U.S. patent application number 11/470427 was filed with the patent office on 2007-03-08 for composite building material for cementitious material wall assembly.
This patent application is currently assigned to BENJAMIN OBDYKE INCORPORATED. Invention is credited to Melissa Grimes.
Application Number | 20070051069 11/470427 |
Document ID | / |
Family ID | 37872008 |
Filed Date | 2007-03-08 |
United States Patent
Application |
20070051069 |
Kind Code |
A1 |
Grimes; Melissa |
March 8, 2007 |
Composite Building Material for Cementitious Material Wall
Assembly
Abstract
A composite building material includes at least one membrane, a
spacer material bonded to one face of the membrane, and a lath
bonded to an opposite face of the membrane. The components of the
composite building material are installed simultaneously as an
integral unit within a wall, roof or like assembly. The lath is
preferably made of plastic or metal and is used to support
cementitious material such as stucco, mortar, plaster, concrete and
the like. The spacer material provides ventilation and drainage
passages and is preferably provided as separate or
integrally-formed spacer elements, an openwork mat, a corrugated
material, or the like. Preferably, the membrane is building paper,
tar paper, roofing felt, house-wrap material or like
weather-resistive material. A wall/roof assembly and a method of
assembling a wall/roof structure are also disclosed.
Inventors: |
Grimes; Melissa; (Telford,
PA) |
Correspondence
Address: |
HOWSON AND HOWSON
SUITE 210
501 OFFICE CENTER DRIVE
FT WASHINGTON
PA
19034
US
|
Assignee: |
BENJAMIN OBDYKE
INCORPORATED
199 Precision Drive
Horsham
PA
|
Family ID: |
37872008 |
Appl. No.: |
11/470427 |
Filed: |
September 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60714882 |
Sep 7, 2005 |
|
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|
Current U.S.
Class: |
52/782.1 ;
52/506.01 |
Current CPC
Class: |
E04B 1/7069 20130101;
E04B 2/707 20130101; E04F 13/04 20130101 |
Class at
Publication: |
052/782.1 ;
052/506.01 |
International
Class: |
E04C 2/00 20060101
E04C002/00; E04C 2/54 20060101 E04C002/54 |
Claims
1. A composite building material, comprising: at least one membrane
having opposite faces; a spacer material bonded to one of said
faces of said at least one membrane and providing ventilation and
drainage passages along said face; and a lath bonded to the
opposite face of said at least one membrane and adapted to provide
a base for cementitious material.
2. A composite building material according to claim 1, wherein said
at least one membrane is a single layer membrane.
3. A composite building material according to claim 1, wherein said
at least one membrane is a multi-layer membrane.
4. A composite building material according to claim 1, wherein said
composite building material is adapted to be stored and shipped in
a spiral roll.
5. A composite building material according to claim 1, wherein said
composite building material is adapted to be stored and shipped in
sheets.
6. A composite building material according to claim 1, wherein said
lath is made of plastic or metal.
7. A composite building material according to claim 6, wherein said
lath is bonded to said at least one membrane.
8. A composite building material according to claim 6, wherein said
at least one membrane is selected from a group consisting of a
weather-resistive membrane, a building paper, a tar paper, a
roofing felt, and a house-wrap material.
9. A composite building material according to claim 8, wherein said
spacer material is selected from a group consisting of a plurality
of separate spacer elements, an openwork material, an openwork mat
of randomly convoluted polymeric filaments, a corrugated material,
a thermoformed web of thermoplastic material, and a vacuum-stamped
web of thermoplastic material.
10. A composite building material according to claim 8, wherein
said spacer material is bonded to said at least one membrane.
11. A wall or roof assembly of a building, comprising: an inner
structural component, said inner structural component being a
sheathing member or open studs; an exterior finish including a
cementitious material; and a composite building material installed
between said inner structural component and said exterior finish,
said composite building material comprising at least one membrane,
a spacer material bonded to one face of said at least one membrane,
and a lath bonded to an opposite face of said at least one
membrane.
12. An assembly according to claim 11, wherein said composite
building material is positioned within said assembly such that said
lath confronts said exterior finish and said spacer material faces
said inner structural component.
13. An assembly according to claim 12, wherein said lath and spacer
material are bonded to said at least one membrane before being
installed within said assembly.
14. An assembly according to claim 13, wherein said at least one
membrane is a single layer membrane.
15. An assembly according to claim 13, wherein said at least one
membrane is a multi-layer membrane.
16. An assembly according to claim 13, further comprising a
fastener that connects the composite building material, including
said at least one membrane, spacer material and lath, to the inner
structural component.
17. An assembly according to claim 16, wherein said fastener is a
nail, a nail with a washer, or a staple.
18. An assembly according to claim 16, wherein said lath is made of
plastic or metal.
19. An assembly according to claim 18, wherein said cementitious
material is selected from a group consisting of stucco, mortar,
concrete and plaster.
20. An assembly according to claim 18, wherein said exterior finish
is selected from a group consisting of stucco, masonry, natural
stone, and synthetic stone.
21. An assembly according to claim 18, wherein said at least one
membrane is selected from a group consisting of a weather-resistive
membrane, a building paper, a tar paper, a roofing felt, and a
house-wrap material.
22. An assembly according to claim 21, wherein said spacer material
is selected from a group consisting of a plurality of separate
spacer elements, an openwork material, an openwork mat of randomly
convoluted polymeric filaments, a corrugated material, a
thermoformed web of thermoplastic material, and a vacuum-stamped
web of thermoplastic material.
23. An assembly according to claim 22, further comprising an
optional second weather-resistive membrane positioned between said
inner sheathing member and said composite building material.
24. An assembly according to claim 23, wherein said optional second
weather-resistive membrane is a building paper, tar paper, roofing
felt or house-wrap material.
25. A method of assembling a wall or roof of a building comprising
the steps of: fastening a composite building material to an inner
structural component of a building structure, said inner structural
component being a sheathing member or open studs, said composite
building material comprising at least one membrane, a spacer
material bonded to one face of said at least one membrane, and a
lath bonded to an opposite face of said at least one membrane; and
applying cementitious material on the lath of the composite
building material to form an exterior finish.
26. A method according to claim 25, further comprising the step of
providing the composite building material in a spiral roll and
unrolling the composite building material before or during said
fastening step.
27. A method according to claim 25, further comprising the step of
providing the composite building material in sheets.
28. A method according to claim 25, wherein said lath and spacer
material are bonded to said at least one membrane before said
composite building material is fastened to said inner structural
component.
29. A method according to claim 28, wherein said fastening step
includes applying a fastener through all layers of the composite
building material to simultaneously secure all layers of the
composite building material to the inner structural component in a
one step process.
30. A method according to claim 29, wherein said spacer material
faces the inner structural component and provides ventilation and
drainage passages that extend between the at least one membrane and
the inner structural component.
31. A method according to claim 30, further comprising the optional
step of securing a weather-resistive membrane to the inner
sheathing member before fastening the composite building material
to the inner structural component.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 USC
.sctn.119(e) of U.S. Provisional Patent Application No. 60/714,882,
filed Sep. 7, 2005.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a wall assembly having an
outer finish layer including stucco, mortar, stone, masonry,
concrete, plaster or like cementitious material, and more
specifically to a composite building material that is used within
such a wall assembly and that prevents the accumulation of moisture
therein.
[0003] Moisture permitted to accumulate within a wall, roof or like
structure of a building typically will cause premature
deterioration of the structure. Moisture accumulation can be
avoided by providing ventilation/drainage passages within the
wall/roof assembly. For example, see U.S. Pat. No. 5,099,627 issued
to Coulton et al. and U.S. Pat. Nos. 6,594,965 B2 and 6,786,013 B2
issued to Coulton and U.S. Patent Application Publication No.
2004/0045242 A1 of Lake, which are all assigned to Benjamin Obdyke,
Inc., the assignee of the present application.
[0004] Laths are known for use in mounting plaster and like
substances to substrates. For example, see U.S. Pat. Nos. 5,287,673
and 5,481,843 issued to Kreikemeier and by U.S. Patent Application
Publication No. 2002/0108333 A1 of Clayton.
[0005] Various composite materials have been utilized in wall
assemblies. For example, see U.S. Pat. Nos. 6,131,353, 6,745,531 B1
and 6,804,922 B1 issued to Egan, U.S. Pat. Nos. 6,395,401 B1 and
6,759,135 B2 issued to Bramlett et al., U.S. Pat. No. 5,826,390
issued to Sacks, U.S. Pat. No. 6,233,890 B1 issued to Tonyan, U.S.
Pat. Nos. 6,869,901 B2, 6,761,006 B2 and 6,550,212 B2 issued to
Lubker, II, U.S. Pat. No. 5,518,799 issued to Finestone et al.,
U.S. Pat. No. 6,794,316 B1 issued to Buscher et al., and U.S. Pat.
No. 4,315,392 issued to Sylvest and JP 1-83805 of Sato.
[0006] Although the drainage and/or ventilation products, building
papers, house-wraps, laths and composite materials disclosed in the
above referenced patents may function satisfactorily for their
intended purpose, there remains a need for a composite building
material for use in the assembly of a wall, roof or like structure
having an exterior finish layer including a cementitious material,
such as stucco. The composite building material should prevent
moisture infiltration and provide drainage paths and ventilation
air spaces between an inner sheathing member and the exterior
cementitious material. The composite building material should
simplify assembly of a wall, roof or like structure and be capable
of efficient and inexpensive manufacture.
BRIEF SUMMARY OF THE INVENTION
[0007] More specifically, the present invention is a composite
building material including at least one membrane, a spacer
material bonded to one face of the at least one membrane, and a
lath bonded to an opposite face of the at least one membrane such
that all the components of the composite building material can be
installed simultaneously as an integral unit within a wall or roof
assembly. The lath is preferably made of plastic or metal and can
be used to support cementitious material such as stucco, mortar,
plaster and the like. The spacer material provides ventilation and
drainage passages and is preferably provided as separate or
integrally-formed spacer elements, an openwork mat, a corrugated
material, or the like. Preferably, the at least one membrane is
building paper, tar paper, roofing felt, house-wrap material or the
like.
[0008] According to another aspect of the present invention, a wall
or roof assembly of a building is provided. The assembly includes
an inner structural component, an exterior finish at least
partially formed of cementitious material, and a composite building
material installed between the inner structural component and
exterior finish. The inner structural component can be a sheathing
member or open studs. The composite building material comprises at
least one membrane, a spacer material bonded to one face of the at
least one membrane, and a lath bonded to an opposite face of the at
least one membrane. The spacer material is oriented toward the
inner structural component, and the lath supports the cementitious
material of the exterior finish.
[0009] According to yet another aspect of the present invention, a
method of assembling a wall or roof of a building is provided. A
composite building material is fastened to an inner structural
component, such as a sheathing member or open studs, of a building
structure. The composite building material includes at least one
membrane, a spacer material bonded to one face of the at least one
membrane, and a lath bonded to an opposite face of the at least one
membrane. The spacer material is oriented toward the inner
structural component, and the exposed lath is applied with an
exterior finish that includes cementitious material. The composite
building material can be provided in a spiral roll or sheets.
BREF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing and other objects, features and advantages of
the present invention should become apparent from the following
description when taken in conjunction with the accompanying
drawings, in which:
[0011] FIG. 1 is a perspective view of a wall assembly according to
the present invention;
[0012] FIG. 1A is a partial view of the wall assembly of FIG. 1
utilizing an alternate spacer material according to the present
invention;
[0013] FIG. 2 is a cross-sectional view of the wall assembly of
FIG. 1 along line 2-2;
[0014] FIG. 3 is a perspective view of a spiral roll of the
composite building material of the present invention; and
[0015] FIG. 4 is a perspective view of a sheet of an alternate
composite building material according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Referring now to the drawings, FIGS. 1 and 1A illustrate a
wall assembly 10 of a building structure. Of course, the assembly
can also be utilized to form roofs or other structures of a
building. The assembly 10 includes an inner structural component,
12 or 14. In the illustrated embodiment, the inner structural
component is provided as an inner sheathing member 12 that is
affixed to support posts, or studs, 14. The inner sheathing member
12 can be panels of plywood, oriented strand board, particle board,
insulated concrete, or like materials permitted by local building
codes. Alternatively, the inner structural component can be
provided by the support posts, or studs, 14, such as when open stud
construction is utilized. In open stud construction, the sheathing
members 12 would be eliminated.
[0017] A composite building material 16 is fastened as an integral
unit to an external side of the inner sheathing member 12.
Alternatively, the composite building material is fastened directly
to the studs 14 when open stud construction is utilized. The
composite building material 16 provides a support for cementitious
material 18 applied thereto. The cementitious material 18 can be
stucco, mortar, plaster, concrete or the like. The cementitious
material 18 itself can form an exterior finish 20 of the assembly
10, or it can be utilized to secure other building elements, such
as masonry materials, natural or synthetic stones, or the like to
the assembly 10.
[0018] The composite material 16 includes three separately-formed
components including a membrane 22, a spacer material 24, and a
lath 26. The membrane 22 is preferably a building paper; however,
it can also be tar paper, roofing felt, polymeric house-wrap
material, or any other type of weather-resistive sheet material.
The membrane 22 can be a single layer or multilayer membrane and
more than one membranes 22 can be utilized. For instance, several
like or different membranes can be secured together to form a
multilayer membrane.
[0019] The membrane 22 has opposite faces, 28 and 30, and is
sandwiched between the spacer material 24 and lath 26. Preferably,
the spacer material 24 is bonded to one face 28 of the membrane 22,
while the lath 26 is bonded to the other face 30. As an example,
the spacer material 24 and lath 26 can be bonded to the membrane 22
with adhesives or via thermal, ultrasonic, mechanical, chemical or
like bonding techniques. The composite material 16 can be provided
in a spiral roll 32 as illustrated in FIG. 3 or in sheets 34 as
illustrated in FIG. 4.
[0020] The lath 26 is preferably a plastic or metal mesh material
that provides a base for the application of cementitious material.
Thus, after the composite building material 16 is fastened to the
inner structural component, 12 or 14, with the lath 26 facing
outwardly, cementitious material 18 can be applied directly on the
lath 26 to form an exterior finish 20 of the assembly 10.
[0021] The spacer material 24 provides open ventilation and
drainage passages 36 adjacent the inner sheathing member 12 and/or
studs 14. Thus, any condensation, liquid moisture or moisture vapor
that collects between the exterior finish 20 and inner structural
components, 12 or 14, will be directed downwardly and outwardly of
the assembly 10 or will be evaporated and removed via air flow
through the passages 36. To achieve this purpose, the spacer
material 24 can be a corrugated material as illustrated in the
drawings or can be provided as an openwork mat, a plastic sheet
material thermoformed or vacuum-stamped with outwardly projecting
spacer elements from one or both faces thereof, or a plurality of
separate spacer discs or elements secured to the membrane 22. For
example, a corrugated plastic sheet of material 38 with
perforations 40 provides the spacer material 24 in the assembly 10
of FIG. 1. In contrast, the spacer material 24 in FIG. 1A is
provided as a corrugated web 42 of randomly convoluted polymeric
filaments.
[0022] If inner sheathing members 12 are utilized in the assembly
10, the members 12 are secured with nails 44 or like fasteners to
posts 14. As an option, a weather-resistive membrane (not shown)
can be applied directly over the inner sheathing member 12.
Alternatively, the inner sheathing members 12 can remain exposed.
If utilized, the weather-resistive membrane on the sheathing
members 12 can be a building paper, tar paper, roofing felt or a
polymeric house-wrap material that permits moisture vapor to exit
outwardly therethrough.
[0023] The composite building material 16 can then be fastened to
the inner sheathing members 12 with fasteners 46. Alternatively, if
open stud construction is utilized, the composite building material
16 is fastened directly to the studs 14. The fasteners 46 can be
nails with relatively large nailheads, nails utilized with
relatively-large diameter washers, or staples. Thus, all layers 22,
24 and 26 of the composite building material 16 are connected
simultaneously with the fastener 46 to the inner sheathing member
12, or studs 14. If the composite building material 16 is provided
in a spiral roll, it is unrolled before or as the fasteners 46 are
applied. The composite building material 16 can also be provided
and applied in sheet form.
[0024] After the composite building material 16 is fastened to and
covers the inner sheathing member 12 or open studs, cementitious
material 18, such as stucco, is applied with a trowel or like tool
to the outwardly facing lath 26 of the composite building material
16. The membrane 22 prevents ingress of the cemeintitious material
18 into the passages 36 provided by the spacer material 24.
[0025] While preferred composite building materials, wall
assemblies, and methods of assembling wall structures have been
described in detail, various modifications, alterations, and
changes may be made without departing from the spirit and scope of
the present invention as defined in the appended claims.
* * * * *