Abstract:
Furred woven wire fabric lathing is provided which incorporates a plurality of wires twisted together forming a wire mesh with a major portion of the wire in a plane with a portion of the mesh comprising furr portions extending out of the plane of the mesh and configured for embedment in plaster upon application of plaster to the wire mesh.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This is an ordinary application of Provisional Application Ser. No. 60/869,658, filed Dec. 12, 2006, the contents of which are expressly incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Furred lathing (woven wire fabric) structure, referred to as ‘channel fur’, that results in more consistent, reliable furring, i.e., the indentation in the wire that holds the wire fabric (stucco wire) off the wall to allow plaster to fill around the wire thereby embedding the wire and enhancing the ease of use of the wire fabric, is discussed herein. 
         [0003]    Laths with self-furring are well known and are disclosed in, for example U.S. Pat. Nos. 7,287,356 and 5,540,023, the contents of each of which are expressly incorporated herein by reference. Generally speaking, ‘furring’ has been done along the ‘knot’ of woven wire laths, where the wire is twisted together to make a wire fabric. Consequently, prior furring procedures result in the following complications in both producing and using the woven wire product: 
         [0004]    1. Furring at the knot moves a disproportionate amount of wire and a high ‘tag point’ (section of high coefficient of friction with the plaster) out of the plaster. 
         [0005]    2. Furring at the knot relies on the largest area of woven density to be in the furring and out of the plaster. The practice of rolling the product for shipment makes it all but impossible for this large furring to nest within itself with the result that the furring is flattened and the wire does not stand a desired distance away from the wall, thereby reducing or eliminating proper wire embedment within the plaster. 
         [0006]    3. The current practice of furring at the knot re-stresses the one point in the fabric that has been stressed the highest during fabric formation. The end result is wire breakage that can cause problems in woven wire fabric products and during building and after construction. 
         [0007]    4. Forming the furr on the knot deforms the wire permanently in a location where two wires are joint by twisting, resulting in the formation of a hinge which is easily flattened. Thus, during rolling and usage, only a light force is required to flatten the wire mesh and consequently to remove the furring. 
         [0008]    Therefore there is a need for a more reliable and consistent furring without the shortcomings of prior art practice of furring. Additionally, there is also a need for a method of making the desired furring. 
       SUMMARY 
       [0009]    Aspects of the present invention include a wire lath comprising a plurality of wires twisted together thereby forming a wire mesh with the major portion of the wire located in a plane with a portion of the plurality of wires comprising a plurality of furr portions spaced from a plurality of twisted pair of wire connections extending out of the plane of the wire mesh and configured for embedment in coating upon application of the coating to the wire mesh. 
         [0010]    Preferably, the wire mesh comprises a plurality of six-sided cells. In certain embodiments, the furr portions are aligned in generally parallel rows of furr portions. Still more preferably, the furr portions are aligned in generally parallel rows of furr portions and have at least one row of twisted wire connections located between a pair of rows of furr portions with each furr portion preferably comprising a vertex. 
         [0011]    Although different materials may be used, the plurality of wires is preferably made from galvanized steel. 
         [0012]    In other aspects of the present invention, there is provided a method for making a woven wire lath comprising twisting a plurality of wires to form a mesh having a plurality of twisted pairs of wires forming a plurality of cells positioned generally along a plane; furring portions of the mesh to form furr portions so that the furr portions extend away from the plane; and spacing the furr portions away from the plurality of twisted pairs of wires. 
         [0013]    The method also includes forming a plurality of rows of furr portions each located approximately six rows of twisted pair of wires apart from an adjacent row of furr portions. 
         [0014]    In other aspects of the present invention, the furr portions are aligned in generally parallel rows of furr portions. More preferably, at least one row of twisted wire connections is located between a pair of rows of furr portions. 
         [0015]    In still other aspects of the present invention, there is provided a woven wire lath comprising a plurality of wires twisted together thereby forming a wire mesh with the major portion of the wire located in a plane with a portion of the plurality of wires comprising a plurality of furr portions spaced from a plurality of twisted pair of wire connections extending out of the plane of the wire mesh and configured for embedment in plaster upon application of plaster to the wire mesh; and wherein the furr portions are aligned in spaced apart rows of furr portions having a plurality of rows of twisted pair of wire connections located between a pair of rows of furr portions. 
         [0016]    In another aspect of the present invention, there is provided a method for increasing wire density and gripping surfaces of a woven wire lath. The method comprising twisting a plurality of wires to form a mesh having a plurality of twisted pairs of wires forming a plurality of cells positioned generally along a plane, the twisted pairs of wires having greater wire density than a single wire that is not twisted with another wire; furring portions of the mesh to form furr portions so that the furr portions extend away from the plane; spacing the furr portions away from the plurality of twisted pairs of wires; and configuring the twisted pair of wires having greater wire density to be embedded inside a coating material when the woven wire lath is coated with coating material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    These and other features, aspects and advantages of the present invention will be more fully understood when considered with respect to the following detailed description, appended claims, and accompanying drawings, wherein: 
           [0018]      FIG. 1  is an end view of the channel furr wire mesh provided in accordance with practice of the present invention. 
           [0019]      FIG. 2  is a perspective view of the channel furr wire mesh of the present invention showing the furr portion at its connection points. 
           [0020]      FIG. 3  is a side elevation view of one of the furring wires. 
           [0021]      FIG. 4  is a plan view of the channel furr wire mesh provided in accordance with practice of the present invention. 
           [0022]      FIG. 5  is an enlarged plan view of a woven wire lath showing rows of furr portions and twisted wire portions. 
           [0023]      FIG. 6  is a plan view of an alternative woven wire lath showing rows of furr portions and twisted wire portions provided in accordance with aspects of the present invention. 
           [0024]      FIG. 7  is a plan view of yet another alternative woven wire lath showing rows of furr portions and twisted wire portions provided in accordance with aspects of the present invention. 
           [0025]      FIG. 8  is a perspective view of a woven wire lath showing rows of furr portions and twisted wire portions provided in accordance with aspects of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0026]    The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of the channel furr in accordance with the present invention and is not intended to represent the only forms in which the present invention may be constructed or utilized. The description sets forth the features and the steps for constructing and using the channel furr of the present invention in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention. Also, as denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features. 
         [0027]    Referring now to  FIG. 1 , there is shown an end view of a wire fabric lath comprising a channel furr provided in accordance with practice of the present invention, which is generally designated  10 . The wire lath  10  is shown mounted on a wall  12  by means of furring nails  14  driven through furring standoffs  16 , which extend between the bottom of the mesh  40 , formed by woven a plurality of strands of wires, and the wall  12 . The mesh  40 , except for the furring portions or furrs  18  located on the mesh, lies generally along a first plane or a mesh plane  42 , which is spaced from the wall  12 . The standoffs can be formed from wood, plastic or other materials suitable for engaging and holding a nail. The portions of the wire which are extended out of the mesh plane  42  constitute furrs or furr portions  18 . The height of each furr  18  ranges from about ¼″ in depth measured from the mesh plane  42  to about ⅜″ in depth but can be made to any desired depth required for any particular application and for any particular building code. The furring is configured to space the mesh  40  away from the framing material, i.e., the wall or other structure to which the lath  10  is hung. Although not shown, a water resistant membrane, such as building paper or building wrap, should be positioned between the wall and the wire fabric lath  10 . 
         [0028]    Turning to  FIG. 2  in addition to  FIG. 1 , there is shown a perspective view of the channel furr wire mesh  10  of the present invention showing the furred portions  18  of the wire mesh located between adjacent pairs of twisted wires or knots  20 , where two wires are twisted or connected together. The furring may be done to the furring portions  18  by known furring methods and in one exemplary embodiment the furr portions are each shaped like a “v” with an apex or vertex  44 . Wire gauge or size can be made to any local or national building standards. In certain aspects of the present invention, the wire gauge is at least nineteen gauge or larger, such as 17 gauge wire. Although galvanized steel wire is preferred, drawn steel, stainless, steel, aluminum, copper, or other metal of sufficient durability and applicability may be used. By furring the mesh at a location spaced from the twisted wires  20 , the twisted wires  20  are configure to remain embedded inside coating material, such as stucco and plaster, and the higher density wire portions, consisting of twisted pair of wires as opposed to a single strand of wire, provide greater gripping surfaces for the coating material to grip than when the furring portions are incorporated at the twisted wire portions. 
         [0029]    Turning to  FIG. 3 , there is shown a side elevation view of the lath  10  of  FIG. 2  showing the furring portions  18  and furring connections  20 . In one exemplary embodiment, a pair or two rows of furring portions  18  are separated from one another by six generally parallel rows of furring connections  20 . Additionally, each furr portion  20  is located between two furring connections  20 , also referred to as twisted pair or braided pair of wires ( FIG. 4 ). In other words, each furring portion is located at least between two twisted pair or braided pair of wires. However, each pair of successive braided wires may not have a furr portion located therebetween because rows of furring portions  18  are spaced apart from one another. As shown in  FIG. 3 , the two furring portions  18  have six generally parallel rows of furr connections  20  located therebetween, or a distance of bout 4⅜ inches measured from an apex of one row to an apex of another row in accordance with one aspect of the present invention. 
         [0030]    Turning to  FIG. 4 , there is shown a plan view of the wire fabric lath  10  of  FIG. 1  provided in accordance with practice of the present invention, which in the present embodiment is a woven wire fabric lath. As is well known in the art, a woven wire fabric lath is formed by woven different sets of three adjoining wires together. For example, in  FIG. 4 , wire  50  is woven with wire  52 , located to its right when viewing  FIG. 4 , and with wire  54 , located to its left when viewing  FIG. 4 . The resultant woven wire lath  10  comprises a plurality of generally parallel rows of twisted pairs of wires or furr connections  20 , with lines  56  and  58  shown depicting two such generally parallel rows. The resultant woven wire lath  10  also comprises a plurality of six-sided cells  60  having six sides and six vertices or hexagon shape. 
         [0031]      FIG. 4  also shows a plurality of furr portions  18 . In certain embodiments, furring is performed to individual wires along their respective entire lengths. In the embodiment shown, a plurality of furr portions  18  are shown positioned in generally parallel rows. Each row of furr portions  18  is located about six-parallel rows of twisted pairs of wires  56 ,  58  apart from an adjacent row of furr portions. With reference to  FIG. 2  in addition to  FIG. 4 , the vertex  44  of each furr portion in a row of furr portions generally align along a single line, with some expected deviation being possible. In certain embodiment, a row of vertices  44  of furr portions  18  is measured approximately 4 inches to about 5 inches from another row of vertices  44  of furr portions  18 , with 4⅜ inches being more preferred and with some deviation being acceptable. However, depending on the frame or wall for which the woven wire lath  10  is to be hung, the furring can be done closer together or further apart without deviating from the spirit and scope of the present invention. 
         [0032]      FIG. 5  is an enlarged view of a woven wire lath  10  depicting a plurality of rows of furr portions  18  and a plurality of twisted pair of wires  20 . In certain embodiment, the furr portions  18  not only extend away from the wire mesh plane  42  ( FIG. 1 ), but also at an angle laterally. 
         [0033]      FIG. 6  depicts an alternative woven wire lath  62  comprising a plurality of six-sided cells  64 . The cells  64  are formed with different side lengths to produce a hexagon with non-uniform angles at the vertices. The different side lengths allow the furr portions to be made deeper or at a greater lateral angle away from the mesh plane  42  ( FIG. 1 ). 
         [0034]      FIG. 7  depicts yet another alternative woven wire lath  66  comprising a plurality of six-sided cells  68 . The cells  68  have different side lengths compared to the cells  64  of  FIG. 6  to produce yet different dimensioned cells. This in turn allows the furr portions  18  to be made even more pronounced or deeper. 
         [0035]      FIG. 8  is a perspective view of a section of a woven wire mesh  70  provided in accordance with aspects of the present invention. Four rows  72  of furr portions  18  are shown, each located approximately six rows  56  of furr connections  20  apart from an adjacent row of furr portions  18 . However, as readily understood by a person of ordinary skill in the art, more or less rows of furr portions  18  may be incorporated with each row of furr portions being closer or further apart from an adjacent row of furr portions depending on the desired application. 
         [0036]    Embodiments of the present invention include a method for making a woven wire lath by twisting a plurality of wires into plurality of cells and furring portions of the woven wire lath so that the furr portions extend away from a plane of wire mesh. Preferably, the furr portions are aligned in spaced apart rows of furr portions. More preferably, the rows of furr portions are each located approximately six rows of twisted pair of wires apart from an adjacent row of furr portions with different number of rows being acceptable. 
         [0037]    In one embodiment, the wires used to make the wire mesh each comprises galvanized steel and have a diameter of about 0.036 inch. Again, it should be understood that wires fabricated of other materials and of different diameters can be used. 
         [0038]    Although the preferred embodiments of the invention have been described with some specificity, the description and drawings set forth herein are not intended to be delimiting, and persons of ordinary skill in the art will understand that various modifications may be made to the embodiments discussed herein without departing from the scope of the invention, and all such changes and modifications are intended to be encompassed within the appended claims. Various changes to the materials and configuration of the wire mesh may be made including changing the shape, the size of the furr, the overall dimensions, etc. Accordingly, many alterations and modifications may be made by those having ordinary skill in the art without deviating from the spirit and scope of the invention.