Bead stop for a wall having interior cement board layer
11629503 · 2023-04-18
Assignee
Inventors
Cpc classification
E06B2001/622
FIXED CONSTRUCTIONS
E06B2001/624
FIXED CONSTRUCTIONS
E06B1/62
FIXED CONSTRUCTIONS
International classification
Abstract
Methods, systems, and an apparatus for constructing a termination point in a wall are provided. A rigid, cured cement board is attached to exterior sheathing of the wall. A stop bead apparatus is attached to the rigid, cured cement board at a terminating location of the wall. An edge of a rigid, cured cement board is inserted into a gap formed between a base panel of the stop bead apparatus and the exterior sheathing. A finish layer is applied to an exterior surface of the cement board, whereby the finish layer covers the base panel of the stop bead apparatus.
Claims
1. A stop bead apparatus at a termination point in a wall at a location against a jamb of a door or window in a stucco or thin veneered stone wall with a rigid cured cement board backing, the stop bead apparatus comprising: a substantially planar base panel; a stop bead wall extending in a fixed, substantially perpendicular angle from the base panel, the stop bead wall being free from holes or openings and being positioned substantially parallel to the jamb; a flexible spacing member extending from a first side of the stop bead wall, wherein the flexible spacing member is compressed against the jamb thereby maintaining a tight bond against the jamb; a front wall connected to the stop bead wall, the front wall having an exterior edge which forms an outermost portion of the stop bead apparatus; and a gap formed between an interior face of the base panel and a location proximate to an inner, terminating end of the stop bead wall, wherein a dimension of an entire length of the stop bead wall between an interior face of the base panel and exterior sheathing of the stucco or thin veneered stone wall is less than a thickness of the rigid, cured cement board such that the inner surface of the base panel remains in a contacted position with the exterior surface of the rigid, cured cement board, wherein a terminating edge of a rigid, cured cement board is removably insertable into the gap, wherein the terminating edge of the rigid, cured cement board is positioned between the exterior sheathing and the base panel.
2. The stop bead apparatus of claim 1, wherein a finish layer of the stucco or a mortar of the thin veneered stone is applied over the rigid, cured cement board and the base panel, whereby the finish layer of the stucco or the mortar of the thin veneered stone contacts and at least partially embeds into at least one aperture of the base panel.
3. A system for terminating a wall at a location against a jamb of a door or window, the system comprising: a rigid, cured cement board attached to exterior sheathing of the wall; a stop bead apparatus affixed to the rigid, cured cement board proximate to the jamb of a door or window, the stop bead apparatus having: a substantially planar base panel; a stop bead wall extending in a fixed, substantially perpendicular angle from the base panel, the stop bead wall being free from holes or openings and being positioned substantially parallel to the jamb; a flexible spacing member extending from a first side of the stop bead wall to the jamb, wherein the flexible spacing member is compressed against the jamb thereby maintaining a tight bond against the jamb; and a front wall connected to the stop bead wall, the front wall having an exterior edge being the outermost portion of the stop bead apparatus, wherein a gap is formed between the base panel and the exterior sheathing of the wall, wherein a terminating edge of the rigid, cured cement board is positioned with the gap such that the terminating edge of the rigid, cured cement board is positioned between the exterior sheathing and the base panel, wherein a dimension of an entire length of the stop bead wall between an interior surface of the base panel and the exterior sheathing of the wall is less than a thickness of the rigid, cured cement board such that the inner surface of the base panel remains in a contacted position with the exterior surface of the rigid, cured cement board, and wherein cement forming the rigid, cured cement board is cured prior to insertion into the gap; and a finish layer applied to an exterior surface of the rigid, cured cement board, wherein the finish layer covers the base panel of the stop bead apparatus.
4. The system of claim 3, further comprising a caulked joint between the stop bead apparatus and the jamb.
5. The system of claim 4, further comprising a bond-breaking tape positioned between an exterior surface of the spacing member and the caulked joint between the stop bead apparatus and the jamb.
6. The system of claim 3, wherein a terminating edge of the finish layer is secured to at least a portion of the front wall and the base panel of the stop bead apparatus.
7. The system of claim 3, wherein the exterior edge further comprises one of: a pointed terminating end of the stop bead wall; a terminating end of the stop bead wall, the terminating end having substantially right angles; a curved terminating end of the stop bead wall, the curved terminating end extending back towards the base panel; or a terminating end of the stop bead wall, the terminating end having a rounded edge with a curvilinear shape.
8. A method for constructing a termination point in a wall at a location against a jamb of a door or window, the method comprising the steps of: attaching a rigid, cured cement board to exterior sheathing of the wall; attaching a stop bead apparatus to the rigid, cured cement board along a terminating location of the wall proximate to a jamb of a door or window, the stop bead apparatus having a flexible spacing member mounted to a stop bead wall, the stop bead wall extending in a fixed, substantially perpendicular angle from a base panel and being free from holes or openings and being positioned substantially parallel to the jamb, wherein the flexible spacing member is compressed against the jamb thereby maintaining a tight bond against the jamb, wherein a terminating edge of the rigid, cured cement board is positioned with a gap formed between the exterior sheathing of the wall and the base panel of the stop bead apparatus, and wherein a dimension of an entire length of the stop bead wall between an interior surface of the base panel and the exterior sheathing of the wall is less than a thickness of the rigid, cured cement board such that the inner surface of the base panel remains in a contacted position with the exterior surface of the rigid, cured cement board; and applying a finish layer to an exterior surface of the cement board, whereby the finish layer covers the base panel of the stop bead apparatus.
9. The method of claim 8, further comprising the step of caulking a joint between the stop bead apparatus and the jamb.
10. The method of claim 9, further comprising a bond-breaking tape positioned between an exterior surface of the spacing member and the caulking within the joint between the stop bead apparatus and the jamb.
11. The method of claim 8, wherein applying the finish layer to the exterior surface of the cement board further comprises securing a terminating edge of the finish layer to at least a portion of a front wall of the stop bead apparatus.
12. The method of claim 8, wherein a front wall of the stop bead apparatus comprises an exterior edge, the exterior edge being an outermost portion of the stop bead apparatus, whereby the base panel is positioned inset relative to the exterior edge such that the finish layer formed over the base panel is substantially flush with the exterior edge.
13. The method of claim 12, wherein the exterior edge further comprises one of: a pointed terminating end of the stop bead wall; a terminating end of the stop bead wall, the terminating end having substantially right angles; a curved terminating end of the stop bead wall, the curved terminating end extending back towards the base panel; or a terminating end of the stop bead wall, the terminating end having a rounded edge with a curvilinear shape.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
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DETAILED DESCRIPTION
(12) To improve upon the shortcomings of the prior art, as described in the Background, the subject disclosure provides a system for terminating a wall. The wall is constructed with a rigid cement board as an interior layer, replacing scratch layer and effectively replacing the brown layer.
(13) To lessen the time it takes to finish the exterior wall of a structure, these rigid cement boards 10 may be used in place of the scratch layer and/or brown layer on conventional stucco or plaster walls. Specifically, the installer may install the cement board 10 directly on the sheathing of the wall, or over another material placed on the sheathing, such as a vapor or moisture barrier. The cement board 10 may be secured with fasteners, such as screws, which affix the cement board to the sheathing. Once the wall is appropriately covered, the installer may then apply a finish coat to the wall, including filling any cracks between the adjacent edges of the cement board 10. Because the cement board 10 is already cured and rigid, the wall does not need to be given time to cure and shrink, as is required with conventional stucco and plaster walls. Thus, it is possible for an installer to effectively install the entirety of a stucco or plaster wall in one single day using cement board 10 versus the 8-15 days required with conventional stucco or plaster walls. This time savings allows the installer to be more efficient and also minimizes the risk of damage to an unfinished wall due to rain or moisture exposure.
(14) The subject invention is directed to a system 20 for terminating a wall 22 which uses rigid, cured cement board 10 as an interior layer of the wall's 22 exterior surface.
(15) The stop bead apparatus 30 is affixed to the rigid, cured cement board 10, where the stop bead apparatus 30 has a substantially planar base panel 32 which is positioned along the exterior, planar surface of the rigid, cured cement board 10. Unlike most conventional stop bead devices which have a base panel positioned against sheathing 24 of the wall 22, with one side of the base panel abutting the sheathing 24, the base panel 32 of the apparatus 30 has a base panel 32 which is positioned on the exterior of the rigid, cured cement board 10, such that the base panel 32 does not contact the sheathing 24. The base panel 32 may have a height dimension (in a direction away from the stop bead wall 34) which allows it to be positioned substantially along an adequate portion of the cement board 10. For example, the height dimension of the base panel 32 may be larger than a thickness of the stop bead wall 34 or any other structures extending from the stop bead wall 34. In one example, the height dimension of the base panel 32 may be at least 2, 3, 4, or 5 times greater than a width dimension of the stop bead wall 34, as measured between the sheathing 24 and the front wall 42. While the specific dimensions may vary, in one example, the height dimension of the base panel 32 is greater than 1.5 inches, greater than 2 inches, greater than 3 inches, greater than 4 inches, greater than 5 inches, or greater than 10 inches.
(16) The stop bead apparatus 30 may be positioned on the rigid, cured cement board 10, in locations of the wall 22 which abut termination points of the wall 22, commonly at jambs of doors or windows or at other termination locations. In these locations, the stop bead apparatus 30 provides for a termination joint or junction within the wall to the jamb or other structure. The stop bead apparatus 30, and any components thereof, may be constructed from extrusion, molding or other manufacturing technique using plastic, vinyl, metal, metal compounds, fiber glass, or other materials.
(17) The stop bead apparatus 30 includes a stop bead wall 34 extending in a substantially perpendicular angle from the base panel 32 along a first edge 36 of the base panel 32. The first edge 36 may be in contact with the sheathing 24 of the wall 22, such that the stop bead wall 34 extends in substantially a perpendicular direction extending outwards from the plane of the wall sheathing 24, whereby it has an interior side which can contact the cement board 10 and an exterior side that faces towards the jamb of the door or window. In one example, only an interior surface of the stop bead wall 34 at the first edge 36 contacts the sheathing 24 of the wall 22. A flexible spacing member 38 extends from a first side 40 (exterior side) of the stop bead wall 34 to a jamb (
(18) The stop bead apparatus 30 also has a front wall 42 which is connected to the stop bead wall 34. The front wall 42 may have a variety of shapes and positions. As shown in
(19) As is shown in
(20) Since the cement used to form the rigid cement board 10 is cured at a factory or other venue prior to insertion into the gap 44, the rigid cement board 10 can be first installed with appropriate fasteners to the wall sheathing 24. For instance, the installer may cover the sheathing 24 of the wall 22 with a plurality of cement boards 10, thereby constructing a base or interior layer of the exterior surface of the wall 22. Once the rigid cement board 10 is appropriately positioned on the sheathing 24, it may be fastened to the sheathing 24 with a screw, nail, or other fastener (not shown). This fastener structurally retains the cement board 10 to the sheathing 24. Then, once the rigid, cured cement board 10 is affixed to the wall sheathing 24, the stop bead apparatus 30 can be installed with the base panel 32 positioned against the exterior surface 16 of the cement board 10 in locations around a jamb, and with the stop bead wall 34 substantially in contact with the terminating end of the rigid, cured cement board 10. The installer may use one or more fasteners to retain the stop bead apparatus 30 to the cement board 10, or the installer may use a quantity of cementitious material, such as the same material used with a finish layer 60, to temporarily hold the stop bead apparatus 30 in place until the finished layer 60 is completed.
(21) After the cement board 10 is installed on a wall 22 surface and the stop bead apparatus 30 is installed against the cement board 10, the installer may then apply a finish layer 60 to the exterior face 16 of the rigid cement board 10. The finish layer 60 may include a variety of different materials and/or techniques, depending on the design of the wall. For example, it may be common for the installer to fill in any gaps between the edges of the cement boards 10 and then apply the finish layer. This may include first applying a wire mesh 62 which is fastened to the cement board 10. To the wire mesh 62, a finish coat 64 of stucco and/or plaster may then be applied, where the stucco and/or plaster material impregnates the wire mesh 62, which effectively holds it to the cement board 10. Additionally, the finish coat 60 can impregnate a plurality of holes or apertures 35 within the base panel 32, such that the base panel 32 is secured in place with the wire mesh 62 against the cement board 10. In other examples of the finish layer 60, the finish layer 60 may include other materials or techniques. For example, the installer may still install a brown coat, but the thickness of the brown coat may be substantially less than that of conventional stucco or plaster walls, such that the drying or curing time may be far less than the conventional time of 7-10 days. The finish layer 60 may also include other materials beyond plaster or stucco, such as thin veneered stone, or other natural or artificial stone materials which can be applied to the wall as the finish layer 60.
(22) Regardless of how the finish layer 60 is applied, the edge of the finish layer 60 may be interfaced with at least a portion of the front wall 42 of the stop bead apparatus 30, thereby allowing the installer to achieve clean, event termination edges of the finish layer 60. For instance, the finish layer 60 may be troweled to be substantially the same height as the terminating end of the front wall 42, such that the front wall 42 acts as a guide for application of the finish layer 60, both for the thickness of the finish layer 60 and to provide a clean, durable edge for termination of the wall 22 at the location of the jamb.
(23) It is noted that the front wall 42 may include one or a plurality of features 46, such as holes, grooves, channels, or similar structural features, which catch the stucco or plaster material used in the finish layer 60, thereby securing, holding, or catching the edge of the finish layer 60. This may prevent the edge of the finish layer 60 from falling off the wall 22. These same features 46 may also be included or used with the stop bead wall 32 to increase the structural durability of the stop bead apparatus 30 and ensure a strong connection to the cement board 10. Additionally, the installer may install the finish layer 60 up to an exterior point 48 of the front wall 42, which effectively acts as a finish edge for the finish layer 60. This exterior point 48 which can be used to create a finish edge may have a variety of different shapes and dimensions, such as depicted relative to
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(25) As can be seen in
(26) While the dimensions of the structure may vary, in one example the base panel 32 is 1.75 inches and the front wall 42 is approximately 0.75 inches in length with the first wall portion 52 being approximately 0.25 inches. The angular position of the first wall portion 52 may extend back towards the base panel 32 approximately 0.125 inches. The gap 44 may be approximately 0.5 inches or less, such that it is sized to receive a cement board 10 having a 0.5 inch thickness. For cement board 10 having other thicknesses, the gap 44 may be sized differently. Also, the space of the gap 44 may be slightly smaller than the thickness of the intended cement board 10, such that when the base panel 32 is abutting the planar surface of the cement board 10, the inner, terminating end of the stop bead wall 34 is slightly spaced from contact with the sheathing 24. In this way, it is possible to ensure the base panel 32 remains in a flush, fully contacted position with the cement board 10, thereby creating a tight joint.
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(32) As is shown by block 102, a rigid, cured cement board is attached to exterior sheathing of a wall. A stop bead apparatus is attached to the rigid, cured cement board along terminating location of the wall, wherein an edge of the rigid, cured cement board is positioned with a gap formed between the exterior sheathing of the wall and the base panel of the stop bead apparatus (block 104). A finish layer is applied to an exterior surface of the cement board, whereby the finish layer covers the base panel of the stop bead apparatus (block 106).
(33) As discussed previously, this method may save considerable time to installers of stucco or plaster walls by using cement boards which are cured and rigid, as opposed to scratch layers applied on-site. The stop bead apparatus may further enhance the time savings by allowing installers to easily and efficiently terminate the wall at a jamb or other structure, all while ensuring that the wall termination is durable and high-quality. It is noted that the method may include any number of additional steps, variations, or functions beyond those illustrated in
(34) It should be emphasized that the above-described embodiments of the present disclosure, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.