U.S. patent application number 14/816668 was filed with the patent office on 2017-02-09 for stucco wall structure.
This patent application is currently assigned to Bayer MaterialScience LLC. The applicant listed for this patent is Bayer MaterialScience LLC. Invention is credited to Bruce Dickson, Anthony Grisolia.
Application Number | 20170037637 14/816668 |
Document ID | / |
Family ID | 56802665 |
Filed Date | 2017-02-09 |
United States Patent
Application |
20170037637 |
Kind Code |
A1 |
Grisolia; Anthony ; et
al. |
February 9, 2017 |
STUCCO WALL STRUCTURE
Abstract
Wall structures and methods for producing wall structures are
described in this specification. The wall structures include a
frame, a sheathing board attached to the frame, a foam layer, a
bond break layer, a lath layer, and a stucco layer.
Inventors: |
Grisolia; Anthony;
(Leechburg, PA) ; Dickson; Bruce; (West Mifflin,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bayer MaterialScience LLC |
Pittsburgh |
PA |
US |
|
|
Assignee: |
Bayer MaterialScience LLC
|
Family ID: |
56802665 |
Appl. No.: |
14/816668 |
Filed: |
August 3, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 13/06 20130101;
Y02B 30/94 20130101; B32B 2607/00 20130101; E04C 2/386 20130101;
B32B 3/14 20130101; B32B 5/024 20130101; B32B 21/02 20130101; B32B
27/32 20130101; Y02A 30/00 20180101; B32B 5/32 20130101; E04F 13/04
20130101; B32B 5/022 20130101; B32B 2260/042 20130101; E04C 2/284
20130101; B32B 2266/0278 20130101; B32B 2266/0228 20130101; E04F
13/047 20130101; Y02B 30/90 20130101; B32B 2260/028 20130101; E04C
2/205 20130101; B32B 2419/00 20130101; B32B 3/266 20130101; E04B
2/707 20130101; E04B 2103/04 20130101; B32B 13/04 20130101; Y02A
30/261 20180101; B32B 3/08 20130101; B32B 27/304 20130101; E04B
1/10 20130101; B32B 15/02 20130101; B32B 13/06 20130101; B32B 3/06
20130101 |
International
Class: |
E04F 13/04 20060101
E04F013/04; E04B 2/70 20060101 E04B002/70; E04F 13/06 20060101
E04F013/06; E04B 1/76 20060101 E04B001/76 |
Claims
1. A wall structure comprising: a frame comprising: a first member;
a second member spaced apart from the first member; and two side
members extending between the first member and the second member,
wherein the first member, the second member, and the two side
members each comprise a front surface and a rear surface that form
a front frame surface and a rear frame surface; a sheathing board
attached to the front frame surface, wherein the sheathing board,
the first and second members, and the two side members define a
cavity within the frame; a foam layer located within the cavity and
adhered to a rear-facing surface of the sheathing board; a bond
break layer located adjacent to a front-facing surface of the
sheathing board; a lath layer located adjacent to the bond break
layer; and a stucco layer integrated into the lath layer, wherein
the sheathing board comprises a polyisocyanurate foam layer and a
facer material attached to a front face and a rear face of the
polyisocyanurate foam layer.
2. The wall structure of claim 1, wherein the bond break layer
comprises an asphalt-impregnated kraft paper, an
asphalt-impregnated felt paper, an extruded polystyrene layer, an
expanded polystyrene layer, a polyiso layer, a polyethylene sheet
or film, a polypropylene sheet or film, a poly(vinyl chloride)
sheet or film, a woven house wrap, a perforated housewrap, a
nonmoven and spunbonded polyolefin sheet or film, a woven and
perforated polyolefin sheet or film, a layer comprising a
three-dimensional matrix of randomly-oriented extruded polymer
filaments, or a fiberboard.
3. The wall structure of claim 1, wherein the bond break layer
comprises a Grade D 60-minute building paper.
4. The wall structure of claim 1, wherein the lath layer comprises
a self-furred steel wire lath.
5. The wall structure of claim 1, wherein the bond break layer and
the lath layer are pre-bonded together, and wherein the pre-bonded
combination of the bond break layer and the lath layer are
positioned on the front-facing surface of the sheathing board and
attached to the frame with one set of fasteners that penetrate
through the sheathing board.
6. The wall structure of claim 5, wherein the pre-bonded
combination of the bond break layer and the lath layer comprises a
bond break layer comprising paper and a lath layer comprising metal
wire lath.
7. (canceled)
8. The wall structure of claim 1, wherein the facer material
comprises fiberglass mat, glass fiber-reinforced cellulosic felt,
coated and polymer-bonded fiber mat, foil, coated foil,
foil/membrane laminate, foil/glass composite, or polyolefin
film.
9. (canceled)
10. The wall structure of claim 1, wherein the foam layer comprises
polyurethane or polyisocyanurate, or mixtures thereof.
11. The wall structure of claim 1, wherein the sheathing board is
attached to the front faces of the first and second members, and to
the front faces of the two side members, with fasteners.
12. The wall structure of claim 1, wherein the sheathing board is
attached to the front faces of the first and second members, and to
the front faces of the two side members, with an adhesive.
13. The wall structure of claim 1, wherein the foam layer comprises
a thickness extending from the rear-facing surface of the sheathing
board to a position intermediate the front frame surface and the
rear frame surface such that a gap is formed within the frame
between a rear-facing surface of the foam layer and the rear frame
surface.
14. A method for producing the wall structure of claim 1
comprising: providing a wall panel, the wall panel comprising: a
frame comprising: a first member; a second member spaced apart from
the first member; and two side members extending between the first
member and the second member, wherein the first member, the second
member, and the two side members each comprise a front surface and
a rear surface that form a front frame surface and a rear frame
surface; a sheathing board attached to the front frame surface,
wherein the sheathing board, the first and second members, and the
two side members define a cavity within the frame; and a foam layer
located within the cavity and adhered to a rear-facing surface of
the sheathing board; positioning a bond break layer and a lath
layer adjacent to a front-facing surface of the sheathing board;
attaching the bond break layer and the lath layer to the frame; and
applying a stucco layer integrated into the lath layer, wherein the
sheathing board comprises a polyisocyanurate foam layer and a facer
material attached to a front face and a rear face of the
polyisocyanurate foam layer.
15. The method of claim 14, further comprising: assembling multiple
wall panels into an incomplete wall structure; positioning the bond
break layer and the lath layer adjacent to the front-facing
surfaces of the sheathing board and over the incomplete wall
structure; attaching the bond break layer and the lath layer to the
frames of the multiple assembled panels; and applying a stucco
layer integrated into the lath layer to complete the wall
structure.
16. The method of claim 14, wherein the lath layer comprises a
self-furred steel wire lath, and wherein the bond break layer
comprises an asphalt-impregnated kraft paper, an
asphalt-impregnated felt paper, an extruded polystyrene layer, an
expanded polystyrene layer, a polyiso layer, a polyethylene sheet
or film, a polypropylene sheet or film, a poly(vinyl chloride)
sheet or film, a woven house wrap, a perforated housewrap, a
nonmoven and spunbonded polyolefin sheet or film, a woven and
perforated polyolefin sheet or film, a layer comprising a
three-dimensional matrix of randomly-oriented extruded polymer
filaments, or a fiberboard.
17. The method of claim 14, wherein the bond break layer and the
lath layer are pre-bonded together, and wherein the pre-bonded
combination of the bond break layer and the lath layer are
positioned on the front-facing surface of the sheathing board and
attached to the frame with one set of fasteners that penetrate
through the sheathing board.
18. The method of claim 17, wherein the pre-bonded combination of
the bond break layer and the lath layer comprises a paper-backed
metal wire lath.
19. The method of claim 18, wherein the bond break layer comprises
a Grade D 60-minute building paper and the metal wire lath
comprises a self-furred steel wire lath.
20. (canceled)
21. The method of claim 14, wherein the facer materials comprise
fiberglass mat, glass fiber-reinforced cellulosic felt, coated and
polymer-bonded fiber mat, foil, coated foil, foil/membrane
laminate, foil/glass composite, or polyolefin film.
22. (canceled)
23. The method of claim 14, wherein the foam layer comprises
polyurethane or polyisocyanurate, or mixtures thereof.
24. The method of claim 14, wherein applying the stucco layer
comprises: applying a brown coat integrated into the lath layer;
and applying a finish coating onto the brown coat.
25. The method of claim 14, wherein applying the stucco layer
comprises: applying a scratch coat integrated into the lath layer;
applying a brown coat onto the scratch coat; and applying a finish
coating onto the brown coat.
Description
BACKGROUND
[0001] The information described in this background section is not
admitted to be prior art.
[0002] Modern stucco is a cement-based material used primarily as a
cladding/veneer on the exterior-facing walls of residential and
commercial buildings. Most stucco compositions comprise a mixture
of sand, Portland cement, lime, and water. Specific stucco
formulations can also comprise additives including, for example,
pigments or other colorants, reinforcing fibers, and synthetic
acrylic polymers. In residential and commercial construction,
stucco is typically applied by hand to form the exterior-facing
surface of building walls. In the United States, for example,
stucco-clad buildings, including residential homes and commercial
structures, are commonly constructed in the relatively drier
southwest portions of the country (e.g., in the states of Arizona,
New Mexico, Nevada, and southern California). However, the
combination of low cost, low maintenance, fire-resistance,
weather-resistance, and high racking strength make stucco an
excellent material of construction for buildings in many
environments.
SUMMARY
[0003] This specification relates to wall structures and methods
for producing wall structures.
[0004] In one example, a wall structure comprises a frame, a
sheathing board attached to the frame, a foam layer, a bond break
layer, a lath layer, and a stucco layer.
[0005] In another example, a wall structure comprises a frame and a
sheathing board attached to the frame. The frame comprises a first
member, a second member spaced apart from the first member, and two
side members extending between the first member and the second
member. The first member, the second member, and the two side
members each comprise a front surface and a rear surface that form
a front frame surface and a rear frame surface. The sheathing board
is attached to the front frame surface. The sheathing board, the
first and second members, and the two side members define a cavity
within the frame, and a foam layer is located within the cavity and
adhered to a rear-facing surface of the sheathing board. A bond
break layer is located adjacent to a front-facing surface of the
sheathing board. A lath layer is located adjacent to the bond break
layer. A stucco layer is integrated into the lath layer.
[0006] In another example, a method for producing a wall structure
comprises providing a wall panel. The wall panel comprises a frame
comprising a first member, a second member spaced apart from the
first member, and two side members extending between the first
member and the second member. The first member, the second member,
and the two side members each comprise a front surface and a rear
surface that form a front frame surface and a rear frame surface. A
sheathing board is attached to the front frame surface. The
sheathing board, the first and second members, and the two side
members define a cavity within the frame, and a foam layer is
located within the cavity and adhered to a rear-facing surface of
the sheathing board. The method further comprises positioning a
bond break layer and a lath layer adjacent to the front-facing
surface of the sheathing board, attaching the bond break layer and
the lath layer to the frame, and applying a stucco layer integrated
into the lath layer.
[0007] It is understood that the inventions described in this
specification are not necessarily limited to the examples
summarized in this Summary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Various features and characteristics of the inventions
described in this specification may be better understood by
reference to the accompanying figures, in which:
[0009] FIG. 1A is a front perspective view, partial sectional
schematic diagram of a wall structure comprising a frame, a
sheathing board attached to the frame, a foam layer, a bond break
layer, a lath layer, and a stucco layer; and FIG. 1B is a front
plan view, partial sectional schematic diagram of the wall
structure shown in FIG. 1A;
[0010] FIG. 2A is a front perspective view, partial sectional
schematic diagram of a wall structure comprising a frame, a
sheathing board attached to the frame, a foam layer, a bond break
layer, a lath layer, and a stucco layer (showing the underlying
frame structure in dashed line); and FIG. 2B is a front plan view,
partial sectional schematic diagram of the wall structure shown in
FIG. 2A;
[0011] FIG. 3 is a side cross-sectional schematic diagram of the
wall structure shown in FIGS. 1A-2B;
[0012] FIG. 4 is a side cross-sectional schematic diagram of a
sheathing board comprising a polyisocyanurate foam layer and facer
materials attached to a front face and a rear face of the
polyisocyanurate foam layer;
[0013] FIG. 5A is a front perspective view schematic diagram of a
frame component of a wall panel; and FIG. 5B is a rear perspective
view schematic diagram of the frame shown in FIG. 5A;
[0014] FIGS. 6A-6E are a series of perspective view schematic
diagrams showing the construction of a wall structure comprising a
frame, a sheathing board attached to the frame, a foam layer, a
bond break layer, a lath layer, and a stucco layer;
[0015] FIGS. 7A-7E are a series of side cross-sectional schematic
diagrams respectively corresponding to FIGS. 6A-6E and showing the
construction of a wall structure comprising a frame, a sheathing
board attached to the frame, a foam layer, a bond break layer, a
lath layer, and a stucco layer;
[0016] FIG. 8 is a side view schematic diagram of a bonded
combination of a bond break layer and an offset lath layer;
[0017] FIG. 9A is a front perspective view of a wall panel frame;
and FIG. 9B is a rear perspective view of the wall structure frame
shown in FIG. 9A;
[0018] FIG. 10A is a front perspective view of a wall panel
comprising a sheathing board and a foam layer shown in partial
sectional view; and FIG. 10B is rear perspective view of the wall
panel shown in FIG. 10A;
[0019] FIG. 11 is a front view of a wall panel frame with a window
opening;
[0020] FIG. 12 is a front view of a wall panel frame with a
door;
[0021] FIG. 13 is a top cross-sectional view of the wall panel
shown in FIGS. 10A and 10B;
[0022] FIG. 14A is a side cross-sectional view of the wall panel
shown in FIGS. 10A and 10B; and FIG. 14B is a side cross-sectional
view of the wall panel shown in FIG. 14A; and
[0023] FIG. 15 is a top cross-sectional view of the wall panel
having a door or window opening.
[0024] The reader will appreciate the foregoing features and
characteristics, as well as others, upon considering the following
detailed description of the inventions according to this
specification.
DESCRIPTION
[0025] As used in this specification, the term "front" refers to
the side, face, or surface of a structure or component oriented
towards the outside direction of an exterior wall of a building,
and the term "rear" refers to the side, face, or surface of a
structure or component oriented towards the inside direction of an
exterior wall of a building.
[0026] Exterior stucco wall construction typically involves a
number of labor intensive steps. For example, an open stud frame is
erected on site, (typically with oriented strand board (OSB) shear
panels or let-in T-bracing installed at the exterior wall corners),
the primary drainage plane is attached to the frame (e.g., a
shingled layer of building paper), bond break panels are attached
to the frame over the primary drainage plane (e.g., expanded
polystyrene (EPS) panels), and a lath is attached to the frame over
both the bond break panels and the primary drainage plane. The
stucco material is then applied to the lath.
[0027] In this typical method of stucco construction, at least
three separate sets of fasteners, such as nails and staples,
penetrate the various layers and engage the wooden studs of the
frame: (1) the fasteners attaching the primary drainage plane to
the frame; (2) the fasteners attaching the bond break panels to the
frame, which necessarily penetrate through the primary drainage
plane; and (3) the fasteners attaching the lath to the frame, which
necessarily penetrate through both the bond break panels and the
primary drainage plane.
[0028] Additionally, in a typical method of stucco construction,
preliminary flashing is installed on the sills and jambs of window
and door openings before the attachment of the primary drainage
plane. Like the primary drainage plane, the bond break panels, and
the lath, the preliminary flashing is attached to the frame with
fasteners, such as nails and staples, which creates a fourth
fastener penetration to the frame near windows, doors, or other
flashed penetrations through the exterior wall.
[0029] After the installation of the intermediate layers between
the frame and the exterior stucco cladding (e.g., the primary
drainage plane, the bond break panels, and the lath), the interior
side of the frame must be inspected for fasteners that penetrate
through the layers but miss the frame and therefore stick-out into
the interior of the wall structure. These exposed fasteners create
direct pathways for water infiltration and must be sealed-off, for
example, by covering with a layer of caulking, before the
installation of utility components (e.g., electrical wiring,
plumbing, HVAC conduits, etc.), wall cavity insulation (e.g.,
fiberglass), and interior wall cladding (e.g., drywall).
[0030] The multiple sets of fastener penetrations of the various
intermediate layers between the frame and the exterior stucco
cladding (e.g., the primary drainage plane, the bond break panels,
and the lath), create undesirable direct and indirect pathways for
water infiltration into the interior portions of the wall. Also, as
noted, the typical method of exterior stucco wall construction
involves a number of labor intensive steps. Therefore, a new stucco
wall structure and method of producing the wall structure that
decreases the number of fastener penetrations, and also decreases
the number of on-site construction steps, would be advantageous.
The wall structure and the method of producing a wall structure
described in this specification advantageously decrease both the
number of fastener penetrations and the number of on-site
construction steps to produce an exterior stucco wall.
[0031] As described above, the wall structure comprises a frame, a
sheathing board attached to the frame, a foam layer, a bond break
layer, a lath layer, and a stucco layer. Referring to FIGS. 1A-3,
5A, and 5B, a wall structure 110 comprises a frame 111. The frame
111 comprises a first member 112, a second member 114 spaced apart
from the first member 112, and two side members 116 extending
between the first member 112 and the second member 114. The first
member 112, the second member 114, and the two side members 116
each comprise a front surface (112a, 114a, and 116a, respectively)
and a rear surface (112b, 114b, and 116b, respectively) that
collectively form a front frame surface 111a and a rear frame
surface 111b. The constituent members (112, 114, and 116) of the
frame 111 can be made out of a suitable material of construction
such as wood. For example, the constituent members (112, 114, and
116) of the frame 111 can comprise wooden 2.times.4 members (i.e.,
structural members made of wood having nominal thicknesses of about
2-inches, nominal widths of about 4-inches, and suitable lengths)
secured together with fasteners such as nails, nail plates, screws,
staples, bolts, or rivets, or a combination of any thereof.
[0032] As shown in FIGS. 1A-3, 5A, and 5B, the frame 111 further
comprises a primary support member 117, which comprises a front
surface 117a and a rear surface 117b. The front surface 117a and
the rear surface 117b correspond to the front frame surface 111a
and the rear frame surface 111b. It is understood, however, that a
wall structure and/or a frame can omit any primary support members
or include any number of primary support members. Additionally, if
a wall structure and/or a frame includes one or more primary
support members, the front surface and the rear surface of any
primary support member may or may not correspond to the front frame
surface and the rear frame surface, respectively.
[0033] A sheathing board 170 is attached to the front frame surface
111a. As used in this specification, the term "sheathing board"
refers to a board comprising either extruded polystyrene (XPS) or
polyisocyanurate. For example, referring to FIG. 4, the sheathing
board 170 can comprise a polyiso board comprising a
polyisocyanurate foam layer 175 and a facer material 177a/177b
attached to a front face 175a and/or a rear face 175b of the
polyisocyanurate foam layer 175. Although FIG. 4 shows facer
materials 177a and 177b respectively attached to both the front
face 175a and the rear face 175b of the polyisocyanurate foam layer
175, it is understood that a sheathing board can comprise a facer
material attached to just the front face of a polyisocyanurate foam
layer. Additionally, although FIG. 4 shows a polyiso board
comprising a polyisocyanurate foam layer, it is understood that a
board comprising extruded polystyrene can also comprise additional
facers materials, as described below.
[0034] In implementations in which the sheathing board comprises a
polyiso board, the sheathing board generally meets the requirements
of ASTM C1289-15: Standard Specification for Faced Rigid Cellular
Polyisocyanurate Thermal Insulation Board, which is
incorporated-by-reference into this specification. Polyiso boards
generally comprise facer materials attached to and covering both
sides (the front and rear faces) of a polyisocyanurate foam layer.
For example, facer materials can comprise glass mats filled with
recycled cardboard and colored with carbon black. Facers materials
can also comprise foil or foil/glass composites. Facer materials
can also comprise fibrous materials such as fiberglass materials or
other fiber-reinforced sheet-like materials. Examples of suitable
facer materials include, but are not limited to, fiberglass mats,
glass fiber-reinforced cellulosic felts, coated and polymer-bonded
fiber mats (e.g., fibrous glass mats bonded with an organic polymer
binder and coated with an organic polymer coating, clay, or other
inorganic coating), foils (e.g., aluminum foil), coated foils,
foil/membrane laminates, foil/glass composites, and polyolefin
films (such as TYVEK.RTM. materials, available from DuPont; or
TYPAR.RTM. materials, available from Fiberweb, Inc.).
[0035] If a sheathing board comprises facer materials on both the
front and rear faces of the polyisocyanurate foam layer, then the
facer material on the front face may be the same as or may be
different than the facer material on the rear face. The facer
materials should meet the requirements described in ASTM
D226/D226M-09: Standard Specification for Asphalt-Saturated Organic
Felt Used in Roofing and Waterproofing; or ASTM E2556/E2556M-10:
Standard Specification for Vapor Permeable Flexible Sheet
Water-Resistive Barriers Intended for Mechanical Attachment; or
otherwise qualify as a water-resistive barrier in accordance with
International Residential Code (IRC) 703.2 (2012), which are each
incorporated-by-reference into this specification. In
implementations in which the sheathing board comprises a polyiso
board, the front facer material functions as a primary drainage
plane for the wall structure; and in implementations in which the
sheathing board comprises an extruded polystyrene board, the
front-facing surface of the XPS board (or any optional front facer
material) functions as a primary drainage plane for the wall
structure.
[0036] Referring again to FIGS. 1A-3, the sheathing board 170 may
be attached to the front frame surface 111a. The sheathing board
170 can be attached to any of the front faces (112a, 114a, 116a,
and/or 117a) of the constituent members (112, 114, 116, and 117) of
the frame 111. For example, the sheathing board 170 can be attached
to the front faces 112a and 114a of the first and second members
112 and 114, and to the front faces 116a of the two side members
116. The sheathing board 170 also can be attached to the front face
117a of the primary support member 117. The sheathing board 170 can
be attached to the front frame surface 111a with fasteners and/or
an adhesive (not shown). Attachment fasteners can include, but are
not limited to, nails, staples, screws, bolts, or rivets, or a
combination of any thereof. Attachment adhesives can comprise a
construction adhesive that is compatible with the adjoining
materials. For example, an adhesive used to attach a sheathing
board to a frame can comprise a foam material (which may be the
same foam material or a different foam material as the foam
material comprising the foam layer, described below).
[0037] The sheathing board, the first member 112, the second member
114, the two side members 116, and the primary support member 117
define cavities 118 within the frame 111. Foam layers 130 are
located within the cavities 118. The foam layers 130 adhere to the
rear-facing surface 170b of the sheathing board 170. If a wall
structure omits a primary support member, then the sheathing board,
the first and second members, and the two side members can define
one cavity within the frame, and a foam layer can be located in the
cavity. If a wall structure includes two or more primary support
members, then the sheathing board, the first and second members,
the two side members, and the plurality of primary support members
can define three or more cavities within the frame and foam layers
can be located in the plurality of cavities (see, e.g., FIGS.
10A-13).
[0038] The foam layer 130 (and, optionally, any foam-based adhesive
used to attach the sheathing board 170 to the frame 111) can
comprise, for example, polyurethane or polyisocyanurate, or
mixtures thereof. The foam layer 130 can be substantially free,
essentially free, or completely free of halogen-containing flame
retardant additives.
[0039] As used in this specification, the term "foam" refers to a
substance that is formed by trapping pockets of gas in a liquid or
solid. A foam layer can comprise a closed-cell foam, wherein the
term "closed-cell foam" refers to foam that contains discrete,
non-interconnecting cells formed by the trapped pockets of gas.
Examples of foam materials include, but are not limited to, foams
made with polyurethane, polyisocyanurate (also referred to as
polyiso), and mixtures thereof. Foam materials (including the foam
layer 130) may be substantially free, may be essentially free, or
may be completely free of halogen-containing flame retardant
additives. The term "halogen" refers to the halogen elements, which
include fluorine, chlorine, bromine, and iodine, and the term
"halogen-containing flame retardant additives" refers to a
substance that may be used to inhibit or resist the spread of fire,
and which contains halogen groups such as a fluoro, chloro, bromo,
and/or iodo groups. Further, the term "substantially free," as used
in this specification, means the foam material contains less than
1000 parts per million (ppm), "essentially free" means less than
100 ppm, and "completely free" means less than 20 parts per billion
(ppb) of halogen-containing flame retardant additives.
[0040] Referring to FIG. 3, the foam layer 130 comprises a
thickness T extending from the rear-facing surface 170b of the
sheathing board 170 to a position intermediate the front frame
surface 111a and the rear frame surface 111b. In this manner, a gap
140 may be formed within the frame 111 between a rear-facing
surface 130b of the foam layer 130 and the rear frame surface 111b.
The gap 140 in the wall structure 110 can be used to accommodate
electrical wiring, electrical fixtures such as outlet boxes,
plumbing, HVAC conduits, or other utility components incorporated
into the wall structure. Alternatively, although FIG. 3 shows the
foam layer 130 comprising a thickness T extending from the
rear-facing surface 170b of the sheathing board 170 to a position
intermediate the front frame surface 111a and the rear frame
surface 111b, it is understood that the foam layer 130 can
alternatively comprise a thickness extending from the rear-facing
surface 170b of the sheathing board 170 to the rear frame surface
111b, in which case no gap is formed within the frame 111 between
the rear-facing surface 130b of the foam layer 130 and the rear
frame surface 111b.
[0041] A bond break layer 160 is located adjacent to the front
facing surface 170a of the sheathing board 170. A lath layer 165 is
located adjacent to the bond break layer 160.
[0042] The bond break layer 160 can comprise a material that does
not readily adhere to the underlying surface of the sheathing
board, which, as described above, functions as the primary drainage
plane for the wall structure. The bond break layer 160 can comprise
a material layer such as, for example, an asphalt-impregnated kraft
paper (30-minute or 60-minute), an asphalt-impregnated felt paper
(30-minute or 60-minute), an extruded polystyrene (XPS) layer, an
expanded polystyrene (EPS) layer, a polyiso layer, a polyethylene
sheet or film, a polypropylene sheet or film, a poly(vinyl
chloride) sheet or film, a woven house wrap, a perforated
housewrap, a nonmoven and spunbonded polyolefin sheet or film
(e.g., TYVEK.RTM. materials, available from DuPont; or TYPAR.RTM.
materials, available from Fiberweb, Inc.), a woven and perforated
polyolefin sheet or film (e.g., WEATHERMATE housewrap, available
from The Dow Chemical Company), a layer comprising a
three-dimensional matrix of randonly-oriented extruded polymer
filaments (e.g., SLICKER.RTM. materials, available from Benjamin
Obdyke Inc., which are sheets comprising a three-dimensional matrix
of randonly-oriented extruded polycaprolactam (nylon 6) filaments),
or a fiberboard (e.g., adhesive-bonded and laminated cellulosic
fiberboards (e.g., Thermo-ply.RTM. boards, available from OX
Engineered Products), asphalt-impregnated cellulosic fiberboards
(e.g., Celotex@ boards, available from Blue Ridge Fiberboard), or
thermoset resin-wood composite boards (e.g., low-density fiberboard
(particle board) and medium-density fiberboard)).
[0043] In one example, the bond break layer 160 comprises a Grade D
60-minute building paper (e.g., U.S. Federal Supply Service,
General Services Administration, Federal Specification UU-B-790a,
Type I-Barrier paper, Grade D-Water vapor permeable, Style
2-Uncreped, not reinforced, saturated). Grade D 60-minute building
paper generally comprises an asphalt-saturated kraft-type paper
having a water resistance rating of at least 60-minutes determined
according to ASTM D779-03: Standard Test Method for Water
Resistance of Paper, Paperboard, and Other Sheet Materials by the
Dry Indicator Method, which is incorporated-by-reference into this
specification.
[0044] The bond break layer 160 can be positioned adjacent to the
front facing surface 170a of the sheathing board 170 and attached
to the frame 111 using fasteners such as staples, screws, ring
clips, or nails, for example. The bond break layer 160 can be
positioned on the sheathing board 170 and attached to the frame 111
in a shingled fashion, beginning at the bottom of the wall
structure, so that horizontally-positioned rows of bond break
material have a vertical overlap along the horizontal width of the
wall structure (see overlap regions 169 in FIG. 6C).
[0045] The lath layer 165 can comprise a steel wire lath. For
example, the lath layer 165 can comprise a galvanized steel or
stainless steel, 17-gauge or 20-gauge, wire mesh lath. A steel wire
lath layer can be self-furred. As used in this specification, the
term "self-furred" means that the lath pulls away from the
underlying bond break layer by a sufficient distance to allow
applied stucco material to key into the lath layer and embed the
wire into the overlying stucco material. Self-furred wire laths can
be produced, for example, by crimping, dimpling, grooving, or
otherwise deforming the mesh in discrete locations to ensure that a
gap forms between the lath layer and the underlying bond break
layer when the lath layer is positioned adjacent to the bond break
layer. The gap between a self-furred steel wire lath and the
underlying bond break layer provides space for applied stucco
material to key into the mesh structure, embedding the wire into
the overlying stucco material. In this manner, stucco material
applied onto a lath layer comprising a self-furred steel wire lath
integrates into the lath layer and forms a wire-reinforced stucco
layer.
[0046] The lath layer 165 can be positioned adjacent to the bond
break layer 160 and attached to the frame 111 using fasteners such
as staples, screws, ring clips, or nails, for example. The lath
layer 165 can be positioned over the bond break layer 160 and
attached to the frame 111 in a shingled fashion, beginning at the
bottom of the wall structure, so that horizontally-positioned rows
of lath material have a vertical overlap along the horizontal width
of the wall structure (see overlap regions 169 in FIG. 6C). The
lath layer can be positioned over the bond break layer and attached
to the frame in accordance with ASTM C1063-15: Standard
Specification for Installation of Lathing and Furring to Receive
Interior and Exterior Portland Cement-Based Plaster, which is
incorporated-by-reference into this specification.
[0047] The bond break layer 160 and the lath layer 165 can be
bonded together and the pre-bonded combination attached to the
frame 111 simultaneously. In this manner, the pre-bonded
combination of the bond break layer 160 and the lath layer 165 can
be positioned on the front-facing surface 170a of the sheathing
board 170 and attached to the frame 111 with one set of fasteners
(e.g., nails, staples, ring clips, or screws, or a combination of
any thereof) that penetrate through the sheathing board 170 and
into the frame 111. The pre-bonded combination of the bond break
layer 160 and the lath layer 165 can comprise any of the bond break
layer materials described above. For example, the pre-bonded
combination of the bond break layer 160 and the lath layer 165 can
comprise a paper-backed metal wire lath, wherein the bond break
layer comprises a Grade D 60-minute building paper (or other
building paper) and the metal wire lath comprises a self-furred
steel wire lath. The bond break layer 160 and the lath layer 165
can be bonded together, for example, with an interpenetrating wire
and/or an adhesive.
[0048] In one implementation, the bond break layer 160 and the lath
layer 165 can comprise a paper-backed metal wire lath (e.g., a
self-furred steel wire lath bonded to a Grade D 60-minute building
paper with an interpenetrating wire and/or an adhesive) wherein the
lath layer 165 is offset on the bond break layer 160. For example,
referring to FIG. 8, the lath layer 165 is offset on the bond break
layer 160 so that two perpendicular edges of the overlying lath
layer 165 (a short edge 166a and a long edge 167a) overhang the
corresponding edges (161a and 162a) of the underlying bond break
layer 160, and two perpendicular edges of the underlying bond break
layer 165 (a short edge 161b and a long edge 162b) overhang the
corresponding edges (166b and 167b) of the overlying lath layer
165. The overhanging portions of the lath layer 165 and the bond
break layer 160 facilitate the positioning of the paper-backed
metal wire lath on the exterior-facing surface of the sheathing
board in a shingled fashion, beginning at the bottom of the wall
structure, so that horizontally-positioned rows of paper-backed
metal wire lath have a vertical overlap along the horizontal width
of the wall structure (see overlap regions 169 in FIG. 6C).
[0049] Still referring to FIGS. 1A-3, stucco layer 150 is
integrated into the lath layer 165. As noted above, the lath layer
165 can comprise a self-furred steel wire lath, which provides
space for applied stucco material to key into the mesh structure,
embedding the wire into the overlying stucco, and thereby
integrating the stucco material into the lath layer and forming a
wire-reinforced stucco layer. Although not shown, the stucco layer
150 can comprise one, two, three, or more separately-applied layers
of stucco material. For example, the stucco layer 150 can comprise
two separately-applied stucco layers: (1) a brown coat integrated
into the lath layer; and (2) a finish coat applied onto the brown
coat. As an alternative example, the stucco layer 150 can comprise
three separately-applied stucco layers: (1) a scratch coat
integrated into the lath layer; (2) a brown coat applied onto the
scratch coat; and (3) a finish coat applied onto the brown
coat.
[0050] A method for producing a wall structure as described above
can comprise providing a wall panel, attaching a bond break layer
and a lath layer to the wall panel (either separately or as a
pre-bonded combination), and applying a stucco layer integrated
into the lath layer. The wall panel can comprise a frame comprising
a first member, a second member spaced apart from the first member,
and two side members extending between the first member and the
second member. The first member, the second member, and the two
side members each comprise a front surface and a rear surface that
form a front frame surface and a rear frame surface, and a
sheathing board is attached to the front frame surface. The
sheathing board can comprise an extruded polystyrene board or a
polyiso board comprising a polyisocyanurate foam layer and a facer
material attached to at least the front face of the
polyisocyanurate foam layer. The sheathing board, the first and
second members, and the two side members define a cavity within the
frame, and a foam layer is located within the cavity and adhered to
the rear-facing surface of the sheathing board. Wall panels can be
provided in pre-fabricated form as described, for example, in U.S.
Patent Application Publication No. 2015/0093535 A1, which is
incorporated-by-reference into this specification.
[0051] FIGS. 6A-6B and 7A-7B illustrate the pre-fabrication of a
wall panel 109. Referring to FIGS. 6A and 7A, a partially-complete
wall panel 107 comprises a frame 111 and a sheathing board 170
attached to the front frame surface 111a. The constituent members
of the frame 111 (i.e., members 112, 114, 116, and 117) define
cavities 118 in the frame 111. Referring to FIGS. 6B and 7B, foam
layers 130 are deposited in the cavities 118 in the frame and
adhere to the sheathing board 170. The frame 111, the attached
sheathing board 170, and the deposited foam layers 130 collectively
form the wall panel 109.
[0052] FIGS. 6C-6E and 7C-7E illustrate a method for producing a
wall structure. Referring to FIGS. 6C and 7C, a bond break layer
160 and a lath layer 165 are positioned adjacent to the
front-facing surface 170a of the sheathing board 170 of the wall
panel 109. As described above, the bond break layer 160 and the
lath layer 165 can be positioned on the sheathing board 170 and
attached to the frame 111 either sequentially as separately-applied
layers or simultaneously as a pre-bonded combination (e.g., as a
paper-backed metal wire lath). In either option, the bond break
layer 160 can comprise, for example, a Grade D 60-minute building
paper or any of the other materials described above, and the lath
layer 165 can comprise a self-furred steel wire lath. If the bond
break layer 160 and the lath layer 165 are pre-bonded together,
then the pre-bonded combination of the bond break layer 160 and the
lath layer 165 can be simultaneously positioned adjacent to the
front-facing surface 170a of the sheathing board 170 and attached
to the frame 111 with one set of fasteners that penetrate through
the sheathing board.
[0053] Referring to FIGS. 6D and 7D, the stucco layer 150 is
applied onto the lath layer 165. As described above, the stucco
layer 150 is integrated into the lath layer 165. For example, the
lath layer 165 can comprise a self-furred steel wire lath, which
provides space for the applied stucco material to key into the mesh
structure, embedding the wire into the overlying stucco layer, and
thereby integrating the stucco layer into the lath layer and
forming a wire-reinforced stucco layer. Although not shown, the
stucco layer 150 can be applied as one, two, three, or more
separately-applied layers of stucco material. For example, the
application of the stucco layer 150 can comprise the separate
application of: (1) a brown coat applied onto the lath layer; and
(2) a finish coat applied onto the brown coat. As an alternative
example, the application of the stucco layer 150 can comprise the
separate application of: (1) a scratch coat integrated into the
lath layer; (2) a brown coat applied onto the scratch coat; and (3)
a finish coat applied onto the brown coat.
[0054] Referring to FIGS. 6E and 7E, an interior wall cladding
material 120 (e.g., drywall, plaster board, wood paneling,
composite paneling, or other inside wall cladding material) can be
applied and attached to the rear-facing surface 111a of the frame
111. A gap 140 is shown located between the foam layer 130 and an
interior wall cladding 120, but it is understood that,
alternatively, the foam layer can fill the space between the
sheathing board and the interior wall cladding.
[0055] For ease of illustration, FIGS. 6C-6E illustrate the
production of a wall structure 110 comprising one wall panel 109.
However, it is understood that the wall structures described in
this specification can comprise any number of separate wall panels
joined together to form the wall structure. For example, referring
to FIGS. 6B and 7B, any number of wall panels 109 can be provided
at a building site (e.g., delivered to the building site) and
assembled into an incomplete exterior wall structure. The
incomplete exterior wall structure comprising multiple wall panels
can be assembled on and attached to a building foundation. A roof
structure can be installed on the incomplete exterior wall
structure. A bond break layer and a lath layer, as described above,
can be applied to the incomplete exterior wall structure covering
the multiple assembled wall panels. A stucco layer can be applied
onto and integrated into the lath layer over the multiple assembled
wall panels to complete the exterior-facing surface of the wall
structure.
[0056] Additionally, the production of a wall structure comprising
multiple assembled wall panels can comprise the installation of
additional stucco cladding components such as, for example, corner
beads, weep screeds, control joints, and expansion joints.
[0057] FIGS. 9A-15 illustrate additional features of the wall
panels used to produce the wall structures described in this
specification. For example referring to FIGS. 10A and 10B, a wall
panel 10 includes a frame 11, at least one primary support member
17, a sheathing board 70, and a foam layer 30. As shown in FIGS. 9A
and 9B, the frame 11 may be defined by a first member 12, a second
member 14 spaced apart from the first member 12, and two side
members 16 extending between the first member 12 and the second
member 14. The first member 12, the second member 14, and the two
side members 16 each have a front surface 12a, 14a, 16a and a rear
surface 12b, 14b, 16b that define a front frame surface 11a and a
rear frame surface 11b, respectively.
[0058] The frame 11 can be constructed into different shapes
depending on its intended use in the production of a stucco wall
structure. For example, as shown in FIGS. 9A and 9B, the frame 11
can be constructed as a conventional industry standard rectangular
or square frame 11. The first member 12 and the second member 14
may be spaced apart and extend parallel to each other, and the two
side members 16 may extend perpendicular to the first member 12 and
the second member 14 so as to from a rectangular or square frame
11. The shape and design of the frame 11 is not so limited and can
be constructed into any desired shape. Generally, the shape and
design of the frame 11 is constructed in accordance with the floor
plans designed for a particular home or building.
[0059] Referring to FIGS. 10A and 10B, at least one primary support
member 17 may be positioned between the two side members 16. The
primary support members 17 may extend between the first member 12
and the second member 14. The primary support members 17 may define
a front primary support surface 17a and a rear primary support
surface 17b. As shown in FIGS. 10A and 10B, the front primary
support surface 17a and the rear primary support surface 17b
correspond to the front frame surface 11a and the rear frame
surface 11b of the frame 11. The primary support members 17 may be
spaced apart to form cavities 18. The cavities 18 may be defined by
the space formed within the frame 11 between the primary support
members 17, the side members 16, the first member 12, and/or the
second member 14. The size of each cavity 18 can vary based on the
size of the frame 11, the distance between consecutively positioned
primary support members 17, and the number of primary support
members 17 present. The primary support members 17, the side
members 16, the first member 12, and/or the second member 14 may
comprise one or more plates, boards, beams, studs, or the like. For
example, as shown in FIGS. 9A-10B, the first member 12 may include
two beams.
[0060] The two side members 16 and/or the primary support members
17 may be fixedly engaged to the first member 12 and the second
member 14. For example, the two side members 16 and/or the primary
support members 17 may be fixedly engaged to the first member 12
and the second member 14 with fasteners. Suitable fasteners
include, but are not limited to, nails, nail plates, staples,
bolts, screws, and rivets. The first member 12, the second member
14, the two side members 16, and the primary support members 17 can
be made of various materials. For example, the first member 12, the
second member 14, the two side members 16, and the primary support
members 17 can be made of wood, metal, fiberglass, plastic,
wood-polymer composite materials, or a combination of any thereof.
The first member 12, the second member 14, the two side members 16,
and the primary support members 17 can be made of the same material
or different materials.
[0061] The dimensions of the first member 12, the second member 14,
the two side members 16, and the primary support members 17 can
vary depending on the intended use of the frame 11. The first
member 12, the second member 14, the two side members 16, and the
primary support members 17 can each have any dimension. The first
member 12, the second member 14, the two side members 16, and the
primary support members 17 can have the same dimensions. For
example, the first member 12, the second member 14, the two side
members 16, and the primary support members 17 may have the same
thickness and width dimensions, and the same or different length
dimensions. For example, the first member 12, the second member 14,
the two side members 16, and the primary support members 17 can all
have a thickness and width and height dimension of nominally
2.times.4 inches. In another example, the first member 12, the
second member 14, the two side members 16, and the primary support
members 17 can all have thickness and width dimensions of nominally
2.times.6 inches.
[0062] The first member 12, the second member 14, and the two side
members 16 can have the same dimensions, which may be different
than the dimensions of the primary support members 17. For example,
the first member 12, the second member 14, and the two side members
16 may have the same thickness and width dimensions, and the
primary support members 17 may have thickness and/or width
dimensions that may be different than the dimensions of the first
member 12, the second member 14, and the two side members 16. For
example, the first member 12, the second member 14, and the two
side members 16 can have thickness and width dimensions of
nominally 2.times.6 inches, and the primary support members 17 can
have thickness and width dimension of nominally 2.times.4
inches.
[0063] Referring to FIGS. 11 and 12, a wall structure can comprise
one or more secondary support members 20, and/or tertiary support
members 22. The secondary support members 20 and the tertiary
support members 22 may comprise one or more plates, boards, beams,
studs, or the like. The secondary support members 20 and the
tertiary support members 22 can be incorporated into the frame 11
to provide additional structural support, for example, to form
spaces for windows, doors, and the like. The secondary support
members 20 and the tertiary support members 22 can have dimensions
that are the same as or different than the primary support members
17, the side members 16, the first member 12, and/or the second
member 14. For example, the secondary support member 20 and the
tertiary support members 22 can have shorter lengths than the
primary support members 17, the side members 16, the first member
12, and/or the second member 14.
[0064] As shown in FIGS. 11 and 12, the secondary support members
20 may have a front secondary support surface 20a and a rear
secondary support surface (not shown) that correspond with the
front and rear frame surfaces 11a and 11b, and the front and rear
primary support surfaces 17a and 17b. Similarly, the tertiary
support members 22 may have a front tertiary support surface 22a
and a rear tertiary support surface 22b (see FIG. 27) that
correspond with the front and rear frame surfaces 11a and 11b and
the front and rear primary support surfaces 17a and 17b.
[0065] The secondary support members 20 extend between and attach
to the primary support members 17, or alternatively, the secondary
support members 20 extend between and attach to a primary support
member 17 and a side member 16. The tertiary support members 22
extend between two secondary support members 20 or between a
secondary support member 22 and the first member 12 and/or the
second member 14.
[0066] The secondary support members 20, the tertiary support
members 22, the primary support members 17, the side members 16,
the first member 12, and/or the second member 14 form a secondary
cavity 26. As shown in FIGS. 11 and 12, the secondary cavity 26 can
be used as a space for a window, a door, or any other opening. For
example, the secondary support members 20, the tertiary support
members 22, the primary support members 17, the side members 16,
the first member 12, and the second member 14 can be constructed as
a conventional industry standard rectangular or square wall panel
having a window, door, or any other opening. For example, referring
to FIG. 11, a rectangular or square wall structure having a window
can be formed as follows: a first member 12 and a second member 14
may be spaced apart and extend parallel to each other; two side
members 16 may extend between the first member 12 and the second
member 14 in a direction perpendicular to the first member 12 and
the second member 14; primary support members 17 may be positioned
between the side members 16 and extend between the first member 12
and the second member 14 in a direction perpendicular to the first
member 12 and the second member 14; two secondary support members
20 may be spaced apart and extend between the primary support
members 17 in a direction parallel to the first member 12 and the
second member 14; and two tertiary support members 22 may be spaced
apart and extend between the two secondary members 20 in a
direction perpendicular to the secondary support members 20 and the
first member 12 and the second member 14. In addition, the primary
support members 17 can also extend between the secondary members 20
and the first member 12 and/or the second member 14. As shown in
FIG. 11, a secondary cavity 26 may be formed between the secondary
support members 20 and the tertiary support members 22. The
resulting rectangular or square wall panel can be used in a
residential home or building. The shape and design of the frame 11
of the wall panel 10 is not so limited and can assume any shape and
design as desired.
[0067] Additional support members and structural elements may also
be used depending on the intended use of the wall panel 10. For
example, and as shown in FIGS. 11 and 12, a header 28 may be used
to provide additional support for a door or window. Other
additional support members may be used for structural purposes,
design purposes, and the like.
[0068] Referring to FIGS. 13, 14A, and 14B, a sheathing board 70
may be attached to at least a portion of the front frame surface.
As described above, the sheathing board can comprise an extruded
polystyrene board or a polyiso board comprising a sheet or slab or
section comprising polyisocyanurate-modified polyurethane foam
(i.e., a polyisocyanurate foam layer). Polyiso boards can also
comprise facer materials, as described above, located on the rear
face and/or front face of the polyisocyanurate foam layer. Compared
to polyurethane foams, polyiso foams have a much higher isocyanate
content. Through the use of certain catalysts the isocyanate is
able to react with itself forming a ring-like structure
(polyisocyanurate) that is very stable. Sheathing boards (i.e., XPS
boards and polyiso boards) typically have a thickness which varies
depending on the application. For example, a sheathing board can
have a thickness of about 1/2-inch to about 3-inches, or any
sub-range subsumed therein such as, for example, about 3/4-inch to
about 2-inches.
[0069] The sheathing board may be attached to the front frame
surface by various attachment mechanisms. For example, the
sheathing board can be attached to the front frame surface by
fasteners. The fasteners used to attach the sheathing board to the
front frame surface are not necessarily the same as the fasteners
used to engage the first and second members, as described above.
Suitable fasteners may include nails, staples, screws, bolts, or
rivets, or a combination of any thereof. Because sheathing boards
comprise polyisocyanurate foam or extruded polystyrene, which have
relatively low fastener pull-out strength, care must be used when
mechanically fastening sheathing boards to frames so as not to
damage the sheathing board.
[0070] Alternatively, the sheathing board can be attached to the
front frame surface by the use of one or more adhesives. The
adhesives may be selected from latex-based adhesives, reactive hot
melts, polyester adhesives, polyamide adhesives, acrylic adhesives,
one-component epoxy-based adhesives, one-component
polyurethane-based adhesives, two-component polyurethane-based
adhesives, and combinations of any thereof. Also, as described
above, a foam material may be used as the adhesive. For example, a
layer of foam may be applied to the sheathing board, the front
frame surface, or both, before positioning and attaching the
sheathing board to the front frame surface.
[0071] As described above, sheathing boards can comprise facers on
both sides of a polyisocyanurate foam layer or an extruded
polystyrene layer, which may be the same or different. Examples of
suitable facer materials include, but are not limited to,
fiberglass mats, glass fiber-reinforced cellulosic felts, coated
and polymer-bonded fiber mats (e.g., fibrous glass mats bonded with
an organic polymer binder and coated with an organic polymer
coating, clay, or other inorganic coating), foils (e.g., aluminum
foil), coated foils, foil/membrane laminates, foil/glass
composites, and polyolefin films (such as TYVEK.RTM. materials,
available from DuPont; or TYPAR.RTM. materials, available from
Fiberweb, Inc.).
[0072] The sheathing board 70 attached to the frame 11 may comprise
multiple separate sheathing boards (i.e., multiple sections) which
may be joined together by tape or caulk or polyurethane foam to
form the sheathing board 70. The foam layer 30, which adheres to
the sheathing board, comprises a foam material deposited into the
frame 11. As used in this specification, the term "foam material"
refers to a substance that is formed by trapping pockets of gas in
a liquid or solid. For example, a foam material can be a
"closed-cell foam," which as used in this specification refers to
foam that contains discrete, non-interconnecting cells. Examples of
foam material that can be used with the present invention include
foam materials made with polyurethane, polyisocyanurate (also
referred to as polyiso, as described above), and mixtures thereof.
As described above, the foam material may be substantially free,
may be essentially free, and may be completely free of halogen
containing flame retardant additives.
[0073] As shown in FIGS. 10A, 10B, 13, 14A, 14B, and 15, the foam
material can be deposited into the frame 11 such that the foam
material forms a foam layer 30 within at least a portion of the
frame 11 between the front frame surface 11a and the rear frame
surface 11b, and adheres to the sheathing board 70.
[0074] Referring to FIGS. 13, 14A, and 14B, the foam layer 30 can
be dimensioned to expand to a position intermediate the front frame
surface 11a and the rear frame surface 11b, thereby forming a gap
40 within the wall panel 10 between the foam layer 30 and the rear
frame surface 11b. FIGS. 10A and 10B further show that the gap 40
can be used as an area to incorporate home utility components 42
such as electrical wires, cords, heating and cooling pipes, and
plumbing fixtures. These home utility components may be inserted
into the gap 40 located between the foam layer 30 and the rear
frame surface 11b such that utilities components are not surrounded
by or contacting the foam layer 30. In one example, the gap 40 can
comprises at least two inches as measured between the foam layer
and the rear frame surface 14.
[0075] When secondary support members 20 and/or tertiary support
members 22 are used with the wall panel 10 to form a secondary
cavity 26, the secondary cavity 26 can be free of foam. For
example, the foam layer 30 does not extend beyond and over the
front secondary support surfaces 20a of the secondary members 20,
the front tertiary support surfaces 22a of the tertiary support
members 22, and/or beyond and over at least a portion of the front
surfaces of other members that help form the secondary cavity 26.
FIG. 15, for example, shows a top cross-sectional view with the
foam layer 30 not extending beyond the front tertiary support
surface 22a of the tertiary members 22. In such cases,
corresponding openings may also be present in the sheathing board
70.
[0076] The foam layer 30 can be formed in-situ during the
manufacturing process. The term "formed in-situ during the
manufacturing process," as used in this specification, refers to
the formation of a foam layer 30 as described in this specification
during manufacturing of the foam wall panel 10 off-site at a
facility remote or away from a building construction site. As such,
the foam layer 30 may be formed not at a construction site as is
required by conventional methods, but instead as a component of the
pre-fabricated wall panel 10.
[0077] The foam layer 30 is able to fill tight spaces and seal gaps
that may not be visible to the naked eye. The foam layer 30 can
also act as a vapor and thermal insulating barrier, which reduces
energy consumption in buildings and residential homes when the wall
panel 10 is used as a constituent wall panel. The foam layer 30 may
provide structural stability to the wall panel 10, such as improved
wall racking strength, which refers to the ability of a wall
structure to maintain its shape under shear stress.
[0078] The wall panels described above in connection with FIGS.
10A-15 can be used for the production of the wall structures
described in this specification. For example, the wall panels
(comprising a frame, an attached sheathing board, and a foam layer
positioned in a cavity) can be provided at a building site (e.g.,
delivered to the building site) and assembled into an incomplete
exterior wall structure. The incomplete exterior wall structure
comprising multiple wall panels can be assembled on and attached to
a building foundation. A roof structure can be installed on the
incomplete exterior wall structure. Additional stucco cladding
components, such as, for example, corner beads, weep screeds,
control joints, and expansion joints, can be installed. A bond
break layer and a lath layer, as described above, can be applied to
the incomplete exterior wall structure covering the multiple
assembled wall panels. A stucco layer can be applied onto and
integrated into the lath layer over the multiple assembled wall
panels to complete the exterior-facing surface of the wall
structure.
[0079] The wall structures and the method of producing the wall
structures described in this specification eliminate many of the
typical construction steps involved in the production of stucco
walls and provide a more robust system in terms of ease of
installation, racking strength, insulating properties (R-values),
and durability. For example, the wall panels (comprising the frame,
the attached sheathing board, and the foam layer positioned in the
frame cavities) can be engineered and pre-fabricated off-site and
provided as necessary to building sites. This eliminates the site
framing of walls and the installation of cavity insulation such as
fiberglass into the walls. The facer material attached to the front
face of a polyisocyanurate foam layer of a polyiso board (e.g., a
glass mat material, foil, or the like), or the front face (with or
without optional facer materials) of an extruded polystyrene board,
provides a primary drainage plane integrated into the sheathing
board that eliminates the separate application of building paper or
other wrapping product over the open frame structure. The sheathing
board also eliminates the need for window, door, or other
penetration pre-flashing. The pre-attachment of the sheathing
boards to the frames eliminates the need for on-site shear bracing
with OSBs or T-bracing. The sheathing boards simultaneously provide
thermal insulation, an integral drainage plane, and a rigid backing
for the application of the exterior stucco layer, which eliminates
the need for the separate installation of an EPS bond break layer
over the primary drainage plane.
[0080] Additionally, as noted above, typical methods of stucco
construction require at least three separate sets of fasteners,
such as nails and staples, to penetrate the various layers and
engage the wooden studs of the frame: (1) the fasteners attaching
the primary drainage plane to the frame; (2) the fasteners
attaching the bond break panels to the frame, which necessarily
penetrate through the primary drainage plane; and (3) the fasteners
attaching the lath to the frame, which necessarily penetrate
through both the bond break panels and the primary drainage plane.
The wall structure and method described in this specification can
decrease the sets of fastener penetrations from three to one with
the use of a pre-bonded combination of a bond break layer and a
lath layer (e.g., a paper-backed metal wire lath), in which the
bond break layer and the lath layer are simultaneously attached to
the frame with one set of fasteners that penetrate through the
sheathing board. The decrease in the number of fasteners improves
the overall durability of the system by eliminating approximately
two-thirds of the pathways for water infiltration into the interior
of the wall structure. Furthermore, the wall structure eliminates
the need for the inspection and caulking of fasteners that miss the
frame because such fasteners would penetrate into the cavity foam
layer and therefore be automatically encapsulated and isolated in
the wall structure.
EXAMPLES
[0081] Various features and characteristics of examples of the
invention include, but are not limited to, the following numbered
clauses:
[0082] 1. A wall structure comprising: a frame comprising: a first
member; a second member spaced apart from the first member; and two
side members extending between the first member and the second
member, wherein the first member, the second member, and the two
side members each comprise a front surface and a rear surface that
form a front frame surface and a rear frame surface; a sheathing
board attached to the front frame surface, wherein the sheathing
board, the first and second members, and the two side members
define a cavity within the frame; a foam layer located within the
cavity and adhered to a rear-facing surface of the sheathing board;
a bond break layer located adjacent to a front-facing surface of
the sheathing board; a lath layer located adjacent to the bond
break layer; and a stucco layer integrated into the lath layer.
[0083] 2. The wall structure of clause 1, wherein the bond break
layer comprises an asphalt-impregnated kraft paper, an
asphalt-impregnated felt paper, an extruded polystyrene layer, an
expanded polystyrene layer, a polyiso layer, a polyethylene sheet
or film, a polypropylene sheet or film, a poly(vinyl chloride)
sheet or film, a woven house wrap, a perforated housewrap, a
nonmoven and spunbonded polyolefin sheet or film, a woven and
perforated polyolefin sheet or film, a layer comprising a
three-dimensional matrix of randonly-oriented extruded polymer
filaments, or a fiberboard.
[0084] 3. The wall structure of clause 1 or clause 2, wherein the
bond break layer comprises a Grade D 60-minute building paper.
[0085] 4. The wall structure of any one of clauses 1-3, wherein the
lath layer comprises a self-furred steel wire lath.
[0086] 5. The wall structure of any one of clauses 1-4, wherein the
bond break layer and the lath layer are pre-bonded together, and
wherein the pre-bonded combination of the bond break layer and the
lath layer are positioned on the front-facing surface of the
sheathing board and attached to the frame with one set of fasteners
that penetrate through the sheathing board.
[0087] 6. The wall structure of clause 5, wherein the bond break
layer and the lath layer are pre-bonded together with an
adhesive.
[0088] 7. The wall structure of clause 5, wherein the one set of
fasteners attaching the combination of the bond break layer and the
lath layer to the frame comprise nails, staples, or screws, or a
combination of any thereof.
[0089] 8. The wall structure of clause 5, wherein the pre-bonded
combination of the bond break layer and the lath layer comprises a
paper-backed metal wire lath.
[0090] 9. The wall structure of clause 8, wherein the bond break
layer comprises a Grade D 60-minute building paper.
[0091] 10. The wall structure of clause 8, wherein the metal wire
lath comprises a self-furred steel wire lath.
[0092] 11. The wall structure of any one of clauses 1-10, wherein
the sheathing board comprises a polyiso board comprising facer
materials attached to and covering a front face and a rear face of
a polyisocyanurate foam layer.
[0093] 12. The wall structure of clause 11, wherein the facer
materials comprise fiberglass mat, glass fiber-reinforced
cellulosic felt, coated and polymer-bonded fiber mat, foil, coated
foil, foil/membrane laminate, foil/glass composite, or polyolefin
film.
[0094] 13. The wall structure of any one of clauses 1-10, wherein
the sheathing board comprises an extruded polystyrene board.
[0095] 14. The wall structure of any one of clauses 1-13, wherein
the foam layer comprises polyurethane or polyisocyanurate, or
mixtures thereof.
[0096] 15. The wall structure of any one of clauses 1-13, wherein
the foam layer is substantially free of halogen-containing flame
retardant additives.
[0097] 16. The wall structure of any one of clauses 1-13, wherein
the foam layer is completely free of halogen containing flame
retardant additives.
[0098] 17. The wall structure of any one of clauses 1-16, wherein
the sheathing board is attached to the front faces of the first and
second members, and to the front faces of the two side members,
with fasteners.
[0099] 18. The wall structure of clause 17, wherein the fasteners
comprise nails, staples, or screws, or a combination of any
thereof.
[0100] 19. The wall structure of any one of clauses 1-18, wherein
the sheathing board is attached to the front faces of the first and
second members, and to the front faces of the two side members,
with an adhesive.
[0101] 20. The wall structure of clause 19, wherein the adhesive
comprises a foam material that is the same material comprising the
foam layer.
[0102] 21. The wall structure of any one of clauses 1-20, wherein
the foam layer comprises a thickness extending from the rear-facing
surface of the sheathing board to a position intermediate the front
frame surface and the rear frame surface such that a gap is formed
within the frame between a rear-facing surface of the foam layer
and the rear frame surface.
[0103] 22. The wall structure of any one of clauses 1-21, further
comprising a primary support member positioned between the two side
members and extending between the first member and the second
member, wherein the primary support member comprises a front
primary support surface and an opposite rear primary support
surface, and wherein the front primary support surface corresponds
to the front frame surface.
[0104] 23. The wall structure of clause 22, wherein the rear
primary support surface corresponds to the rear frame surface.
[0105] 24. The wall structure of clause 22, wherein the sheathing
board is attached to the front frame surface and the front primary
support surface.
[0106] 25. The wall structure of clause 22, wherein the sheathing
board, the first and second members, the two side members, and the
primary support member define a two or more cavities within the
frame, and wherein the foam layer is located within the two or more
cavities and adhered to the sheathing board.
[0107] 26. The wall structure of clause 22, wherein the frame
further comprises one or more secondary support members extending
between two adjacent primary support members, or extending between
a primary support member and a side member, such that a secondary
opening is formed within the frame.
[0108] 27. The wall structure of clause 26, wherein the secondary
opening is free of foam, and a corresponding opening is present in
the sheathing board.
[0109] 28. The wall structure of clause 26, wherein the frame
further comprises one or more tertiary support members extending
between two secondary support members, or extending between a
secondary support member and the first member or the second
member.
[0110] 29. A method for producing a wall structure comprising:
providing a wall panel, the wall panel comprising: a frame
comprising: a first member; a second member spaced apart from the
first member; and two side members extending between the first
member and the second member, wherein the first member, the second
member, and the two side members each comprise a front surface and
a rear surface that form a front frame surface and a rear frame
surface; a sheathing board attached to the front frame surface,
wherein the sheathing board, the first and second members, and the
two side members define a cavity within the frame; and a foam layer
located within the cavity and adhered to a rear-facing surface of
the sheathing board; positioning a bond break layer and a lath
layer adjacent to a front-facing surface of the sheathing board;
attaching the bond break layer and the lath layer to the frame; and
applying a stucco layer integrated into the lath layer.
[0111] 30. The method of clause 29, further comprising: assembling
multiple wall panels into an incomplete wall structure; positioning
the bond break layer and the lath layer adjacent to the
front-facing surfaces of the sheathing board and over the
incomplete wall structure; attaching the bond break layer and the
lath layer to the frames of the multiple assembled panels; and
applying a stucco layer integrated into the lath layer to complete
the wall structure.
[0112] 31. The method of clause 29 or clause 30, wherein the bond
break layer comprises an asphalt-impregnated kraft paper, an
asphalt-impregnated felt paper, an extruded polystyrene layer, an
expanded polystyrene layer, a polyiso layer, a polyethylene sheet
or film, a polypropylene sheet or film, a poly(vinyl chloride)
sheet or film, a woven house wrap, a perforated housewrap, a
nonmoven and spunbonded polyolefin sheet or film, a woven and
perforated polyolefin sheet or film, a layer comprising a
three-dimensional matrix of randonly-oriented extruded polymer
filaments, or a fiberboard.
[0113] 32. The method of any one of clauses 29-31, wherein the bond
break layer comprises a Grade D 60-minute building paper.
[0114] 33. The method of any one of clauses 29-32, wherein the lath
layer comprises a self-furred steel wire lath.
[0115] 34. The method of any one of clauses 29-33, wherein the bond
break layer and the lath layer are pre-bonded together, and wherein
the pre-bonded combination of the bond break layer and the lath
layer are positioned on the front-facing surface of the sheathing
board and attached to the frame with one set of fasteners that
penetrate through the sheathing board.
[0116] 35. The method of clause 34, wherein the pre-bonded
combination of the bond break layer and the lath layer comprises a
paper-backed metal wire lath.
[0117] 36. The method of any one of clauses 29-35, wherein the
sheathing board comprises a polyiso board comprising facer
materials attached to and covering a front face and/or a rear face
of a polyisocyanurate foam layer.
[0118] 37. The method of clause 36, wherein the facer materials
comprise fiberglass mat, glass fiber-reinforced cellulosic felt,
coated and polymer-bonded fiber mat, foil, coated foil,
foil/membrane laminate, foil/glass composite, or polyolefin
film.
[0119] 38. The method of any one of clauses 29-35, wherein the
sheathing board comprises an extruded polystyrene board.
[0120] 39. The method of any one of clauses 29-38, wherein the foam
layer comprises polyurethane or polyisocyanurate, or mixtures
thereof.
[0121] 40. The method of any one of clauses 29-39, wherein applying
the stucco layer comprises: applying a brown coat integrated into
the lath layer; and applying a finish coating onto the brown
coat.
[0122] 41. The method of any one of clauses 29-40, wherein applying
the stucco layer comprises: applying a scratch coat integrated into
the lath layer; applying a brown coat onto the scratch coat; and
applying a finish coating onto the brown coat.
[0123] Various features and characteristics of the inventions are
described in this specification to provide an overall understanding
of the disclosed wall structures and method of production. It is
understood that the various features and characteristics described
in this specification can be combined in any suitable manner
regardless of whether such features and characteristics are
expressly described in combination in this specification. The
Applicant expressly intends such combinations of features and
characteristics to be included within the scope of this
specification. As such, the claims can be amended to recite, in any
combination, any features and characteristics expressly or
inherently described in, or otherwise expressly or inherently
supported by, this specification. Furthermore, the Applicant
reserves the right to amend the claims to affirmatively disclaim
features and characteristics that may be present in the prior art,
even if those features and characteristics are not expressly
described in this specification. Therefore, any such amendments
will not add new matter to the specification or claims, and will
comply with written description and sufficiency of description
requirements (e.g., 35 U.S.C. .sctn.112(a) and Article 123(2) EPC).
The wall structures and methods disclosed in this specification can
comprise, consist of, or consist essentially of the various
features and characteristics described in this specification.
[0124] Also, any numerical range recited in this specification
describes all sub-ranges of the same numerical precision (i.e.,
having the same number of specified digits) subsumed within the
recited range. For example, a recited range of "1.0 to 10.0"
describes all sub-ranges between (and including) the recited
minimum value of 1.0 and the recited maximum value of 10.0, such
as, for example, "2.4 to 7.6," even if the range of "2.4 to 7.6" is
not expressly recited in the text of the specification.
Accordingly, the Applicant reserves the right to amend this
specification, including the claims, to expressly recite any
sub-range of the same numerical precision subsumed within the
ranges expressly recited in this specification. All such ranges are
inherently described in this specification such that amending to
expressly recite any such sub-ranges will not add new matter to the
specification or claims, and will comply with written description
and sufficiency of description requirements (e.g., 35 U.S.C.
.sctn..sctn.112(a) and Article 123(2) EPC). Additionally, numerical
parameters described in this specification should be construed in
light of the number of reported significant digits, the numerical
precision of the number, and by applying ordinary rounding
techniques. It is also understood that numerical parameters
described in this specification will necessarily possess the
inherent variability characteristic of the underlying measurement
techniques used to determine the numerical value of the
parameter.
[0125] Any patent, publication, or other disclosure material
identified in this specification is incorporated by reference into
this specification in its entirety unless otherwise indicated, but
only to the extent that the incorporated material does not conflict
with existing descriptions, definitions, statements, or other
disclosure material expressly set forth in this specification. As
such, and to the extent necessary, the express disclosure as set
forth in this specification supersedes any conflicting material
incorporated by reference. Any material, or portion thereof, that
is incorporated by reference into this specification, but which
conflicts with existing definitions, statements, or other
disclosure material set forth in this specification, is only
incorporated to the extent that no conflict arises between that
incorporated material and the existing disclosure material.
Applicant reserves the right to amend this specification to
expressly recite any subject matter, or portion thereof,
incorporated by reference.
[0126] The grammatical articles "one", "a", "an", and "the", as
used in this specification, are intended to include "at least one"
or "one or more", unless otherwise indicated. Thus, the articles
are used in this specification to refer to one or more than one
(i.e., to "at least one") of the grammatical objects of the
article. By way of example, "a component" means one or more
components, and thus, possibly, more than one component is
contemplated and can be employed or used in an implementation of
the described processes, compositions, and products. Further, the
use of a singular noun includes the plural, and the use of a plural
noun includes the singular, unless the context of the usage
requires otherwise.
* * * * *