APPARATUSES AND METHODS FOR A LATH AND RAIN SCREEN ASSEMBLY

Abstract

A lath and rain screen assembly for fastening to an exterior building surface or the like is provided. The lath and rain screen assembly comprises (a) a rain screen having a first side and a second side and defining a first plane, the first side including a plurality of first side spacer elements extending outwardly in a first direction substantially perpendicular to the first plane; and (b) a lath defining a second plane spaced apart from and substantially parallel to the first plane, the lath being operatively attached to an outermost surface of each of the first side spacer elements positioned adjacent the second plane. In certain embodiments, the lath and rain screen assembly further comprises a plurality of second side spacer elements extending outwardly in a second direction. A method of applying the lath and rain screen assembly is also provided.

Description

BACKGROUND OF THE INVENTION

In the construction of buildings, frequently used construction products include exterior cladding materials. Exterior cladding materials can be used to cover the exterior surfaces formed from various framing structures. Non-limiting examples of exterior cladding materials include masonry products, such as for example, stone and brick and stucco.

In certain instances, the exterior building cladding is applied to sub-structures that are attached to the exterior surfaces of the framing structures. One example of a sub-structure is rain screens. Generally speaking, rain screens are configured to create a cavity between the exterior cladding materials and the exterior surface of the framing structure. The cavity allows weather-related moisture to easily pass through and away from the building. Another example of a sub-structure is laths. Laths are materials configured to support mortar or plasterwork.

Historically, rain screens and laths were provided as separate stand-alone products that could be sequentially attached to the exterior surfaces of framing structures. As a result, significant amounts of time were necessary for installation, contributing, at least in part, to increasingly rising occurrences of delay and cost overruns in a variety of projects contexts.

Further, traditional methods of installation of stand-alone rain screens and laths often inadvertently created moisture barriers between the rain screens and any moisture resistant layers incorporated between the rain screens and the exterior surfaces of the framing structures. Such led to potential issues regarding ventilation and drying due to impediments to the removal of both liquid water and water vapor.

Accordingly, it would be advantageous if various sub-structures could be improved to alleviate these and other problems and inefficiencies.

SUMMARY OF THE INVENTION

In accordance with the purposes of the present invention as described herein, a lath and rain screen assembly is provided for fastening to an exterior building surface. The lath and rain screen assembly comprises (a) a rain screen having a first side and a second side and defining a first plane, the first side including a plurality of first side spacer elements extending outwardly in a first direction substantially perpendicular to the first plane; and (b) a lath defining a second plane spaced apart from and substantially parallel to the first plane, the lath being operatively attached to an outermost surface of each of the first side spacer elements positioned adjacent the second plane. In certain embodiments, the lath and rain screen assembly further comprises a plurality of second side spacer elements extending outwardly in a second direction substantially perpendicular to the first plane, the second direction being substantially 180 degrees from that of the first direction.

In accordance with an additional aspect of the present invention as described herein, a lath and rain screen assembly is provided for fastening to an exterior building surface. The lath and rain screen assembly comprises (a) a rain screen having a first side and a second side and defining a first plane, the first side including a plurality of first side spacer elements extending outwardly in a first direction substantially perpendicular to the first plane; and (b) a lath defining a second plane spaced apart from and substantially parallel to the first plane, the lath being operatively attached to an outermost surface of each of the first side spacer elements positioned adjacent the second plane such that attachment of the lath to the outermost surface creates a first cavity. In certain embodiments, the first cavity is configured to receive at least a portion of a first layer of mortar such that the first layer substantially encapsulates the lath. In still other embodiments, the lath includes a plurality of spaced apart apertures configured to permit passage of the first layer of mortar substantially through the lath, further substantially encapsulating the lath.

In accordance with an additional aspect of the present invention, a method of applying a lath and rain screen assembly to an exterior building surface is provided. The method comprises the steps of: (a) positioning the lath and rain screen assembly adjacent the exterior building surface, the lath and rain screen assembly comprising a rain screen having a first side with a plurality of outwardly extending first side spacer elements and a second side with a plurality of oppositely outwardly extending second side spacer elements; and (b) applying a first layer of mortar onto the lath.

Various advantages of this invention will become apparent to those skilled in the art from the following detailed description of the invention, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings:

FIG. 1 is an exploded perspective view of a lath and rain screen assembly;

FIG. 2 is a side view, in elevation, of the lath and rain screen assembly of FIG. 1;

FIG. 3 is a cross sectional side view, in elevation, illustrating the lath and rain screen assembly of FIG. 1 installed on exterior building framework and configured to support exterior cladding material in the form of masonry products;

FIG. 4 is a side view, in elevation, illustrating the lath and rain screen assembly of FIG. 1 installed on exterior building framework and configured to support exterior cladding material in the form of stucco;

FIG. 5 is a front view of a rain screen of the lath and rain screen assembly of FIG. 1;

FIG. 6 is a front view of a lath of the lath and rain screen assembly according to additional various embodiments; and

FIG. 7 is a front view of the lath and rain screen assembly according to even further various embodiments.

Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

The description and figures disclose lath and rain screen assemblies configured for attachment to an exterior building framework and further configured as a support surface for external cladding materials. The term “lath”, as used herein, is defined to mean a pattern of material configured to support mortar or plasterwork. The term “rain screen”, as used herein, is defined to mean an infrastructure positioned on exterior building framework and configured to (1) create a cavity that allows weather-related moisture to easily pass through and away from the building; and (2) provide the potential for ventilation and drying to assist in the removal of both liquid water and water vapor. The term “external cladding material”, as used herein, is defined to mean a covering of one or more materials on the exterior of a building.

Referring now to FIGS. 1 and 2, a first embodiment of a lath and rain screen assembly is shown generally at 10. Generally, the lath and rain screen assembly 10 according to various embodiments is attached to an exterior framework of a building and configured as a support for subsequently installed exterior cladding materials, such as for example, masonry products, stonework or stucco. As will be described in more detail below, the lath and rain screen assembly 10, in certain embodiments, further forms an air barrier or air cavity between the exterior framework of the building and the exterior cladding material. The air cavity is configured in these embodiments to allow ventilation and removal of any water that may enter the cavity. As will be further discussed below, the lath and rain screen assembly 10 can be provided to installers in the form of a roll. As a result, in various embodiments, installation of the lath and rain screen assembly 10 can be as simple as unrolling against and fastening adjacent rows of the lath and rain screen assembly 10 to the exterior framework of a building.

Referring again to FIGS. 1 and 2, the lath and rain screen assembly 10 is formed according to various embodiments from the assembly of a rain screen 12 and a lath 14. The rain screen 12, in various embodiments, includes a sheet 16 having a first side 18 and a second side 20. In certain embodiments, the first side 18 of the sheet 16 includes a plurality of spaced apart first side nodules 22 (a.k.a. spacer elements), in the configuration shown having a partial spherical shape. The first side nodules 22 in these embodiments extend in a direction away from the first side 18 of the sheet 16. It may be seen that inwardly-directed concave depressions or “dimples” are in the back side of the nodules, due to the generally consistent thickness of the rain screen.

Similarly, in certain embodiments, the second side 20 of the sheet 16 includes a plurality of spaced apart second side nodules 24 (a.k.a. spacer elements). The second side nodules in these embodiments extend in a direction away from the second side 20 of the sheet 16. In other embodiments, the first and second side nodules, 22 and 24, may be arranged in alternative manners; however the first and second side nodules are generally oriented such that they extend in opposing directions. In this regard, the first and second side nodules, 22 and 24, will be discussed in more detail below.

The body of the rain screen 12 can be thought of as being planar with a nominal thickness intermediate opposing primary planar first and second sides, with the first and second sides lying in corresponding first and second co-parallel planes. The nodules (a.k.a. spacer elements) extend from these sides. The dimples lie between the planes

Referring again to FIGS. 1 and 2, the sheet 16 according to various embodiments has a height H and a length L. In the illustrated embodiment, the height H of the sheet 16 is in a range of from about 3.0 ft to about 4.0 ft. In other embodiments, the height H of the sheet 16 may be less than about 3.0 ft or more than about 4.0 ft. In the illustrated embodiment, the length L of the sheet 16 is in a range of from about 25.0 ft. to about 100.0 ft. In other embodiments, the length L of the sheet 16 may be any desired length based on a variety of considerations such as, for example, the diameter (and potentially weight) of the sheet 16 in a rolled form.

In various embodiments, as shown in FIG. 2, the sheet 16 has a thickness t. In the illustrated embodiment, the thickness t of the sheet 16 is in a range of from about 0.005 inches to about 0.040 inches. In other embodiments, the thickness t of the sheet 16 may be less than about 0.005 inches or more than about 0.040 inches. In still other embodiments, the thickness t of the sheet 16 may be in a range of from about 0.010 inches to about 0.020 inches.

In the illustrated embodiment, the sheet 16 is formed from a polymer-based material, such as for example polyvinyl chloride. In other embodiments, the sheet 16 may be formed from other polymer-based materials, including the non-limiting examples of polystyrene, polyethylene and polypropylene. In still other embodiments, the sheet 16 may be formed from combinations of polymer-based materials.

In various embodiments, the sheet 16 may be configured for moisture transmission. That is, the sheet 16 may be configured to substantially retard the flow of gases (e.g. air and moisture), without requiring the use of a separate vapor or air barrier or an incorporated vapor or air barrier. In the illustrated embodiment, the sheet 16 has a permeability value in a range of from about 80 coulombs to about 250 coulombs as determined by water vapor transmission tests, such as, for example ASTM C1202 and/or Standard E-96. Typical water vapor transmission tests, such as the ASTM C1202, evaluate the transfer of water vapor through semi-permeable and permeable materials over a period of time. In other embodiments, the sheet 16 can have a permeability rating of less than about 80 coulombs or more than about 250 coulombs.

Referring now to FIG. 5, the sheet 16 according to various embodiments includes the plurality of spaced apart first side nodules 22 and the plurality of spaced apart second side nodules 24. In certain embodiments, the first side nodules 22 are arranged in spaced apart, diagonally oriented rows A, C, E, G, I, and K. Likewise, in certain embodiments, the second side nodules 24 are arranged in spaced apart, diagonally oriented rows B, D, F, H, J, and L. In the illustrated embodiment, the rows having the first side nodules 22 (i.e., A, C, E, G, I, and K) are arranged in an alternating pattern with the rows having the second side nodules 24 (i.e., B, D, F, H, J, and L).

As will be explained in more detail below, the alternating pattern of the first and second side nodules, 22 and 24, according to various embodiments is configured, for example, to provide support for the lath 14 when the lath and screen assembly 10 is positioned on the exterior of a building. It should be appreciated that in other embodiments, the first side nodules 22 and the second side nodules 24 can be arranged in other desired patterns sufficient to provide similar degrees of support for the lath 14 when the lath and screen assembly 10 is positioned on the exterior of a building.

Referring again to FIG. 5, in various embodiments, the rows A, C, E, G, I, and K of the first side nodules 22 are equally spaced apart an angular distance D1. In certain embodiments, the distance D1 is in a range of from about 1.0 inch to about 4.0 inches. In other embodiments, the distance D1 may be less than about 1.0 inch or more than about 4.0 inches. In still other embodiments, the distance D1 may be in a range of from about 1.5 inches to about 2.5 inches. In the illustrated embodiment, the distance D1 is approximately 2.0 inches.

Similarly, as also shown in FIG. 5, in various embodiments, the rows B, D, F, H J, and L of the second side nodules 24 are equally spaced apart an angular distance D2. In certain embodiments, the distance D2 is in a range of from about 1.0 inch to about 4.0 inches. In other embodiments, the distance D2 may be less than about 1.0 inch or more than about 4.0 inches. In still other embodiments, the distance D2 may be in a range of from about 1.5 inches to about 2.5 inches. In the illustrated embodiment, the distance D2 is approximately 2.0 inches.

Referring again to FIG. 5, in various embodiments, an angular distance D3 is formed between the first side nodules 22 and adjacent second side nodules 24. In certain embodiments, the distance D3 is in a range of from about 0.50 inch to about 2.00 inches. In other embodiments, the distance D3 may be less than about 0.50 inch or more than about 2.00 inches. In still other embodiments, the distance D3 may be in a range of from about 0.75 inch to about 1.25 inch. In the illustrated embodiment, the distance D1 is approximately 1.0 inch.

In various embodiments, as shown generally in FIG. 5, the angular distance D3 is typically approximately half the distance of angular distances, D1 and D2. Further, as shown in FIG. 5, the rows, A through L, may be alternatively shown extending from the bottom left side of the sheet 16 to the top right side of the sheet, in which case, corresponding distances (not shown) would correspond generally with those of D1 through D3.

Returning to FIG. 1, according to various embodiments the lath 14 of the lath and rain screen assembly 10 includes a sheet 30 having a plurality of spaced apart apertures 32. As will be discussed in more detail below, the sheet 30 and the apertures 32 are generally configured in various embodiments to provide support for subsequently installed external cladding materials. In the illustrated embodiment, the sheet 30 is formed from a fiberglass-based material such as, for example, alkaline resistant (AR) fiberglass. In other embodiments, the sheet 30 may be formed from other materials sufficient to provide a comparable degree of support for subsequently installed external cladding material. In one embodiment, the sheet 30 may be formed from a combination of AR fiberglass and poly-based fiber, which provides the requisite degree of support. In still other embodiments, the sheet 30 may be woven in nature.

In those embodiments having a woven sheet 30, the sheet may be formed by threading (e.g., weaving) a plurality of individual fibers 31 into a plurality of straps 33, each of the straps comprising a portion of the plurality of individual fibers, as generally shown in FIG. 6. According to these various embodiments, each of the straps 33 may then be threaded with a plurality of similarly formed straps 33 to form a mesh or lattice-like structure constituting the lath 14. Notably, the weaving of the individual fibers 31 and the plurality of straps 33 relative to one another may be performed sequentially (as described above), or simultaneously, as shown in FIG. 6, whereby the individual fibers 31 of respective straps 33 further intertwine adjacently woven straps. It should be understood that the specific manner of threading (e.g., weaving) to form this mesh or lattice-like configuration may be through any of a variety of techniques, as commonly known and understood in the art of weaving.

The sheet 30 according to various embodiments may have any desired thickness sufficient to provide support for subsequently installed external cladding material. In certain embodiments, the sheet 30 may have a thickness of 1/64 of an inch to about ¼ of an inch. In other embodiments, the sheet 30 may have a thickness of approximately 1/32 of an inch. In any of these and other embodiments, an overall thickness of the sheet 16 of the rain screen 12, the nodules of the rain screen, and the sheet 30 of the lath 14 may be from about ¼ of an inch to ½ of an inch. In certain embodiment, the overall thickness may be approximately ⅜ of an inch.

In various embodiments, the spaced apart apertures 32 form a mesh or grid structure for the sheet 16, as generally depicted in FIG. 1. In certain embodiments, where the sheet 16 is formed of a fiberglass material, the apertures 32 have a generally rectangular shape resulting from the lath 14 being woven into a mesh or lattice-like structure as discussed above. In various embodiments, the mesh structure is woven such that the apertures 32 have a major dimension in a range of from about 0.10 inches to about 0.50 inches. In certain embodiments, the apertures 32 may have a major dimension of less than 0.10 inches or more than about 0.50 inches, depending on the degree of support desired from the assembled lath and rain screen assembly 10. In other embodiments, the apertures 32 can have other shapes or configurations such as, for example, the non-limiting options of a circular shape or an oval shape.

Referring now to FIG. 2, the rain screen 12 and the lath 14 are shown assembled together according to various embodiments so as to form the lath and rain screen assembly 10. In the assembled configuration of certain embodiments, the lath 14 is attached to and supported by the first side nodules 22. In the illustrated embodiment, the lath 14 is attached to the first side nodules 22 by a heat bonding process. In other embodiments, the lath 14 may be attached to the first side nodules 22 by other processes, including the non-limiting examples of adhesives or mechanical fasteners.

Referring now to FIG. 7, the lath 14 may be sized such that, when attached to the first side nodules 22, according to various embodiments, the lath 14 may be sized such that, when attached to the first side nodules 22, one corner of every other aperture 32 within a set of four apertures 32 each contacts four adjacently positioned nodules 22. Such is generally depicted in FIG. 7 as configuration A, whereby four apertures 32 are positioned substantially within a perimeter defined by four adjacently positioned nodules 22. In other embodiments, the lath 14 may be sized such that, when attached to the first side nodules 22, one corner of every fourth aperture 32 within a set of sixteen apertures 32 each contacts four adjacently positioned nodules 22. Such is generally depicted in FIG. 7 as configuration B, whereby sixteen apertures 32 are positioned substantially within a perimeter defined by four adjacently positioned nodules 22. In still other embodiments, the lath 14 may be sized in any of a variety of manners such that any of a variety of numbers of apertures 32 reside within a perimeter defined by four adjacently positioned nodules 22, thereby capturing any of a variety of aperture sizes, as may be desired or envisioned.

Referring now to FIG. 3, the lath and rain screen assembly 10 according to various embodiments used with exterior cladding material is illustrated. A portion of a building is illustrated generally at 40. The building 40 includes an exterior facing wall 42. The wall 42 is configured to define interior space within the building 40 and to support additional structural components. Among other building components, the wall 42 according to certain embodiments is formed from a plurality of framing members 44 extending in both vertical and horizontal directions. In the illustrated embodiment, the framing members 44 are made of wood. In other embodiments, the framing members 44 can be made of other desired materials, including the non-limiting example of steel. Further, the framing members 44 according to various embodiments may have any of a variety of desired dimensions.

Referring again to FIG. 3, the exterior wall 42 according to various embodiments is covered by exterior sheathing 46 attached to an exterior side of the framing members 44. In certain embodiments, the exterior sheathing 46 is configured to provide rigidity to the exterior wall 42. In other embodiments, the exterior sheathing 46 is further configured to provide a surface for sub-structures and exterior cladding material. In the illustrated embodiment, the exterior sheathing 46 is made of oriented strand board (OSB). In other embodiments, the exterior sheathing 46 may be made of other materials, such as for example the non-limiting options of plywood, waferboard, rigid foam, or fiberboard, so long as such options provide a sufficient degree of rigidity to the exterior wall 42 and a surface for receiving sub-structures and exterior cladding material. Further, the exterior sheathing 46 according to various embodiments has an exterior surface 48.

According to various embodiments, as shown in FIG. 3, a moisture resistant layer 50 is attached to the exterior surface 48 of the exterior sheathing 46. The moisture resistance layer 50 is configured to substantially retard the flow of gases (e.g. air and moisture) through between the exterior of the building and the interior of the building. One example of a moisture resistance layer 50 is PINK WRAP® marketed by Owens Corning Corporation, headquartered in Toledo, Ohio. In other embodiments, the moisture resistant layer 50 may be traditional building paper. In still other embodiments, a moisture resistant layer 50 may not be present at all.

In various embodiments, the moisture resistant layer 50 may have any desired thickness and any desired permeability value. In the illustrated embodiment of FIG. 3, the moisture resistant layer 50 is fastened to the exterior surface 48 of the exterior sheathing 46 by staples (not shown). However, it should be appreciated that in other embodiments, the moisture resistant layer 50 may be fastened to the exterior surface 48 of the exterior sheathing 46 by any of a variety of other desired methods or means.

Referring again to FIG. 3, the lath and rain screen assembly 10 according to various embodiments is positioned over the moisture resistant layer 50 and fastened to the exterior sheathing 46 using a plurality of spaced apart fasteners 52. In the illustrated embodiment, the fasteners 52 are staples. Alternatively, other desired fasteners, sufficient to fasten the lath and rain screen assembly 10 to the exterior sheathing 46 can be used in other embodiments. In certain embodiments, the fasteners 52 can be spaced apart a distance in a range of from about 4.0 inches to about 8.0 inches. In other embodiments, the fasteners 52 can be spaced apart a distance less than about 4.0 inches or more than about 8.0 inches. In still other embodiments that do not incorporate the moisture resistant layer 50, the fasteners 52 can be used to attach the lath and rain screen assembly 10 directly to the exterior sheeting 46.

As shown in the cross sectional view of FIG. 3, in the installed position, various embodiments of the lath and rain screen assembly 10 create a first space or cavity 54 between the moisture resistant layer 50 (or, alternatively, the exterior sheathing 46) and the sheet 16. In certain embodiments, the first space 54 provides for moisture management behind the lath and rain screen assembly 10 in two forms. First, in various embodiments, the first space 54 creates a pathway for moisture to pass through and/or exit the first space flowing in the direction indicated by the leftmost arrow D1 Second, in various embodiments, the first space 54 provides a pathway for ventilation air to pass through and/or exit the first space flowing in the direction indicated by the leftmost arrow D2. Notably, in certain embodiments, the first space 54 may, alternatively or concurrently, provide for moisture management in the direction indicated by the leftmost arrow D2 with ventilation provided in the direction indicated by the leftmost arrow D1. In still other embodiments, the first space 54 may provide moisture management and ventilation features in any of a variety of envisioned combinations of the directions indicated by the leftmost arrows D1 and D2.

In various embodiments, the first space 54 has a width, as generally depicted in FIG. 3, in a range of from about 0.125 inches to about 0.50 inches. In other embodiments, the first space 54 may be less than about 0.125 inches or more than about 0.50 inches. In the illustrated embodiment, the first space 54 is approximately 0.25 inches.

Referring again to the cross-sectional view of FIG. 3, in the installed position, various embodiments of the lath and rain screen assembly 10 form a second space 56 between the sheet 16 and the lath 14. In certain embodiments, the second space 56, in an analogous fashion as described above with respect to the first space 54, provides for moisture management between the lath 14 and rain screen 12 in two forms. First, in various embodiments, the second space 56 creates a pathway for moisture to pass through and/or exit the second space flowing in the direction indicated by the rightmost arrow D1. Second, in various embodiments, the second space 56 provides a pathway for ventilation air to pass through and/or exit the second space flowing in the direction indicated by the rightmost arrow D2. Notably, in certain embodiments, the second space 56 may, alternatively or concurrently, provide for moisture management in the direction indicated by the rightmost arrow D2 with ventilation provided in the direction indicated by the rightmost arrow D1. In still other embodiments, the second space 56 may provide moisture management and ventilation features in any of a variety of envisioned combinations of the directions indicated by the leftmost arrows D1 and D2.

In various embodiments, the second space 56, as depicted in at least the cross-sectional view of FIG. 3, is configured in certain embodiments to create a standoff to accommodate a thickness for a first layer 58 of subsequently installed mortar such that the mortar substantially encapsulates the lath 14. In certain embodiments, the second space 56 is in a range of from about 0.125 inches to about 0.50 inches, sufficient to accommodate a thickness of the first layer 58 of mortar of about 0.50 inches, thereby encapsulating the lath 14. In other embodiments, the second space 56 may be less than about 0.125 inches or more than about 0.50 inches and may be configured to accommodate a thickness of the first layer 58 of mortar of more or less than approximately 0.50 inches. In the illustrated embodiment, the second space 56 is approximately 0.25 inches, thereby accommodating a thickness of the first layer 58 of mortar sufficient to substantially encapsulate the lath 14. In still other embodiments, the first layer 58 of mortar is of sufficient thickness to totally encapsulate the lath 14.

In various embodiments, a combined width 55 of the first space 54 and the second space 56 may have a width 55, as generally depicted in FIG. 3, in a range of from about ¼ of an inch to about ¾ of an inch. In other embodiments, the combined width 55 may be less than about ¼ of an inch or more than about ¾ of an inch. In the illustrated embodiment, the combined width 55 is approximately ½ of an inch.

In various embodiments, as shown in FIG. 3, the first layer 58 (e.g., scratch coat layer) of mortar substantially encapsulates (e.g., envelops) the lath 14. In certain embodiments, the first layer 58 of mortar fully encapsulates the lath 14. Further, in various embodiments, the first layer 58 of mortar, when allowed to cure, forms a base for a second layer 60 of mortar. The second layer 60 of mortar is traditionally known as a “brown coat” and is used in various embodiments as a bedding layer for masonry products 62. In any of these various embodiments, the first and second layers, 58 and 60, of mortar can be any desired composition of mortar. Further, in any of these various embodiments, a rough texture may be applied to one or both of the first and second layers, 58 and 60, of mortar using, for example, a stucco comb or other comparable tools and methods.

While the various embodiments of the lath and rain screen assembly 10 illustrated in FIG. 3 provide support for the masonry products 62, it should be appreciated that in still other embodiments, the lath and rain screen assembly 10 can provide support for other exterior cladding materials. As a non-limiting example, a lath and rain screen assembly 110, as shown in FIG. 4 is configured to provide support for exterior cladding material in the form of stucco.

Referring again to FIG. 4, a portion of a building 140 is generally depicted as including an exterior facing wall 142 formed from a plurality of framing members 144. In various embodiments, the exterior wall 142 may be covered by exterior sheathing 146 attached to an exterior side of the framing members 144. In other embodiments, no exterior sheathing 146 may be incorporated. In those embodiments having an exterior sheathing 146, the exterior sheathing has an exterior surface 148. In the illustrated embodiment, the portion of the building 140, exterior wall 142, framing members 144 and exterior sheathing 146 are substantially the same as, or substantially similar to, the structure, shape, and/or configuration of the portion of the building 40, exterior wall 42, framing members 44 and exterior sheathing 46 illustrated in FIG. 3 and discussed above. Alternatively, the portion of the building 140, exterior wall 142, framing members 144 and exterior sheathing 146 can be substantially different in structure, shape, and/or configuration from that of the portion of the building 40, exterior wall 42, framing members 44 and exterior sheathing 46 illustrated in FIG. 3 and discussed above.

According to various embodiments, as shown in FIG. 4, a moisture resistant layer 150 may be fastened to the exterior surface 148 of the exterior sheathing 146 by staples (not shown). In certain embodiments, the lath and rain screen assembly 110 may be positioned over the moisture resistant layer 150 and fastened to the exterior sheathing 150 using a plurality of spaced apart fasteners 152. In these and other envisioned embodiments, a first layer 158 of mortar is applied such that it substantially encapsulates (e.g., envelops) the lath 114 such that when the first layer 158 is allowed to cure, it forms a base for a second layer 160 of mortar. In the illustrated embodiment, the moisture resistant layer 150, lath and rain screen assembly 110, first layer 158 of mortar and second layer of mortar 160 are substantially the same, or substantially similar in structure, shape, and/or configuration as the moisture resistant layer 50, lath and rain screen assembly 10, first layer 58 of mortar and second layer of mortar 60 illustrated in FIG. 3 and discussed above. Alternatively, in other various embodiments, the moisture resistant layer 150, lath and rain screen assembly 110, first layer 158 of mortar and second layer of mortar 160 may be substantially different in structure, shape, and/or configuration from the moisture resistant layer 50, lath and rain screen assembly 10, first layer 58 of mortar and second layer of mortar 60 illustrated in FIG. 3 and discussed above.

Referring again to FIG. 4, the second layer 160 of mortar, accordingly to various embodiments, forms a base for a layer of stucco material 164. In any of the various envisioned embodiments, the layer of stucco material can have any desired composition and can be any of a variety of desired thickness.

A method of installing a lath and rain screen assembly 10 according to various embodiments will now be described in detail with reference to FIG. 3. The first step of the method according to certain embodiments provides for positioning of the lath and rain screen assembly 10 adjacent an exterior sheathing 46 on a building portion 40. In other embodiments, the lath and rain screen assembly 10 may be positioned adjacent a moisture resistant layer 50 that has been previously attached to the exterior sheathing 46. In certain embodiments, the positioning of the lath and rain screen assembly 10, whether adjacent the exterior sheathing 46 or the moisture resistant layer 50 involves positioning the second side nodules 24 (see FIG. 2) adjacent the exterior sheathing or the moisture resistant layer. In this manner, in these embodiments, the second side 18 of the rain screen sheet 16 is spaced from the exterior sheathing or the moisture resistant layer. In various embodiments, the positioning of the second side 18 and the second side nodules 24 of the rain screen sheet 16 create a first space 54, as discussed above in further detail.

The next step of the method according to various embodiments, involves the application of a first layer 58 of mortar to the lath 14 such that the first layer substantially encapsulates the lath 14, as generally depicted in FIG. 3. In certain embodiments, the method involves the application of a sufficient amount of mortar as the first layer 58 to totally encapsulate the lath 14. In various embodiments, the method further comprises applying a second layer 60 of mortar after allowing the first layer 58 to cure. In certain of these embodiments, the second layer 60 provides a bedding layer for subsequent application of one or more masonry products 62.

Generally speaking, the installation of a lath and rain screen assembly 110, as shown in FIG. 4, may be accomplished in substantially the same manner as described above with respect to installation of the lath and rain screen assembly 10.

Various embodiments of the above-described lath and rain screen assemblies, 10 and 110, advantageously provide several benefits over traditional stand alone rain screens and laths, although all of the benefits may not be present in all embodiments. First, in certain embodiments, the lath and rain screen assemblies, 10 and 110, combine the traditional stand alone lath and the stand alone rain screen into a single integrated product, thereby allowing for reduced installation time and installation cost. Second, in certain embodiments, the lath and rain screen assemblies, 10 and 110, create a pathway between the moisture resistant layer and the sheet. In contrast, traditional rain screens are prone to trapping moisture between the moisture resistant layer and the rain screen.

The foregoing description of the various embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way.

Claims

1. A lath and rain screen assembly configured for fastening to an exterior building surface, the lath and rain screen assembly comprising:

A) a rain screen configured to encourage ventilation and drying, said rain screen including 1) a substantially planar body having a nominal thickness, said body having opposing primary planar first and second sides lying in corresponding first and second coparallel planes; and 2) a plurality of first side spacer elements, each of said first side spacer elements extending from said first side of said rain screen body along a direction substantially parallel to a first axis being substantially normal to said first plane, each of said first side spacer elements terminating in a free end, the tips of each of said free ends lying in a first free end plane being substantially coparallel to said first and second coparallel planes; and

B) a lath configured to receive at least a portion of a first mortar layer, said lath including a substantially planar body having a nominal thickness, said body defining a third plane spaced apart from and substantially parallel to said first plane of said rain screen body,

said lath being operably connected to said rain screen at least in part by a plurality of connections between said body of said lath and each of said free ends of said spacer elements,

such that said rain screen and said lath are spaced apart so as to provide an intermediate first cavity therebetween configured for permitting the passage of liquid water and water vapor.

2. The apparatus as claimed in claim 1, wherein said rain screen further comprises a plurality of second side spacer elements, each of said second side spacer elements extending from said second side of said rain screen body in a direction substantially opposite to that of said first side spacer elements, said direction being substantially parallel to said first axis, each of said second side spacer elements terminating in a free end.

3. The apparatus as claimed in claim 1, wherein the first side spacer elements and the second side spacer elements are arranged in an alternating pattern.

4. The apparatus as claimed in claim 1, wherein said connections between said body of said lath and each of said free ends of said spacer elements are provided by heat bonding.

5. The apparatus as claimed in claim 1, wherein said lath and rain screen assembly further comprises adhesive for providing said connections between said body of said lath and each of said free ends of said spacer elements.

6. The apparatus as claimed in claim 1, wherein said first cavity has a width of from about 0.25 inches to about 0.50 inches.

7. The apparatus as claimed in claim 1, wherein the rain screen is formed from a polymer-based material.

8. The apparatus as claimed in claim 7, wherein said polymer-based material is selected from a group consisting of: polyvinyl chloride, polystyrene, polyethylene, polypropylene, or any combination thereof.

9. The apparatus as claimed in claim 1, wherein the rain screen has a thickness in a range of about 0.005 inches to about 0.040 inches.

10. The apparatus as claimed in claim 1, wherein the rain screen has a permeability value in a range of about 80 coulombs to about 250 coulombs.

11. The apparatus as claimed in claim 1, wherein said lath includes a plurality of spaced apart apertures configured to permit passage of the first layer of mortar substantially through the lath.

12. The apparatus as claimed in claim 1, wherein the lath is formed from a fiberglass-based material.

13. The apparatus as claimed in claim 12, wherein said lath is formed by weaving the fiberglass-based material into a mesh configuration.

14. The apparatus as claimed in claim 1, wherein the first side spacer elements and the second side spacer elements are each spaced apart relative to their respective adjacent first and second side spacer elements an equal distance.

15. The apparatus as claimed in claim 14, wherein the equal distance is from about one inch to about four inches.

16. The apparatus as claimed in claim 14, wherein:

each of the first side spacer elements are spaced apart a distance of approximately two inches relative to adjacently located first side spacer elements;

each of the second side spacer elements are spaced apart a distance of approximately two inches relative to adjacently located second side spacer elements; and

each of the first and second side spacer elements are spaced apart a distance of approximately one inch relative to one other.

17. The apparatus as claimed in claim 1, wherein said lath and rain screen assembly is capable of being stored in a rolled-up fashion.

18. A method of providing a lath and rain screen assembly configured to be attached to an exterior building surface, said method comprising the steps of:

A) providing a rain screen configured to encourage ventilation and drying, said rain screen including 1) a substantially planar body having a nominal thickness, said body having opposing primary planar first and second sides lying in corresponding first and second coparallel planes; and 2) a plurality of first side spacer elements, each of said first side spacer elements extending from said first side of said rain screen body along a direction substantially parallel to a first axis being substantially normal to said first plane, each of said first side spacer elements terminating in a free end;

B) providing a lath configured to receive at least a portion of a first mortar layer, said lath including a substantially planar body having a nominal thickness, said body defining a third plane spaced apart from and substantially parallel to said first plane of said rain screen body; and

C) providing said lath and rain screen assembly by connecting said rain screen and said lath at least in part by connections between said body of said lath and each of said free ends of said spacer elements, such that said rain screen and said lath are spaced apart so as to provide an intermediate first cavity therebetween configured for permitting the passage of liquid water and water vapor.

19. The method as claimed in claim 18, wherein in Step “C” said connection between said rain screen and said lath is provided by heat bonding.

20. The method as claimed in claim 18, wherein in Step “C” said connection between said rain screen and said lath is provided by adhesive.

21. The method as claimed in claim 18, wherein in Step “B” said lath is provided with apertures configured to permit passage of mortar therethrough.

22. The method as claimed in claim 18, wherein in Step “A” said rain screen is provided with a permeability value in a range of about 80 coulombs to about 250 coulombs.

23. A method of applying a lath and rain screen assembly to an exterior building surface to facilitate the attachment of exterior cladding materials, said method comprising the steps of:

A) providing a rain screen configured to encourage ventilation and drying, said rain screen including 1) a substantially planar body having a nominal thickness, said body having opposing primary planar first and second sides lying in corresponding first and second coparallel planes; and 2) a plurality of first side spacer elements, each of said first side spacer elements extending from said first side of said rain screen body along a direction substantially parallel to a first axis being substantially normal to said first plane, each of said first side spacer elements terminating in a free end;

B) providing a lath configured to receive at least a portion of a first mortar layer, said lath including a substantially planar body having a nominal thickness, said body defining a third plane spaced apart from and substantially parallel to said first plane of said rain screen body;

C) providing said lath and rain screen assembly by connecting said rain screen and said lath at least in part by connections between said body of said lath and each of said free ends of said spacer elements, such that said rain screen and said lath are spaced apart so as to provide an intermediate first cavity therebetween configured for permitting the passage of liquid water and water vapor;

D) positioning said lath and rain screen assembly adjacent said exterior building surface;

E) applying a first layer of mortar onto the lath; and

F) attaching a plurality of exterior cladding materials to aid lath at least partially with the use of said mortar.

24. The method as claimed in claim 23, wherein in Step “E” said first cavity receives at least a portion of a first layer of mortar.

25. The method as claimed in claim 23, wherein in step “B” said lath is provided with a plurality of spaced apart apertures configured to permit passage of a portion of said first layer of mortar substantially through the lath in Step “E”, and wherein in Step “F”, said first layer of mortar, upon passing substantially through the lath, further substantially encapsulates the lath.

26. The method as claimed in claim 23, wherein step “E” furthers comprises the step of applying a second layer of mortar onto the first layer of mortar once the first layer has been allowed to cure.

27. The method as claimed in claim 23, wherein said step “D” of positioning said lath and rain screen assembly adjacent said exterior building surface comprises positioning said plurality of second side spacer elements in contact with the exterior building surface.

28. The method as claimed in claim 23, wherein said step “D” of positioning said plurality of second side spacer elements adjacent said exterior building surfaces creates a second cavity configured to provide a pathway for moisture management and ventilation between said second side spacer elements and the exterior building surface.

29. The method as claimed in claim 28, wherein following Step “D” said second cavity has a width of from about 0.125 inches to about 0.50 inches.