Stucco Composite Building Panel
A Stucco Composite Building Panel is disclosed, in which a sheet of exterior wall sheathing and a cement board are attached together to form an improved sheet of building material for the construction of exterior stucco walls. This composite building panel reduces the amount of individual layers required to build a conventional stucco wall by providing an exterior wall building panel that is mounted directly to the stud framing that is ready for a finish layer of stucco to be applied.
This application claims the benefits of the earlier filing dates of U.S. Provisional Application No. 61/814,023 filed Apr. 19, 2013. The disclosure U.S. Provisional Application 61/814,023 is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTIONCompleting a conventional stucco exterior surface of commercial and residential buildings is a time and cost intensive process. After the frame of the house is complete, several layers of materials are applied to the exterior frame of the house. Depending on the method, these layers include oriented strand board, foam insulation, stucco, a vapor barrier, a water resistant barrier, and other materials. Each layer adds to the cost of the building project not only due to the cost of materials, but also due to the cost of labor involved with applying multiple layers. Some methods of applying exterior stucco can take as long as three weeks, and if cracks develop, then additional repair is required, costing valuable resources.
In one typical process, a layer of black felt paper or spunbond olefin fiber such as Tyvek moisture barrier is applied to the exterior frame of the building. A sheet of foam insulation is then applied on top of the barrier attached to the framing. Wire mesh is then wrapped around the outside of the foam. After this, an initial layer of Portland cement (stucco) is applied to the wire mesh by hand and a brush is used to rough the surface in order to help the next layer of stucco bond to the surface. Once the stucco is applied to the exterior, it has to cure, which can take as long as two weeks. Once it cures, cracks can form in the stucco, which have to be patched, taking additional time and resources. Despite the intensive process of applying it, stucco appeals to builders and homeowners due to its appearance and versatility. However, this process poses many challenges to home builders, for example:
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- 1. The conventional multi-layer stucco process is time intensive and can take up to 20 days or longer to complete;
- 2. Each layer in the process has to be individually applied to the exterior, which consumes excessive labor and increases the risks of an incorrect application;
- 3. The multi-layer process produces waist and excessive clean up;
- 4. Water damage and mold growth over time can occur due to improper applications of multiple layers.
- 5. It is difficult to control the precise thickness of Stucco layers being applied by hand resulting in varied finished wall thicknesses that can lead to future problems such as cracking and water damage.
Thus there is a need for a stucco wall system that eliminates the process of applying multiple layers and is light, protective, and cost efficient.
BRIEF SUMMARY OF THE INVENTIONThe present invention provides a composite exterior stucco wall system with shear strength that is ready to accept a finish coat of stucco by coupling with adhesive a thin layer of cementitious board such as Hardie Backer or Durock with an exterior sheathing such as oriented strand board, plywood or an exterior gypsum board such as DensGlass Gold.
In another aspect of the invention, the adhesive that bonds the cement board to the substrate contains a water resistant element to protect the wood substrate from moisture.
In another aspect of the invention, a sheet of black builders paper or spunbond olefin fiber such as Tyvek is placed in between the composite board and substrate to protect the wood substrate from moisture.
In another aspect of the invention the composite building panel is mounted to the wall frame with conventional fasteners such as screws, nails or staples. The wood substrate layer prevents the fasteners from pulling through and compromising the finished stucco wall.
In another aspect of the invention, the combination of a thinner layer of fiber cement board laminated together with the substrate makes cement board easier to cut with a skill saw, jigsaw, or other cutting means without the cement board crumbling.
In another aspect of the invention, the corner edges and butt joints of the substrate are treated to seal against water damage and other elements, either by elastomeric caulk or a similar sealing material.
In another aspect of the invention, the joints are covered with elastomeric joint tape or mesh tape and a layer of water resistant mortar over mesh tape to avoid cracking and to seal the joints to protect the wood substrate portion of the composite board.
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
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Claims
1. A composite building panel comprising: a sheet of exterior wall sheathing and a layer of cementitious board, wherein the cement board is laminated to one side of the sheathing forming a stucco wall building material sheet with shear strength that is ready to receive a finish layer of stucco replacing the base coat of conventional stucco methods.
2. The composite building panel of claim 1, wherein a water resistant coating is applied to the sheathing to protect the wall from moisture.
3. The composite building panel of claim 1, wherein, the adhesive that bonds the cement board to the sheathing contains a water resistant acrylic.
4. The composite building panel of claim 1, wherein a sheet of black builders paper is laminated in between the cement board and the sheathing to function as a water resistant barrier.
5. The composite building panel of claim 1, wherein a sheet of black builders paper is laminated to the back of the sheathing to function as a water resistant barrier.
6. The composite building panel of claim 1, wherein a sheet of spunbond olefin fiber such as Tyvek is laminated in between the cement board and the sheathing to function as a water resistant barrier.
7. The composite building panel of claim 1, wherein a sheet of spunbond olefin fiber such as Tyvek is laminated to the back of the sheathing to function as a water resistant barrier.
8. The composite building panel of claim 1, wherein, the method of installation includes a moisture resistant sealant applied to the butt joint edges preventing water damage or other elements from damaging the wall.
9. The composite building panel of claim 1, wherein, the method of installation includes a water resistant mortar applied over mesh tape to seal the joining edges, preventing cracking and creating a sealed exterior wall ready for a final finish coat of stucco.
10. The composite building sheet of claim 1, wherein, the method of installation includes filling the seams and joints in with elastomeric joint tape and joint sealer after it is mounted, to prevent moisture penetration and cracking at the joints.
11. The composite building panel of claim 1, wherein, the method of installation includes fasteners such as screws, nails or staples with the sheathing portion of the composite panel preventing fasteners from pulling through.
12. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board such as Durock laminated to a sheet of sheathing.
13. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board such as Hardie Backer laminated to a sheet of sheathing.
14. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of plywood sheathing.
15. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of fiberglass gypsum sheathing such as DensGlass Gold.
16. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of sheathing material manufactured from polymer.
17. The composite building panel of claim 1, wherein, the composite board consists of a sheet of cement board laminated to a sheet of oriented strand board sheathing.
18. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board such as Hardie Backer laminated to a sheet of plywood sheathing.
19. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board laminated to a sheet of fiberglass gypsum sheathing such as DensGlass Gold.
20. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board laminated to a sheet of sheathing material manufactured from polymer.
21. The composite building panel of claim 1, wherein, the composite board consists of a sheet of fiber cement board laminated to a sheet of sheathing material manufactured from fiberglass.
22. The composite building panel of claim 1, wherein, the layer of fiber cement board laminated together with the substrate makes cement board easier to cut with a skill saw, jigsaw, or other cutting means without the cement board crumbling.
Type: Application
Filed: Apr 18, 2014
Publication Date: Oct 23, 2014
Inventor: Dan B. Pool (Scottsdale, AZ)
Application Number: 14/256,863
International Classification: E04F 13/04 (20060101); E04C 2/04 (20060101);