U.S. patent application number 14/256863 was filed with the patent office on 2014-10-23 for stucco composite building panel.
The applicant listed for this patent is Dan B. Pool. Invention is credited to Dan B. Pool.
Application Number | 20140311073 14/256863 |
Document ID | / |
Family ID | 51727934 |
Filed Date | 2014-10-23 |
United States Patent
Application |
20140311073 |
Kind Code |
A1 |
Pool; Dan B. |
October 23, 2014 |
Stucco Composite Building Panel
Abstract
A Stucco Composite Building Panel is disclosed, in which a sheet
of exterior wall sheathing and a cement board are attached together
to form an improved sheet of building material for the construction
of exterior stucco walls. This composite building panel reduces the
amount of individual layers required to build a conventional stucco
wall by providing an exterior wall building panel that is mounted
directly to the stud framing that is ready for a finish layer of
stucco to be applied.
Inventors: |
Pool; Dan B.; (Scottsdale,
AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pool; Dan B. |
Scottsdale |
AZ |
US |
|
|
Family ID: |
51727934 |
Appl. No.: |
14/256863 |
Filed: |
April 18, 2014 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61814023 |
Apr 19, 2013 |
|
|
|
Current U.S.
Class: |
52/309.17 |
Current CPC
Class: |
E04C 2/26 20130101; E04F
13/042 20130101; E04F 13/148 20130101; E04C 2/043 20130101; E04F
13/04 20130101; E04F 13/0898 20130101 |
Class at
Publication: |
52/309.17 |
International
Class: |
E04F 13/04 20060101
E04F013/04; E04C 2/04 20060101 E04C002/04 |
Claims
1. A composite building panel comprising: a sheet of exterior wall
sheathing and a layer of cementitious board, wherein the cement
board is laminated to one side of the sheathing forming a stucco
wall building material sheet with shear strength that is ready to
receive a finish layer of stucco replacing the base coat of
conventional stucco methods.
2. The composite building panel of claim 1, wherein a water
resistant coating is applied to the sheathing to protect the wall
from moisture.
3. The composite building panel of claim 1, wherein, the adhesive
that bonds the cement board to the sheathing contains a water
resistant acrylic.
4. The composite building panel of claim 1, wherein a sheet of
black builders paper is laminated in between the cement board and
the sheathing to function as a water resistant barrier.
5. The composite building panel of claim 1, wherein a sheet of
black builders paper is laminated to the back of the sheathing to
function as a water resistant barrier.
6. The composite building panel of claim 1, wherein a sheet of
spunbond olefin fiber such as Tyvek is laminated in between the
cement board and the sheathing to function as a water resistant
barrier.
7. The composite building panel of claim 1, wherein a sheet of
spunbond olefin fiber such as Tyvek is laminated to the back of the
sheathing to function as a water resistant barrier.
8. The composite building panel of claim 1, wherein, the method of
installation includes a moisture resistant sealant applied to the
butt joint edges preventing water damage or other elements from
damaging the wall.
9. The composite building panel of claim 1, wherein, the method of
installation includes a water resistant mortar applied over mesh
tape to seal the joining edges, preventing cracking and creating a
sealed exterior wall ready for a final finish coat of stucco.
10. The composite building sheet of claim 1, wherein, the method of
installation includes filling the seams and joints in with
elastomeric joint tape and joint sealer after it is mounted, to
prevent moisture penetration and cracking at the joints.
11. The composite building panel of claim 1, wherein, the method of
installation includes fasteners such as screws, nails or staples
with the sheathing portion of the composite panel preventing
fasteners from pulling through.
12. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of cement board such as Durock laminated
to a sheet of sheathing.
13. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of fiber cement board such as Hardie
Backer laminated to a sheet of sheathing.
14. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of cement board laminated to a sheet of
plywood sheathing.
15. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of cement board laminated to a sheet of
fiberglass gypsum sheathing such as DensGlass Gold.
16. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of cement board laminated to a sheet of
sheathing material manufactured from polymer.
17. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of cement board laminated to a sheet of
oriented strand board sheathing.
18. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of fiber cement board such as Hardie
Backer laminated to a sheet of plywood sheathing.
19. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of fiber cement board laminated to a
sheet of fiberglass gypsum sheathing such as DensGlass Gold.
20. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of fiber cement board laminated to a
sheet of sheathing material manufactured from polymer.
21. The composite building panel of claim 1, wherein, the composite
board consists of a sheet of fiber cement board laminated to a
sheet of sheathing material manufactured from fiberglass.
22. The composite building panel of claim 1, wherein, the layer of
fiber cement board laminated together with the substrate makes
cement board easier to cut with a skill saw, jigsaw, or other
cutting means without the cement board crumbling.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefits of the earlier filing
dates of U.S. Provisional Application No. 61/814,023 filed Apr. 19,
2013. The disclosure U.S. Provisional Application 61/814,023 is
hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Completing a conventional stucco exterior surface of
commercial and residential buildings is a time and cost intensive
process. After the frame of the house is complete, several layers
of materials are applied to the exterior frame of the house.
Depending on the method, these layers include oriented strand
board, foam insulation, stucco, a vapor barrier, a water resistant
barrier, and other materials. Each layer adds to the cost of the
building project not only due to the cost of materials, but also
due to the cost of labor involved with applying multiple layers.
Some methods of applying exterior stucco can take as long as three
weeks, and if cracks develop, then additional repair is required,
costing valuable resources.
[0003] In one typical process, a layer of black felt paper or
spunbond olefin fiber such as Tyvek moisture barrier is applied to
the exterior frame of the building. A sheet of foam insulation is
then applied on top of the barrier attached to the framing. Wire
mesh is then wrapped around the outside of the foam. After this, an
initial layer of Portland cement (stucco) is applied to the wire
mesh by hand and a brush is used to rough the surface in order to
help the next layer of stucco bond to the surface. Once the stucco
is applied to the exterior, it has to cure, which can take as long
as two weeks. Once it cures, cracks can form in the stucco, which
have to be patched, taking additional time and resources. Despite
the intensive process of applying it, stucco appeals to builders
and homeowners due to its appearance and versatility. However, this
process poses many challenges to home builders, for example: [0004]
1. The conventional multi-layer stucco process is time intensive
and can take up to 20 days or longer to complete; [0005] 2. Each
layer in the process has to be individually applied to the
exterior, which consumes excessive labor and increases the risks of
an incorrect application; [0006] 3. The multi-layer process
produces waist and excessive clean up; [0007] 4. Water damage and
mold growth over time can occur due to improper applications of
multiple layers. [0008] 5. It is difficult to control the precise
thickness of Stucco layers being applied by hand resulting in
varied finished wall thicknesses that can lead to future problems
such as cracking and water damage.
[0009] Thus there is a need for a stucco wall system that
eliminates the process of applying multiple layers and is light,
protective, and cost efficient.
BRIEF SUMMARY OF THE INVENTION
[0010] The present invention provides a composite exterior stucco
wall system with shear strength that is ready to accept a finish
coat of stucco by coupling with adhesive a thin layer of
cementitious board such as Hardie Backer or Durock with an exterior
sheathing such as oriented strand board, plywood or an exterior
gypsum board such as DensGlass Gold.
[0011] In another aspect of the invention, the adhesive that bonds
the cement board to the substrate contains a water resistant
element to protect the wood substrate from moisture.
[0012] In another aspect of the invention, a sheet of black
builders paper or spunbond olefin fiber such as Tyvek is placed in
between the composite board and substrate to protect the wood
substrate from moisture.
[0013] In another aspect of the invention the composite building
panel is mounted to the wall frame with conventional fasteners such
as screws, nails or staples. The wood substrate layer prevents the
fasteners from pulling through and compromising the finished stucco
wall.
[0014] In another aspect of the invention, the combination of a
thinner layer of fiber cement board laminated together with the
substrate makes cement board easier to cut with a skill saw,
jigsaw, or other cutting means without the cement board
crumbling.
[0015] In another aspect of the invention, the corner edges and
butt joints of the substrate are treated to seal against water
damage and other elements, either by elastomeric caulk or a similar
sealing material.
[0016] In another aspect of the invention, the joints are covered
with elastomeric joint tape or mesh tape and a layer of water
resistant mortar over mesh tape to avoid cracking and to seal the
joints to protect the wood substrate portion of the composite
board.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0017] These and other features, aspects, and advantages of the
present invention will become better understood with reference to
the following description, appended claims, and accompanying
drawings, where:
[0018] FIG. 1 is a top down view of the composite board layers
which consist of cement board, black building paper, and a layer of
OSB (oriented strand board) sheathing laminated together into one
sheet;
[0019] FIG. 2 is a top down view of the composite board layers
which consist of cement board, a layer of water resistant coating
and the OSB sheathing;
[0020] FIG. 3 is a side angle view of another sheet of composite
board being placed adjacent to the second board and directly above
the first board creating a joint;
[0021] FIG. 4 is a side angle view of a sealant being applied to
the edges of the boards to seal them against water and other
elements; and
[0022] FIG. 5 is a side view of mesh tape applied to the adjacent
joining edges of the boards with a water resistant finishing layer
being applied over the mesh tape and the adjacent edges of the
boards.
DETAILED DESCRIPTION OF THE INVENTION
[0023] With reference to FIG. 1, a composite board 10 is composed
of a substrate 11 that is an oriented strand board or a similar
substance such as plywood. A sheet of cementitious board 12 is
affixed to the substrate 11 creating a barrier that seals and
protects the interior wall. In this figure, a sheet of black
builders paper 13 is placed between the cement board 12 and the
substrate 11 as the vapor barrier or water resistant barrier. The
builders paper 13 is glued to the substrate 11, and then the other
side of the builders paper is glued to the cement board 12 such
that the builders paper 13 is between the substrate 11 and the
cement board 12. In other embodiments, a fiber cement board is
attached to the substrate. The composite board consists of a
uniform 1/4'' thick sheet of cement board laminated to a 7/16''
sheet of oriented strand board of plywood. In other embodiments, a
sheet of spunbond olefin fiber such as Tyvek is placed in between
the composite board and substrate to protect the wood substrate
from moisture. A layer of water resistant coating can be applied to
the sheathing to protect the wall from moisture. In other
embodiments, the cementitious board is a sheet of cement board such
as Durock, a sheet of fiberglass gypsum sheathing such as DensGlass
Gold, or a fiber cement board such as Hardie Backer. In other
embodiments, the substrate consists of a sheet of plywood, a sheet
of polymer, or a sheet of fiberglass gypsum.
[0024] In FIG. 2, a composite board 14 is composed of a substrate
15 that is an oriented strand board or a similar substance such as
wood. A sheet of cement board 16 is affixed to the substrate 15
creating a barrier that seals and protects the property. In this
figure, a layer of glue 17 is placed between the cement board 16
and the substrate 15. This glue has a water resistant barrier
element mixed in such as a water resistant acrylic so that the glue
itself serves as the vapor barrier for the exterior wall system and
protects the wooden substrate from moisture.
[0025] FIG. 3 shows three composite boards 18, 19, and 20 fixed to
the exterior frame of a building. Composite board 19 is placed
adjacent to the sheet 20 and above the bottom board 18, creating a
set of joints. A composite board can be attached to the wooden
frames by both glue and screws, glue or screws, or other methods
such as nails or staples. The substrate in the composite boards
provides a backing for a screw, which prevents the cement board
from cracking. The combination of a thinner layer of cement board
or fiber cement board laminated together with the substrate makes
the composite board easier to cut with a skill saw, jigsaw, or
other cutting means without the cement board crumbling.
[0026] FIG. 4 shows the joint of composite board sheets 19 and 20
being sealed with a sealant such as elastomeric caulk or a similar
sealing material 21 such as a water resistant mortar to prevent
water damage or other elements from damaging the substrate.
[0027] FIG. 5 shows mesh tape 22 applied to the adjacent joining
edges where composite board sheets 19 and 20 meet to avoid cracking
and to seal the joints to protect the wood substrate of the
composite board. In other embodiments, the joints are sealed with
elastomeric joint tape. A water resistant finishing layer 23 is
applied over the mesh tape covered joints to seal the edges of the
composite boards 19 and 20. This coating further protects and seals
the exterior wall system.
* * * * *