U.S. patent application number 10/790628 was filed with the patent office on 2005-11-24 for structural panel utilizing a lath and frame member and method for making the same.
Invention is credited to Stevens, Donald A..
Application Number | 20050257471 10/790628 |
Document ID | / |
Family ID | 23226995 |
Filed Date | 2005-11-24 |
United States Patent
Application |
20050257471 |
Kind Code |
A1 |
Stevens, Donald A. |
November 24, 2005 |
Structural panel utilizing a lath and frame member and method for
making the same
Abstract
A structural panel and method of making the same are disclosed
wherein the structural panel has at least one frame member with
receptor pockets extending therein. Ribs protruding from a lath are
resiliently engaged within the receptor pockets thereby securing
the lath against the frame member. A structural coating is secured
to the lath thereby providing a labor-efficient, low-cost
structural panel available for use for a number of different
construction projects.
Inventors: |
Stevens, Donald A.;
(Winchester, VA) |
Correspondence
Address: |
Richard L. Byrne
WEBB ZIESENHEIM LOGSDON ORKIN & HANSON, P.C.
700 Koppers Building
436 7th Avenue
Pittsburgh
PA
15219-1818
US
|
Family ID: |
23226995 |
Appl. No.: |
10/790628 |
Filed: |
March 1, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10790628 |
Mar 1, 2004 |
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PCT/US02/27876 |
Aug 30, 2002 |
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60315994 |
Aug 30, 2001 |
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Current U.S.
Class: |
52/443 |
Current CPC
Class: |
E04B 5/02 20130101; E04F
13/04 20130101; E04B 7/20 20130101; E04B 9/045 20130101; E04F
13/047 20130101; E04B 5/026 20130101; E04C 2/384 20130101; E04B
9/0464 20130101 |
Class at
Publication: |
052/443 |
International
Class: |
E04C 003/16 |
Claims
The invention claimed is:
1. A lath for use with a frame member for a structural panel
comprising: a) a generally planar sheet having a front side and a
back side, b) a plurality of ribs formed within the sheet i)
wherein the ribs protrude from the back side of the sheet, ii)
wherein each rib has a profile with a first side and a second side
which diverge from one another as they extend away from the back
side and then converge, and iii) wherein the maximum height of a
rib occurs at the place of maximum divergence, and c) a plurality
of slats extending through the sheet for adapting the sheet to
receive and retain thereupon a structural coating.
2. The lath in accordance with claim 1, wherein the sheet is
constructed from a thin pliable material such that the ribs are
resilient and the ribs may be compressed to reduce the maximum
height.
3. The lath in accordance with claim 1, wherein the sheet is made
from a material selected from the group consisting of metal,
plastic and carbon fiber composites.
4. The lath in accordance with claim 1, wherein the sheet has a
plurality of segments with slats therein wherein the slats within
adjacent segments are oriented differently to securely engage any
structural coating that may be applied to the sheet.
5. The lath in accordance with claim 4, wherein the slats within a
segment are parallel to one another.
6. The lath in accordance with claim 5, wherein the sheet has a
longitudinal axis, each slat is along a line to define a slat
vertical angle with the longitudinal axis, and wherein the slat
vertical angle formed by the slats in one segment are equal and
opposite to the slat vertical angle formed by the slats in an
adjacent segment.
7. The lath in accordance with claim 1, wherein, when viewed in
section, each segment of slats forms a slat planar angle with the
longitudinal axis and wherein the planar slat angle of the slats in
one segment is equal to and opposite the slat planar angle formed
by the slats in an adjacent segment.
8. The lath in accordance with claim 1, wherein a plurality of
divots are formed within the front side of the sheet to provide
protrusions from the back side of the sheet, such that the sheet
may be spaced from any flat surface upon which it may be
applied.
9. The lath in accordance with claim 1, wherein each rib has a
plurality of holes extending therethrough to provide pressure
relief to any structural coating that may be applied to the
sheet.
10. A lath for use with a frame member for a structural panel
comprising: a) a generally planar sheet having a front side and a
back side, b) a plurality of ribs formed within the sheet i)
wherein the ribs protrude from the back side of the sheet, ii)
wherein each rib has a profile adapted to snap into an opening of
the frame member, and iii) wherein the maximum height of a rib
occurs at the place of maximum divergence, and c) a plurality of
slats extending through the sheet for adapting the sheet to receive
and retain thereupon a structural coating.
11. A lath for use with a frame member for a structural panel
comprising: a) a generally planar sheet having a front side and a
back side, b) a plurality of ribs formed within the sheet i)
wherein the ribs protrude from the back side of the sheet, ii)
wherein each rib has a profile in the shape of a barb adapted to
snap into an opening of the frame member, and iii) wherein the
maximum height of a rib occurs at the place of maximum divergence,
and c) a plurality of slats extending through the sheet for
adapting the sheet to receive and retain thereupon a structural
coating.
12. A structural panel comprising: a) at least one frame member
having a longitudinal axis and a plurality of receptor pockets
extending within the frame member in a direction generally
perpendicular to the longitudinal axis; and b) a lath connected to
the at least one frame member, wherein the lath has a plurality of
resilient ribs extending therefrom and wherein the ribs resiliently
engage corresponding receptor pockets within the at least one frame
member to secure the lath to the at least one frame member.
13. The structural panel in accordance to claim 12, wherein the
receptor pockets extend from a first side of each frame member and
the lath is secured to this first side.
14. The structural panel in accordance with claim 12, where the
receptor pockets extend from both the first side and an opposing
second side of each frame member and further including a second
lath wherein a lath is secured to each the first side and the
second side of the frame member.
15. The structural panel according to claim 12, wherein the lath
further comprises: a) a generally planar sheet having a front side
and a back side, b) wherein the ribs are formed within the sheet
and protrude from the back side of the sheet, c) wherein each rib
has a profile with a first side and a second side which diverge
from one another as they extend away from the back side and then
converge, d) wherein the maximum height of a rib occurs at the
place of maximum divergence, and e) a plurality of slats extending
through the sheet for adapting the sheet to receive and retain
thereupon a structural coating.
16. The structural panel according to claim 12, further including a
mesh between the lath and the frame to provide a backdrop for any
structural coating that may be applied to the structural panel.
17. The structural panel according to claim 16, wherein the mesh is
made from one of the group consisting of fiberglass and carbon
fiber composites.
18. The structural panel according to claim 12, further including a
thermal break between the lath and the frame to provide a thermal
barrier that will disrupt any conductive heat flow from the lath to
the frame.
19. The structural panel according to claim 18, wherein the thermal
break is comprised of a liquid gasket applied over the lath.
20. The structural panel according to claim 18, wherein the thermal
break is comprised of a one piece gasket secured to the frame
member with adhesive.
21. The structural panel according to claim 12, further including
reinforcement bars positioned within the ribs of the lath to lock
the lath within the frame member and to provide additional
structural stiffness to the structural panel.
22. The structural panel according to claim 12, further including a
structural coating applied on the front side of the lath and
permeating through the slats and the receptor pockets to further
secure the lath to the frame member.
23. The structural panel according to claim 22, wherein the
structural coating is stucco.
24. The structural panel according to claim 22, wherein the
structural coating is plaster.
25. The structural panel according to claim 12, wherein the lath is
metal and the frame is light gauge steel.
26. The structural panel according to claim 12, wherein each
receptor pocket extends continuously across the frame member.
27. The structural panel according to claim 12, wherein the
receptor pockets are apertures extending through one or both of the
first side and the second side of the frame member.
28. The structural panel according to claim 12, wherein each rib
extends across the lath in an interrupted pattern.
29. The structural panel according to claim 12, wherein the panel
may be used for at least one structural member from the group
consisting of roofs, floors, ceilings, foundations, basement walls,
verandahs, decks, fences and interior and exterior walls.
30. A method of making a structural panel utilizing at least one
frame member having a longitudinal axis and a plurality of receptor
pockets extending within the frame member in a direction generally
perpendicular to the longitudinal axis and a lath having a
plurality of resilient ribs extending therefrom and adapted to
resiliently engage corresponding receptor pockets within the at
least one frame member, wherein the method comprises the steps of:
a) aligning the ribs of the lath with matching receptor pockets in
each of the frame members; and b) urging each rib within the
matching receptor pocket of the frame member until each rib snaps
into position.
31. The method according to claim 30, further comprising the step
of coating the lath with a structural coating.
32. The method according to claim 30, further comprising, after the
step of urging each rib within the receptor pocket of the frame
member, the step of inserting reinforcement bars within the ribs to
lock the rib within the receptor pocket.
33. The method according to claim 32, further comprising the step
of coating the lath with a structural coating.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of International
Application Number PCT/US02/27876 filed Aug. 30, 2002, which
designates inter alia the United States and which claims the
benefit of U.S. Provisional Application No. 60/315,994 filed Aug.
30, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to prefabricated structural panels
which can be rapidly assembled to form buildings of various types.
Specifically the invention relates to structural panels which
incorporate a lath connected to frame members.
[0004] 2. Description of Related Art
[0005] There is a widespread need for a building system that uses
common construction materials which are readily available
throughout the world and can be quickly erected with a minimal
labor force, is cost effective and whose construction is capable of
withstanding extreme environments. Such a building system must be
environmentally friendly while appearing to be similar to
traditional buildings and structures and also must be constructed
of materials which wisely utilize limited natural resources.
[0006] The demand for buildings, especially homes, in many third
world countries is high. Additionally, current building methods
many times are so slow, outdated and so labor intense that there is
no way to satisfy the existing demand. While structures made from
stone, block and concrete materials are time-tested and have proven
their effectiveness worldwide, a change in building design must
occur in order to keep up with this high demand. Portland cement, a
common natural resource, has been used throughout the world for
over two thousand years to produce concrete, mortar plaster and
stucco. Steel has been used and relied upon since the early 1800s.
Both portland cement and steel are cost effective and readily
available from producers worldwide.
[0007] Therefore, a building utilizing a light gauge steel frame
that can be covered with a cement exterior/interior coating and
that would closely resemble currently existing buildings is
desirable.
[0008] There are existing building systems that use light gauge
laths, meshes, expanded metal or similar materials to build various
types of stucco or plaster covered structures. All of these systems
utilize discrete mechanical fasteners to attach the lath to the
frame and must be used over a solid substrate such as plywood to
provide adequate strength and to provide a material to which the
fasteners can be attached. Once the lath is fastened, stucco or
plaster, each of which is considered to be a cementitious coating,
is applied in a series of layers over the substrate. The lath, once
embedded in the cementitious coating, acts together with the
coating to provide a structure having more strength using a design
technique which offers a greater level of flexibility.
[0009] There are different types of existing commercial laths. The
first type of lath is diamond mesh lath. It is manufactured out of
thin sheets of metal that are slit with knives and stretched apart.
The lath pattern resembles uniformly spaced small diamond shapes.
The diamond mesh lath must be fastened to a substrate with nails or
screws and must be used in conjunction with a solid surface because
this diamond mesh lath is inherently flexible. The diamond shaped
pattern allows the lath not only to be formed for contours but also
provide a smooth surface desirable for ornamental work and smooth
plaster finishes.
[0010] A second type of lath is a self-furring lath which may have
a dimpled diamond or high ribbed surface that spaces the lath away
from a mounting surface. These self-furring laths enable a
structural coating to encapsulate the lath such that the lath is in
the middle of the structural coating thereby providing greater
strength. Self-furring laths, just as the diamond mesh lath, must
be attached to a solid substrate such as plywood or water-resistant
gypsum board using nails or screws.
[0011] A third type of lath is a lath having diamond patterns and
having continuous flat ribs of steel which has a unique shape for
added strength and support. This type of lath can be used over an
open frame and does not require attachment to a solid substrate.
However, this type of lath is limited for use on spans no greater
than 16 inches and is not self-furring. In particular, one typical
lath includes three 16-inch flat ribs spaced on 2-inch centers
which run the continuous length of the lath. However, once again,
these ribbed laths must be mechanically fastened to one another
using discrete fasteners.
[0012] Finally, a flat-ribbed lath having a diamond shape in a
reverse herringbone pattern may have V-shaped ribs that run the
length of the lath. In one instance, 3/8-inch V-shaped ribs are
spaced at 41/2 inch intervals and provide structural support on
open framed cavities having framing members spaced less than 16
inches apart. However, once again this type of lath must be
mechanically fastened using discrete fasteners.
[0013] Each of these laths when used to cover a 2-foot by 8-foot
area, requires between 36-45 fasteners. Not only do these fasteners
add to the overall material costs, but also the time required to
apply these fasteners increases the cost of labor and the overall
time of construction.
[0014] Light gauge framing components made from coils of thin metal
having various thicknesses and widths have existed for more than
forty years. Such framing components typically consist of a web and
a flange extending therefrom.
[0015] European Patent No. 159,764 issued to Illinois Tool Works on
Oct. 30, 1985 shows a fastener for installing a sheet such as a
lath spaced from a support. The lath described therein requires
discrete mechanical fasteners.
[0016] Japanese Patent No. 03,290,555 issued to Adachi et al. on
Dec. 20, 1991 shows a method for fixing an inner wall. This patent
discloses a means of attaching a wood beam such as a ceiling or
floor beam in a steel fitting means. There is neither a teaching
nor a discussion of a lath.
[0017] Japanese Patent No. 03,286,029 issued to Misaka on Dec. 17,
1991 illustrates a steel underground wall and method of
construction. This patent discloses a seismic reinforcement using a
steel grid composed of beams, and neither teaches nor suggests the
use of a lath.
[0018] European Patent No. 434869 issued to International Building
Systems, Inc. on Dec. 15, 1993 illustrates a steel stud and precast
panel which requires a fastening means before the introduction of
concrete over a steel stud.
[0019] Japanese Patent No. 06,158,858 issued to Harino et al. on
Jun. 7, 1994 illustrates a form for concrete foundation and
describes a means of pouring concrete into a panel. This patent
neither teaches nor discusses the use of a lath.
[0020] Japanese Patent No. 08,270,142 issued to Miyata on Oct. 15,
1996 illustrates a steel stud for a partition wall used in a
coupling system for holding fireproof boards. There is neither a
teaching nor a discussion of the use of a lath.
[0021] Japanese Patent No. 09,279,806 issued to Hosoda on Oct. 28,
1997 discloses a method for fixing a rib lath utilizing a means for
fastening a lath including screw attachments to pierce through the
lath at recess points.
[0022] Japanese Patent No. 10,161,189 issued to Hosoda on Jun. 23,
1998 illustrates a ribbed lath used as a form. This patent neither
teaches a self-setting lath system nor suggests that the lath be
applied to a stud.
[0023] Japanese Patent No. 10,237,994 issued to Shiozo et al. on
Sep. 8, 1998 discloses a concrete panel made up of a lath and steel
studs and a method utilizing heat to attach the lath to the steel
studs.
[0024] A design for applying a lath to a frame is desired which
requires no discrete fasteners for permanent connection and
requires no solid substrates upon which to secure the lath.
SUMMARY OF THE INVENTION
[0025] A first embodiment of the subject invention is directed to a
lath for use with a frame member for a structural panel comprising
a generally planar sheet having a front side and a back side with a
plurality of ribs formed within the sheet. The ribs protrude from
the back side of the sheet and each rib has a profile with a first
side and a second side which diverge from one another as they
extend away from the back side and then converge. The maximum
height of a rib occurs at the place of maximum divergence and a
plurality of slats extends through the sheet for adapting the sheet
to receive and retain thereupon a structural coating.
[0026] A second embodiment of the subject invention is directed to
a structural panel comprising at least one frame member having a
longitudinal axis and a plurality of receptor pockets extending
within the frame member in a direction generally perpendicular to
the longitudinal axis. A lath is connected to the at least one
frame member and the lath has a plurality of resilient ribs
extending therefrom. The ribs resiliently engage corresponding
receptor pockets within the at least one frame member to secure the
lath to the at least one frame member.
[0027] A third embodiment of the subject invention is directed to a
method of making a structural panel utilizing at least one frame
member having a longitudinal axis and a plurality of receptor
pockets extending within the frame member in a direction generally
perpendicular to the longitudinal axis. A lath having a plurality
of resilient ribs extending therefrom is adapted to resiliently
engage corresponding receptor pockets within the at least one frame
member. The method comprises the steps of aligning the ribs of the
lath with matching receptor pockets in each of the frame members,
and urging each rib within the matching receptor pocket of the
frame member until each rib snaps into position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 show a front elevation view of a section of a ribbed
channel lath in accordance with the subject invention;
[0029] FIG. 2 is a side view of the lath illustrated in FIG. 1;
[0030] FIG. 3 is an exploded side view of the lath in position to
be mounted upon a frame member;
[0031] FIG. 4 is a side view of the lath mounted upon the frame
member;
[0032] FIG. 5 is an exploded view of the lath mounted upon a frame
member with a structural coating spaced therefrom;
[0033] FIG. 6 is a side view of the components illustrated in FIG.
5 but assembled;
[0034] FIG. 7 is a side view of the assembled frame member, lath
and base structural coating having exploded therefrom a screen and
a supplemental structural coating;
[0035] FIG. 8 is a side view of the elements illustrated in FIG. 7
but assembled;
[0036] FIG. 9 is a perspective view of a structural panel in
accordance with the subject invention;
[0037] FIG. 10 is a perspective view of an enlarged portion circled
in FIG. 9;
[0038] FIG. 11 is an exploded side view of an intermediate barrier,
a lath and frame member;
[0039] FIG. 12 is a side view of the intermediate layer and lath
assembled on a frame member; and
[0040] FIGS. 13A-13G illustrate sketches of different rib
profiles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] The present invention is a light gauge lath and framing
system to provide a structured panel for roofs, floors, ceilings,
foundations, basement walls, verandahs, decks, fences and interior
and exterior walls in building construction. The structural panel
in accordance with the subject invention can be assembled without
the use of discrete fasteners and is able to stand between frame
members without the use of a solid substrate.
[0042] Directing attention to FIGS. 1 and 2, a lath 10 is made up
of a generally planar sheet 15 having a front side 17 and a back
side 19. A plurality of ribs 20 are formed within the sheet 15.
Each rib 20 protrudes from the back side 19 of the sheet 15.
Furthermore, each rib 20 has a profile with a first side 22 and a
second side 24 which diverge from one another as they extend away
from the back side 19 and then the first side 22 and the second
side 24 converge to intersect. Each rib has a maximum height H
which occurs at the place of maximum divergence of the first side
22 and the second side 24. Each rib 20 may extend across the lath
in an interrupted pattern such that each rib 20 is a plurality of
protrusions.
[0043] A plurality of slats 25 extends through the sheet 15 for
adapting the sheet 15 to receive and retain thereupon a structural
coating (not shown). The sheet 15 may be constructed from a thin,
pliable material such that the ribs 20 are resilient and may be
compressed to reduce the maximum height H and snapped into
apertures or slots in a frame member. The sheet 15 may be made from
any number of materials that are resilient and provide the desired
shape such as metal, plastic and carbon fiber composites.
[0044] The sheet 15 has a plurality of segments 30 (distinguished
by reference numbers 30a-30g) with the slats 25 therein wherein the
slats 25 within adjacent segments, segments 30a and 30b for
example, are oriented differently to securely engage any structural
coating (not shown) that may be applied to the sheet 15. As
illustrated in FIG. 1, the slats 25 within a segment 30a are
parallel to one another. The sheet 15 has a longitudinal axis LL
and each slat 25 lies along a line to define a slat vertical angle
A with the longitudinal axis LL. The slat vertical angle A formed
by the slats 25 in one segment 30a, for example, is equal and
opposite to the slat vertical angle A formed by the slats 25 in an
adjacent segment 30b for example. Additionally, each segment 30a-g
of slats 25 may form a slat planar angle B with the longitudinal
axis LL of a lath 10. The slat planar angle B of the slats 25 in
one segment for example, segment 30a may be equal to and opposite
the slat planar angle B formed by the slats 25 in an adjacent
segment, for example, segment 30b.
[0045] A plurality of divots 40 may be formed within the front side
17 of the sheet 15 to provide protrusions from the back side 19 of
the sheet 15, such that the sheet 15 may be spaced from any flat
surface upon which it may be applied.
[0046] A structural coating (not shown) may be applied to the lath
and, for that reason, each rib 20 may have a plurality of holes 45
extending therethrough to provide pressure relief to any structural
coating that may be applied to the sheet 15.
[0047] FIGS. 3 and 4 illustrate the manner in which the lath 10 may
be secured to a frame member 100. As illustrated in FIG. 9, a lath
10 may be secured to a plurality of frame members 100 to form a
structural panel 200.
[0048] Directing attention to FIGS. 3 and 4, the structural panel
200 (FIG. 9) may be comprised of, at least one frame member 100
having a longitudinal axis LF and a plurality of receptor pockets
105 extending within the frame member 100 in a direction generally
perpendicular to the longitudinal axis LF.
[0049] The lath 10 is connected to the frame member 100 through the
plurality of resilient ribs 20 extending therefrom. The ribs 20
resiliently engage corresponding receptor pockets 105 within the
frame member 100 to secure the lath 10 to the frame member 100.
Each receptor pocket 105 extends from a first side 102 of the frame
member 100 and the lath 10 is secured to this first side 102.
[0050] The receptor pockets 105 may extend from both the first side
102 and an opposing second side 104 of a frame member 100. Under
these circumstances, the lath 10 may be secured to the first side
102 of the frame member 100 while a second lath (10 in FIG. 4) may
be secured to the second side 104 of the frame member 100.
[0051] As illustrated in FIGS. 5 and 6, a base structural coating
150 may be applied to the front side 17 of the lath 10. The
structural coating 150 penetrates through the slats 25 (FIG. 1) and
the receptor pockets 105. Since the ribs 20 of the lath 10 must be
compressed to snap within the receptor pockets 105 of the frame
member 100, once the lath 10 is secured to the frame member 100,
when the structural coating 150 is applied, the coating 150 not
only permeates the slats 25 but furthermore fills the remaining
volume within each receptor pocket 105. The structural coating 150
hardens within a receptor pocket 105 and the rib 20 becomes
permanently secured within the receptor pocket 105 because the
hardened structural coating 150 prevents the rib 20 from
compressing, which would be required to remove the rib 20 from the
receptor pocket 105. This provides a permanent connection for the
ribs 20 of the lath 10 into the receptor pockets 105 because of the
unique one-way fitting design of the panel.
[0052] The base structural coating 150 may be stucco or plaster.
The lath 10 may be metal and the frame member 100 may be light
gauge steel.
[0053] Directing attention to FIG. 7, the structural panel may
further include a structural mesh 170 which may be embedded within
the base structural coating 150. In particular, in areas that are
prone to seismic activity and extreme whether conditions, the
structural mesh 170 applied to the base structural coating 150 may
reduce the chance of cracking and increase the overall strength of
the structural panel 200 (FIG. 9). The structural mesh 170 may be
adhered, fabricated or attached to each lath 10 in an offset
pattern. The offset pattern allows for the structural mesh 170 to
overlap other laths 10 by creating a uniform covering which may
overlap for example by as much as two inches on each lath 10.
[0054] The structural mesh 170 may be supported from the top of the
partially constructed structural panel 200 and a person applying
the base structural coating 150 may lift the structural mesh 170 up
while the base structural coating 150 is being applied. Once an
area has been coated with the base structural coating 150, the
structural mesh 170 is then released and lightly pressed into the
base structural coating 150, which has not yet solidified. The
structural mesh 170 may be pressed below the surface of the base
structural coating 150. The texture of the structural mesh 170 will
increase the bond for any subsequent coating which may be added and
furthermore will increase the strength of the base structural
coating 150 and reduce the chance of cracking, surface spalling or
peeling. In addition to the structural mesh 170, it is also
possible to include a supplemental structural coating 180 over the
structural mesh 170 and over the base structural coating 150. This
supplemental structural coating 180 may be formulated to provide a
desirable exterior finish. FIG. 8 illustrates the elements of FIG.
7 assembled. The frame member 100 has attached thereto the lath 10,
the base structural coating 150, the structural mesh 170 and the
supplemental structural coating 180.
[0055] FIG. 9 illustrates a structural panel 200 in which frame
members 100 are secured to mounting members 205, 210. Additionally,
the lath 10 is secured to the frame members 100, the base
structural coating 150 is secured to the lath 10 and the
supplemental structural coating 180 is secured to the base
structural coating 150. It should be understood that the structural
mesh 170 (FIG. 7) may also be included, however, for clarity is not
illustrated in FIG. 9. FIG. 10 illustrates an enlargement of the
portion encircled in FIG. 9 and more clearly illustrates the
details of the lath 10 and its attachments to the frame members
100.
[0056] The base structural coating 150 and the supplemental
structural coating 180 may be applied using one of at least two
methods. In a first method a hand trowel may be used to apply the
structural coatings. Using this method, the structural coatings may
be selectively applied with effectiveness. In a second method, the
structural coatings may be applied by machine spraying.
[0057] Directing attention to FIG. 11 when the structural coatings
are applied by spraying, it is necessary to install a mesh 215
between the lath 10 and the frame member 100 to provide a backdrop.
The purpose of this backdrop mesh 215, which may, for example, be
made of fiberglass or of a carbon fiber composite, is to catch any
structural coating spray that goes through the openings of the lath
10. This backdrop mesh 215, as illustrated in FIG. 11, is placed
between the frame member 100 and the lath 10 is placed over the
backdrop mesh 215 and against the frame member 100 such that the
ribs 20 of the lath 10 pinch and secure the backdrop mesh 215
within the receptor pockets 105 of the frame member 100. When the
lath 10 is pressed into the receptor pockets 105 of the frame
member 100, the backdrop mesh 215 becomes permanently attached
between the lath 10 and the frame member 100 and at the same time
is drawn taut forming another medium upon which the base structural
coating 150 may adhere. Although the mesh 215 is illustrated with a
geometry generally shaped to the receptor pocket 105, it should be
appreciated that the mesh 215 may also be a flat sheet and the
force of the ribs 20 will conform the mesh 215 to the shape of the
receptor pocket 105. The separated parts illustrated in FIG. 11 are
shown assembled in FIG. 12.
[0058] In lieu of, or in addition to the structural coatings being
placed over the lath 10 and into the receptor pockets 105 of the
frame members 100 to increase the strength between spans, as
illustrated in FIG. 12, a reinforcement bar 220 may be positioned
within the ribs 20 of the lath 10 to lock the lath 10 within the
frame member 100 and to provide additional structural stiffness to
the structural panel 200. The use of reinforcement bars 220 inside
the receptor pockets 105 furthermore increases the strength and
reduces the side-to-side rotational movement while at the same time
provides a permanent connection of the lath 10 into the receptor
pockets 105 because of the unique one-way fitting design in the
panel 200. This application would be typical in a floor application
where the live and dead building loads are considerably higher than
the loads to which walls, ceilings and roofs are subjected.
[0059] In areas of dramatic changes in temperature, a thermal break
may be introduced between the lath 10 and the frame member 100.
Referring again to FIGS. 11 and 12, while the backdrop mesh is
indicated by reference number 215, an element having a very similar
appearance could be used as the thermal break. For that reason,
reference number 225 listed in parentheses will also be used in
FIGS. 11 and 12 to indicate that when a thermal break 225 is
utilized, it will appear similar to and be secured in a similar way
as the backdrop mesh 215 illustrated therein. The thermal break 225
positioned between the lath 10 and the frame member 100 provides a
thermal barrier that will disrupt any conductive heat flow from the
lath 10 to the frame member 100. The thermal break 225 may be
comprised of a liquid gasket applied over the lath 10 or, in the
alternative, may be comprised of a one-piece gasket secured to the
frame member 100. As shown the thermal break 225 has a shape
similar to that of the frame member 100 and receptor pockets 105.
However, the thermal break 225 may also be a non-conforming sheet
conformed to the receptor pockets 105 by the force of the ribs 20.
Although the thermal break 225 will be compressed between the lath
10 and the frame member 100, the thermal break 225 may also be
secured to the frame member 100 using adhesive.
[0060] Returning to FIGS. 3 and 4, a method of making the
structural panel 200 herein described, comprises the step of
aligning the ribs 20 of the lath 10 with the matching receptor
pockets 105 at each frame member 100 and then urging each rib 20
within the matching receptor pocket 105 of the frame member 100
until the rib 20 snaps into position. Using a plastic mallet or a
rolling machine, the lath 10 is pushed into the frame member 100.
Directing attention to FIGS. 5 and 6, the method may also comprise
the step of coating the lath 10 with a base structural coating 150.
Furthermore, after the ribs 20 of the lath 10 are positioned within
the receptor pockets 105 of the frame member 100, reinforcement
bars 220 (FIG. 12) may be inserted within the ribs 20 to lock the
ribs 20 within each receptor pocket 105.
[0061] Each lath 10 has a plurality of fastening grooves 27 (FIG.
1) with holes 29 therein, to hold screws used to mount the lath 10
to a structure during shipping only. Optionally, additional screws
can be applied at the four corners of the structural panel 200 to
improve the strength of the panel 200 when shipping and handling.
It should be noted, however, that such screws are not required for
attaching the lath 10 to the frame member 100.
[0062] The subject invention provides a structural panel 200 having
laths 10 which are connected to frame members 100 without the use
of any discrete fasteners. Pressing the lath 10 into the frame
member 100 is a more cost-effective method than attaching a lath 10
to the steel frame 100 since there are no discrete fasteners to
install. Furthermore, installation is safer and labor costs are
reduced.
[0063] The lath 10, in accordance with the subject invention,
provides a continuous surface for structural coatings to be
applied. When these ribs 20 of the lath 10 are integrated within
the receptor pockets 105 of the frame member 100, the increase in
structural integrity keeps the components from side-to-side and
rotational movement.
[0064] The frame member 100, as illustrated in FIG. 9, may be a
C-shaped member comprised of a base 110 having a flange 112 on one
side of the base 110 and an opposing flange 114 on the opposite
side of the base 110. As illustrated in FIG. 9, the frame member
100 includes receptor pockets 105 in only flange 114. Under these
circumstances, the lath 10 may be applied only to a single side of
the frame member 100. In the alternative and as illustrated in FIG.
3, it is possible for the frame member 100 to have receptor pockets
105 on both sides of the frame member 100 thereby, as further
illustrated in FIG. 4, permitting lath 10 to be applied to both
sides of the frame member 100.
[0065] The structural panel 200, in accordance with the subject
invention may have frame members spaced over 24" at canter, thereby
reducing the number of components for a panel which typically has
frame members on 16" centers.
[0066] The figures have illustrated a rib 20 extending completely
across the lath 20 and receptor pockets 105 extending completely
across the frame member 100. It is possible for the rib 20 to
extend across the lath 10 in an interrupted pattern to mate with a
receptor pocket 105 that extends across the front 102 of the frame
member 100 or to mate with receptor pockets 105 that are positioned
on the front 102 of the frame member 100 to correspond with the
locations of the interrupted pattern ribs.
[0067] Furthermore, the ribs 20 so far discussed have been in the
general shape of a tear drop. A number of other rib shapes may be
used in as much as these ribs may be snapped into the frame member
100. FIGS. 13A-13G illustrate a few such rib 320 shapes. In each of
these shapes, the first side 322 diverges from the second side 324
and then converges. As a result, these ribs 320 may snap into an
appropriately sized receptor pocket located in the frame member. As
illustrated in FIGS. 13F and 13G, each rib 320 may resemble a
barb.
[0068] While specific embodiments of the invention have been
described in detail, it will be appreciated by those skilled in the
art that various modifications and alternatives to those details
could be developed in light of the overall teachings of the
disclosure. The presently preferred embodiments described herein
are meant to be illustrative only and not limiting as to the scope
of the invention which is to be given the full breadth of the
appended claims and any and all equivalents thereof.
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