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1. WO2020112977 - ENSEMBLES SUPPORT D'ENDUIT/PARE-PLUIE COMBINÉS ET PROCÉDÉS D'INSTALLATION ET DE FABRICATION

Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

[ EN ]

COMBINATION LATH/RAINSCREEN ASSEMBLIES AND METHODS OF

INSTALLATION AND MANUFACTURE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Serial No.

62/772,740, filed November 29, 2018, which is incorporated in its entirety herein by reference.

FIELD

[0002] The present technology is generally related to laths, rainscreens and methods of installation and manufacture.

BACKGROUND

[0003] Developments in the construction of buildings has generally resulted in

“tighter'* buildings, thus meaning there is less airflow leakage and between the interior and exterior of the building. As a result,“tighter” buildings have an increased risk for moisture and mold problems. Known rainscreen systems reduce the risk of moisture and mold damage by enabling moisture that has penetrated an exterior siding material to swiftly exit the building envelope.

[0004] The present disclosure addresses problems and limitations associated with the related art.

SUMMARY

[0005] The techniques of this disclosure generally relate to a combination lath and rainscreen provided in a single assembly. Various embodiments of the disclosure simplify installation as well as reduce labor costs and requirements. In addition, various embodiments of the disclosure are non-corrosive and are metal-free.

[0006] In one aspect, the present disclosure provides a lath/rainscreen assembly including a sheet or strip defining a lath face and a rainscreen face, a first end and a second end, and a first side and a second side. In one embodiment, the lath/rainscreen assembly further includes a plurality of protrusions extending from the lath face and the rainscreen face. The lath face includes a first area free of protrusions, the first area at least partially defined by the lath face, the first end, the second and the first side. The rainscreen face includes a second area free of protrusions, the second area at least partially defined by the rainscreen face, the first end, the second end and the second side. In an alternate embodiment, the lath face does not include any protrusions and is undisrupted, smooth or flat.

[0007] In another aspect, the disclosure provides a method of installation including providing a building including a wall supported by a flame having a plurality of beams. A water resistant barrier is secured to the wall. Also provided is a first lath/rainscreen assembly including a sheet made of extruded material having a lath face and a rainscreen face; wherein the rainscreen face includes a plurality of protrusions. The lath face can optionally also include protrusions. The method further includes positioning the rainscreen face of the lath/rainscreen assembly against the water resistant barrier such that the protrusions contact die water resistant barrier and inserting a fastener through the sheet and the water resistant barrier and into the wall. The method may also include securing a facade or veneer (e.g., siding, stucco or masonry) to the lath face. In situations where stucco is applied to the lath face, the lath face may include a plurality of protrusions to provide a structure to grip the stucco. Various methods may also include securing a plurality of lath/rainscreen assemblies together in an overlapping fashion on the wall.

[0008] The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the techniques described in this disclosure will be apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF DRAWINGS

[0009] FIG. 1 is a schematic diagram illustrating a lath/rainscreen assembly secured to a wall of a structure between a water resistant barrier and masonry veneer.

[0010] FIG. 2A is a partial illustration of the lath/rainscreen assembly of FIG. 1 partially rolled-up and having a plurality of protrusions (only a select few of which are referenced for ease of illustration) on a lath face and also a plurality of protrusions on a rainscreen face of a sheet.

[0011] FIG. 2B is a partial illustration of an alternate lath/rainscreen assembly largely similar to that of FIG. 2B but further including a plurality of perforations (only a select few of which are referenced for ease of illustration).

[0012] FIG. 3 is a partial illustration of the lath/rainscreen assembly of FIGS. 1-2 in a flat configuration in which the lath face is facing upward.

[0013] FIG. 4 is a top schematic view of the lath/rainscreen assembly of FIG. 3 illustrating the rainscreen face of the sheet.

[0014] FIG. 5 is a schematic end view of the lath/rainscreen assembly of FIGS. 1-4.

[0015] FIG. 6 is a partial, schematic view of the lath/rainscreen assembly FIGS. 1-5.

[0016] FIG. 7 is a partial, schematic illustration of two lath/rainscreen assemblies of FIGS. 1-2A and 3-6 arranged for installation.

[0017] FIGS. 8-11 schematically illustrate various alternate protrusion configurations.

[0018] FIG. 12 is a schematic diagram illustrating a plurality of lath/rainscreen assemblies secured to the structure between the water resistant barrier and siding veneer.

[0019] FIG. 13 is a perspective view of an alternate lath/rainscreen assembly.

DETAILED DESCRIPTION

[0020] Figures 1-6 collectively illustrate one embodiment of a lath/rainscreen assembly 10. In FIG. 1, the lath/rainscreen assembly 10 is operatively secured to a structure S having a frame F including beams B and a wall W sheathed in a water resistant barrier WRB and a weep screed WS positioned between the wall W and the water resistant barrier WRB. The water resistant barrier WRB and weep screed WS can be of any of the type known and used in building construction. The lath/rainscreen assembly 10 is positioned outboard of the water resistant barrier WRB and secured to the wall W of the structure S with mechanical fasteners (not shown) such as galvanized nails, staples, or the like. In some embodiments, a plurality of lath/rainscreen assemblies 10 are provided to be installed overlapping one another. In such embodiments, each lath/rainscreen assembly 10 can overlap an adjacent lath/rainscreen assembly 10 at least 1 inch. In other embodiments, the lath/rainscreen assemblies 10 overlap at least 1.5 inches.

[0021] As indicated by its name, each lath/rainscreen assembly 10 includes a sheet 12 having a lath face 14a and a rainscreen face 14b. The sheet 12 further includes first and second ends 16a, 16b as well as first and second sides 18a, 18b. The lath face 14a is installed exterior with respect to the rainscreen face 14b and supports a facade or veneer V (e.g., stucco, siding, masonry veneer including brick or stone, for example) applied the structure S. In some embodiments, a plurality of protrusions 20a (only a select few of which are referenced for ease of illustration) extend from the sheet 12 and form at least part of the lath face 14a. In one embodiment, the sheet 12 and protrusions 20a collectively serve as a substrate for adhered stucco or other veneer V. In various embodiments, the plurality of protrusions 20a are arranged to form a grid of linear intersecting channels 22, 24 oriented vertical, horizontal or diagonal with respect to the sheet 12 (only a few select channels are referenced for ease of illustration) hi one illustrative embodiment, die intersecting channels 22, 24 each have a width of approximately 1/8 inch or more. The protrusions 20a can take a variety for forms as will be discussed in greater detail below. In the present example, the protrusions 20a include a stem 30 having a first end 32 and a second end 34. The first end 32 is secured to the sheet 12 and the second end 34 terminates at a head 36. The head 36 can be rectangular shaped, for example, and provides a structure onto which stucco can be applied for a more secure adherence or connection and provides a flat surface 38 on which the veneer V can be positioned. The flat surface 38 can be parallel to a plane defined by the sheet 12. The lath face 14a forms voids between the sheet 12 and the protrusions 20a, and the voids allow stucco to be received and retained therein. Because, in some embodiments, the protrusions 20a are larger proximate their distal ends, the stucco has a more secure connection thereto. In the illustrated embodiment the stem 30 is tapered to have a greater diameter at the first end 32 as compared to the second end 34. As best seen in FIG. 6, each protrusion 20a can have a height D1 and the sheet 12 can have a thickness D2. In one embodiment, for example, the height D1 could be

approximately in a range of 0.25 to 3/16 inches and the sheet 12 could have a thickness D2 less than 0.25 inch. In one embodiment D2 is in a range of about 0.035 to about 0.045 inches. In various embodiments, the sheet 12 is solid, linear and has a uniform thickness D2. In an embodiment, the protrusions 20a are spaced apart a distance D3 of

approximately 1/5 inches. It is recognized that any dimensions could be different than the examples provided throughout the description because several factors, such as but limited to structural accommodations, manufacturing processes, and shipping accommodations, could affect the dimensions.

[0022] The rainscreen face 14b of the sheet 12 can be similarly configured to the lath face 14a and includes a plurality of protrusions 20b (only a select few of which are referenced for ease of illustration) extending from the sheet 12. As with the protrusions 20a, the protrusions 20b collectively define a plurality of linear, intersecting channels 40, 42 that serve as an air gap and pathways for water to flow via gravity to the weep screen S (FIG. 4). The channels 40, 42 can be oriented vertically, horizontally or diagonally with respect to the sheet 12. The protrusions 20b on the rainscreen face 14b can be identically configured to the protrusions 20a of the lath face 14a or can differ in configuration and arrangement. Except as expressly stated, the lath face 14a and the rainscreen face 14b are preferably identically configured. In this way, there is no“front” and *¾ack” side of the sheet 12 as both faces 14a, 14b are the interchangeable and this provides for easier installation.

[0023] As indicated above, it is envisioned that multiple lath/rainscreen assemblies 10 can be applied to the structure S and will be positioned on the structure S to overlap so that there are no gaps in coverage along the water resistant barrier WRB. To enable the lath/rainscreen assemblies 10 to be positioned in an overlapping configuration without bulging and creating the potential for moisture ingress, one end 16a, 16b of each face 14a, 14b of the sheet 12 includes an area 50a, 50b that does not include protrusions 20a, 20b. In addition, the areas 50a, 50b that do not include protrusions 20a, 20b can be rounded around building comers for securing to the next beam B. FIGS. 2A-7 collectively illustrate die lath face 14a having a protrusion-free area 50a at the first side 18a and the rainscreen face 14b has a protrusion free area 50b at the second side 18b of the sheet 12. In one example embodiment, each protrusion-free area has a width D4 of 1 inch or more. In another embodiment, the width D4 is 1.5 inches or more. In this way, as is depicted in FIG. 7, multiple lath/rainscreen assemblies 10 can be assembled to the structure S in an overlapping fashion to provide a plurality of lath/rainscreen assemblies 10 having a continuous arrangement of protrusions 20a, 20b on both the lath face 14a and the rainscreen face 14b. In various embodiments, the protrusions 20a, 20b are all vertically and horizontally aligned and arranged in rows. In one example, one sheet 12 is configured to span three conventionally-spaced beams B (i.e. the width of the sheet is about 33.5 inches wide). The present disclosure, however, is not intended to be limited to any specific dimensions. As indicated above, the lath face 14a can optionally be identically configured as compared to the rainscreen face 14b with the exception of one area free of protrusions 50a is located proximate the first side 18a of the sheet 12 and the second area free of protrusions 50b is located proximate the second side 18b of the sheet 12.

[0024] Optionally, the sheet 12 can include a plurality of apertures or perforations 52 (only a select few of which are referenced in FIG. 2 A for ease of illustration) that extend through an entire thickness of the sheet 12 that can serve to allow moisture to pass from the water resistant barrier WRB, through the sheet 12. The apertures 52 can be positioned within one or more areas 50a, 50b and/or can also be positioned amongst the protrusions 20a, 20b, within channels 22, 24, 40, 42, as desired. In one example, one or more of areas 50a, 50b includes two rows of apertures 52 extending along a length of the respective area 50a, 50b. In one example, a row of apertures 52 arranged in linear fashion is provided within one or more of the channels 42. As indicated with like reference numbers, lath/rainscreen assembly 10’ is otherwise identical to lath/rainscreen assembly 10 disclosed herein.

[0025] As previously stated, the protrusions 20a, 20b can take a variety of forms. In one alternate embodiment illustrated in FIG. 8, each protrusion 120a, 120b includes a stem 130a, 130b and a head 136a, 136b. The stem 130a, 130b defines a plurality of channels 150a, 150b and peaks 152a, 152b (both generally referenced) defining approximately a 90 degree angle. The head 136 forms a flat engagement surface 138a, 138b. Each flat engagement surface 138a, 138b being parallel with respect to a plane defined by faces 14a, 14b of the sheet 12.

[0026] In another alternate embodiment illustrated in FIG. 9, each protrusion 220a, 220b includes a stem 230a, 230b and a head 236a, 236b. The stem 230 forms a plurality of channels 250a, 250b and peaks 252a, 252b each forming an edge that is parallel to a flat engagement surface 238a, 238b of the rectangular head 236a, 236b.

[0027] In FIG. 10, each protrusion 320a, 320b includes a stem 330a, 330b and a head 336a, 336b. Each stem 330a, 330b includes a first end 332a, 332b connected to the sheet 12 and a second end 334a, 334b connected to the head 336a, 336b. Each head 336a, 336b

is generally square shaped and each stem 330a, 330b tapers such that the first end 332a, 332b has a greater width as compared to the second end 334a, 334b. Each head 336a, 336b forms a flat engagement surface 338a, 338b that is parallel with respect to a plane defined by the sheet 12.

[0028] In an additional embodiment illustrated in FIG. 11 , each protrusion 420a, 420b includes a stem 430a, 340b and a head 436a, 436b. Each stem 430a, 430b can include a tapered portion 432a, 432b and a straight portion 434a, 434b interconnecting the tapered portion 432a, 432b and a head 436a, 436b. Each head 436a, 436b can be rectangular and include a flat engagement surface 438a, 438b. In some embodiments, the protrusion configurations of the disclosure provided on the lath/rainscreen assembly may not all be identical and may vary both with respect to other protrusions on the respective face and as compared to the opposing lath face or rainscreen face of the sheet

[0029] It is recognized that other configurations of protrusions could be used and the examples provided herein should not be limiting.

[0030] Methods of installation the disclosed lath/rainscreen assemblies (e.g., lath/rainscreen assemblies 10, 10’) can include providing the building B including the wall W supported by the ftame F having the plurality of beams B as is generally depicted in FIG. 1. The method includes securing the water resistant barrier WRB to the wall W in any known manner. In addition one first lath/rainscreen assembly 10, 10’ is provided, the lath/rainscreen assembly 10, 10’ being any of the type disclosed herein. In one

embodiment, die lath/rainscreen assembly 10, 10’ includes the sheet 12 made of extruded material having a lath face 14a and a rainscreen face 14b. The lath face 14a can optionally include the plurality of protrusions 20a, 20b and the rainscreen face 14b does include a plurality of protrusions. The rainscreen face 14b of the lath/rainscreen assembly 10, 10* is positioned against the water resistant barrier WRB such that the protrusions 20a, 20b contact the water resistant barrier WRB. For ease of installation, the lath face 14a and the rainscreen face 14b can be interchangeable (i.e. identical). In some embodiments, the sheet 12 preferably spans three 2x4 inch beams, spaced 16 inches on center (e.g., a width of the sheet 12 or dimension of ends 16a, 16b can be 33.5 inches). Because the sheet 12 is made of a flexible material, the sheet 12 can be wrapped around a comer of the building B, as needed. The method further includes inserting a fastener through the sheet 12 and the water resistant barrier WRB and into die wall W.

[0031] As indicated above, the first lath/rainscreen assembly (e.g., lath/rainscreen assembly 10, 10’) can include an area free of protrusions 50a, 50b. With such a lath/rainscreen assembly, the method further includes the step of providing a second lath/rainscreen assembly (e.g., lath/rainscreen assembly 10, 10’) and securing the second lath/rainscreen assembly 10, 10’ on top of the area free of protrusions 50a, 50b. The step of securing the second lath/rainscreen assembly 10, 10’ can include inserting a fastener through the first lath/rainscreen assembly 10, 10, second lath/rainscreen assembly 10, 10’, and into wall W and frame F, perhaps at beam B.

[0032] In some embodiments, the method includes providing a weep screed WS and securing the weep screed WS between the wall W and the water resistant barrier WRB, adjacent one end 16b of the first lath/rainscreen assembly 10, 10’.

[0033] In one method, stucco V is secured/applied to tire lath face 14a and is positioned between the protrusions 20a, 20b, within the channels 20, 22 and the sheet 12 on the lath face 14a. Such stucco V can be applied to the lath face 14a in any manner known for securing stucco to a known lath.

[0034] Figure 12 illustrates yet another embodiment of the disclosure including a lath/rainscreen assembly 510. The lath/rainscreen assembly 510 includes a sheet or strip 512 having a lath face 514a and a rainscreen face 514b. The rainscreen face 514b includes a plurality of protrusions 520, which can be of any of the type disclosed herein or similar. The protrusions 520 (a select few of which are referenced for ease of illustration) are configured to be positioned against a water resistant barrier WRB secured to the wall W of the structure S. In one embodiment, each lath/rainscreen assembly 510 is secured along (i.e. is aligned with) one support beam B of the structure S and terminates at a vented metal edge E as is shown in FIG. 12. In some embodiments the lath/rainscreen assembly 510 has a width that is less than 33.5 inches, however, the disclosure is not intended to be limited to any particular dimensions. The lath/rainscreen assembly 510 can be secured to the water resistant barrier WRB with mechanical fasteners (not shown) including galvanized nails, staples or the like. The lath face 514a is protrusion free (i.e. generally smooth or flat) and provides a surface over which siding or other veneer V can be secured in any known manner. The lath/rainscreen assembly 510 and protrusions 520, for example, can otherwise be identically configured similar to other disclosed lath/rainscreen assemblies 10, 10*. Furthermore, the lath/rainscreen assembly 510 can be identically configured and installed to lath/rainscreen assemblies 10, 10’, except as explicitly stated.

[0035] In some embodiments, methods of installing the disclosed lath/rainscreen assemblies 510 can include providing a building B including a wall W supported by a frame F having a plurality of beams B as is generally depicted in FIG. 12. The method includes securing the water resistant barrier WRB to the wall W in any known manner. In addition a first lath/rainscreen assembly 510 is provided, the lath/rainscreen assembly 510 being any of die type disclosed herein. In one embodiment, the lath/rainscreen assembly 510 includes the sheet 512 made of extruded material having the lath face 514a and the rainscreen face 514b. The lath face 514a is flat and does not include a plurality of protrusions and the rainscreen face 514b includes a plurality of protrusions 520. The rainscreen face 514b of the lath/rainscreen assembly 510 is positioned against the water resistant barrier WRB such that the protrusions 520 contact the water resistant barrier. The method further includes inserting a fastener through the sheet 512 and the water resistant barrier WRB and into the wall W, optionally into the beam B.

[0036] In other various embodiments, the building or structure S includes a vented metal edge E and further wherein the lath/rainscreen assembly 510 is positioned on the water resistant barrier WRB such that the sheet 512 terminates at the vented metal edge E and is aligned with one beam B of the frame F.

[0037] Depending on the veneer V to be attached to the lath/rainscreen assembly 510, various methods include the step of securing siding V or die like to the lath face 514a. Siding panels V may extend between two or more lath/rainscreen assemblies 510 and can be secured to the lath/rainscreen assemblies 510 in any known manner.

[0038] Referring now also to FIG. 13, which illustrates an alternate lath/rainscreen assembly 610. The lath/rainscreen assembly 610 includes a sheet 612 having a lath face 614a and a rainscreen face 614b. The sheet 612 further includes first and second ends 616a, 616b as well as first and second sides 618a, 618b. The lath face 614a is installed exterior with respect to the rainscreen face 614b and supports the facade or veneer V (e.g., stucco, siding, masonry veneer including brick or stone, for example) applied the structure S in the same manner as described above with respect to other embodiments. Optionally, plurality of protrusions 620a (only a select few of which are referenced for ease of illustration) extending from the sheet 12 and form a portion of the lath face 614. In one embodiment, the lath face 614a and protrusions 620a collectively serve as a substrate for the adhered stucco or other veneer V. In various embodiments, the plurality of protrusions 620a are arranged to form a grid of linear intersecting channels 622, 624 oriented vertical, horizontal or diagonal with respect to the sheet 612 (only a few select channels are referenced for ease of illustration). In one illustrative embodiment, the intersecting channels 622, 624 each have a width of approximately 1/8 inch or more. The protrusions 620a can take any of the forms disclosed herein.

[0039] The rainscreen free 614b of the sheet 612 can be similarly configured to the lath face 614a and includes a plurality of protrusions 620b extending therefrom (only a select few of which are referenced for ease of illustration). As with the protrusions 620a, the protrusions 620b collectively define a plurality of linear, intersecting channels 640,

642 (a select few of which are referenced) that serve as an air gap and pathways for water to flow via gravity to the weep screen S (FIG. 4). The channels 640, 642 can be oriented vertically, horizontally or diagonally with respect to the sheet 612. The protrusions 620b on the rainscreen lace 614b can be identically configured to the protrusions 620a of the lath face 614a. Except as expressly stated, the lath face 614a and the rainscreen free 614b are preferably identically configured.

[0040] As described above with respect to other embodiments, it is envisioned that multiple lath/rainscreen assemblies 610 can be applied to the structure S and will be positioned on the structure S to overlap so that there are no gaps in coverage along the water resistant barrier WRB. To enable the lath/rainscreen assemblies 610 to be positioned in an overlapping configuration without bulging and creating the potential for moisture ingress, one end 616a, 616b of each face 614a, 614b of the sheet 612 includes at least one area 650a-c that does not include protrusions 620a, 620b. In addition, die areas 650a-c that do not include protrusions 620a, 620b can be rounded around building comers for securing to the next beam B. In the illustrated example of FIG. 13, the lath free 614a includes one area free of protrusions 650a extending along the first side 618a from the first end 616a to the second end 616a. The rainscreen face 614b incudes one area free of protrusions 650b extending along the second end 616b from the first side 618a to the second side 618b. In addition, the rainscreen face 614 includes one area free of protrusions 650c extending from the first end 616a to the second end 616b. In one example embodiment, each protrusion-free area 650a, 650b, 650c has a width of 1 inch or more. In another embodiment, the width is 1.5 inches or more. In this way, multiple lath/rainscreen assemblies 610 can be assembled to the structure S overlapping at both the ends 616a,

616b and/or the sides 618b, 618b to provide a plurality of lath/rainscreen assemblies 610 having a continuous arrangement of protrusions 620a, 620b on both the lath face 614a and the rainscreen face 614b. In various embodiments, the protrusions 620a, 620b are all vertically and horizontally aligned and arranged in rows. The lath/rainscreen assembly 610 and methods of installation can otherwise be identical as compared to lath/rainscreen assemblies disclosed above.

[0041] The lath/rainscreen assemblies disclosed herein can be manufactured in a variety of ways. In one method, the process begins with extruding a solid sheet of extruded material, such as plastic. In one implementation, the sheet of extruded material is a plastic material having fire resistant characteristics or high impact poly styrene, for example. In one embodiment, the solid sheet of extruded material is 33.5 inches by 8-12 feet by 9/16 inches. Forming the lath/rainscreen assembly from a non-metal extruded material is beneficial in that it results in a product that is generally easier to work with, does not corrode or disrupt electrical or other signals, can be made of a fire retardant material and can be rolled-up for shipping and storage. It could also sene as a fire retardant. Once the sheet is extruded, the protrusions can optionally be formed via cutting with router blades to result in the desired protrusion configuration. In addition, apertures or perforations 52, such as those shown in FIG. 2B can be punched in the sheet, as desired.

[0042] It should be understood that various aspects disclosed herein may be combined in different combinations than the combinations specifically presented in the description and accompanying drawings. It should also be understood that, depending on the example, certain acts or events of any of the processes or methods described herein may be performed in a different sequence, may be added, merged, or left out altogether (e.g., all described acts or events may not be necessary to carry out the techniques).