the area within the second transition edge.

[0151] Item 7. The system of item 6 wherein the crown section comprises a center void 101.

[0152] Item 8. The system of item 7 wherein the crown section comprises a plurality of pegs originating from the bottom side.

[0153] Item 9. The system of item 8 wherein the bottom edges of the legs extend to a plane level with the bottom side of the flat outer perimeter area.

[0154] Item 10. The system of item 8 wherein the perimeter distal edge defines a plurality of outer notches 105.

[0155] Item 11. The system of item 10 wherein the flat outer perimeter area defines a plurality of circle voids 153.

[0156] Item 12. The system of item 11 wherein the mid-concentric transition section defines a plurality of circle voids 166.

[0157] Item 13. The system of item 12 wherein the crown section defines a plurality of circular void areas 102.

[0158] Item 14. The system of item 13 wherein the top side of the crown section defines a plurality of dimples 172.

[0159] Item 15. The system of item 14 wherein the center void is further defined by a flat side 106, the flat side adjacent to the center receiving area.

[0160] Item 16. A method of reducing stucco cracks, the method comprising:

[0161] a) attaching a corner element 100 at a corner point 303 of a door or window; and

[0162] b) applying a coat of stucco material over the corner element 100.

[0163] Item 17. The method of item 16 including the step of filling voids of the corner element with the stucco coat.

[0164] Item 18. The method of item 16 including the step of securing the corner element 100 by use of a plurality of fasteners set through the corner element.