U.S. patent application number 13/154093 was filed with the patent office on 2012-12-06 for apparatuses and methods for an improved lath, vapor control layer and rain screen assembly.
This patent application is currently assigned to Boral Stone Products LLC. Invention is credited to Wayne Buoni, Frank Russell Fork, David Chris Hines.
Application Number | 20120304565 13/154093 |
Document ID | / |
Family ID | 45953245 |
Filed Date | 2012-12-06 |
United States Patent
Application |
20120304565 |
Kind Code |
A1 |
Hines; David Chris ; et
al. |
December 6, 2012 |
Apparatuses and Methods for an Improved Lath, Vapor Control Layer
and Rain Screen Assembly
Abstract
An improved lath and rain screen assembly for fastening to an
exterior building surface or the like is provided. The lath and
rain screen assembly comprises a rain screen configured to
encourage ventilation and drying, and a lath configured to receive
at least a portion of a first mortar layer. In various embodiments,
the rain screen comprises a first and a second body, defining
respective co-parallel first and second planes, while the lath
comprises a third body spaced apart from and substantially parallel
to at least the first plane. In certain embodiments, the first body
and the lath are spaced apart so as to provide a first intermediate
pathway. In certain embodiments, the first intermediate pathway is
at least partially defined by the second body of the rain screen. A
method of applying the improved lath and rain screen assembly is
also provided.
Inventors: |
Hines; David Chris;
(Swanton, OH) ; Buoni; Wayne; (New Albany, OH)
; Fork; Frank Russell; (Pataskala, OH) |
Assignee: |
Boral Stone Products LLC
|
Family ID: |
45953245 |
Appl. No.: |
13/154093 |
Filed: |
June 6, 2011 |
Current U.S.
Class: |
52/302.1 ;
52/741.4; 52/747.1 |
Current CPC
Class: |
E04F 13/007 20130101;
E04F 13/14 20130101; E04F 13/04 20130101; E04B 1/7069 20130101;
E04B 2/707 20130101; E04F 13/047 20130101 |
Class at
Publication: |
52/302.1 ;
52/741.4; 52/747.1 |
International
Class: |
E04B 2/00 20060101
E04B002/00; E04B 1/66 20060101 E04B001/66; E04B 1/70 20060101
E04B001/70 |
Claims
1. A lath and rain screen assembly configured for fastening to an
exterior building surface, the lath and rain screen assembly
comprising: A) a rain screen configured to encourage ventilation
and drying, said rain screen including 1) a first substantially
planar body, said first body having a nominal thickness and
opposing primary planar first and second sides, said first body
further defining a first plane; and 2) a second substantially
planar body, said second body having a nominal thickness and
opposing primary planar first and second sides, said first side
being operably connected to said second side of said first body,
said second body further defining a second plane, said second plane
being substantially parallel to said first plane of said first
body; and B) a lath configured to receive at least a portion of a
first mortar layer, said lath including a third substantially
planar body having a nominal thickness, said third body being
operably connected to said second side of said second body, said
third body further defining a third plane spaced apart from and
substantially parallel to said first plane, such that at least said
first body of said rain screen and said third body of said lath are
spaced apart so as to provide a first intermediate pathway
therebetween configured for permitting the passage of liquid water
and water vapor.
2. The lath and rain screen assembly of claim 1, wherein: said
second body is formed from a permeable material; and said permeable
material of said second body substantially defines said first
intermediate pathway.
3. The lath and rain screen assembly of claim 2, wherein said
permeable material of said second body has a permeability value in
a range of about 15 perms to about 35 perms.
4. The lath and rain screen assembly of claim 1, wherein said
connections between said second body of said rain screen and said
third body of said lath are provided by heat bonding.
5. The lath and rain screen assembly of claim 1, wherein said first
intermediate pathway has a width of from about 0.0625 inches to
about 0.50 inches, said width being defined at least in part by
said nominal thickness of said second body.
6. The lath and rain screen assembly of claim 1, wherein said
nominal thickness of said second body is in a range of about 0.0625
inches to about 0.50 inches.
7. The lath and rain screen assembly of claim 1, wherein said first
body of said rain screen is formed from a polymer-based
material.
8. The lath and rain screen assembly of claim 7, wherein said
polymer-based material is selected from a group consisting of:
polyvinyl chloride, polystyrene, polyethylene, polypropylene, or
any combination thereof.
9. The lath and rain screen assembly of claim 1, wherein said
nominal thickness of said first body is in a range of about 0.005
inches to about 0.50 inches.
10. The lath and rain screen assembly of claim 1, wherein said rain
screen further comprises a fourth substantially planar body, said
fourth body having a nominal thickness and opposing primary planar
first and second sides, said second side being operably connected
to said first side of said first body, said first side defining a
fourth plane, said fourth plane being spaced apart from and
substantially parallel to said first plane of said first body.
11. The lath and rain screen assembly of claim 10, wherein: said
fourth body is formed from a permeable material; and said permeable
material of said fourth body substantially defines a second
intermediate pathway, said second pathway being located
substantially between said fourth plane of said fourth body and
said first plane of said first body, and said second pathway being
configured for permitting the passage of liquid water and water
vapor.
12. The lath and rain screen assembly of claim 11, wherein said
permeable material of said fourth body has a permeability value in
a range of about 15 perms to about 35 perms.
13. The lath and rain screen assembly of claim 10, wherein: said
second body is formed from a permeable material; and said permeable
material of said second body substantially defines said first
intermediate pathway.
14. The lath and rain screen assembly of claim 13, wherein said
permeable material of said second body has a permeability value in
a range of about 15 perms to about 35 perms.
15. The lath and rain screen assembly of claim 13, wherein said
permeable material of said second body and said permeable material
of said fourth body are substantially the same.
16. The lath and rain screen assembly of claim 11, wherein said
second intermediate pathway has a width of from about 0.0625 inches
to about 0.50 inches, said width being defined at least in part by
said nominal thickness of said fourth body.
17. The lath and rain screen assembly of claim 10, wherein said
nominal thickness of said fourth body is in a range of about 0.0625
inches to about 0.50 inches.
18. The lath and rain screen assembly of claim 1, wherein said
first body is formed from a substantially impermeable material,
said impermeable material having a permeability value in a range of
about 0.06 perms to about 5 perms.
19. The lath and rain screen assembly of claim 1, wherein said
connections between said rain screen and said lath are provided by
heat bonding.
20. The lath and rain screen assembly of claim 1, wherein said lath
includes a plurality of spaced apart apertures configured to permit
passage of the first layer of mortar substantially through the
lath.
21. The lath and rain screen assembly of claim 1, wherein the lath
is formed from a fiberglass-based material.
22. The lath and rain screen assembly of claim 21, wherein said
lath is formed by weaving the fiberglass-based material into a mesh
configuration.
23. The lath and rain screen assembly of claim 1, wherein said lath
and rain screen assembly is capable of being stored in a rolled-up
fashion.
24. The lath and rain screen assembly of claim 1, wherein said lath
has a width of from about 1/64 inches to about 0.25 inches, said
width being defined at least in part by said nominal thickness of
said third body.
25. A method of providing a lath and rain screen assembly
configured to be attached to an exterior building surface, said
method comprising the steps of: A) providing a rain screen
configured to encourage ventilation and drying, said rain screen
including: 1) a first substantially planar body, said first body
having a nominal thickness and opposing primary planar first and
second sides, said first body further defining a first plane; and
2) a second substantially planar body, said second body having a
nominal thickness and opposing primary planar first and second
sides, said first side being operably connected to said second side
of said first body, said second body further defining a second
plane, said second plane being substantially parallel to said first
plane of said first body; B) providing a lath configured to receive
at least a portion of a first mortar layer, said lath including a
third substantially planar body having a nominal thickness, said
third body being operably connected to said second side of said
second body, said third body further defining a third plane spaced
apart from and substantially parallel to said first plane; and C)
providing said lath and rain screen assembly by connecting said
rain screen and said lath, such that at least said first body of
said rain screen and said third body of said lath are spaced apart
so as to provide a first intermediate pathway therebetween
configured for permitting the passage of liquid water and water
vapor.
26. The method as claimed in claim 25, wherein in Step "C" said
connection between said rain screen and said lath is provided by
heat bonding.
27. The method as claimed in claim 25, wherein in Step "C" said
connection between said rain screen and said lath is provided by
adhesive.
28. The method as claimed in claim 25, wherein in Step "B" said
lath is provided with apertures configured to permit passage of
mortar therethrough.
29. The method as claimed in claim 25, wherein in Step "A" said
first body of said rain screen is provided with a permeability
value in a range of about 0.06 perms to about 5 perms.
30. The method as claimed in claim 25, wherein in Step "A" said
second body of said rain screen is provided with a permeability
value in a range of about 15 perms to about 35 perms.
31. A method of applying a lath and rain screen assembly to an
exterior building surface to facilitate the attachment of exterior
cladding materials, said method comprising the steps of: A)
providing a rain screen configured to encourage ventilation and
drying, said rain screen including: 1) a first substantially planar
body, said first body having a nominal thickness and opposing
primary planar first and second sides, said first body further
defining a first plane; and 2) a second substantially planar body,
said second body having a nominal thickness and opposing primary
planar first and second sides, said first side being operably
connected to said second side of said first body, said second body
further defining a second plane, said second plane being
substantially parallel to said first plane of said first body; B)
providing a lath configured to receive at least a portion of a
first mortar layer, said lath including a third substantially
planar body having a nominal thickness, said third body being
operably connected to said second side of said second body, said
third body further defining a third plane spaced apart from and
substantially parallel to said first plane; C) providing said lath
and rain screen assembly by connecting said rain screen and said
lath, such that said first body of said rain screen and said third
body of said lath are spaced apart so as to provide a first
intermediate pathway therebetween configured for permitting the
passage of liquid water and water vapor; D) positioning said lath
and rain screen assembly adjacent said exterior building surface;
E) applying a first layer of mortar onto said lath; and F)
attaching a plurality of exterior cladding materials to said lath
at least partially with the use of said mortar.
32. The method as claimed in claim 31, wherein in Step "E" said
first intermediate pathway receives at least a portion of a first
layer of mortar.
33. The method as claimed in claim 31, wherein in step "B" said
lath is provided with a plurality of spaced apart apertures
configured to permit passage of a portion of said first layer of
mortar substantially through the lath in Step "E", and wherein in
Step "F", said first layer of mortar, upon passing substantially
through the lath, further substantially encapsulates the lath.
34. The method as claimed in claim 31, wherein step "E" furthers
comprises the step of applying a second layer of mortar onto said
first layer of mortar once said first layer has been allowed to
cure.
35. The method as claimed in claim 31, wherein: A) said step "A" of
providing a rain screen comprises a rain screen further including a
fourth substantially planar body, wherein: 1) said fourth body has
opposing primary planar first and second sides, said second side
being operably connected to said first side of said first body,
said first side defining a fourth plane, said fourth plane being
spaced apart from and substantially parallel to said first plane of
said first body; and 2) said fourth body substantially defines a
second intermediate pathway, said second pathway being located
substantially between said fourth plane of said fourth body and
said first plane of said first body, and said second pathway being
configured for permitting the passage of liquid water and water
vapor; and B) said step "D" of positioning said lath and rain
screen assembly adjacent said exterior building surface comprises
positioning said first side of said fourth body of said rain screen
in contact with the exterior building surface.
36. The method as claimed in claim 35, wherein following Step "D"
said second intermediate pathway has a width of from about 0.0625
inches to about 0.50 inches.
Description
BACKGROUND OF THE INVENTION
[0001] In the construction of buildings, frequently used
construction products include exterior cladding materials. Exterior
cladding materials can be used to cover the exterior surfaces
formed from various framing structures. Non-limiting examples of
exterior cladding materials include masonry products, such as for
example, stone and brick and stucco.
[0002] In certain instances, the exterior building cladding is
applied to sub-structures that are attached to the exterior
surfaces of the framing structures. One example of a sub-structure
is rain screens. Generally speaking, rain screens are configured to
create a cavity between the exterior cladding materials and the
exterior surface of the framing structure. The cavity allows
weather-related moisture to easily pass through and away from the
building. Another example of a sub-structure is laths. Laths are
materials configured to support mortar or plasterwork.
[0003] Historically, rain screens and laths were provided as
separate stand-alone products that could be sequentially attached
to the exterior surfaces of framing structures. As a result,
significant amounts of time were necessary for installation,
contributing, at least in part, to increasingly rising occurrences
of delay and cost overruns in a variety of projects contexts.
[0004] Further, traditional methods of installation of stand-alone
rain screens and laths often inadvertently created moisture
barriers between the rain screens and any moisture resistant layers
incorporated between the rain screens and the exterior surfaces of
the framing structures. Such led to potential issues regarding
ventilation and drying due to impediments to the removal of both
liquid water and water vapor.
[0005] Accordingly, it would be advantageous if various
sub-structures could be improved to alleviate these and other
problems and inefficiencies.
SUMMARY OF THE INVENTION
[0006] In accordance with the purposes of the present invention as
described herein, an improved lath and rain screen assembly is
provided for fastening to an exterior building surface. The lath
and rain screen assembly comprises a rain screen configured to
encourage ventilation and drying, and a lath configured to receive
at least a portion of a first mortar layer. The rain screen
comprises 1) a first substantially planar body, the first body
having a nominal thickness and opposing primary planar first and
second sides, the first body further defining a first plane; and 2)
a second substantially planar body, the second body having a
nominal thickness and opposing primary planar first and second
sides, the first side being operably connected to the second side
of the first body, the second body further defining a second plane,
the second plane being substantially parallel to the first plane of
the first body. The lath comprises a third substantially planar
body having a nominal thickness, the third body being operably
connected to the second side of the second body, the third body
further defining a third plane spaced apart from and substantially
parallel to the first plane. In this manner, according to certain
embodiments, at least the first body of the rain screen and the
third body of the lath are spaced apart so as to provide a first
intermediate pathway therebetween configured for permitting the
passage of liquid water and water vapor.
[0007] In accordance with an additional aspect of the present
invention as described herein, a lath and rain screen assembly is
provided for fastening to an exterior building surface. The lath
and rain screen assembly comprises a rain screen configured to
encourage ventilation and drying, and a lath configured to receive
at least a portion of a first mortar layer. The rain screen
comprises 1) a first substantially planar body, the first body
having a nominal thickness and opposing primary planar first and
second sides, the first body further defining a first plane; 2) a
second substantially planar body, the second body having a nominal
thickness and opposing primary planar first and second sides, the
first side being operably connected to the second side of the first
body, the second body further defining a second plane, the second
plane being substantially parallel to the first plane of the first
body; and 3) a fourth substantially planar body, the fourth body
having a nominal thickness and opposing primary planar first and
second sides, the second side being operably connected to the first
side of the first body, the first side defining a fourth plane, the
fourth plane being spaced apart from and substantially parallel to
the first plane of the first body. The lath comprises a third
substantially planar body having a nominal thickness, the third
body being operably connected to the second side of the second
body, the third body further defining a third plane spaced apart
from and substantially parallel to the first plane. In this manner,
according to certain embodiments, at least the first body of the
rain screen and the third body of the lath are spaced apart so as
to provide a first intermediate pathway therebetween configured for
permitting the passage of liquid water and water vapor. In various
embodiments, the fourth body substantially defines a second
intermediate pathway, the second pathway being located
substantially between the fourth plane of the fourth body and the
first plane of the first body, and the second pathway being
configured for permitting the passage of liquid water and water
vapor.
[0008] In accordance with an additional aspect of the present
invention, a method of applying an improved lath and rain screen
assembly to an exterior building surface is provided. The method
comprises the steps of: A) providing a rain screen configured to
encourage ventilation and drying, the rain screen including: 1) a
first substantially planar body, the first body having a nominal
thickness and opposing primary planar first and second sides, the
first body further defining a first plane; and 2) a second
substantially planar body, the second body having a nominal
thickness and opposing primary planar first and second sides, the
first side being operably connected to the second side of the first
body, the second body further defining a second plane, the second
plane being substantially parallel to the first plane of the first
body; B) providing a lath configured to receive at least a portion
of a first mortar layer, the lath including a third substantially
planar body having a nominal thickness, the third body being
operably connected to the second side of the second body, the third
body further defining a third plane spaced apart from and
substantially parallel to the first plane; and C) providing the
lath and rain screen assembly by connecting the rain screen and the
lath, such that at least the first body of the rain screen and the
third body of the lath are spaced apart so as to provide a first
intermediate pathway therebetween configured for permitting the
passage of liquid water and water vapor.
[0009] In accordance with an additional aspect of the present
invention, a method of applying an improved lath and rain screen
assembly to an exterior building surface is provided. The method
comprises the steps of: A) providing a rain screen configured to
encourage ventilation and drying, the rain screen including: 1) a
first substantially planar body, the first body having a nominal
thickness and opposing primary planar first and second sides, the
first body further defining a first plane; and 2) a second
substantially planar body, the second body having a nominal
thickness and opposing primary planar first and second sides, the
first side being operably connected to the second side of the first
body, the second body further defining a second plane, the second
plane being substantially parallel to the first plane of the first
body; B) providing a lath configured to receive at least a portion
of a first mortar layer, the lath including a third substantially
planar body having a nominal thickness, the third body being
operably connected to the second side of the second body, the third
body further defining a third plane spaced apart from and
substantially parallel to the first plane; C) providing the lath
and rain screen assembly by connecting the rain screen and the
lath, such that the first body of the rain screen and the third
body of the lath are spaced apart so as to provide a first
intermediate pathway therebetween configured for permitting the
passage of liquid water and water vapor; D) positioning the lath
and rain screen assembly adjacent the exterior building surface; E)
applying a first layer of mortar onto the lath; and F) attaching a
plurality of exterior cladding materials to the lath at least
partially with the use of the mortar.
[0010] Various advantages of this invention will become apparent to
those skilled in the art from the following detailed description of
the invention, when read in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings incorporated herein and forming a
part of the specification, illustrate several aspects of the
present invention and together with the description serve to
explain certain principles of the invention. In the drawings:
[0012] FIG. 1 is an exploded perspective view of an improved lath
and rain screen assembly according to various embodiments;
[0013] FIG. 2 is a side view, in elevation, of the lath and rain
screen assembly of FIG. 1;
[0014] FIG. 3 is a cross sectional side view, in elevation,
illustrating the lath and rain screen assembly of FIG. 1 installed
on exterior building framework and configured to support exterior
cladding material in the form of masonry products;
[0015] FIG. 4 is a side view, in elevation, illustrating the lath
and rain screen assembly of FIG. 1 installed on exterior building
framework and configured to support exterior cladding material in
the form of stucco;
[0016] FIG. 5 is a front view of two drainage and ventilation
layers of the rain screen of the lath and rain screen assembly of
FIG. 1;
[0017] FIG. 6 is a front view of an improved lath of the lath and
rain screen assembly according to additional various embodiments;
and
[0018] FIG. 7 is a front view of the lath and rain screen assembly
according to even further various embodiments.
[0019] Reference will now be made in detail to the present
preferred embodiment of the invention, examples of which are
illustrated in the accompanying drawings.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION
[0020] Various embodiments of the present invention will now be
described more fully hereinafter with occasional reference to the
accompanying drawings, in which some, but not all embodiments of
the invention are shown. Indeed, the invention may be embodied in
many different forms and should not be construed as limited to the
embodiments set forth herein. Rather, these embodiments are
provided so that this disclosure will satisfy applicable legal
requirements. Like numbers refer to like elements throughout.
[0021] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0022] Unless otherwise indicated, all numbers expressing
quantities of dimensions such as length, width, height, and so
forth as used in the specification and claims are to be understood
as being modified in all instances by the term "about."
Accordingly, unless otherwise indicated, the numerical properties
set forth in the specification and claims are approximations that
may vary depending on the desired properties sought to be obtained
in embodiments of the present invention. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
the invention are approximations, the numerical values set forth in
the specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0023] The description and figures disclose lath and rain screen
assemblies configured for attachment to an exterior building
framework and further configured as a support surface for external
cladding materials. The term "lath", as used herein, is defined to
mean a pattern of material configured to support mortar or
plasterwork. The term "rain screen", as used herein, is defined to
mean an infrastructure positioned on exterior building framework
and configured to (1) create a cavity that allows weather-related
moisture to easily pass through and away from the building; and (2)
provide the potential for ventilation and drying to assist in the
removal of both liquid water and water vapor. The term "external
cladding material", as used herein, is defined to mean a covering
of one or more materials on the exterior of a building.
[0024] Referring now to FIGS. 1 and 2, a first embodiment of a lath
and rain screen assembly is shown generally at 10. Generally, the
lath and rain screen assembly 10 according to various embodiments
is attached to an exterior framework of a building and configured
as a support for subsequently installed exterior cladding
materials, such as for example, masonry products, stonework or
stucco. As will be described in more detail below, the lath and
rain screen assembly 10, in certain embodiments, further forms one
or more air and moisture pathways between the exterior framework of
the building and the exterior cladding material. The air and
moisture pathways are configured in these embodiments to allow
drainage, ventilation, and removal of any air and/or moisture that
may exist between the exterior framework of the building and the
exterior cladding material. As will be further discussed below, the
lath and rain screen assembly 10 can be provided to installers in
the form of a roll. As a result, in various embodiments,
installation of the lath and rain screen assembly 10 can be as
simple as unrolling against and fastening adjacent rows of the lath
and rain screen assembly 10 to the exterior framework of a
building.
[0025] Referring again to FIGS. 1 and 2, the lath and rain screen
assembly 10 is formed according to various embodiments from the
assembly of a rain screen 12 and a lath 14. The rain screen 12, in
various embodiments, includes at least first sheet 15, a second
sheet 16, and a third sheet 17. The body of the rain screen 12 can
be thought of as being generally planar with a nominal thickness
intermediate opposing primary planar first and second sides, with
the first and second sides lying in corresponding first and second
co-parallel planes.
[0026] The first sheet 15 of the rain screen 12, according to
various embodiments, as shown in FIG. 2, may have a thickness 54.
In the illustrated embodiment, the thickness 54 of the first sheet
15 is in a range of from about 0.125 inches to about 0.375 inches.
In other embodiments, the thickness 54 of the first sheet 15 may be
less than about 0.125 inches or more than about 0.375 inches. In
still other embodiments, the thickness 54 of the first sheet 15 may
be in a range of from about 0.0625 inches to about 0.50 inches.
[0027] Turning to FIGS. 1 and 5, the first sheet 15 of the rain
screen 12 according to various embodiments may be formed from a
polymer-based material, such as for example polyvinyl chloride. In
other embodiments, the first sheet 15 may be formed from other
polymer-based materials, including the non-limiting examples of
polystyrene, polyethylene and polypropylene. In still other
embodiments, the first sheet 15 may be formed from any of a variety
of combinations of polymer-based materials, as commonly known and
understood in the art.
[0028] In various embodiments, as best understood from FIG. 5, the
first sheet 15 may be formed from a plurality of polymer-based
fibers 82. In certain embodiments, the fibers 82 may loosely spun
such that they may be loosely intertwined relative to one another
so as to create a plurality of apertures 84 positioned throughout
the first sheet 15. In this and other envisioned embodiments, the
spun fibers 82 may be loosely intertwined by drizzling the spun
fibers, when in a heated state, over a molded shape (not shown),
and subsequently allowing the spun fibers to cool and thus harden
into the sheet form, as depicted. Alternatively, the spun fibers 82
may, in still other embodiments, be loosely intertwined by any of a
variety of industrial processes, as commonly known and understood
in the art. In any of these and still other envisioned embodiments,
the degree with which the spun fibers 82 are loosely intertwined
may, at least in part, influence the permeability characteristics
of the first sheet 15, as described in further detail below.
[0029] Returning to FIG. 1, the first sheet 15 according to various
embodiments, may exhibit a substantially planar structural shape.
In certain embodiments, as will be described in further detail
below, the substantially planar structure enables attachment (e.g.,
during the manufacturing assembly process) of the first sheet 15
with at least one side of the second sheet 16 of the rain screen
12. In these and other embodiments, the substantially planar
structural shape is achieved during the process of forming the
first sheet 15, such as, for example, by drizzling the spun fibers
82 of the first sheet 15 over a substantially planar mold (as
previously discussed, and not shown). In still other embodiments,
the first sheet 15 may exhibit any of a variety of structural
shapes, such as the non-limiting example of a washboard structure,
provided any such structural shape is sufficient to provide support
for subsequently installed external cladding material, as described
in further detail below.
[0030] In various embodiments, the first sheet 15 may be configured
for moisture transmission (e.g., drainage and ventilation). That
is, the first sheet 15 may be configured to minimally, if at all,
impede the flow of gases (e.g. air and moisture) that may be
trapped between exterior framework of the building and the second
sheet 16 of the rain screen 12, as will be described in further
detail below. In the illustrated embodiment, the first sheet 15 has
a permeability value in a range of from about 15 perms to about 35
perms, as determined by water vapor transmission tests, such as,
for example Standard E-96. Typical water vapor transmission tests
of this nature evaluate the transfer of water vapor through
semi-permeable and permeable materials over a period of time. In
other embodiments, the first sheet 15 may have a permeability
rating of less than about 15 perms or more than about 35 perms. In
still other embodiments, the first sheet 15 may have any of a
variety of commonly considered "very high" permeability ratings,
provided such minimally impede the transportation of any trapped
gases through and/or along the first sheet 15.
[0031] The second sheet 16 of the rain screen 12, according to
various embodiments, as shown in FIG. 2, may have a thickness 75.
In the illustrated embodiment, the thickness 75 of the second sheet
16 is in a range of from about 1/64 inches to about 1/8 inches. In
other embodiments, the thickness 75 of the second sheet 16 may be
less than about 1/64 inches or more than about 1/8 inches. In still
other embodiments, the thickness 75 of the second sheet 16 may be
in a range of from about 0.005 inches to about 0.50 inches.
[0032] Turning to FIGS. 1 and 5, the second sheet 16 of the rain
screen 12 according to various embodiments may be formed from a
polymer-based material, such as for example polyvinyl chloride. In
other embodiments, the second sheet 16 may be formed from other
polymer-based materials, including the non-limiting examples of
polystyrene, polyethylene and polypropylene. In still other
embodiments, the second sheet 16 may be formed from any of a
variety of combinations of materials, as commonly known and
understood in the art to substantially retard the transmission of
moisture, as will be described in further detail below. In any of
these and any other envisioned embodiments, the second sheet 16 may
be formed from substantially the same material as the first sheet
15 and/or the third sheet 17 of the rain screen 12, while in still
other envisioned embodiments the material of any of the three
sheets may be substantially different relative to one another.
[0033] In still other various envisioned embodiments (not shown,
but best understood from at least FIGS. 1 and 2, at least a portion
of the second sheet 16 may further include any of a variety of
materials having a self-sealing property. Such self-sealing
properties enable the second sheet 16 of such embodiments to create
moisture-tight (e.g., water-tight) seals around any nails and/or
nail holes created in the second sheet. In at least one of such
embodiments, the self-sealing material may be the non-limiting
example of rubber, although any of a variety of analogous
materials, as commonly known and understood in the art. Further, in
certain embodiments, the self-sealing material may be embedded
within the second sheet 16 during the manufacturing process, while,
in still other embodiments, the self-sealing material may be coated
upon or even drizzled over one or more surfaces of the second sheet
16, as may be desired for a particular application.
[0034] Returning to FIG. 1, the second sheet 16 according to
various embodiments, may exhibit a substantially planar structural
shape. In certain embodiments, as will be described in further
detail below, the substantially planar structure enables attachment
(e.g., during the manufacturing assembly process) of the second
sheet 16 with at least one side of each of the first 15 and the
third 17 sheets of the rain screen 12. In still other embodiments,
the second sheet 16 may exhibit any of a variety of structural
shapes, such as the non-limiting example of a washboard structure,
provided any such structural shape is sufficient to provide support
for subsequently installed external cladding material, as described
in further detail below. In any of these and any other envisioned
embodiments, the second sheet 16 may be formed to have
substantially the same structural shape as the first sheet 15
and/or the third sheet 17 of the rain screen 12, while in still
other envisioned embodiments the structural shape of any of the
three sheets may be substantially different relative to one
another.
[0035] In various embodiments, the second sheet 16 may be
configured for moisture transmission. That is, unlike at least the
first sheet 15 and the third sheet 17 (as described in further
detail below), the second sheet 16 may be configured to
substantially retard the flow of gases (e.g. air and moisture),
without requiring the use of a separate vapor or air barrier or an
incorporated vapor or air barrier. In at least the illustrated
embodiment, the second sheet 16 has a permeability value in a range
of from about 0.06 perms to about 5 perms, as determined by water
vapor transmission tests, such as, for example Standard E-96.
Typical water vapor transmission tests of this nature evaluate the
transfer of water vapor through semi-permeable and permeable
materials over a period of time. In other embodiments, the second
sheet 16 can have a permeability rating of less than about 0.06
perms or more than about 5 perms.
[0036] The third sheet 17 of the rain screen 12, according to
various embodiments, as shown in FIG. 2, may have a thickness 56.
In the illustrated embodiment, the thickness 56 of the third sheet
17 is in a range of from about 0.125 inches to about 0.375 inches.
In other embodiments, the thickness 56 of the third sheet 17 may be
less than about 0.125 inches or more than about 0.375 inches. In
still other embodiments, the thickness 56 of the third sheet 17 may
be in a range of from about 0.0625 inches to about 0.50 inches. In
certain embodiments, the thickness 56 of the third sheet 17 may be
substantially the same as the thickness 54 of the first sheet 15,
while in still other embodiments the thicknesses may be
substantially different relative to one another. The sheets, 15,
16, and 17, may further, according to various embodiments, have a
combined thickness 55 that is in a range of from about 0.375 inches
to about 0.625 inches. In other embodiments, the thickness 55 may
be approximately 0.50 inches. In still other embodiments, the
thickness 55 may be less than about 0.375 inches or more than about
0.625 inches.
[0037] Returning now to FIGS. 1 and 5, the third sheet 17 of the
rain screen 12 according to various embodiments may be formed from
a polymer-based material, such as for example polyvinyl chloride.
In other embodiments, the third sheet 17 may be formed from other
polymer-based materials, including the non-limiting examples of
polystyrene, polyethylene and polypropylene. In still other
embodiments, the third sheet 17 may be formed from any of a variety
of combinations of polymer-based materials, as commonly known and
understood in the art. In any of these and any other envisioned
embodiments, the third sheet 17 may be formed from substantially
the same material as the first sheet 15 and/or the second sheet 16
of the rain screen 12, while in still other envisioned embodiments
the material of any of the three sheets may be substantially
different relative to one another.
[0038] In various embodiments, as best understood from FIG. 5, the
third sheet 17 may be formed from a plurality of polymer-based
fibers 86. In certain embodiments, the fibers 82 may loosely spun
such that they may be loosely intertwined relative to one another
so as to create a plurality of apertures 88 positioned throughout
the third sheet 17. In this and other envisioned embodiments, the
spun fibers 86 may be loosely intertwined by drizzling the spun
fibers, when in a heated state, over a molded shape (not shown),
and subsequently allowing the spun fibers to cool and thus harden
into the sheet form, as depicted. Alternatively, the spun fibers 86
may, in still other embodiments, be loosely intertwined by any of a
variety of industrial processes, as commonly known and understood
in the art.
[0039] Even further, as also evident from at least FIG. 5, the spun
fibers 86 may, according to various embodiments, be spun into
relatively thicker straps (not shown), which may in turn be loosely
intertwined by any of a variety of industrial processes, as
described herein, or otherwise commonly known and understood in the
art. In any of these and still other envisioned embodiments, the
degree with which the spun fibers 86 (and/or straps) are loosely
intertwined may, at least in part, influence the permeability
characteristics of the third sheet 17, as described in further
detail below. In any of these and any other envisioned embodiments,
the fibers 86 (and/or straps) of the third sheet 17 may be spun,
loosely intertwined, and/or drizzled over a mold or pan in
substantially the same manner as used to form the first sheet 15 of
the rain screen 12, while in still other envisioned embodiments,
the manner of formation (e.g., spinning, intertwining, and/or
drizzling) 1 of the first and third sheets may be substantially
different relative to one another.
[0040] Returning to FIG. 1, the third sheet 17 according to various
embodiments, may exhibit a substantially planar structural shape.
In certain embodiments, as will be described in further detail
below, the substantially planar structure enables attachment (e.g.,
during the manufacturing assembly process) of the third sheet 17
with at least one side (e.g., that opposite of the side to which
the first sheet 15 is attached) of the second sheet 16 of the rain
screen 12. In these and other embodiments, the substantially planar
structural shape is achieved during the process of forming the
third sheet 17, such as, for example, by drizzling the spun fibers
86 of the third sheet 17 over a substantially planar mold (as
previously discussed, and not shown). In still other embodiments,
the third sheet 17 may exhibit any of a variety of structural
shapes, such as the non-limiting example of a washboard structure,
provided any such structural shape is sufficient to provide support
for subsequently installed external cladding material, as described
in further detail below. In any of these and any other envisioned
embodiments, the third sheet 17 may be formed to have substantially
the same structural shape as the first sheet 15 and/or the second
sheet 16 of the rain screen 12, while in still other envisioned
embodiments the structural shape of any of the three sheets may be
substantially different relative to one another.
[0041] In various embodiments, the third sheet 17 may be configured
for moisture transmission (e.g., drainage and ventilation). That
is, the third sheet 17 may be configured to minimally, if at all,
impede the flow of gases (e.g. air and moisture) that may be
trapped between the second sheet 16 of the rain screen 12 and the
external cladding material, as will be described in further detail
below. In the illustrated embodiment, the third sheet 17 has a
permeability value in a range of from about 15 perms to about 35
perms, as determined by water vapor transmission tests, such as,
for example Standard E-96. Typical water vapor transmission tests
of this nature evaluate the transfer of water vapor through
semi-permeable and permeable materials over a period of time. In
other embodiments, the third sheet 17 may have a permeability
rating of less than about 15 perms or more than about 35 perms. In
still other embodiments, the third sheet 17 may have any of a
variety of commonly considered "very high" permeability ratings,
provided such minimally impede the transportation of any trapped
gases through and/or along the third sheet 17. In any of these and
any other envisioned embodiments, the permeability rating of the
third sheet 17 may be substantially the same as that of the first
sheet 15 of the rain screen 12, while in still other envisioned
embodiments the permeability ratings of the first and third sheets
may be substantially different relative to one another.
[0042] Referring again to FIGS. 1 and 2, the sheets, 15, 16, and
17, according to various embodiments, each have a height H and a
length L. In the illustrated embodiment, the height H of each of
the sheets, 15, 16, and 17, may be a range of from about 3.0 ft to
about 4.0 ft. In other embodiments, the height H of the sheets, 15,
16, and 17, may be less than about 3.0 ft or more than about 4.0
ft. In still other embodiments, the height H of the sheets, 15, 16,
and 17, may be in a range from approximately 2.0 ft to about 6.0
ft. In the illustrated embodiment, the length L of each of the
sheets, 15, 16, and 17, is in a range of from about 25.0 ft. to
about 100.0 ft. In other embodiments, the length L of the sheets,
15, 16, and 17, may be approximately 50.0 ft. In still other
embodiments, the length L of the sheets, 15, 16, and 17, may be any
desired length based on a variety of considerations such as, for
example, the diameter (and potentially weight) of the sheets in a
rolled form. In any of these and any other envisioned embodiments,
the heights H of the sheets, 15, 16, and 17, may be substantially
the same relative to each other, while in still other envisioned
embodiments the heights H of the sheets, 15, 16, and 17, may be
substantially different relative to one another.
[0043] Returning to FIG. 1, according to various embodiments the
lath 14 of the lath and rain screen assembly 10 includes a sheet 30
having a plurality of spaced apart apertures 32. As will be
discussed in more detail below, the sheet 30 and the apertures 32
are generally configured in various embodiments to provide support
for subsequently installed external cladding materials. In the
illustrated embodiment, the sheet 30 is formed from a
fiberglass-based material such as, for example, alkaline resistant
(AR) fiberglass. In other embodiments, the sheet 30 may be formed
from other materials sufficient to provide a comparable degree of
support for subsequently installed external cladding material. In
one such other embodiment, the sheet 30 may be formed from a
combination (e.g., a blend) of AR fiberglass and poly-based fiber,
which provides the requisite degree of support. In still other
embodiments, the sheet 30 may be woven in nature.
[0044] In those embodiments having a woven sheet 30, the sheet may
be formed by threading (e.g., weaving) a plurality of individual
fibers 31 into a plurality of straps 33, each of the straps
comprising a portion of the plurality of individual fibers, as
generally shown in FIG. 6. According to these various embodiments,
each of the straps 33 may then be threaded with a plurality of
similarly formed straps 33 to form a mesh or lattice-like structure
constituting the lath 14. Notably, the weaving of the individual
fibers 31 and the plurality of straps 33 relative to one another
may be performed sequentially (as described above), or
simultaneously, as shown in FIG. 6, whereby the individual fibers
31 of respective straps 33 further intertwine adjacently woven
straps. It should be understood that the specific manner of
threading (e.g., weaving) to form this mesh or lattice-like
configuration may be through any of a variety of techniques, as
commonly known and understood in the art of weaving.
[0045] Returning to FIG. 2, the sheet 30 according to various
embodiments may have any desired thickness sufficient to provide
support for subsequently installed external cladding material. In
certain embodiments, the sheet 30 may have a thickness 76 that is
in a range of from about 1/64 inches to about 0.25 inches. In other
embodiments, the thickness 76 may be approximately 1/32 inches. In
still other embodiments, the thickness 76 may be less than about
1/64 inches or more than about 0.25 inches. In any of these and
other embodiments, an overall thickness 77 of the lath and rain
screen assembly 10, namely the summation of the rain screen 12
(e.g., the three combined sheets, 15, 16, and 17) and the sheet 30
of the lath 14 may be in a range from about 0.50 inches to about
0.75 inches. In other embodiments, the overall thickness 77 may be
approximately 9/16 of an inch. In still other embodiments, the
overall thickness 77 may be less than about 0.50 inches or more
than about 0.75 inches.
[0046] In various embodiments, the spaced apart apertures 32 form a
mesh or grid structure for the sheet 30, as generally depicted in
at least FIGS. 1 and 6. In certain embodiments, where the sheet 30
is formed of a fiberglass or a fiberglass blend material, the
apertures 32 may have a generally rectangular shape resulting from
the lath 14 being woven into a mesh or lattice-like structure as
discussed above. In various embodiments, the mesh structure is
woven such that the apertures 32 have a major dimension in a range
of from about 0.10 inches to about 0.50 inches. In certain
embodiments, the apertures 32 may have a major dimension of less
than 0.10 inches or more than about 0.50 inches, depending on the
degree of support desired from the assembled lath and rain screen
assembly 10. In other embodiments, the apertures 32 may have other
shapes or configurations such as, for example, the non-limiting
options of a circular shape, a triangular shape, or an oval
shape.
[0047] Referring now again to FIG. 2, the respective sheets 15, 16,
and 17 of the rain screen 12 are shown assembled together with the
lath 14 according to various embodiments so as to form the lath and
rain screen assembly 10. In the assembled configuration of certain
embodiments, the lath 14 is attached to and supported by a second
side (e.g., the right-most side, as depicted in FIG. 2) of the
third sheet 17 of the rain screen 12. In the illustrated
embodiment, the lath 14 is attached to the first side of the third
sheet 17 by a heat bonding process. In other embodiments, the lath
14 may be attached to the third sheet 17 by other processes,
including the non-limiting examples of adhesives or mechanical
fasteners.
[0048] As may also be understood from FIG. 2, the respective sheets
15, 16, and 17 of the rain screen 12 according to various
embodiments may be likewise attached to and supported relative to
one another. In certain embodiments, a first side (e.g., the
left-most side, as depicted in FIG. 2) of the first sheet 15 may be
attached to an exterior building framework, as will be described in
further detail below. In those and other embodiments, a second side
(e.g., the right-most side, as depicted in FIG. 2) of the first
sheet 15 may be attached to a first side (e.g., the left-most side)
of the second sheet 16, while a second side of the second sheet may
further be attached to a first side of the third sheet 17 such that
the second sheet 16 is positioned substantially intermediate the
first sheet 15 and the third sheet. It should be understood that in
still other embodiments (not shown), the sheets 15, 16, and 17 may
be attached relative to each other in any of a variety of orders,
as may be desired for a particular application.
[0049] Further, any combination of each of the sheets 15, 16, and
17 according to various embodiments may be attached relative to one
another by a heat bonding process. In other embodiments, any
combination of each of the sheets 15, 16, and 17 may be attached
relative to one another by other processes, including the
non-limiting examples of adhesives or mechanical fasteners. In
these and still other embodiments, it should be understood that one
or more of the sheets 15, 16, and 17 may be attached relative to
one another by substantially the same process as the lath 14 may be
attached to, for example, the third sheet 17. Alternatively, one or
more of the sheets 15, 16, and 17 may be attached relative to one
another by substantially differently from the process used to
attach the lath 14 relative to, for example, the third sheet
17.
[0050] Referring now to FIG. 7, according to various embodiments,
the lath 14 may be sized such that, when attached to the fibers 86
of the third sheet 17, one corner of every other aperture 32 within
a set of four apertures 32 each contacts four adjacently positioned
fibers 86. Such is generally depicted in FIG. 7 as configuration A,
whereby four apertures 32 are positioned substantially within a
perimeter defined by four adjacently positioned fibers 86. In other
embodiments, the lath 14 may be sized such that, when attached to
the fibers 86, one corner of every fourth aperture 32 within a set
of sixteen apertures 32 each contacts four adjacently positioned
fibers 86. Such is generally depicted in FIG. 7 as configuration B,
whereby sixteen apertures 32 are positioned substantially within a
perimeter defined by four adjacently positioned fibers 86. In still
other embodiments, the lath 14 may be sized in any of a variety of
manners such that any of a variety of numbers of apertures 32
reside within a perimeter defined by four adjacently fibers 86,
thereby capturing any of a variety of aperture sizes, as may be
desired or envisioned for a particular degree of support inherent
to the lath 14.
[0051] Referring now to FIG. 3, the lath and rain screen assembly
10 according to various embodiments used with exterior cladding
material is illustrated. A portion of a building is illustrated
generally at 40. The building 40 includes an exterior facing wall
42. The wall 42 is configured to define interior space within the
building 40 and to support additional structural components. Among
other building components, the wall 42 according to certain
embodiments is formed from a plurality of framing members 44
extending in both vertical and horizontal directions. In the
illustrated embodiment, the framing members 44 are made of wood. In
other embodiments, the framing members 44 can be made of other
desired materials, including the non-limiting example of steel.
Further, the framing members 44 according to various embodiments
may have any of a variety of desired dimensions.
[0052] Referring again to FIG. 3, the exterior wall 42 according to
various embodiments is covered by exterior sheathing 46 attached to
an exterior side of the framing members 44. In certain embodiments,
the exterior sheathing 46 is configured to provide rigidity to the
exterior wall 42. In other embodiments, the exterior sheathing 46
is further configured to provide a surface for sub-structures and
exterior cladding material. In the illustrated embodiment, the
exterior sheathing 46 is made of oriented strand board (OSB). In
other embodiments, the exterior sheathing 46 may be made of other
materials, such as for example the non-limiting options of plywood,
waferboard, rigid foam, or fiberboard, so long as such options
provide a sufficient degree of rigidity to the exterior wall 42 and
a surface for receiving sub-structures and exterior cladding
material. Further, the exterior sheathing 46 according to various
embodiments has an exterior surface 48.
[0053] According to various embodiments, as shown in FIG. 3, a
moisture resistant layer 50 may also be attached to the exterior
surface 48 of the exterior sheathing 46. The moisture resistance
layer 50 is configured to substantially retard the flow of gases
(e.g. air and moisture) through and between the exterior of the
building and the interior of the building. One example of a
moisture resistance layer 50 is PINK WRAP.RTM. marketed by Owens
Corning Corporation, headquartered in Toledo, Ohio. In other
embodiments, the moisture resistant layer 50 may be traditional
building paper. In still other embodiments, a moisture resistant
layer 50 may not be present at all.
[0054] In various embodiments, the moisture resistant layer 50 may
have any desired thickness and any desired permeability value. In
the illustrated embodiment of FIG. 3, the moisture resistant layer
50 is fastened to the exterior surface 48 of the exterior sheathing
46 by staples (not shown). However, it should be appreciated that
in other embodiments, the moisture resistant layer 50 may be
fastened to the exterior surface 48 of the exterior sheathing 46 by
any of a variety of other desired methods or means.
[0055] Referring again to FIG. 3, the lath and rain screen assembly
10 according to various embodiments is positioned over the moisture
resistant layer 50 and fastened to the exterior sheathing 46 using
a plurality of spaced apart fasteners 52. In the illustrated
embodiment, the fasteners 52 are staples. Alternatively, other
desired fasteners, sufficient to fasten the lath and rain screen
assembly 10 to the exterior sheathing 46 can be used in other
embodiments. In certain embodiments, the fasteners 52 can be spaced
apart a distance in a range of from about 4.0 inches to about 8.0
inches. In other embodiments, the fasteners 52 can be spaced apart
a distance less than about 4.0 inches or more than about 8.0
inches. In still other embodiments that do not incorporate the
moisture resistant layer 50, the fasteners 52 can be used to attach
the lath and rain screen assembly 10 directly to the exterior
sheeting 46.
[0056] As shown in at least FIGS. 2 and 3, in the installed
position, various embodiments of the lath and rain screen assembly
10 include a first sheet 15 having a thickness 54, which itself at
least partially defines a first space or cavity 94 (see, in
particular, FIG. 2) between the moisture resistant layer 50 (or,
alternatively, the exterior sheathing 46) and the second sheet 16.
In certain embodiments, the first space 94 provides for moisture
management behind the second sheet 16 of the lath and rain screen
assembly 10 in two forms. First, in various embodiments, the first
space 94 creates a pathway for moisture to pass through and/or exit
the first space flowing in the direction indicated by the leftmost
arrow D1 (see, in particular, FIG. 3). Second, in various
embodiments, the first space 94 provides a pathway for ventilation
air to pass through and/or exit the first space flowing in the
direction indicated by the leftmost arrow D2. Notably, in certain
embodiments, the first space 94 may, alternatively or concurrently,
provide for moisture management in the direction indicated by the
leftmost arrow D2 with ventilation provided in the direction
indicated by the leftmost arrow D1. In still other embodiments, the
first space 94 may provide moisture management and ventilation
features in any of a variety of envisioned combinations of the
directions indicated by the leftmost arrows D1 and D2.
[0057] In various embodiments, the first space 94 has a width, as
generally depicted in FIG. 3, in a range of from about 0.125 inches
to about 0.375 inches. In other embodiments, the width of the first
space 94 may be less than about 0.125 inches or more than about
0.375 inches. In still other embodiments, the width of the first
space 94 of the first sheet 15 may be in a range of from about
0.0625 inches to about 0.50 inches. In the illustrated embodiment,
the width of the first space 94 is approximately 0.25 inches. In
any of these and other envisioned embodiments, it should be
understood that the width of the first space 94 is substantially
the same as the thickness 54 of the first sheet 15, although in
further alternative embodiments, the width of the first space and
the thickness of the first sheet may be substantially
different.
[0058] Referring again to at least FIGS. 2 and 3, in the installed
position, various embodiments of the lath and rain screen assembly
10 include a third sheet 17 having a thickness 56, which itself at
least partially defines a second space 96 between the second sheet
16 and the lath 14. In certain embodiments, the second space 96, in
an analogous fashion as described above with respect to the first
space 94, provides for moisture management between the lath 14 and
rain screen 12 in two forms. First, in various embodiments, the
second space 96 creates a pathway for moisture to pass through
and/or exit the second space flowing in the direction indicated by
the rightmost arrow D1. Second, in various embodiments, the second
space 96 provides a pathway for ventilation air to pass through
and/or exit the second space flowing in the direction indicated by
the rightmost arrow D2. Notably, in certain embodiments, the second
space 96 may, alternatively or concurrently, provide for moisture
management in the direction indicated by the rightmost arrow D2
with ventilation provided in the direction indicated by the
rightmost arrow D1. In still other embodiments, the second space 96
may provide moisture management and ventilation features in any of
a variety of envisioned combinations of the directions indicated by
the leftmost arrows D1 and D2.
[0059] In various embodiments, the second space 96, as depicted in
at least FIGS. 2 and 3, is configured in certain embodiments to
create a standoff to accommodate a thickness for a first layer 58
of subsequently installed mortar such that the mortar substantially
encapsulates the lath 14.
[0060] In the illustrated embodiment, the thickness 56 of the third
sheet 17 is in a range of from about 0.125 inches to about 0.375
inches. In other embodiments, the thickness 56 of the third sheet
17 may be less than about 0.125 inches or more than about 0.375
inches. In still other embodiments, the thickness 56 of the third
sheet 17 may be in a range of from about 0.0625 inches to about
0.50 inches
[0061] In certain embodiments, a width of the second space 96 is in
a range of from about 0.125 inches to about 0.375 inches,
sufficient to accommodate a thickness of a first layer 58 of mortar
(e.g., a scratch coat layer) of about 0.50 inches, thereby
encapsulating the lath 14. In other embodiments, the width of the
second space 96 may be less than about 0.125 inches or more than
about 0.375 inches and may be configured to accommodate a thickness
of the first layer 58 of mortar of more or less than approximately
0.50 inches. In the illustrated embodiment, the width of the second
space 96 is approximately 0.25 inches, thereby accommodating a
thickness of the first layer 58 of mortar sufficient to
substantially encapsulate the lath 14. In other embodiments, the
first layer 58 of mortar may be of sufficient thickness to totally
encapsulate the lath 14. In still other embodiments, the first
layer 58 of mortar may be of sufficient thickness to totally
encapsulate the lath 14 and approximately 90% of the thickness 56
of the third sheet 17 of the rain screen 12. Any even further
envisioned embodiments, the first layer 58 of mortar may be of
sufficient thickness and/or the width of the second space 96 and/or
the third sheet 17 may be appropriately dimensioned such that the
first layer of mortar substantially encapsulates the lath 14 and at
least a portion of the third sheet 17.
[0062] In various embodiments, a combined width (not numbered, but
visible in at least FIG. 2) of the first space 94 and the second
space 96 may be in a range of from about 0.25 inches to about 0.75
inches. In other embodiments, the combined width may be less than
about 0.25 inches or more than about 0.75 inches. In the
illustrated embodiment, the combined width is approximately 0.50
inches.
[0063] In various embodiments, as shown in FIG. 3, the first layer
58 (e.g., the scratch coat layer) of mortar substantially
encapsulates (e.g., envelops) the lath 14. In certain embodiments,
the first layer 58 of mortar fully encapsulates the lath 14. In
other embodiments, as described above, the first layer 58 of mortar
may fully encapsulate the lath 14 and also at least a portion of
the third sheet 17 of the rain screen 12. Further, in various
embodiments, the first layer 58 of mortar, when allowed to cure,
forms a base for a second layer 60 of mortar. The second layer 60
of mortar is traditionally known as a "brown coat" and is used in
various embodiments as a bedding layer for masonry products 62. In
any of these various embodiments, the first and second layers, 58
and 60, of mortar can be any desired composition of mortar.
Further, in any of these various embodiments, a rough texture may
be applied to one or both of the first and second layers, 58 and
60, of mortar using, for example, a stucco comb or other comparable
tools and methods.
[0064] While the various embodiments of the lath and rain screen
assembly 10 illustrated in FIG. 3 provide support for the masonry
products 62, it should be appreciated that in still other
embodiments, the lath and rain screen assembly 10 can provide
support for other exterior cladding materials. As a non-limiting
example, a lath and rain screen assembly 110, as shown in FIG. 4 is
configured to provide support for exterior cladding material in the
form of stucco. In the illustrated embodiment, the lath 114, the
first sheet 115, the second sheet 116, and the third sheet 117 of
the lath and rain screen assembly 110 are substantially the same,
or substantially similar in structure, shape, and/or configuration
as the lath 14, the first sheet 15, the second sheet 16, and the
third sheet 17 of the lath and rain screen assembly 10 illustrated
in FIG. 3 and discussed above. Alternatively, in other various
embodiments, the lath 114, the first sheet 115, the second sheet
116, and the third sheet 117 of the lath and rain screen assembly
110 may be substantially different in structure, shape, and/or
configuration from the lath 14, the first sheet 15, the second
sheet 16, and the third sheet 17 of the lath and rain screen
assembly 10 illustrated in FIG. 3 and discussed above.
[0065] Referring again to FIG. 4, a portion of a building 140 is
generally depicted as including an exterior facing wall 142 formed
from a plurality of framing members 144. In various embodiments,
the exterior wall 142 may be covered by exterior sheathing 146
attached to an exterior side of the framing members 144. In other
embodiments, no exterior sheathing 146 may be incorporated. In
those embodiments having an exterior sheathing 146, the exterior
sheathing has an exterior surface 148. In the illustrated
embodiment, the portion of the building 140, exterior wall 142,
framing members 144 and exterior sheathing 146 are substantially
the same as, or substantially similar to, the structure, shape,
and/or configuration of the portion of the building 40, exterior
wall 42, framing members 44 and exterior sheathing 46 illustrated
in FIG. 3 and discussed above. Alternatively, the portion of the
building 140, exterior wall 142, framing members 144 and exterior
sheathing 146 can be substantially different in structure, shape,
and/or configuration from that of the portion of the building 40,
exterior wall 42, framing members 44 and exterior sheathing 46
illustrated in FIG. 3 and discussed above.
[0066] According to various embodiments, as shown in FIG. 4, a
moisture resistant layer 150 may be fastened to the exterior
surface 148 of the exterior sheathing 146 by staples (not shown).
In certain embodiments, the lath and rain screen assembly 110 may
be positioned over the moisture resistant layer 150 and fastened to
the exterior sheathing 150 using a plurality of spaced apart
fasteners 152. In these and other envisioned embodiments, a first
layer 158 of mortar is applied such that it substantially
encapsulates (e.g., envelops) the lath 114 such that when the first
layer 158 is allowed to cure, it forms a base for a second layer
160 of mortar. In the illustrated embodiment, the moisture
resistant layer 150, lath and rain screen assembly 110, first layer
158 of mortar and second layer of mortar 160 are substantially the
same, or substantially similar in structure, shape, and/or
configuration as the moisture resistant layer 50, lath and rain
screen assembly 10, first layer 58 of mortar and second layer of
mortar 60 illustrated in FIG. 3 and discussed above. Alternatively,
in other various embodiments, the moisture resistant layer 150,
lath and rain screen assembly 110, first layer 158 of mortar and
second layer of mortar 160 may be substantially different in
structure, shape, and/or configuration from the moisture resistant
layer 50, lath and rain screen assembly 10, first layer 58 of
mortar and second layer of mortar 60 illustrated in FIG. 3 and
discussed above.
[0067] Referring again to FIG. 4, the second layer 160 of mortar,
accordingly to various embodiments, forms a base for a layer of
stucco material 164. In any of the various envisioned embodiments,
the layer of stucco material can have any desired composition and
can be any of a variety of desired thickness.
[0068] A method of installing a lath and rain screen assembly 10
according to various embodiments will now be described in detail
with reference to FIG. 3. The first step of the method according to
certain embodiments provides for positioning of the lath and rain
screen assembly 10 adjacent an exterior sheathing 46 on a building
portion 40. In other embodiments, the lath and rain screen assembly
10 may be positioned adjacent a moisture resistant layer 50 that
has been previously attached to the exterior sheathing 46. In
certain embodiments, the positioning of the lath and rain screen
assembly 10, whether adjacent the exterior sheathing 46 or the
moisture resistant layer 50 involves positioning the first sheet 15
of the rain screen 12 (see FIG. 2) adjacent the exterior sheathing
or the moisture resistant layer. In this manner, in these and other
envisioned embodiments, the second sheet 16 of the rain screen 12
is spaced from the exterior sheathing or the moisture resistant
layer. In various embodiments, the positioning of the first and
second sheets, 15 and 16, of the rain screen 12 create a first
space 94 substantially between the exterior sheathing (or the
moisture resistant layer, if present) and the second sheet 16, as
discussed above in further detail.
[0069] The next step of the method according to various
embodiments, involves the application of a first layer 58 of mortar
to the lath 14 such that the first layer substantially encapsulates
the lath 14, as generally depicted in FIG. 3. In certain
embodiments, the method involves the application of a sufficient
amount of mortar as the first layer 58 to totally encapsulate the
lath 14. In other embodiments, the method involves the application
of a sufficient amount of mortar as the first layer 58 to totally
encapsulate the lath 14 and additionally encapsulate at least a
portion of the thickness 56 of the third sheet 17 of the rain
screen 12. In still other embodiments, the method involves the
application of a sufficient amount of mortar as the first layer 58
to encapsulate the lath 14 along with approximately 90% of the
thickness 56 of the third sheet 17 of the rain screen 12. In
various embodiments, the method further comprises applying a second
layer 60 of mortar after allowing the first layer 58 to cure. In
certain of these embodiments, the second layer 60 provides a
bedding layer for subsequent application of one or more masonry
products 62.
[0070] Generally speaking, the installation of a lath and rain
screen assembly 110, as shown in FIG. 4, may be accomplished in
substantially the same manner as described above with respect to
installation of the lath and rain screen assembly 10. Although, it
should be understood that, in alternative embodiments, the
installation of the lath and rain screen assembly 110 may be at
least partially, or even substantially different than the manner as
described above with respect to installation of the lath and rain
screen assembly 10.
[0071] Various embodiments of the above-described lath and rain
screen assemblies, 10 and 110, advantageously provide several
benefits over traditional stand alone rain screens and laths,
although all of the benefits may not be present in all embodiments.
First, in certain embodiments, the lath and rain screen assemblies,
10 and 110, combine the traditional stand alone lath and the stand
alone rain screen into a single integrated product, thereby
allowing for reduced installation time and installation cost.
Second, in certain embodiments, the lath and rain screen
assemblies, 10 and 110, create at least one pathway between the
moisture resistant layer and the sheet. In contrast, traditional
rain screens may be cumbersome to install and inherently prone to
trapping moisture between the moisture resistant layer and the rain
screen.
[0072] The foregoing description of the various embodiments of the
present invention has been presented for purposes of illustration
and description. It is not intended to be exhaustive or to limit
the invention to the precise form disclosed. Obvious modifications
or variations are possible in light of the above teachings. The
embodiments were chosen and described to provide the best
illustration of the principles of the invention and its practical
application to thereby enable one of ordinary skill in the art to
utilize the invention in various embodiments and with various
modifications as are suited to the particular use contemplated. All
such modifications and variations are within the scope of the
invention as determined by the appended claims when interpreted in
accordance with the breadth to which they are fairly, legally and
equitably entitled. The drawings and preferred embodiments do not
and are not intended to limit the ordinary meaning of the claims in
their fair and broad interpretation in any way.
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