U.S. patent application number 15/680367 was filed with the patent office on 2018-02-22 for metal lath accessory with metal lath attachment feature.
The applicant listed for this patent is Clarkwestern Dietrich Building Systems LLC. Invention is credited to Nick Joseph Apanovich, Hernando Garcia, Christopher K. Little, Erenio Reyes, Jeremy Ryan Smith.
Application Number | 20180051470 15/680367 |
Document ID | / |
Family ID | 61191297 |
Filed Date | 2018-02-22 |
United States Patent
Application |
20180051470 |
Kind Code |
A1 |
Smith; Jeremy Ryan ; et
al. |
February 22, 2018 |
METAL LATH ACCESSORY WITH METAL LATH ATTACHMENT FEATURE
Abstract
A metal lath accessory comprising a metal lath attachment
feature that includes a side wall, a first flange extending from
the side wall, and a second flange extending from the side wall.
The first flange comprises at least one barb that projects from the
first flange towards the second flange. In some embodiments, the
second flange comprises at least one barb that projects from the
second flange toward the first flange. The barbs may be configured
to engage a piece of metal lath that is inserted between the first
flange and the second flange.
Inventors: |
Smith; Jeremy Ryan;
(Carrollton, VA) ; Apanovich; Nick Joseph; (Tampa,
FL) ; Reyes; Erenio; (Miami, FL) ; Little;
Christopher K.; (Suwanee, GA) ; Garcia; Hernando;
(Doral, FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Clarkwestern Dietrich Building Systems LLC |
West Chester |
OH |
US |
|
|
Family ID: |
61191297 |
Appl. No.: |
15/680367 |
Filed: |
August 18, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62377067 |
Aug 19, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 2013/066 20130101;
E04F 13/045 20130101; E04F 19/062 20130101; E04F 13/074 20130101;
E04F 19/061 20130101; E04F 13/047 20130101 |
International
Class: |
E04F 13/04 20060101
E04F013/04 |
Claims
1. A metal lath accessory comprising: a. a side wall; b. a first
flange, wherein the first flange extends from the sidewall in a
first direction; c. a second flange, wherein the second flange
extends from the sidewall in the first direction such that the
first flange and the second flange are spaced apart from each
other; and d. a first barb, wherein the first barb projects from
the first flange toward the second flange.
2. The metal lath accessory of claim 1, wherein the first barb
comprises a first ramped portion.
3. The metal lath accessory of claim 2, wherein the side wall, the
first flange, and the second flange at least partially define a
channel comprising an opening, and wherein the first ramped portion
is facing the opening of the channel.
4. The metal lath accessory of claim 2, wherein the first barb
further comprises a first shoulder portion.
5. The metal lath accessory of claim 4, wherein the first shoulder
portion is facing the side wall.
6. The metal lath accessory of claim 1 further comprising a second
barb, wherein the second barb projects from the second flange
toward the first flange.
7. The metal lath accessory of claim 1, wherein the first flange is
substantially parallel to the second flange.
8. The metal lath accessory of claim 1, wherein the first flange
comprises a first plurality of openings.
9. The metal lath accessory of claim 8, wherein the second flange
comprises a second plurality of openings.
10. The metal lath accessory of claim 9, wherein each of the first
plurality of openings in the first flange is aligned with a
corresponding one of the second plurality of openings in the second
flange.
11. The metal lath accessory of claim 1, wherein the first flange
further comprises an angled portion located at a free end of the
first flange.
12. The metal lath accessory of claim 1, wherein the first barb
comprises a substantially triangular cross-section.
13. The metal lath accessory of claim 1, wherein the side wall, the
first flange, the second flange and the first barb are of unitary
construction.
14. A metal lath accessory comprising: a. a side wall; b. a first
flange comprising a first plurality of openings, wherein the first
flange extends from the sidewall in a first direction; c. a second
flange, wherein the second flange extends from the sidewall in the
first direction such that the first flange and the second flange
are spaced apart from each other; d. a first plurality of barbs,
wherein the first plurality of barbs project from the first flange
toward the second flange, wherein at least one of the first
plurality of openings is positioned between a pair of adjacent
barbs of the first plurality of barbs.
15. The metal lath accessory of claim 14, wherein the second flange
comprises a second plurality of openings.
16. The metal lath accessory of claim 15 further comprising a
second plurality of barbs, wherein the second plurality of barbs
project from the second flange toward the first flange, wherein at
least one of the second plurality of openings is positioned between
a pair of adjacent barbs of the second plurality of barbs.
17. The metal lath accessory of claim 14, wherein at least one of
the first plurality of openings comprises a substantially
triangular opening.
18. The metal lath accessory of claim 14, wherein at least one of
the first plurality of openings comprises a substantially
trapezoidal opening.
19. An assembly comprising a. a metal lath accessory, wherein the
metal lath accessory comprises i. a side wall, ii. a first flange,
wherein the first flange is connected to the side wall, iii. a
second flange, wherein the second flange is connected to the side
wall, iv. a channel, wherein the channel is at least partially
defined by the side wall, the first flange and the second flange,
and v. a first barb, wherein the first barb projects from the first
flange into the channel; b. a piece of metal lath, wherein the
piece of metal lath comprises a plurality of openings, wherein the
piece of metal lath is inserted into the channel such that the
first barb engages the piece of metal lath via one of the plurality
of openings in the piece of metal lath.
20. The assembly of claim 20, wherein the metal lath accessory
further comprises a second barb, wherein the second barb projects
from the second flange into the channel, and wherein the piece of
metal lath is inserted into the channel such that the second barb
engages the piece of metal lath via one of the plurality of
openings in the piece of metal lath.
Description
PRIORITY
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 62/377,067, filed Aug. 19, 2017, entitled
"METAL LATH ACCESSORY WITH METAL LATH ENGAGEMENT FEATURE," the
disclosure of which is incorporated by reference herein.
BACKGROUND
[0002] In typical building construction, metal lath is installed
against a substrate to provide reinforcement to a finishing
material, such as portland-based cement, or stucco. Metal lath
accessories are used to ensure proper alignment of the metal lath
during application of the finishing material. Various types of
metal lath accessories can include, but are not limited to, casing
beads, control joints, expansion joints, and reveals. These metal
lath accessories may be manufactured from steel, vinyl, zinc, and
other materials. The metal lath is typically attached to the metal
lath accessory with metal tie wires at a spacing of about every 7
inches. To provide more consistency in construction, reduce labor
costs, and reduce material costs, it may be desirable to provide a
metal lath accessory that comprises an attachment feature for the
metal lath in a single component to replace multiple components or
materials.
[0003] While a variety of metal lath accessories have been made and
used, it is believed that no one prior to the inventors has made or
used an invention as described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] It is believed the present invention will be better
understood from the following description of certain examples taken
in conjunction with the accompanying drawings, in which like
reference numerals identify the same elements and in which:
[0005] FIG. 1 depicts a top perspective view of an embodiment of a
metal lath accessory that includes a metal lath attachment
feature;
[0006] FIG. 2 depicts a front elevational view of the metal lath
accessory of FIG. 1;
[0007] FIG. 3 depicts a right side elevational view of the metal
lath accessory of FIG. 1;
[0008] FIG. 4 depicts a left side elevational view of the metal
lath accessory of FIG. 1;
[0009] FIG. 5 depicts a top plan view of the metal lath accessory
of FIG. 1;
[0010] FIG. 6 depicts a bottom plan view of the metal lath
accessory of FIG. 1;
[0011] FIG. 7 depicts a top perspective view of the metal lath
accessory of FIG. 1 coupled with a piece of metal lath;
[0012] FIG. 8 depicts a top view of the metal lath accessory of
FIG. 1 coupled with two pieces of metal lath (shown schematically)
and attached to a substrate;
[0013] FIG. 9 depicts a front elevational view of the assembly of
FIG. 8 with a coating of a finishing material partially applied
thereto.
[0014] FIG. 10 depicts a top perspective view of another embodiment
of a metal lath accessory that includes a metal lath attachment
feature;
[0015] FIG. 11 depicts a front elevational view of the metal lath
accessory of FIG. 10;
[0016] FIG. 12 depicts a top plan view of the metal lath accessory
of FIG. 10;
[0017] FIG. 13 depicts a bottom plan view of the metal lath
accessory of FIG. 10;
[0018] FIG. 14 depicts a left side elevational view of the metal
lath accessory of FIG. 10;
[0019] FIG. 14A depicts a detailed view of the portion of the metal
lath accessory, as indicated in FIG. 14;
[0020] FIG. 15 depicts a right side elevational view of the metal
lath accessory of FIG. 10;
[0021] FIG. 16 depicts a top perspective view of another embodiment
of a metal lath accessory that includes a metal lath attachment
feature;
[0022] FIG. 17 depicts a front elevational view of the metal lath
accessory of FIG. 16;
[0023] FIG. 18 depicts a top plan view of the metal lath accessory
of FIG. 16;
[0024] FIG. 19 depicts a bottom plan view of the metal lath
accessory of FIG. 16;
[0025] FIG. 20 depicts a left side elevational view of the metal
lath accessory of FIG. 16;
[0026] FIG. 21 depicts a right side elevational view of the metal
lath accessory of FIG. 16;
[0027] FIG. 22 depicts a top perspective view of another embodiment
of a metal lath accessory that includes a metal lath attachment
feature;
[0028] FIG. 23 depicts a front elevational view of the metal lath
accessory of FIG. 22;
[0029] FIG. 24 depicts a top plan view of the metal lath accessory
of FIG. 22;
[0030] FIG. 25 depicts a bottom plan view of the metal lath
accessory of FIG. 22;
[0031] FIG. 26 depicts a left side elevational view of the metal
lath accessory of FIG. 22;
[0032] FIG. 27 depicts a right side elevational view of the metal
lath accessory of FIG. 22;
[0033] FIG. 28 depicts a top perspective view of another embodiment
of a metal lath accessory that includes a metal lath attachment
feature and a removable leg;
[0034] FIG. 29 depicts a front elevational view of the metal lath
accessory of FIG. 28;
[0035] FIG. 30 depicts a top perspective view of the metal lath
accessory of FIG. 28 with the removable leg in the process of being
separated from the metal lath accessory;
[0036] FIG. 31 depicts a front elevational view of the metal lath
accessory of FIG. 28 with the removable leg in the process of being
separated from the metal lath accessory;
[0037] FIG. 32 depicts a top plan view of the metal lath accessory
of FIG. 28 with the removable leg in the process of being separated
from the metal lath accessory;
[0038] FIG. 33 depicts a bottom plan view of the metal lath
accessory of FIG. 28;
[0039] FIG. 34 depicts a left side elevational view of the metal
lath accessory of FIG. 28 with the removable leg in the process of
being separated from the metal lath accessory;
[0040] FIG. 35 depicts a right side elevational view of the metal
lath accessory of FIG. 28 with the removable leg in the process of
being separated from the metal lath accessory;
[0041] FIG. 36 depicts an exploded top perspective view of another
embodiment of a metal lath accessory that includes a metal lath
attachment feature, wherein the metal lath accessory comprises a
lath clip and a solid-flange metal lath accessory;
[0042] FIG. 37 depicts a front elevational view of the lath clip of
FIG. 36;
[0043] FIG. 38 depicts a front elevational view of the sold-flange
metal lath accessory of FIG. 36;
[0044] FIG. 39 depicts an exploded, top plan view of the lath clip
and solid-flange metal lath accessory of FIG. 36;
[0045] FIG. 40 depicts an exploded, left side elevational view of
the lath clip and solid-flange metal lath accessory of FIG. 36;
[0046] FIG. 41 depicts a top perspective view of the assembled
metal lath accessory of FIG. 36;
[0047] FIG. 42 depicts a front elevational view of the assembled
metal lath accessory of FIG. 41;
[0048] FIG. 43 depicts a top plan view of the assembled metal lath
accessory of FIG. 41;
[0049] FIG. 44 depicts a left side elevational view of the
assembled metal lath accessory of FIG. 41;
[0050] FIG. 45 depicts a top perspective view of another embodiment
of a metal lath accessory that includes a metal lath attachment
feature;
[0051] FIG. 46 depicts a front elevational view of the metal lath
accessory of FIG. 45;
[0052] FIG. 47 depicts a right side elevation view of the metal
lath accessory of FIG. 45;
[0053] FIG. 48 depicts a left side elevation view of the metal lath
accessory of FIG. 45;
[0054] FIG. 49 depicts a top plan view of the metal lath accessory
of FIG. 45;
[0055] FIG. 50 depicts a bottom plan elevational view of the metal
lath accessory of FIG. 45;
[0056] FIG. 51 depicts a top perspective view of another embodiment
of a metal lath accessory that includes a metal lath attachment
feature;
[0057] FIG. 52 depicts a front elevational view of the metal lath
accessory of FIG. 51;
[0058] FIG. 53 depicts a left side elevational view of the metal
lath accessory of FIG. 51;
[0059] FIG. 54 depicts a right side elevational view of the metal
lath accessory of FIG. 51;
[0060] FIG. 55 depicts a top plan view of the metal lath accessory
of FIG. 51;
[0061] FIG. 56 depicts a bottom plan view of the metal lath
accessory of FIG. 51; and
[0062] FIG. 57 depicts a front elevational view of another
embodiment of a metal lath accessory that includes a metal lath
attachment feature.
[0063] The drawings are not intended to be limiting in any way, and
it is contemplated that various embodiments of the invention may be
carried out in a variety of other ways, including those not
necessarily depicted in the drawings. The accompanying drawings
incorporated in and forming a part of the specification illustrate
several aspects of the present invention, and together with the
description serve to explain the principles of the invention; it
being understood, however, that this invention is not limited to
the precise arrangements shown.
DETAILED DESCRIPTION
[0064] The following description of certain examples of the
invention should not be used to limit the scope of the present
invention. Other examples, features, aspects, embodiments, and
advantages of the invention will become apparent to those skilled
in the art from the following description, which is by way of
illustration, one of the best modes contemplated for carrying out
the invention. As will be realized, the invention is capable of
other different and obvious aspects, all without departing from the
invention. Accordingly, the drawings and descriptions should be
regarded as illustrative in nature and not restrictive.
[0065] There is a desire for metal lath accessories that comprise a
metal lath attachment feature. By including the metal lath
attachment feature in the metal lath accessory, the need for
additional components to attach the metal lath to the metal lath
accessory, such as metal ties or other fasteners, may be
eliminated. The combining of these functions may also reduce
installation time and total material cost.
[0066] FIGS. 1-9 show a metal lath accessory (10) that can be used
to attach metal lath to a substrate, such as a wall. In the
illustrated embodiment, the metal lath accessory (10) comprises a
control joint having a central portion (14) positioned between a
pair of side walls (12). The metal lath accessory (10) can comprise
other suitable accessory configurations in addition to a control
joint, including but not limited to casing beads, expansion joints,
reveals, reveal control joints, reveal expansion joints,
intersections, crosses, outside corners, inside corners, T's, and
connectors. As shown in FIG. 2, the central portion (14) comprises
a recess to form a V-shape, but other suitable shapes for central
portion (14) can be used.
[0067] As shown in FIGS. 1-9, the metal lath accessory (10)
comprises a lower flange (20) extending outwardly from a bottom
portion of each side wall (12). The metal lath accessory (10)
further comprises an upper flange (22) extending outwardly from
each side wall (12) at a position above the lower flange (20). In
some embodiments, one or more of the central portion (14), side
walls (12), lower flanges (20), and upper flanges (22) may comprise
a single, integral piece that is of unitary construction. In some
embodiments, one or more of the central portion (14), side walls
(12), lower flanges (20), and upper flanges (22) may be extruded or
co-extruded together to form a product of unitary construction. In
other embodiments, one or more of the central portion (14), side
walls (12), lower flanges (20), and upper flanges (22) may comprise
non-integral, separate components that are attached to each other.
In the illustrated embodiment, each upper flange (22) is
substantially parallel to the corresponding lower flange (20). In
some embodiments, one or both of the upper flange (22) and the
lower flange (20) may extend substantially perpendicularly relative
to the respective side wall (12), while in other embodiments, one
or both of the upper flange (22) and the lower flange (20) may
extend obliquely relative to the respective side wall (12). Lower
and upper flanges (20, 22) thereby form a channel to receive the
metal lath (30) within the metal lath accessory (10), as shown in
FIGS. 7 and 8. Accordingly, the upper flange (22) may be spaced
apart from the lower flange (20) any distance suitable to allow the
metal lath accessory (10) to receive and engage various thicknesses
of metal lath (30). By way of example only, in some embodiments the
upper flange (22) may be spaced apart from the lower flange (20)
about 0.230 inches and the tip of the barbs (26, 28) may be spaced
apart from each other about 0.140 inches. In some embodiments, the
upper flange (22) may extend obliquely relative to the lower flange
(20). For example, in some embodiments, the upper flange (22) may
extend downwardly toward the lower flange (20) such that the height
of the channel defined, at least in part, by the upper flange (22)
and the lower flange (20) is larger at the fixed end of the upper
flange (22) than the height of the channel at the free end of the
upper flange (22).
[0068] The metal lath accessory (10) further comprises a pair of
metal lath attachment features configured to receive and engage the
metal lath (30) so that the metal lath (30) and the metal lath
accessory (10) are attached to each other. In the illustrated
embodiment, each metal lath attachment feature comprises an upper
flange (22), a corresponding lower flange (20), and at least one
barb (26, 28) positioned on each of the upper flange (22) and the
lower flange (20). As shown in FIG. 2, each lower flange (20)
comprises at least one barb (26) extending upwardly from the lower
flange (20) toward the upper flange (22). Each upper flange (22)
comprises at least one barb (28) extending downwardly from the
upper flange (20) toward the lower flange (20). As shown, the barbs
(26, 28) are sized and shaped to substantially fit within or
otherwise engage an opening of the metal lath (30) to secure the
metal lath (30) to the metal lath accessory (10). Each lower and
upper flange (20, 22) comprises a plurality of barbs (26, 28) along
a length of the flanges (20, 22), as shown in FIGS. 3 and 4. This
can provide a plurality of attachment points between the metal lath
(30) and the metal lath accessory (10) along the length of the
metal lath accessory (10). As shown, adjacent barbs (26) on the
lower flange (20) are separated by openings (16) in the lower
flange (20). Similarly, in this embodiment, adjacent barbs (28) on
the upper flange (22) are separated by openings (16) in the upper
flange (22). Of course, any suitable number of barbs (26, 28) can
be used to sufficiently secure the metal lath (30) to the metal
lath accessory (10). In other embodiments, the metal lath
attachment feature may comprise one or more different structures
instead of or in addition to the barbs (26, 28), including but not
limited to a flange, a snap-down leg, and a channel.
[0069] As shown in FIG. 2, each barb (26, 28) comprises a ramped
surface (26a, 28a) facing the opening of the channel between the
lower and upper flanges (20, 22) and a shoulder surface (26b, 28b)
facing the respective side wall (12). In some embodiments, the
shoulder surface (26b, 28b) may be substantially perpendicular
relative to the respective flange (20, 22) the barb (26, 28)
projects from. This may allow the metal lath (30) to slide along
the ramped surface (26a, 28a) of each barb (26, 28) when the metal
lath (30) is inserted within the metal lath accessory (10) such
that the metal lath accessory (10) is more easily able to receive
the metal lath (30). As shown, after the metal lath (30) has been
received within the channel between the lower and upper flanges
(20, 22), the shoulder surface (26b, 28b) of each of the barbs (26,
28) is configured to engage the metal lath (30) to prevent the
metal lath (30) from being easily removed from the metal lath
accessory (10). In the illustrated embodiment, barbs (26, 28) have
a substantially triangular cross-section. In other embodiments,
barbs (26, 28) may have a different cross-sectional shape suitable
to sufficiently engage the metal lath while still allowing the
metal lath to be received within the channel between the lower and
upper flanges (20, 22). As shown, the barbs (26) on the lower
flange (20) and the barbs (28) on the upper flange (22) have
identical cross-sections. In other embodiments, the barbs on the
lower flange and the barbs on the upper flange may have different
cross-sections. In still other embodiments, barbs (26, 28) on the
same flange (20, 22) may have different cross-sections.
[0070] In the embodiment shown in FIGS. 1-9, each upper flange (22)
further comprises an angled portion (24) at the free end of each
upper flange (22). Angled portion (24) may be positioned at about a
45 degree angle relative to the upper flange (22), but any other
suitable configuration may be used. This may help guide the metal
lath (30) into the channel between the lower flange (20) and the
upper flange (22) when the metal lath (30) is inserted into the
metal lath accessory (10). It should be noted that angled portion
(24) of the upper flange (22) is merely optional.
[0071] When the metal lath (30) is inserted within the metal lath
accessory (10), the upper flange (22) may be sufficiently resilient
such that the upper flange (22) flexes slightly upwardly to allow
the metal lath (30) to slide between the upper flange (22) and the
lower flange (20), past the barbs (26, 28), and adjacent to the
side wall (12). Once the metal lath (30) is inserted between the
lower and upper flanges (20, 22), the upper flange (22) can flex
downwardly to its original position such that at least one of the
barbs (26, 28) engages the metal lath (30). Barbs (26, 28) thus
hold the metal lath (30) within the metal lath accessory (10) and
prevent the metal lath (30) from pulling away from the metal lath
accessory (10). Barbs (26, 28) may be substantially aligned
opposite each other, or, alternatively, they may be offset from
each other along the width of the lower and upper flanges (20, 22).
In some embodiments, barbs (26, 28) may be positioned in
corresponding pairs, while in other embodiments barbs (26, 28) may
be staggered between the upper flange (22) and the lower flange
(20) along the length of the metal latch accessory (10).
[0072] Either before or after the metal lath (30) is inserted
within the metal lath accessory (10), the lower flange (20) of the
metal lath accessory (10) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). The
substrate (5) may be any suitable structure, such as a wall
comprising any suitable material, such as plywood, cinder blocks,
or any other similar material. As shown in FIG. 9, once the metal
lath (30) is inserted within the metal lath accessory (10) and
metal lath accessory (10) is secured to the substrate (5), one or
more coats (e.g., a scratch coat and a finishing coat) of a
finishing material (35), such as stucco, plaster or other similar
material, can then be applied over the lower and upper flanges (20,
22) of the metal lath accessory (10) and the metal lath (30).
[0073] In the illustrated embodiment, the lower and upper flanges
(20, 22) of the metal lath accessory (10) comprise a plurality of
openings (16) that may allow the finishing material to better bond
to the metal lath accessory (10), but these openings (16) are
merely optional and may be sized, shaped and arranged in any
suitable configuration. By way of example only, FIGS. 45-50 depict
another embodiment of a metal lath accessory (710) that comprises a
control joint that is substantially similar to metal lath accessory
(10) shown in FIGS. 1-9, except that metal lath accessory (710) has
an alternate hole pattern and configuration and upper flange (722)
is wider than upper flange (22). As shown in FIGS. 1-9, openings
(16) are substantially circular and vary in size, while openings
(716) shown in FIGS. 45-50 include a plurality of circular openings
(716a, 716c), a plurality of substantially trapezoidal openings
(716b), and a plurality of substantially triangular openings
(716d). In the illustrated embodiment of metal lath accessory (10),
the openings (16) located in the upper flange (22) are positioned
directly above openings (16) in the lower flange (20) that
correspond in size and shape to the openings (16) in the upper
flange (22). The embodiment illustrated in FIGS. 1-9 also includes
a pair of angled members (25) extending from a respective side wall
(12) adjacent to the juncture of each upper flange (22) and the
respective side wall (12). The angled members (25) are merely
optional and may be arranged at any suitable angle and positioned
at any suitable position along the side wall (12) or omitted
entirely. Of course, other suitable profiles and configurations for
the metal lath accessory (10) will be apparent to one of ordinary
skill in the art in view of the teachings herein.
[0074] FIGS. 10-15 show another embodiment of a metal lath
accessory (110) that is configured as a casing bead that comprises
a side wall (112) extending upwardly from an end of a lower flange
(120). An upper flange (122) extends outwardly from the side wall
(112) at a position spaced above the lower flange (120). In the
illustrated embodiment, the upper flange (122) is substantially
parallel to the lower flange (120). In some embodiments, one or
both of the upper flange (122) and the lower flange (120) may
extend substantially perpendicularly relative to the side wall
(112), while in other embodiments, one or both of the upper flange
(122) and the lower flange (120) may extend obliquely relative to
the side wall (112). Lower and upper flanges (120, 122) thereby
form a channel to receive the metal lath (30) within the metal lath
accessory (110). Accordingly, the upper flange (122) may be spaced
apart from the lower flange (120) any distance suitable to allow
the metal lath accessory (110) to receive and engage various
thicknesses of metal lath (30). By way of example only, in some
embodiments the upper flange (122) may be spaced apart from the
lower flange (120) about 0.230 inches and the tip of the barbs
(126, 128) may be spaced apart from each other about 0.140 inches.
In some embodiments, the upper flange (122) may extend obliquely
relative to the lower flange (120). For example, in some
embodiments, the upper flange (122) may extend downwardly toward
the lower flange (120) such that the height of the channel defined,
at least in part, by the upper flange (122) and the lower flange
(120) is larger at the fixed end of the upper flange (122) than the
height of the channel at the free end of the upper flange (122). At
an upper end of the side wall (112), a lip (114) extends outwardly
from the side wall (112) having a first portion that extends
substantially parallel to the upper flange (122) and a second
portion that extends downward towards the upper flange (122). In
some embodiments, one or more of the side wall (112), lip (114),
lower flange (120), and upper flange (122) may comprise a single,
integral piece that is of unitary construction. In some
embodiments, one or more of the side wall (112), lip (114), lower
flange (120), and upper flange (122) may be extruded or co-extruded
together to form a product of unitary construction. In other
embodiments, one or more of the side wall (112), lip (114), lower
flange (120), and upper flange (122) may comprise non-integral,
separate components that are attached to each other.
[0075] The metal lath accessory (110) further comprises a metal
lath attachment feature configured to receive and engage the metal
lath (30) so that the metal lath (30) and the metal lath accessory
(110) are attached to each other. In the illustrated embodiment,
the metal lath attachment feature comprises the upper flange (122),
the lower flange (120), and at least one barb (126, 128) positioned
on each of the upper flange (122) and the lower flange (120). As
shown in FIG. 11, the lower flange (120) comprises a barb (126)
extending upwardly from the lower flange (120) toward the upper
flange (122). The upper flange (122) comprises a barb (128)
extending downwardly from the upper flange (120) toward the lower
flange (120). As shown, the barbs (126, 128) are sized and shaped
to fit substantially within or otherwise engage an opening of the
metal lath (30) to secure the metal lath (30) with the metal lath
accessory (110). Each lower and upper flange (120, 122) comprises a
plurality of barbs (126, 128) along a length of the flanges (120,
122), as shown in FIG. 14. This can provide a plurality of
attachment points between the metal lath (30) and the metal lath
accessory (110) along the length of the metal lath accessory (110).
As shown, adjacent barbs (126) on the lower flange (120) are
separated by openings (116) in the lower flange (120). Similarly,
in this embodiment, adjacent barbs (128) on the upper flange (122)
are separated by openings (116) in the upper flange (122). Of
course, any suitable number of barbs (126, 128) can be used to
sufficiently secure the metal lath (30) to the metal lath accessory
(110). In other embodiments, the metal lath attachment feature may
comprise one or more different structures instead of or in addition
to the barbs (126, 128), including but not limited to a flange, a
snap-down leg, and a channel.
[0076] As shown in FIG. 11, each barb (126, 128) comprises a ramped
surface (126a, 128a) facing the opening of the channel between
lower and upper flanges (120, 122) and a shoulder surface (126b,
128b) facing the respective side wall (112). In some embodiments,
the shoulder surface (126b, 128b) may be substantially
perpendicular relative to the respective flange (120, 122) the barb
(126, 128) projects from. This may allow the metal lath (30) to
slide along the ramped surface of each barb (126, 128) when the
metal lath (30) is inserted within the metal lath accessory (110)
such that the metal lath accessory (110) is more easily able to
receive the metal lath (30). After the metal lath (30) has been
received within the channel between the lower and upper flanges
(120, 122), the shoulder surface (126b, 128b) of each of the barbs
(126, 128) is configured to engage the metal lath (30) to prevent
the metal lath (30) from being easily removed from the metal lath
accessory (110). In the illustrated embodiment, barbs (126, 128)
have a substantially triangular cross-section. In other
embodiments, barbs (126, 128) may have a different cross-sectional
shape suitable to sufficiently engage the metal lath while still
allowing the metal lath to be received within the channel between
the lower and upper flanges (120, 122). As shown, the barbs (126)
on the lower flange (120) and the barbs (128) on the upper flange
(122) have identical cross-sections. In other embodiments, the
barbs on the lower flange and the barbs on the upper flange may
have different cross-sections. In still other embodiments, barbs on
the same flange may have different cross-sections.
[0077] Similar to the angled portion (24) described above, in some
embodiments, the upper flange (122) may comprise an angled portion
at the free end of the upper flange (122). This may help guide the
metal lath (30) into the channel between the lower flange (120) and
the upper flange (122) when the metal lath (30) is inserted within
the metal lath accessory (110). Of course, any such angled portion
is merely optional.
[0078] When the metal lath (30) is inserted within the metal lath
accessory (110), the upper flange (122) may be sufficiently
resilient such that the upper flange (122) flexes upwardly to allow
the metal lath (30) to slide between the upper flange (122) and the
lower flange (120), past the barbs (126, 128), and adjacent to the
side wall (112). Once the metal lath (30) is inserted between the
lower and upper flanges (120, 122), the upper flange (122) can flex
downwardly to its original position such that at least one of the
barbs (126, 128) engages the metal lath (30). Barbs (126, 128) thus
hold the metal lath (30) within the metal lath accessory (110) and
prevent the metal lath (30) from pulling away from the metal lath
accessory (110). Barbs (126, 128) may be substantially aligned
opposite each other, or, alternatively, they may be offset from
each other along the width of the lower and upper flanges (120,
122). In some embodiments, barbs (126, 128) may be positioned in
corresponding pairs, while in other embodiments barbs (126,128) may
be staggered between the upper flange (122) and the lower flange
(120) along the length of the metal latch accessory (110).
[0079] Either before or after the metal lath (30) is inserted
within the metal lath accessory (110), the lower flange (120) of
the metal lath accessory (110) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). Once the
metal lath (30) is inserted within the metal lath accessory (110)
and metal lath accessory (110) is secured to the substrate (5), one
or more coats (e.g., a scratch coat and a finishing coat) of a
finishing material (35), such as stucco, plaster or other similar
material, can then be applied over the lower and upper flanges
(120, 122) of the metal lath accessory (110) and the metal lath
(30).
[0080] In the illustrated embodiment, the lower and upper flanges
(120, 122) of the metal lath accessory (110) comprise a plurality
of openings (116) that may allow the finishing material to better
bond to the metal lath accessory (110), but these openings (116)
are merely optional and may be sized, shaped and arranged in any
suitable configuration. As shown, the openings (116) located in the
upper flange (122) are positioned directly above openings (116) in
the lower flange (120) that correspond in size and shape to the
openings (116) in the upper flange (122). Of course, other suitable
profiles and configurations for the metal lath accessory (110) will
be apparent to one of ordinary skill in the art in view of the
teachings herein.
[0081] FIGS. 16-21 show another embodiment of a metal lath
accessory (210) that is configured as a casing bead similar to the
metal lath accessory (110), except that the metal lath accessory
(210) comprises a second side wall (218) that is spaced away from
the first side wall (212) along the width of the lower flange
(220). As shown, the first side wall (212) extends upwardly from an
end of the lower flange (220), and the second side wall (218) is
positioned to extend upwardly from an intermediate portion of the
lower flange (220). The upper flange (222) extends outwardly from
an upper end of the second side wall (218) such that the upper
flange (222) is spaced apart from and above the lower flange (220).
In the illustrated embodiment, the upper flange (222) is
substantially parallel to the lower flange (220). In some
embodiments, one or both of the upper flange (222) and the lower
flange (220) may extend substantially perpendicularly relative to
the second side wall (218), while in other embodiments, one or both
of the upper flange (222) and the lower flange (220) may extend
obliquely relative to the second side wall (218). Lower and upper
flanges (220, 222) thereby form a channel to receive the metal lath
(30) within the metal lath accessory (210). Accordingly, the upper
flange (222) may be spaced apart from the lower flange (220) any
distance suitable to allow the metal lath accessory (210) to
receive and engage various thicknesses of metal lath (30). By way
of example only, in some embodiments the upper flange (222) may be
spaced apart from the lower flange 2(20) about 0.230 inches and the
tip of the barbs (226, 228) may be spaced apart from each other
about 0.140 inches. In some embodiments, the upper flange (222) may
extend obliquely relative to the lower flange (220). For example,
in some embodiments, the upper flange (222) may extend downwardly
toward the lower flange (220) such that the height of the channel
defined, at least in part, by the upper flange (222) and the lower
flange (220) is larger at the fixed end of the upper flange (222)
than the height of the channel at the free end of the upper flange
(222). At an upper end of the first side wall (212), a lip (214)
extends outwardly from the side wall (212) having a first portion
that extends substantially parallel to the lower flange (220) and a
second portion that extends downward towards the lower flange
(220). In some embodiments, one or more of the first side wall
(212), second side wall (218), lip (214), lower flange (220), and
upper flange (222) may comprise a single, integral piece that is of
unitary construction. In some embodiments, one or more of the first
side wall (212), second side wall (218), lip (214), lower flange
(220), and upper flange (222) may be extruded or co-extruded
together to form a product of unitary construction. In other
embodiments, one or more of the first side wall (212), second side
wall (218), lip (214), lower flange (220), and upper flange (222)
may comprise non-integral, separate components that are attached to
each other.
[0082] The metal lath accessory (210) further comprises a metal
lath attachment feature configured to receive and engage the metal
lath (30) so that the metal lath (30) and the metal lath accessory
(210) are attached to each other. In the illustrated embodiment,
the metal lath attachment feature comprises the upper flange (222),
the lower flange (220), and at least one barb (226, 228) positioned
on each of the upper flange (222) and the lower flange (220). As
shown in FIG. 17, the lower flange (220) comprises at least one
barb (226) extending upwardly from the lower flange (220) toward
the upper flange (222). The upper flange (222) comprises at least
one barb (228) extending downwardly from the upper flange (220)
toward the lower flange (220). As shown, the barbs (226, 228) are
sized and shaped to substantially fit within or otherwise engage an
opening of the metal lath (30) to secure the metal lath (30) to the
metal lath accessory (210). The lower and upper flanges (220, 222)
comprise a plurality of barbs (226, 228) along a length of the
flanges (220, 222), as shown in FIG. 20. This can provide a
plurality of attachment points between the metal lath (30) and the
metal lath accessory (210) along the length of the metal lath
accessory (210). As shown, adjacent barbs (226) on the lower flange
(220) are separated by openings (216) in the lower flange (220).
Similarly, in this embodiment, adjacent barbs (228) on the upper
flange (222) are separated by openings (216) in the upper flange
(222). Of course, any suitable number of barbs (226, 228) can be
used to sufficiently secure the metal lath (30) with the metal lath
accessory (210). In other embodiments, the metal lath attachment
feature may comprise one or more different structures instead of or
in addition to the barbs (226, 228), including but not limited to a
flange, a snap-down leg, and a channel.
[0083] As shown in FIG. 17, each barb (226, 228) comprises a ramped
surface (226a, 228a) facing the opening of the channel between
lower and upper flanges (220, 222) and a shoulder surface (226b,
228b) facing the second side wall (218). In some embodiments, the
shoulder surface (226b, 228b) may be substantially perpendicular
relative to the respective flange (220, 222) the barb (226, 228)
projects from. This may allow the metal lath (30) to slide along
the ramped surface (226a, 228a) of each barb (226, 228) when the
metal lath (30) is inserted within the metal lath accessory (210)
such that the metal lath accessory (210) is more easily able to
receive the metal lath (30). After the metal lath (30) has been
received within the channel between the lower and upper flanges
(220, 222), the shoulder surface (226b, 228b) of each of the barbs
(226, 228) is configured to engage the metal lath (30) to prevent
the metal lath (30) from being easily removed from the metal lath
accessory (210). In the illustrated embodiment, barbs (226, 228)
have a substantially triangular cross-section. In other
embodiments, barbs (226, 228) may have a different cross-sectional
shape suitable to sufficiently engage the metal lath while still
allowing the metal lath to be received within the channel between
the lower and upper flanges (220, 222). As shown, the barbs (226)
on the lower flange (220) and the barbs (228) on the upper flange
(222) have identical cross-sections. In other embodiments, the
barbs on the lower flange and the barbs on the upper flange may
have different cross-sections. In still other embodiments, barbs on
the same flange may have different cross-sections.
[0084] In the illustrated embodiment, the upper flange (222)
further comprises an angled portion (224) at the free end of the
upper flange (222). Angled portion (224) may be positioned at about
a 45 degree angle relative to the upper flange (222), but any other
suitable configuration may be used. This may help guide the metal
lath (30) into the channel between the lower flange (220) and the
upper flange (222) when the metal lath (30) is inserted into the
metal lath accessory (210). It should be noted that angled portion
(224) of the upper flange (222) is merely optional.
[0085] When the metal lath (30) is inserted within the metal lath
accessory (210), the upper flange (222) may be sufficiently
resilient such that the upper flange (222) flexes slightly upwardly
to allow the metal lath (30) to slide between the upper flange
(222) and the lower flange (220), past the barbs (226, 228), and
adjacent to the side wall (218). Once the metal lath (30) is
inserted between the lower and upper flanges (220, 222), the upper
flange (222) can flex downwardly to its original position such that
at least one of the barbs (226, 228) engages the metal lath (30).
Barbs (226, 228) thus hold the metal lath (30) within the metal
lath accessory (210) and prevent the metal lath (30) from pulling
away from the metal lath accessory (210). Barbs (226, 228) may be
substantially aligned opposite each other, or, alternatively, they
may be offset from each other along the width of the lower and
upper flanges (220, 222). In some embodiments, barbs (226, 228) may
be positioned in corresponding pairs, while in other embodiments
barbs (226, 228) may be staggered between the upper flange (222)
and the lower flange (220) along the length of the metal latch
accessory (210).
[0086] Either before or after the metal lath (30) is inserted
within the metal lath accessory (210), the lower flange (220) of
the metal lath accessory (210) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). The
substrate (5) may be any suitable structure, such as a wall
comprising any suitable material, such as plywood, cinder blocks,
or any other similar material. Once the metal lath (30) is inserted
within the metal lath accessory (210) and metal lath accessory
(210) is secured to the substrate (5), one or more coats (e.g., a
scratch coat and a finishing coat) of a finishing material (35),
such as stucco, plaster or other similar material can then be
applied over the lower and upper flanges (220, 222) of the metal
lath accessory (210) and the metal lath (30).
[0087] In the illustrated embodiment, the lower and upper flanges
(220, 222) of the metal lath accessory (210) comprise a plurality
of openings (216) that may allow the finishing material to better
bond to the metal lath accessory (210), but these openings (216)
are merely optional and may be sized, shaped and arranged in any
suitable configuration. As shown, the openings (216) located in the
upper flange (222) are positioned directly above openings (216) in
the lower flange (220) that correspond in size and shape to the
openings (216) in the upper flange (222). Of course, other suitable
configurations for the metal lath accessory (210) will be apparent
to one of ordinary skill in the art in view of the teachings
herein.
[0088] FIGS. 22-27 show another embodiment of a metal lath
accessory (310) that can be used to attach metal lath to a
substrate. In the illustrated embodiment, the metal lath accessory
(310) comprises a connector having a central portion (314)
positioned between a pair of side walls (312). As shown in FIG. 23,
the central portion (314) comprises a recess to form a U-shape in
combination with the side walls (312), but other suitable shapes
for central portion (314) can be used. In the illustrated
embodiment, the metal lath accessory (310) comprises a lower flange
(320) extending outwardly from a bottom portion of each side wall
(312). The metal lath accessory (310) further comprises an upper
flange (322) extending outwardly from each side wall (312) at a
position above the lower flange (320). As shown, the upper flanges
(322) each extend from an upper end of a respective side wall
(312), although in other embodiments, the side walls (312) may
extend above the respective upper flange (322). In the illustrated
embodiment, each upper flange (322) is substantially parallel to
the corresponding lower flange (320). In some embodiments, one or
both of the upper flange (322) and the lower flange (320) may
extend substantially perpendicularly relative to the respective
side wall (312), while in other embodiments, one or both of the
upper flange (322) and the lower flange (320) may extend obliquely
relative to the respective side wall (312). Lower and upper flanges
(320, 322) thereby form a channel to receive the metal lath (30)
within the metal lath accessory (310). Accordingly, the upper
flange (322) may be spaced apart from the lower flange (320) any
distance suitable to allow the metal lath accessory (310) to
receive and engage various thicknesses of metal lath (30). By way
of example only, in some embodiments the upper flange (322) may be
spaced apart from the lower flange (320) about 0.230 inches and the
tip of the barbs (326, 328) may be spaced apart from each other
about 0.140 inches. In some embodiments, one or both of the upper
flanges (322) may extend obliquely relative to a corresponding
lower flange (320). For example, in some embodiments, one or both
of the upper flanges (322) may extend downwardly toward a
corresponding lower flange (320) such that the height of the
channel defined, at least in part, by the upper flange (322) and
the lower flange (320) is larger at the fixed end of the upper
flange (322) than the height of the channel at the free end of the
upper flange (322). In some embodiments, one or more of the side
walls (312), central portion (314), lower flanges (320) and upper
flanges (322) may comprise a single, integral piece that is of
unitary construction. In some embodiments, one or more of the side
walls (312), central portion (314), lower flanges (320) and upper
flanges (322) may be extruded or co-extruded together to form a
product of unitary construction. In other embodiments, one or more
of side walls (312), central portion (314), lower flanges (320) and
upper flanges (322) may comprise non-integral, separate components
that are attached to each other.
[0089] The metal lath accessory (310) further comprises a pair of
metal lath attachment features configured to receive and engage the
metal lath (30) so that the metal lath (30) and the metal lath
accessory (310) are attached to each other. In the illustrated
embodiment, each metal lath attachment feature comprises an upper
flange (322), a corresponding lower flange (320), and at least one
barb (326, 328) positioned on each of the upper flange (322) and
the lower flange (320). As shown in FIG. 23, each lower flange
(320) comprises at least one barb (326) extending upwardly from the
lower flange (320) toward the upper flange (322). Each upper flange
(322) comprises at least one barb (328) extending downwardly from
the upper flange (320) toward the lower flange (320). As shown, the
barbs (326, 328) are sized and shaped to substantially fit within
or otherwise engage an opening of the metal lath (30) to secure the
metal lath (30) to the metal lath accessory (310). Each lower and
upper flange (320, 322) comprises a plurality of barbs (326, 328)
along a length of the flanges (320, 322), as shown in FIGS. 26 and
27. This can provide a plurality of attachment points between the
metal lath (30) and the metal lath accessory (310) along the length
of the metal lath accessory (10). As shown, adjacent barbs (326) on
the lower flange 3(20) are separated by openings (316) in the lower
flange (320). Similarly, in this embodiment, adjacent barbs (328)
on the upper flange (322) are separated by openings (16) in the
upper flange (322). Of course, any suitable number of barbs (326,
328) can be used to sufficiently secure the metal lath (30) to the
metal lath accessory (310). In other embodiments, the metal lath
attachment feature may comprise one or more different structures
instead of or in addition to the barbs (326, 328), including but
not limited to a flange, a snap-down leg, and a channel.
[0090] As shown in FIG. 23, each barb (326, 328) comprises a ramped
surface (326a, 328a) facing the opening of the channel between
lower and upper flanges (320, 322) and a shoulder surface (326b,
328b) facing the respective side wall (312). In some embodiments,
the shoulder surface (326b, 328b) may be substantially
perpendicular relative to the respective flange (320, 322) the barb
(326, 328) projects from. This may allow the metal lath (30) to
slide along the ramped surface (326a, 328a) of each barb (326, 328)
when the metal lath (30) is inserted within the metal lath
accessory (310) such that the metal lath accessory (310) is more
easily able to receive the metal lath (30). After the metal lath
(30) has been received within the channel between the lower and
upper flanges (320, 322), the shoulder surface (326b, 328b) of each
of the barbs (326, 328) is configured to engage the metal lath (30)
to prevent the metal lath (30) from being easily removed from the
metal lath accessory (310). In the illustrated embodiment, barbs
(326, 328) have a substantially triangular cross-section. In other
embodiments, barbs (326, 328) may have a different cross-sectional
shape suitable to sufficiently engage the metal lath while still
allowing the metal lath to be received within the channel between
the lower and upper flanges (320, 322).
[0091] As shown, the barbs (326) on the lower flange (320) and the
barbs (328) on the upper flange (322) have identical
cross-sections. In other embodiments, the barbs on the lower flange
and the barbs on the upper flange may have different
cross-sections. In still other embodiments, barbs on the same
flange may have different cross-sections.
[0092] In the illustrated embodiment, each upper flange (322)
further comprises an angled portion (324) at the free end of each
upper flange (322). Angled portion (324) may be positioned at about
a 45 degree angle relative to the upper flange (322), but any other
suitable configuration may be used. This may help guide the metal
lath (30) into the channel between the lower flange (320) and the
upper flange (322) when the metal lath (30) is inserted into the
metal lath accessory (310). It should be noted that angled portion
(324) of the upper flange (322) is merely optional.
[0093] When the metal lath (30) is inserted within the metal lath
accessory (310), the upper flange (322) may be sufficiently
resilient such that the upper flange (322) flexes slightly upwardly
to allow the metal lath (30) to slide between the upper flange
(322) and the lower flange (320), past the barbs (326, 328), and
adjacent to the side wall (312). Once the metal lath (30) is
inserted between the lower and upper flanges (320, 322), the upper
flange (322) can flex downwardly to its original position such that
at least one of the barbs (326, 328) engages the metal lath (30).
Barbs (326, 328) thus hold the metal lath (30) within the metal
lath accessory (310) and prevent the metal lath (30) from pulling
away from the metal lath accessory (310). Barbs (326, 328) may be
substantially aligned opposite each other, or, alternatively, they
may be offset from each other along the width of the lower and
upper flanges (320, 322). In some embodiments, barbs (326, 328) may
be positioned in corresponding pairs, while in other embodiments
barbs (326, 328) may be staggered between the upper flange (322)
and the lower flange (320) along the length of the metal latch
accessory (310).
[0094] Either before or after the metal lath (30) is inserted
within the metal lath accessory (310), the lower flange (320) of
the metal lath accessory (310) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). The
substrate (5) may be any suitable structure, such as a wall
comprising any suitable material, such as plywood, cinder blocks,
or any other similar material. Once the metal lath (30) is inserted
within the metal lath accessory (310) and metal lath accessory
(310) is secured to the substrate (5), one or more coats (e.g., a
scratch coat and a finishing coat) of a finishing material (35),
such as stucco, plaster or other similar material can then be
applied over the lower and upper flanges (320, 322) of the metal
lath accessory (310) and the metal lath (30). By inserting a piece
of metal lath (30) between each pair of upper and lower flanges
(320, 322) of the metal lath accessory (310), two pieces of metal
lath (30) can be positioned adjacent to each other without
overlapping. Typically, when two pieces of metal lath (30) are
positioned adjacent to each other, the pieces of metal lath (30)
are positioned to overlap, which can cause an uneven application of
the finishing material. However, the metal lath accessory (310)
allows two pieces of metal lath (30) to be positioned adjacent to
each other without overlapping to prevent uneven application of the
finishing material.
[0095] In the illustrated embodiment, the lower and upper flanges
(320, 322) of the metal lath accessory (310) comprise a plurality
of openings (316) that may allow the stucco to better bond to the
metal lath accessory (310), but these openings (316) are merely
optional and may be sized, shaped and arranged in any suitable
configuration. As shown, the openings (316) located in the upper
flange (322) are positioned directly above openings (316) in the
lower flange (320) that correspond in size and shape to the
openings (316) in the upper flange (322). Of course, other suitable
profiles and configurations for the metal lath accessory (310) will
be apparent to one of ordinary skill in the art in view of the
teachings herein.
[0096] FIGS. 28-35 show another embodiment of a metal lath
accessory (410) that is configured as a casing bead that comprises
a side wall (412) extending upwardly from an end of a lower flange
(420), a backing strip (418) attached to a rear surface of the side
wall (412), and a removable leg (430) that is removably attached to
the rear surface of the side wall (412). An upper flange (422)
extends outwardly from the side wall (412) at a position spaced
above the lower flange (420). In the illustrated embodiment, the
upper flange (422) is substantially parallel to the lower flange
(420). In some embodiments, one or both of the upper flange (422)
and the lower flange (420) may extend substantially perpendicularly
relative to the side wall (412), while in other embodiments, one or
both of the upper flange (422) and the lower flange (420) may
extend obliquely relative to the side wall (412). Lower and upper
flanges (420, 422) thereby form a channel to receive the metal lath
(30) within the metal lath accessory (410). Accordingly, the upper
flange (422) may be spaced apart from the lower flange (420) any
distance suitable to allow the metal lath accessory (410) to
receive and engage various thicknesses of metal lath (30). By way
of example only, in some embodiments the upper flange (422) may be
spaced apart from the lower flange (420) about 0.230 inches and the
tip of the barbs (426, 428) may be spaced apart from each other
about 0.140 inches. In some embodiments, the upper flange (422) may
extend obliquely relative to the lower flange (420). For example,
in some embodiments, the upper flange (422) may extend downwardly
toward the lower flange (420) such that the height of the channel
defined, at least in part, by the upper flange (422) and the lower
flange (420) is larger at the fixed end of the upper flange (422)
than the height of the channel at the free end of the upper flange
(422). At an upper end of the side wall (412), a lip (414) extends
outwardly from the side wall (412) having a first portion that
extends substantially parallel to the upper flange (422) and a
second portion that extends downward towards the upper flange
(422).
[0097] In some embodiments, one or more of the lower flange (420),
upper flange (422), side wall (412), lip (414), and removable leg
(430) may comprise a single, integral piece that is of unitary
construction. In some embodiments, one or more of the lower flange
(420), upper flange (422), side wall (412), lip (414), and
removable leg (430) may be extruded or co-extruded together to form
a product of unitary construction. In other embodiments, one or
more of the lower flange (420), upper flange (422), side wall
(412), lip (414), and removable leg (430) may comprise
non-integral, separate components that are attached to each other.
Metal lath accessory (410) is configured to be installed on a wall
structure adjacent to a window frame or door jamb. In some
applications, metal lath accessory (410) can be installed such that
the outer surface of backing strip (418) abuts or engages the edge
of the window frame or door jamb. Metal lath accessory (410) can be
installed by mounting metal lath accessory (410) onto a wall
structure that includes a backing wall, such as plywood or other
similar material. It will be appreciated that other materials, such
as felt, galvanized wire or lathe may also be attached to the
backing wall (and possibly between metal lath accessory (410) and
the backing wall in some applications). One or more coats (e.g., a
scratch coat and a finishing coat) of a finishing material, such as
stucco, plaster or other similar material, may then be applied to
the wall structure. Side wall (412) and lip (414) of metal lath
accessory (410) are configured to substantially contain the
finishing material and prevent the finishing material from
contacting the window frame or door jamb.
[0098] In the illustrated embodiment, removable leg (430) is
removably attached to side wall (412). As shown, removable leg
(430) is positioned adjacent to the upper end of side wall (412)
near the junction between side wall (412) and lip (414). In other
embodiments, the removable leg (430) may be positioned in another
location along the side wall (412) suitable to prevent finishing
material from contacting the backing strip (418). Removable leg
(430) may be integrally attached to side wall (412).
[0099] The junction between removable leg (430) and side wall (412)
may comprise a thin or weakened section of material configured to
allow a user to separate removable leg (430) by grasping removable
leg (430) and applying force to removable leg (430) in a direction
away from side wall (412) (e.g., an upward force, a downward force,
an outward force, or an angled force generally away from side wall
(412)). FIGS. 28-29 depict removable leg (430) fully attached to
side wall (412), while FIGS. 30-35 depict removable leg (430) in
the process of being removed or separated from side wall (412). In
some embodiments, removable leg (430) may include one or more
openings or perforations along the junction between removable leg
(430) and side wall (412) to facilitate removal of removable leg
(430), although this is not required. The user may use his or her
hand to separate removable leg (430) from side wall (412) or the
user may use a tool, such as a pair of pliers or other similar
gripping device, to grasp removable leg (430) and apply the
necessary force. Other methods for separating removable leg (430)
from side wall (412), including but not limited to slicing
removable leg (430) at its junction with side wall (412) with a
pocket knife or other sharp object, may also be used.
[0100] As shown, removable leg (430) comprises a t-shaped
cross-section. Specifically, in this embodiment removable leg (430)
includes a base member (432) that extends substantially
perpendicular from side wall (412) and a gripping member (434) that
extends substantially perpendicular from base member (432).
Gripping member (434) is configured to facilitate the gripping of
removable leg (430) by a user, which may subsequently facilitate
separation of removable leg (430) from side wall (412). In other
embodiments, removable leg (430) may comprise other cross-sections,
including but not limited to round, rectangular, or square
cross-sections, configured to facilitate the gripping of removable
leg (430) by a user, and in some embodiments, gripping member (434)
may be omitted entirely. In still other embodiments, the entire
removable leg (430) may be omitted entirely.
[0101] The illustrated embodiment of metal lath accessory (410)
includes backing strip (418), which is a separate component
attached to side wall (412). Backing strip (418) may be attached to
side wall (412) using an adhesive or any other conventional
fasteners or attachment methods. In some alternate embodiments,
backing strip (418) may be integral with side wall (412) instead of
being a separate component that is attached to side wall (412).
Backing strip (418) is configured to abut a window frame or door
jamb once metal lath accessory (410) is installed on the desired
wall structure. Once removable leg (430) is removed or separated
from side wall (412), then a user may apply a bead of caulk or
other similar sealant or material in the gap created by side wall
(412), backing strip (418) and the adjacent window frame or door
jamb to substantially seal the joint between metal lath accessory
(410) and the window frame or door jamb. Backing strip (418) may
comprise a resilient or compressible material, including but not
limited to closed cell foam. In some embodiments, backing strip
(418) may comprise a material substantially similar to the material
used for conventional backer rod. In some embodiments, backing
strip (418) may comprise a material that does not bond very well,
if at all, with conventional caulk and other sealants. As a result,
in these embodiments, the caulk or other sealants may have a
stronger bond with side wall (412) of metal lath accessory (410)
and the outer surface of the adjacent window frame or door jamb. In
some embodiments, the backing strip (418) may be omitted entirely
and a backer rod or other similar material may be inserted between
the metal lath accessory (410) and the adjacent window frame or
doorjamb.
[0102] The metal lath accessory (410) further comprises a metal
lath attachment feature configured to receive and engage the metal
lath (30) so that the metal lath (30) and the metal lath accessory
(410) are attached to each other. In the illustrated embodiment,
the metal lath attachment feature comprises the upper flange (422),
the lower flange (420), and at least one barb (426, 428) positioned
on each of the upper flange (422) and the lower flange (420). As
shown in FIG. 31, the lower flange (420) comprises a barb (426)
extending upwardly from the lower flange (420) toward the upper
flange (422). The upper flange (422) comprises a barb (428)
extending downwardly from the upper flange (420) toward the lower
flange (420). As shown, the barbs (426, 428) are sized and shaped
to fit substantially within or otherwise engage an opening of the
metal lath (30) to secure the metal lath (30) with the metal lath
accessory (410). Each lower and upper flange (420, 422) comprises a
plurality of barbs (426, 428) along a length of the flanges (420,
422), as shown in FIG. 34. This can provide a plurality of
attachment points between the metal lath (30) and the metal lath
accessory (410) along the length of the metal lath accessory (410).
As shown, adjacent barbs (426) on the lower flange (420) are
separated by openings (416) in the lower flange (420). Similarly,
in this embodiment, adjacent barbs (428) on the upper flange (422)
are separated by openings (416) in the upper flange (422). Of
course, any suitable number of barbs (426, 428) can be used to
sufficiently secure the metal lath (30) to the metal lath accessory
(410). In other embodiments, the metal lath attachment feature may
comprise one or more different structures instead of or in addition
to the barbs (426, 428), including but not limited to a flange, a
snap-down leg, and a channel.
[0103] As shown in FIGS. 29 and 31, each barb (426, 428) comprises
a ramped surface (426a, 428a) facing the opening of the channel
between lower and upper flanges (420, 422) and a shoulder surface
(426b, 428b) facing the side wall (412). In some embodiments, the
shoulder surface (426b, 428b) may be substantially perpendicular
relative to the respective flange (420, 422) the barb (426, 428)
projects from. This may allow the metal lath (30) to slide along
the ramped surface of each barb (426, 428) when the metal lath (30)
is inserted within the metal lath accessory (410) such that the
metal lath accessory (410) is more easily able to receive the metal
lath (30). After the metal lath (30) has been received within the
channel between the lower and upper flanges (420, 422), the
shoulder surface (426b, 428b) of each of the barbs (426, 428) is
configured to engage the metal lath (30) to prevent the metal lath
(30) from being easily removed from the metal lath accessory (410).
In the illustrated embodiment, barbs (426, 428) have a
substantially triangular cross-section. In other embodiments, barbs
(426, 428) may have a different cross-sectional shape suitable to
sufficiently engage the metal lath while still allowing the metal
lath to be received within the channel between the lower and upper
flanges (420, 422). As shown, the barbs (426) on the lower flange
(420) and the barbs (428) on the upper flange (422) have identical
cross-sections. In other embodiments, the barbs on the lower flange
and the barbs on the upper flange may have different
cross-sections. In still other embodiments, barbs on the same
flange may have different cross-sections.
[0104] Similar to the angled portion (24) described above, in some
embodiments, the upper flange (422) may comprise an angled portion
at the free end of the upper flange (422). This may help guide the
metal lath (30) into the channel between the lower flange (420) and
the upper flange (422) when the metal lath (30) is inserted within
the metal lath accessory (410). Of course, any such angled portion
is merely optional.
[0105] When the metal lath (30) is inserted within the metal lath
accessory (410), the upper flange (422) may be sufficiently
resilient such that the upper flange (422) flexes upwardly to allow
the metal lath (30) to slide between the upper flange (422) and the
lower flange (420), past the barbs (426, 428), and adjacent to the
side wall (412). Once the metal lath (30) is inserted between the
lower and upper flanges (420, 122), the upper flange (422) can flex
downwardly to its original position such that at least one of the
barbs (426, 428) engages the metal lath (30). Barbs (426, 428) thus
hold the metal lath (30) within the metal lath accessory (410) and
prevent the metal lath (30) from pulling away from the metal lath
accessory (410). Barbs (426, 428) may be substantially aligned
opposite each other, or, alternatively, they may be offset from
each other along the width of the lower and upper flanges (420,
122). In some embodiments, barbs (426, 428) may be positioned in
corresponding pairs, while in other embodiments barbs (426,428) may
be staggered between the upper flange (422) and the lower flange
(420) along the length of the metal latch accessory (410).
[0106] Either before or after the metal lath (30) is inserted
within the metal lath accessory (410), the lower flange (420) of
the metal lath accessory (410) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). The
substrate (5) may be any suitable structure, such as a wall
comprising any suitable material, such as plywood, cinder blocks,
or any other similar material. Once the metal lath (30) is inserted
within the metal lath accessory (410) and metal lath accessory
(410) is secured to the substrate (5), one or more coats (e.g., a
scratch coat and a finishing coat) of a finishing material (35),
such as stucco, plaster or other similar material can then be
applied over the lower and upper flanges (420, 422) of the metal
lath accessory (410) and the metal lath (30).
[0107] In the illustrated embodiment, the lower and upper flanges
(420, 422) of the metal lath accessory (410) comprise a plurality
of openings (416) that may allow the stucco to better bond to the
metal lath accessory (410), but these openings (416) are merely
optional and may be sized, shaped and arranged in any suitable
configuration. As shown, the openings (416) located in the upper
flange (422) are positioned directly above openings (416) in the
lower flange (420) that correspond in size and shape to the
openings (416) in the upper flange (422). Of course, other suitable
profiles and configurations for the metal lath accessory (410) will
be apparent to one of ordinary skill in the art in view of the
teachings herein.
[0108] FIGS. 36-44 show an embodiment of a lath clip (510) that is
configured to be used in conjunction with a typical solid flange
metal lath accessory. A typical solid flange metal lath accessory
may comprise a typical metal lath accessory that comprises a lower
flange that is substantially solid (i.e., substantially
unperforated or substantially free of any openings), including but
not limited to a weep screed, an expansion joint, a casing bead, a
corner bead, or a control joint, such as the mid-wall control joint
(610) shown in FIGS. 36 and 38-44 and described below. The lath
clip (510) can be combined with a typical solid flange metal lath
accessory to provide a resulting metal lath accessory (505) that
includes a metal lath attachment feature. As shown, the lath clip
(510) comprises a side wall (512) extending upwardly from a lower
flange (520). An upper flange (522) extends outwardly from the side
wall (512) at a position spaced above the lower flange (520). In
this embodiment, the upper flange (522) extends from an upper end
of the side wall (512), although in other embodiments, the upper
flange (522) may extend from side wall (512) at an intermediate
position below the upper end of the side wall (512). In the
illustrated embodiment, the upper flange (522) is substantially
parallel to the lower flange (520). In some embodiments, one or
both of the upper flange (522) and the lower flange (520) may
extend substantially perpendicularly relative to the side wall
(512), while in other embodiments, one or both of the upper flange
(522) and the lower flange (520) may extend obliquely relative to
the side wall (512). Lower and upper flanges (520, 522) thereby
form a channel to receive the metal lath (30) within the lath clip
(510). Accordingly, the upper flange (522) may be spaced apart from
the lower flange (520) any distance suitable to allow the lath clip
(510) to receive and engage various thicknesses of metal lath (30).
By way of example only, in some embodiments the upper flange (522)
may be spaced apart from the lower flange (520) about 0.230 inches
and the tip of the barbs (526, 528) may be spaced apart from each
other about 0.140 inches. In some embodiments, the upper flange
(522) may extend obliquely relative to the lower flange (520). For
example, in some embodiments, the upper flange (522) may extend
downwardly toward the lower flange (520) such that the height of
the channel defined, at least in part, by the upper flange (522)
and the lower flange (520) is larger at the fixed end of the upper
flange (522) than the height of the channel at the free end of the
upper flange (522). In some embodiments, one or more of the side
wall (512), lower flange (520), and upper flange (522) may comprise
a single, integral piece that is of unitary construction. In some
embodiments, one or more of the side wall (512), lower flange
(520), and upper flange (522) may be extruded or co-extruded
together to form a product of unitary construction. In other
embodiments, one or more of the side wall (512), lower flange
(520), and upper flange (522) may comprise non-integral, separate
components that are attached to each other.
[0109] The lath clip (510) further comprises a metal lath
attachment feature configured to receive and engage the metal lath
(30) so that the metal lath (30) and the lath clip (510) (and the
metal lath (30) and the combined lath clip (510) and associated
metal lath accessory (610)) are attached to each other. In the
illustrated embodiment, the metal lath attachment feature comprises
the upper flange (522), the lower flange (520), and at least one
barb (526, 528) positioned on each of the upper flange (522) and
the lower flange (520). As shown in FIGS. 37 and 42, the lower
flange (520) comprises a barb (526) extending upwardly from the
lower flange (520) toward the upper flange (522). The upper flange
(522) comprises a barb (528) extending downwardly from the upper
flange (520) toward the lower flange (520). As shown, the barbs
(526, 528) are sized and shaped to fit substantially within or
otherwise engage an opening of the metal lath (30) to secure the
metal lath (30) with the lath clip (510). Each lower and upper
flange (520, 522) comprises a plurality of barbs (526, 528) along a
length of the flanges (520, 522), as shown in FIGS. 40 and 44. This
can provide a plurality of attachment points between the metal lath
(30) and the lath clip (510) along the length of the lath clip
(510). As shown, adjacent barbs (526) on the lower flange (520) are
separated by openings (516) in the lower flange (520). Similarly,
in this embodiment, adjacent barbs (528) on the upper flange (522)
are separated by openings (516) in the upper flange (522). Of
course, any suitable number of barbs (526, 528) can be used to
sufficiently secure the metal lath (30) to the lath clip (510). In
other embodiments, the metal lath attachment feature may comprise
one or more different structures instead of or in addition to the
barbs (526, 528), including but not limited to a flange, a
snap-down leg, and a channel.
[0110] As shown in FIGS. 37 and 42, each barb (526, 528) comprises
a ramped surface (526a, 528a) facing the opening of the channel
between lower and upper flanges (520, 522) and a shoulder surface
(526b, 528b) facing the side wall (512). In some embodiments, the
shoulder surface (526b, 528b) may be substantially perpendicular
relative to the respective flange (520, 522) the barb (526, 528)
projects from. This may allow the metal lath (30) to slide along
the ramped surface of each barb (526, 528) when the metal lath (30)
is inserted within the lath clip (510) such that the lath clip
(510) is more easily able to receive the metal lath (30). After the
metal lath (30) has been received within the channel between the
lower and upper flanges (520, 522), the shoulder surface (526b,
528b) of each of the barbs (526, 528) is configured to engage the
metal lath (30) to prevent the metal lath (30) from being easily
removed from the metal lath accessory (510). In the illustrated
embodiment, barbs (526, 528) have a substantially triangular
cross-section. In other embodiments, barbs (526, 528) may have a
different cross-sectional shape suitable to sufficiently engage the
metal lath while still allowing the metal lath to be received
within the channel between the lower and upper flanges (520, 522).
As shown, the barbs (526) on the lower flange (520) and the barbs
(528) on the upper flange (522) have identical cross-sections. In
other embodiments, the barbs on the lower flange and the barbs on
the upper flange may have different cross-sections. In still other
embodiments, barbs on the same flange may have different
cross-sections.
[0111] Similar to the angled portion (24) described above, in some
embodiments, the upper flange (522) may comprise an angled portion
at the free end of the upper flange (522). This may help guide the
metal lath (30) into the channel between the lower flange (520) and
the upper flange (522) when the metal lath (30) is inserted within
the lath clip (510). Of course, any such angled portion is merely
optional.
[0112] When the metal lath (30) is inserted within the lath clip
(510), the upper flange (522) may be sufficiently resilient such
that the upper flange (522) flexes upwardly to allow the metal lath
(30) to slide between the upper flange (522) and the lower flange
(520), past the barbs (526, 528), and adjacent to the side wall
(512). Once the metal lath (30) is inserted between the lower and
upper flanges (520, 522), the upper flange (522) can flex
downwardly to its original position such that at least one of the
barbs (526, 528) engages the metal lath (30). Barbs (526, 528) thus
hold the metal lath (30) within the lath clip (510) and prevent the
metal lath (30) from pulling away from the lath clip (510). Barbs
(526, 528) may be substantially aligned opposite each other, or,
alternatively, they may be offset from each other along the width
of the lower and upper flanges (520, 522). In some embodiments,
barbs (526, 528) may be positioned in corresponding pairs, while in
other embodiments barbs (526,528) may be staggered between the
upper flange (522) and the lower flange (520) along the length of
the metal latch accessory (510).
[0113] In some embodiments, it may be desirable to couple the lath
clip (510) with a typical solid flange metal lath accessory (610).
In the illustrated embodiment, the solid flange metal lath
accessory (610) is shown as a mid-wall control joint that comprises
a first flange (620) and a second flange (618) joined by a V-shaped
joint that is formed by sidewalls (612, 614) and a top portion
(616). The lath clip (510) can be coupled with the solid flange
metal lath accessory (610) by joining a top surface of the first
flange (620) of the solid flange metal lath accessory (610) to a
bottom surface of the lower flange (520) of the lath clip (510).
Alternatively, or additionally, the lath clip (510) can be coupled
with the solid flange metal lath accessory (610) at other areas of
the lath clip (510) and/or solid flange metal lath accessory (610).
The lath clip (510) and solid flange metal lath accessory (610) can
be joined together by ultrasonic welding, welding, fasteners,
adhesives, etc. The lath clip (510) may comprise one or more
substantially solid or substantially unperforated portions that can
serve as weld points and/or used for fasteners or adhesives to
couple the lath clip (510) and the solid flange metal lath
accessory (610). Once the lath clip (510) is coupled to the solid
flange metal lath accessory (610), then the solid flange metal lath
accessory (610) can be secured to a substrate using standard
fasteners and/or fastening methods well known within the art. In
other embodiments, the solid flange metal lath accessory (610) may
be secured to a substrate before the lath clip (510) is coupled to
the solid flange metal lath accessory (610).
[0114] For instance, either before or after the metal lath (30) is
inserted within the lath clip (510), the flange (620) of the solid
flange metal lath accessory (610) can be secured to a substrate (5)
to thereby couple the metal lath (30) to the substrate (5). The
substrate (5) may be any suitable structure, such as a wall
comprising any suitable material, such as plywood, cinder blocks,
or any other similar material. Once the metal lath (30) is inserted
within the metal lath accessory (510) and metal lath accessory
(510) is secured to the substrate (5), one or more coats (e.g., a
scratch coat and a finishing coat) of a finishing material (35),
such as stucco, plaster or other similar material can then be
applied over the lower and upper flanges (520, 522) of the metal
lath accessory (510) and the metal lath (30).
[0115] In the illustrated embodiment, the lower and upper flanges
(520, 522) of the lath clip (510) comprise a plurality of openings
(516) that may allow the stucco to better bond to the lath clip
(510), but these openings (516) are merely optional and may be
sized, shaped and arranged in any suitable configuration. As shown,
the openings (516) located in the upper flange (522) are positioned
directly above openings (516) in the lower flange (520) that
correspond in size and shape to the openings (516) in the upper
flange (522). Of course, other suitable profiles and configurations
for the lath clip (510) will be apparent to one of ordinary skill
in the art in view of the teachings herein.
[0116] While the illustrated embodiment shows the solid flange
metal lath accessory (610) as a mid-wall control joint, other
suitable types of accessories can be used, such as weep screeds,
control joints, expansion joints, casing beads, corner beads, etc.
Accordingly, by coupling the lath clip (510) to the solid flange
metal lath accessory (610), any type of accessory can be assembled
with a piece of metal lath such that the need for additional
components to attach the metal lath to the accessory, such as metal
ties or other fasteners, may be eliminated. The lath clip (510) can
be manufactured as a separate component configured to be joined
with the solid flange metal lath accessory (610), as described
above, or the lath clip (510) and the solid flange metal lath
accessory (610) can be manufactured together as a unitary
component. Other suitable configurations for the lath clip (510)
and/or the solid flange metal lath accessory (610) will be apparent
to one with ordinary skill in the art in view of the teachings
herein.
[0117] FIGS. 45-50 show another embodiment of a metal lath
accessory (710) that is configured as a control joint and is
substantially similar to the metal lath accessory (10), except that
metal lath accessory (710) has an alternate hole pattern and
configuration and upper flange (722) is wider than upper flange
(22). As shown, metal lath accessory (710) comprises a central
portion (714) positioned between a pair of side walls (12). As
shown in FIG. 46, the central portion (714) comprises a recess to
form a V-shape, but other suitable shapes for central portion (714)
can be used.
[0118] As shown in FIGS. 45-50, the metal lath accessory (710)
comprises a lower flange (720) extending outwardly from a bottom
portion of each side wall (712). The metal lath accessory (710)
further comprises an upper flange (722) extending outwardly from
each side wall (712) at a position above the lower flange (720). In
some embodiments, one or more of the central portion (714), side
walls (712), lower flanges (720), and upper flanges (722) may
comprise a single, integral piece that is of unitary construction.
In some embodiments, one or more of the central portion (714), side
walls (712), lower flanges (720), and upper flanges (722) may be
extruded or co-extruded together to form a product of unitary
construction. In other embodiments, one or more of the central
portion (714), side walls (712), lower flanges (720), and upper
flanges (722) may comprise non-integral, separate components that
are attached to each other. In the illustrated embodiment, each
upper flange (722) is substantially parallel to the corresponding
lower flange (720). In some embodiments, one or both of the upper
flange (722) and the lower flange (720) may extend substantially
perpendicularly relative to the respective side wall (712), while
in other embodiments, one or both of the upper flange (722) and the
lower flange (720) may extend obliquely relative to the respective
side wall (712). Lower and upper flanges (720, 722) thereby form a
channel to receive the metal lath (30) within the metal lath
accessory (710). Accordingly, the upper flange (722) may be spaced
apart from the lower flange (720) any distance suitable to allow
the metal lath accessory (710) to receive and engage various
thicknesses of metal lath (30). By way of example only, in some
embodiments the upper flange (722) may be spaced apart from the
lower flange (720) about 0.230 inches and the tip of the barbs
(726, 728) may be spaced apart from each other about 0.140 inches.
In some embodiments, the upper flange (722) may extend obliquely
relative to the lower flange (720). For example, in some
embodiments, the upper flange (722) may extend downwardly toward
the lower flange (720) such that the height of the channel defined,
at least in part, by the upper flange (722) and the lower flange
(720) is larger at the fixed end of the upper flange (722) than the
height of the channel at the free end of the upper flange
(722).
[0119] The metal lath accessory (710) further comprises a pair of
metal lath attachment features configured to receive and engage the
metal lath (30) so that the metal lath (30) and the metal lath
accessory (710) are attached to each other. In the illustrated
embodiment, each metal lath attachment feature comprises an upper
flange (722), a corresponding lower flange (720), and at least one
barb (726, 728) positioned on each of the upper flange (722) and
the lower flange (720). As shown in FIG. 46, each lower flange
(720) comprises at least one barb (726) extending upwardly from the
lower flange (720) toward the upper flange (722). Each upper flange
(722) comprises at least one barb (728) extending downwardly from
the upper flange (720) toward the lower flange (720). As shown, the
barbs (726, 728) are sized and shaped to substantially fit within
or otherwise engage an opening of the metal lath (30) to secure the
metal lath (30) to the metal lath accessory (710). Each lower and
upper flange (720, 722) comprises a plurality of barbs (726, 728)
along a length of the flanges (720, 722), as shown in FIGS. 47 and
48. This can provide a plurality of attachment points between the
metal lath (30) and the metal lath accessory (710) along the length
of the metal lath accessory (710). As shown, adjacent barbs (726)
on the lower flange (720) are separated by openings (716) in the
lower flange (720). Similarly, in this embodiment, adjacent barbs
(728) on the upper flange (722) are separated by openings (716) in
the upper flange (722). Of course, any suitable number of barbs
(726, 728) can be used to sufficiently secure the metal lath (30)
to the metal lath accessory (710). In other embodiments, the metal
lath attachment feature may comprise one or more different
structures instead of or in addition to the barbs (726, 728),
including but not limited to a flange, a snap-down leg, and a
channel.
[0120] As shown in FIG. 46, each barb (726, 728) comprises a ramped
surface (726a, 728a) facing the opening of the channel between the
lower and upper flanges (720, 722) and a shoulder surface (726b,
728b) facing the respective side wall (712). In some embodiments,
the shoulder surface (726b, 728b) may be substantially
perpendicular relative to the respective flange (720, 722) the barb
(726, 728) projects from. This may allow the metal lath (30) to
slide along the ramped surface (726a, 728a) of each barb (726, 728)
when the metal lath (30) is inserted within the metal lath
accessory (710) such that the metal lath accessory (710) is more
easily able to receive the metal lath (30). As shown, after the
metal lath (30) has been received within the channel between the
lower and upper flanges (720, 722), the shoulder surface (726b,
728b) of each of the barbs (726, 728) is configured to engage the
metal lath (30) to prevent the metal lath (30) from being easily
removed from the metal lath accessory (710). In the illustrated
embodiment, barbs (726, 728) have a substantially triangular
cross-section. In other embodiments, barbs (726, 728) may have a
different cross-sectional shape suitable to sufficiently engage the
metal lath while still allowing the metal lath to be received
within the channel between the lower and upper flanges (720, 722).
As shown, the barbs (726) on the lower flange (720) and the barbs
(728) on the upper flange (722) have identical cross-sections. In
other embodiments, the barbs on the lower flange and the barbs on
the upper flange may have different cross-sections. In still other
embodiments, barbs (726, 728) on the same flange (720, 722) may
have different cross-sections.
[0121] In the embodiment shown in FIGS. 45-50, each upper flange
(722) further comprises an angled portion (724) at the free end of
each upper flange (722). Angled portion (724) may be positioned at
about a 45 degree angle relative to the upper flange (722), but any
other suitable configuration may be used. This may help guide the
metal lath (30) into the channel between the lower flange (720) and
the upper flange (722) when the metal lath (30) is inserted into
the metal lath accessory (710). It should be noted that angled
portion (724) of the upper flange (722) is merely optional.
[0122] When the metal lath (30) is inserted within the metal lath
accessory (710), the upper flange (722) may be sufficiently
resilient such that the upper flange (722) flexes slightly upwardly
to allow the metal lath (30) to slide between the upper flange
(722) and the lower flange (720), past the barbs (726, 728), and
adjacent to the side wall (712). Once the metal lath (30) is
inserted between the lower and upper flanges (720, 722), the upper
flange (722) can flex downwardly to its original position such that
at least one of the barbs (726, 728) engages the metal lath (30).
Barbs (726, 728) thus hold the metal lath (30) within the metal
lath accessory (710) and prevent the metal lath (30) from pulling
away from the metal lath accessory (710). Barbs (726, 728) may be
substantially aligned opposite each other, or, alternatively, they
may be offset from each other along the width of the lower and
upper flanges (720, 722). In some embodiments, barbs (726, 728) may
be positioned in corresponding pairs, while in other embodiments
barbs (726, 728) may be staggered between the upper flange (722)
and the lower flange (720) along the length of the metal latch
accessory (710).
[0123] Either before or after the metal lath (30) is inserted
within the metal lath accessory (710), the lower flange (720) of
the metal lath accessory (710) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). The
substrate (5) may be any suitable structure, such as a wall
comprising any suitable material, such as plywood, cinder blocks,
or any other similar material. Once the metal lath (30) is inserted
within the metal lath accessory (710) and metal lath accessory
(710) is secured to the substrate (5), one or more coats (e.g., a
scratch coat and a finishing coat) of a finishing material (35),
such as stucco, plaster or other similar material, can then be
applied over the lower and upper flanges (720, 722) of the metal
lath accessory (710) and the metal lath (30).
[0124] In the illustrated embodiment, the lower and upper flanges
(720, 722) of the metal lath accessory (710) comprise a plurality
of openings (716) that may allow the finishing material to better
bond to the metal lath accessory (710), but these openings (716)
are merely optional and may be sized, shaped and arranged in any
suitable configuration. As shown, the openings (716) located in the
upper flange (722) are positioned directly above openings (716) in
the lower flange (720) that correspond in size and shape to the
openings (716) in the upper flange (722).
[0125] As shown in FIGS. 45-50, the plurality of openings (716)
includes a plurality of exterior circular openings (716a), a
plurality of trapezoidal openings (716b), a plurality of interior
circular openings (716c) and a plurality of triangular openings
(716d). In this embodiment, the exterior circular openings (716a)
are positioned in a row adjacent to the free end of upper flange
(722) and lower flange (720). The trapezoidal openings (716b) are
positioned between the row of exterior circular openings (716a) and
the row of interior circular openings (716c). The triangular
openings (716d) are arranged in repeating groups of three openings
between adjacent trapezoidal openings (716b) and adjacent interior
circular openings (716c). Relative to the opening patterns
illustrated in FIGS. 1-44, the opening pattern illustrated in FIGS.
45-50 may be configured to provide an increased amount of open
space in upper flange (722) and lower flange (720) and, thus, allow
an increased amount of finishing material (35) into the channel
defined, at least in part, by the upper flange (722) and the lower
flange (720) and to contact the substrate (5) beneath lower flange
(720). As a result, the opening pattern illustrated in FIGS. 45-50
may result in a stronger bond between the finishing material (35),
the metal lath (30), finishing accessory (710) and the substrate
(5).
[0126] The embodiment illustrated in FIGS. 45-50 also includes a
pair of angled members (725) extending from a respective side wall
(712) adjacent to the juncture of each upper flange (722) and the
respective side wall (712). The angled members (725) are merely
optional and may be arranged at any suitable angle and positioned
at any suitable position along the side wall (712) or omitted
entirely. Of course, other suitable profiles and configurations for
the metal lath accessory (710) will be apparent to one of ordinary
skill in the art in view of the teachings herein.
[0127] FIGS. 51-56 show another embodiment of a metal lath
accessory (810) that is configured as a control joint and is
substantially similar to the metal lath accessory (110), except
that metal lath accessory (810) has an alternate hole pattern and
configuration and upper flange (822) is wider than upper flange
(122).
[0128] In this embodiment, metal lath accessory (810) comprises a
side wall (812) extending upwardly from an end of a lower flange
(820). An upper flange (822) extends outwardly from the side wall
(812) at a position spaced above the lower flange (820). In the
illustrated embodiment, the upper flange (822) is substantially
parallel to the lower flange (820). In some embodiments, one or
both of the upper flange (822) and the lower flange (820) may
extend substantially perpendicularly relative to the side wall
(812), while in other embodiments, one or both of the upper flange
(822) and the lower flange (820) may extend obliquely relative to
the side wall (812). Lower and upper flanges (820, 822) thereby
form a channel to receive the metal lath (30) within the metal lath
accessory (110). Accordingly, the upper flange (822) may be spaced
apart from the lower flange (820) any distance suitable to allow
the metal lath accessory (810) to receive and engage various
thicknesses of metal lath (30). By way of example only, in some
embodiments the upper flange (822) may be spaced apart from the
lower flange (820) about 0.230 inches and the tip of the barbs
(826, 828) may be spaced apart from each other about 0.140 inches.
In some embodiments, the upper flange (822) may extend obliquely
relative to the lower flange (820). For example, in some
embodiments, the upper flange (822) may extend downwardly toward
the lower flange (820) such that the height of the channel defined,
at least in part, by the upper flange (822) and the lower flange
(820) is larger at the fixed end of the upper flange (822) than the
height of the channel at the free end of the upper flange (822). At
an upper end of the side wall (812), a lip (814) extends outwardly
from the side wall (812) having a first portion that extends
substantially parallel to the upper flange (822) and a second
portion that extends downward towards the upper flange (822). In
some embodiments, one or more of the side wall (812), lip (814),
lower flange (820), and upper flange (822) may comprise a single,
integral piece that is of unitary construction. In some
embodiments, one or more of the side wall (812), lip (814), lower
flange (820), and upper flange (822) may be extruded or co-extruded
together to form a product of unitary construction. In other
embodiments, one or more of the side wall (812), lip (814), lower
flange (820), and upper flange (822) may comprise non-integral,
separate components that are attached to each other.
[0129] The metal lath accessory (810) further comprises a metal
lath attachment feature configured to receive and engage the metal
lath (30) so that the metal lath (30) and the metal lath accessory
(810) are attached to each other. In the illustrated embodiment,
the metal lath attachment feature comprises the upper flange (822),
the lower flange (820), and at least one barb (826, 828) positioned
on each of the upper flange (822) and the lower flange (820). As
shown in FIG. 11, the lower flange (820) comprises a barb (826)
extending upwardly from the lower flange (820) toward the upper
flange (822). The upper flange (822) comprises a barb (828)
extending downwardly from the upper flange (820) toward the lower
flange (820). As shown, the barbs (826, 828) are sized and shaped
to fit substantially within or otherwise engage an opening of the
metal lath (30) to secure the metal lath (30) with the metal lath
accessory (810). Each lower and upper flange (820, 82) comprises a
plurality of barbs (826, 828) along a length of the flanges (820,
822), as shown in FIG. 53. This can provide a plurality of
attachment points between the metal lath (30) and the metal lath
accessory (810) along the length of the metal lath accessory (810).
As shown, adjacent barbs (826) on the lower flange (820) are
separated by openings (816) in the lower flange (820). Similarly,
in this embodiment, adjacent barbs (828) on the upper flange (822)
are separated by openings (816) in the upper flange (822). Of
course, any suitable number of barbs (826, 828) can be used to
sufficiently secure the metal lath (30) to the metal lath accessory
(810). In other embodiments, the metal lath attachment feature may
comprise one or more different structures instead of or in addition
to the barbs (826, 828), including but not limited to a flange, a
snap-down leg, and a channel.
[0130] As shown in FIG. 52, each barb (826, 828) comprises a ramped
surface (826a, 828a) facing the opening of the channel between
lower and upper flanges (820, 822) and a shoulder surface (826b,
828b) facing the respective side wall (812). In some embodiments,
the shoulder surface (826b, 828b) may be substantially
perpendicular relative to the respective flange (820, 822) the barb
(826, 828) projects from. This may allow the metal lath (30) to
slide along the ramped surface of each barb (826, 828) when the
metal lath (30) is inserted within the metal lath accessory (810)
such that the metal lath accessory (810) is more easily able to
receive the metal lath (30). After the metal lath (30) has been
received within the channel between the lower and upper flanges
(820, 822), the shoulder surface (826b, 828b) of each of the barbs
(826, 828) is configured to engage the metal lath (30) to prevent
the metal lath (30) from being easily removed from the metal lath
accessory (810). In the illustrated embodiment, barbs (826, 828)
have a substantially triangular cross-section. In other
embodiments, barbs (826, 828) may have a different cross-sectional
shape suitable to sufficiently engage the metal lath while still
allowing the metal lath to be received within the channel between
the lower and upper flanges (820, 822). As shown, the barbs (826)
on the lower flange (820) and the barbs (828) on the upper flange
(822) have identical cross-sections. In other embodiments, the
barbs on the lower flange and the barbs on the upper flange may
have different cross-sections. In still other embodiments, barbs on
the same flange may have different cross-sections.
[0131] Similar to the angled portion (24) described above, in some
embodiments, the upper flange (822) may comprise an angled portion
at the free end of the upper flange (822). This may help guide the
metal lath (30) into the channel between the lower flange (820) and
the upper flange (822) when the metal lath (30) is inserted within
the metal lath accessory (810). Of course, any such angled portion
is merely optional.
[0132] When the metal lath (30) is inserted within the metal lath
accessory (810), the upper flange (822) may be sufficiently
resilient such that the upper flange (822) flexes upwardly to allow
the metal lath (30) to slide between the upper flange (822) and the
lower flange (820), past the barbs (826, 828), and adjacent to the
side wall (812). Once the metal lath (30) is inserted between the
lower and upper flanges (820, 822), the upper flange (822) can flex
downwardly to its original position such that at least one of the
barbs (826, 828) engages the metal lath (30). Barbs (826, 828) thus
hold the metal lath (30) within the metal lath accessory (810) and
prevent the metal lath (30) from pulling away from the metal lath
accessory (810). Barbs (826, 828) may be substantially aligned
opposite each other, or, alternatively, they may be offset from
each other along the width of the lower and upper flanges (820,
822). In some embodiments, barbs (826, 828) may be positioned in
corresponding pairs, while in other embodiments barbs (826,828) may
be staggered between the upper flange (822) and the lower flange
(820) along the length of the metal latch accessory (810).
[0133] Either before or after the metal lath (30) is inserted
within the metal lath accessory (810), the lower flange (820) of
the metal lath accessory (810) can be secured to a substrate (5) to
thereby couple the metal lath (30) to the substrate (5). Once the
metal lath (30) is inserted within the metal lath accessory (810)
and metal lath accessory (810) is secured to the substrate (5), one
or more coats (e.g., a scratch coat and a finishing coat) of a
finishing material (35), such as stucco, plaster or other similar
material, can then be applied over the lower and upper flanges
(820, 822) of the metal lath accessory (810) and the metal lath
(30).
[0134] In the illustrated embodiment, the lower and upper flanges
(820, 822) of the metal lath accessory (810) comprise a plurality
of openings (816) that may allow the finishing material to better
bond to the metal lath accessory (810), but these openings (816)
are merely optional and may be sized, shaped and arranged in any
suitable configuration. The openings (816) in metal lath accessory
(810) are substantially similar to those in metal lath accessory
(710) described above. As shown, the openings (816) located in the
upper flange (822) are positioned directly above openings (816) in
the lower flange (820) that correspond in size and shape to the
openings (816) in the upper flange (822). Of course, other suitable
profiles and configurations for the metal lath accessory (810) will
be apparent to one of ordinary skill in the art in view of the
teachings herein.
[0135] FIG. 57 shows another embodiment of a metal lath accessory
(810') that is configured as a casing bead and is substantially
similar to the metal lath accessory (810), except that upper flange
(822') extends obliquely relative to lower flange (820').
Specifically, the upper flange (822') extends downwardly toward the
lower flange (820') such that the height of the channel defined, at
least in part, by the upper flange (822') and the lower flange
(820') is larger at the fixed end of the upper flange (822') than
the height of the channel at the free end of the upper flange
(822').
[0136] In some embodiments, the upper flange of the metal lath
accessory (10, 110, 210, 310, 410, 505, 710, 810) can be
resiliently biased such that the upper flange is positioned in an
upward, open position with the metal lath (30) is inserted into the
metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810), and
then the upper flange can be pivoted downward to a closed position
to attach the metal lath accessory (10, 110, 210, 310, 410, 505,
710, 810) to the metal lath (30). In some other embodiments, the
metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810)
comprises a plurality of rows of barbs positioned between the lower
and upper flanges of the metal lath accessory (10, 110, 210, 310,
410, 505, 710, 810).
[0137] The upper flange of the metal lath accessory (10, 110, 210,
310, 410, 505, 710, 810) may comprise any suitable width. In some
embodiments, including but not limited to those shown in FIGS.
1-44, the lower flange may be wider than the upper flange. In other
embodiments, including but not limited to those shown in FIGS.
45-56, the upper flange and the lower flange may comprise
substantially the same width. In still other embodiments, the upper
flange may be wider than the lower flange.
[0138] The metal lath accessories and lath clip described herein
may comprise a plastic material, including but not limited to rigid
polyvinyl chloride (PVC) or chlorinated polyvinyl chloride (CPVC),
a metal material, including but not limited to zinc alloy (99% pure
zinc), galvanized (zinc coated) steel, or anodized aluminum alloy,
or any other suitable material. In some embodiments, the metal lath
accessory or lath clip may be produced using an extrusion or
co-extrusion process.
[0139] Based on the teachings herein, embodiments of the metal lath
attachment features and the lath clip described herein, including
the inclusion of an upper flange and one or more barbs on an upper
and/or lower flange, may be incorporated into and/or used in
conjunction with any metal lath accessory that includes a lower
flange that is attached to a substrate, including but not limited
to casing beads, control joints, expansion joints, reveals, corner
beads, and screeds.
[0140] Having shown and described various embodiments of the
present invention, further adaptations of the methods and systems
described herein may be accomplished by appropriate modifications
by one of ordinary skill in the art without departing from the
scope of the present invention. Several of such potential
modifications have been mentioned, and others will be apparent to
those skilled in the art. For instance, the examples, embodiments,
geometrics, materials, dimensions, ratios, steps, and the like
discussed above are illustrative and are not required. Accordingly,
the scope of the present invention should be considered in terms of
any claims that may be presented and is understood not to be
limited to the details of structure and operation shown and
described in the specification and drawings.
* * * * *