Abstract:
A cost-effective and expeditious method for attaching a water channel layer to lath pre-installation, for subsequent application to an inner wall structure, increasing the efficiency and decreasing the cost of building construction, and also encompasses the stock material made thereby. In one form, there is a stapling frame equipped to be placed in juxtaposition to a water channel layer atop a layer of lath on and adjacent surface. A plurality of staplers mounted to the frame then combine the water channel layer and lath to form an integrated stock material that can then be used in a wall structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority from U.S. Provisional Application No. 62/047,198, filed Sep. 8, 2014, which is incorporated by reference herein in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention generally relates to lath, and more particularly to a stapling system for affixing a drainage material to lath. 
       BACKGROUND OF THE INVENTION 
       [0003]    The use of hard coat stucco has been employed as a building material since literally ancient days. For stucco and plaster applications, a lath or mesh substrate is typically applied to the surface of the wall or ceiling structure. This provides a base for mechanical holding or keying for the unhardened stucco or plaster. Metal lath is often used as the reinforcement when stucco or plaster is applied over open frame construction, sheathed frame construction, or a solid base having a surface that might otherwise provide an unsatisfactory bond for the stucco or plaster. Plastic and other kinds of lath have also been used. When applied over frame construction, one may often employ base coats of plaster with a total thickness of approximately ⅜ inch to approximately ¾ inch to produce a solid base for a decorative finish coat. 
         [0004]    According to the International Conference of Building Officials Acceptance Criteria for Cementitious Exterior Wall Coatings, AC 11, effective Oct. 1, 2002, and evaluation report NER-676, issued Jul. 1, 2003, wire fabric lath should be a minimum of No. 20 gauge, inch (25.4 mm) (spacing) galvanized steel woven-wire fabric. The lath should be self-furred, or furred when applied over all substrates except unbacked polystyrene board. Metal lath has structural integrity, but if made of steel can corrode over time. The metal can also unfavorably react with the chemistry of the plaster or stucco. Hence, plastic or non-metal lath has gained popularity. 
         [0005]    Stone veneer has also gained in popularity. Mounting of stone veneer using lath can present similar issues to that of plaster and stucco. A concern with the stone veneer, and even stucco, is that moisture can find its way behind the outer stone or stucco surface. This can present itself by way of hole penetrations in putting up the lath, and water condensing or otherwise migrating behind the lath. 
         [0006]    Also, a matrix of randomly oriented plastic or other durable fibers which are relatively rigid, or which can be treated to be relatively rigid or organized into a matrix that is relatively rigid, has been employed as the lath. An example of the foregoing kind of material is sold under the name MORTAR NET, sold by Mortar Net, Inc. of Burns Harbor, Ind., and such as disclosed in U.S. Pat. No. Re. 36,676. Such a matrix lath has typically been on the order of around except ¼″ thick (in front-to-back width). 
         [0007]    Mortar Net, Inc. has created a system to allow water which may have penetrated cracks in the stucco or between the mortar and veneer to drain out, and to prevent water from entering the structure. To that end, a layer that forms a water channel layer has been applied in combination with the lath. The water channel layer has typically been of material similar to that of the foregoing matrix lath, but of a smaller fibrous diameter entangled randomly-oriented plastic or other durable fiber, formed in a thinner width, such as 3/16″ or ¼″ WALLNET product, made or sold under that name by Mortar Net, Inc. from stock material made by the Fiber Bond Corporation. More details of the foregoing system and product can be gleaned from U.S. application Ser. No. 13/838,993, filed Mar. 22, 2013. 
       SUMMARY OF THE INVENTION 
       [0008]    An improvement on the foregoing water channel and lath combination is to combine the water channel layer with the lath prior to its installation, as on an inner wall structure, The combination results in a stock material that enables easier, faster installation compared to individual lath and drainage components being assembled in situ. Further, the combination of the two layers can reduce penetrations to other layers or elements of the wall structure which are not desired to necessarily be punctured (leading to water entry points, for instance). 
         [0009]    The implementations discussed herein are a cost-effective and expeditious way of attaching a water channel layer to lath pre-installation, for subsequent application to an inner wall structure, increasing the efficiency and decreasing the cost of building construction. 
         [0010]    In one example, a water channel layer is placed in contact (as in vertically atop) a layer of lath. The surface area of the water channel layer may preferably be less than that of the lath, such that a region of lath remains exposed along at least one long edge and one short edge of the water channel layer. This enables ready overlap of completed combined lath-and-water channel layer constructs in wall construction. 
         [0011]    A stapling mechanism then lowers, such as vertically from an original vertical resting position above the water channel layer applied to the lath surface, to the top surface of the water channel layer at one or more predetermined positions on the surface of the water channel layer, and inserts one staple at the predetermined position or each of the predetermined positions, such that the head of the applied staple or staples is on the surface of the water channel layer and the ends are clinched to engage the backside of the lath (i.e., the side not in contact with the water channel material). The staple or staples may engage in an outward clinch (that is, the staple legs are bent outwardly), such that the bend returns the tip of the staple approximately to the top surface of the water channel layer while engaging the wire of the lath. The lath and water channel layer need not be horizontally oriented for fixation together, but this is currently deemed most desirable. 
         [0012]    In one embodiment, the stapling frame uses multiple pneumatically operated staplers on a frame. The staplers are located to be inboard from the edge of the water channel layer and spaced about the combined water channel layer/lath. The staplers may be simultaneously engaged to perform the stapling operation. The stapling mechanism then rises vertically to its vertical resting position while the water channel layer and lath combination is removed and new, separate rectangular portions of water channel layer and lath of equivalent dimensions to the previous portions are placed in position. The frame could also be hinged along one side to open and receive the combined water channel layer/lath in a clamshell arrangement. Further, the frame could move, in a plane above (or below) the water channel layer/lath, into position for stapling. 
         [0013]    The water channel layer may optionally be 0.25″ or 0.40″ thick, among other possible sizes. The staplers may optionally be positioned to apply one or more staples at the predetermined position(s) evenly spaced along the length of rectangular sections (“sheets”) of water channel layer and lath at a predetermined distance inward from the edge of the surface of the water channel layer. The staplers are preferably positioned to apply one or more staples at predetermined position(s) generally evenly spaced along the width of the rectangular portions of water channel layer and lath at a predetermined distance inward from the edge of the surface of the water channel layer. Although systems using pneumatically operated staplers are discussed herein, many kinds of staplers are available. 
         [0014]    In an alternative embodiment, a rectangular portion of water channel layer, approximately 25.5 inches width by 95.5 inches length, is placed vertically atop of a rectangular portion of lath of approximately 27 inches width by 97 inches length such that the water channel layer and lath are flush along one length and one adjacent width, and along the other length and adjacent width of lath, approximately 1.5 inches of surface area of lath is exposed beyond the edge of the water channel layer. 
         [0015]    In an alternative embodiment, the stapling frame may be a generally solid surface equipped with one or more staplers engaged to deliver staples through apertures in the surface of the frame. The stapling frame is equipped to slide horizontally over an adjacent surface carrying the combined water channel layer atop a layer of lath on such adjacent surface. The frame may be positioned such that it slides over the combined water channel layer/lath just above the same, or it could be slightly lowered once in position, to thereby compress the combined materials. The staplers may then be simultaneously engaged to deliver staples through the apertures in the surface of the frame such that the heads of the applied staples are on the top surface of the water channel layer and the ends of the applied staple are clinched such as to engage the lath. The stapling frame may then slide horizontally to its original starting position so that the attached rectangular portions of water channel layer and lath may be removed and new, separate rectangular portions of water channel and lath may be inserted. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  is a perspective view of a wall structure with lath and water channel layers made by an example stapling system, as applied to a frame construction. 
           [0017]      FIG. 2A  is a partial corner view of a lath and water channel layer as attached by an example stapling system. 
           [0018]      FIG. 2B  shows a lath and water channel layer attached with a staple according to an example embodiment. 
           [0019]      FIG. 3  is a perspective view of a stapling system according to an example embodiment, deployed to operate on lath and water channel layers atop a flat surface. 
           [0020]      FIG. 4  is a perspective view of a stapling system according to another example embodiment, deployed to slide into position to operate on a lath and water channel layer atop a flat surface. 
           [0021]      FIG. 5  is a lath and water channel layer combined into an integrated unit via staples, according to an example embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Referring now to  FIG. 1  in particular, a wall structure with lath and water channel layers previously stapled together by the method discussed herein is depicted. The inner wall is typical, but not limited, to that shown here as using a CMU wall structure. Additionally, the elements shown need not be employed in the exact order shown in  FIG. 1 . The systems and methods discussed herein are directed to combining the water channel layer and lath to yield a stock material for later installation with whatever wall structure is desired, regardless of whether water channel layer  120  surface or lath  115  surface is selected as the outboard surface. A wood (stud) wall structure and others may be used, of course. 
         [0023]    Outboard of an exterior-grade sheathing  100  is a weather resistive barrier  105 , which may be a heavy-duty plastic sheeting, operating as a moisture barrier. Outboard of the weather resistive barrier  105  is the lath-and-water channel layer combination  110 . The lath-and-water channel layer combination  110  is in this illustrative embodiment applied to the sheathing in a conventional manner such that the lath  115  is outboard to the water channel layer  120  and affixed to the sheathing. 
         [0024]    The water channel layer  120  material may be, as noted previously, a fibrous diameter entangled randomly oriented plastic or other durable fiber, formed in a thinner width, such as 3/16″ or ¼″ WALLNET product, made or sold under that name by Mortar Net, Inc. The lath  115  may be any commonly used which is readily combinable with the water channel material by stapling, as hereinafter discussed. There are many known types of lath, including metal and plastic being most commonly used. Fiberglass lath, typically supplied in continuous rolls, may be used. The lath serves as the main supporting structure for receiving and holding plaster or stucco, or some cementitious or other adhesive compound for holding thin stone veneer or stucco finish coat  140 , and may be outboard to the water channel layer  120  as shown here, or inboard to the water channel layer  120 . 
         [0025]      FIG. 1  shows the lath  115  peeled back to illustrate the water channel layer  120 . The surface area of the water channel layer  120  may preferably be less than that of the lath  115  such that a region of lath  115  is exposed along at least one long edge and one short edge of the water channel layer  120 . Consequently, one segment of the lath-and-water channel layer combination  110  may be enabled for ready overlap  125  of an adjacent segment of lath-and-water channel layer constructs, creating code-compliant lath and continuous water channel layer in one. This can also be seen in  FIG. 5 . 
         [0026]    Outboard to the lath-and-water channel layer combination  110  is base coat  130 . Outboard to the base coat  130  is a scratch coat  135 . Finally, outboard to the scratch coat  135  is thin stone veneer or stucco finish coat  140 . It will be understood that some of the foregoing elements need not be employed in the exact order shown in  FIG. 1 . 
         [0027]      FIG. 2A  shows a partial corner vie of an example lath-and-water channel layer combination  200 . The corner view shows that the surface area of the water channel layer  205  may preferably be less than that of the lath  210 , such that a region of lath exposed along at least one long edge and one short edge of the water channel layer  205 . A staple  215  has been applied to the water channel layer  205 , which is also shown in  FIG. 2B . The head  215   a  of the staple  215  is on the top surface  205   a  of the water channel layer  205  and the two ends  215   b,    215   c  of the applied staple  215  are clinched such as to engage the opposite side of the lath  210  (i.e., the side not in facial contact with the layer  205 ). Further, in the example shown in  FIG. 2B , the ends  215   b,    215   c  of the staple  215  are clinched outwardly such that each end returns approximately to the top surface  205   a  of the water channel later  205  while engaging the lath  210 . As noted above the lath-and-water channel layer combination  200  may be installed such that the water channel layer  205  or the lath  210  is the outboard surface. 
         [0028]      FIG. 3  shows a perspective view of the stapling system deployed to operate on lath  305  and water channel layer  310  atop a flat surface  315 . The frame  300 , which is equipped with one or more staplers  320  positioned at predetermined positions, is cooperatively affixed to a vertical deployment mechanism  325  providing for movement of the frame  300  towards and away from the flat surface  315 . The staplers  320  may be simultaneously engaged to perform the stapling operation, although they need not be. The staplers here are pneumatically operated by cooperatively engaging the staplers  320  with pneumatic mechanism  330 . The stapling system may optionally be engaged for use with fiberglass lath, which is typically supplied in continuous rolls, such that the water channel layer would be delivered to the flat surface  315  in a roll to roll process rather than sheets. The staplers and the pneumatic system along with a suitable controller are well known in the art. The arrangement of the components in this system is new. 
         [0029]      FIG. 4  shows a perspective view of an alternative embodiment of a stapling system deployed to operate on lath  405  and water channel layer  410  atop a flat surface  415 . The stapling frame  420  is a surface equipped with one or more staplers  425  engaged to deliver staples through apertures  445  in the surface of the stapling frame  420 . The stapling frame  420  is equipped on its ends  440  to slide horizontally via a sliding mechanism  430  over the adjacent flat surface  415 , and over a rectangular portion of water channel layer  410  atop a rectangular portion of lath  405  on such adjacent flat surface  415 . The staplers  425  may then be simultaneously engaged to deliver staples through the apertures  445  in the surface of the stapling frame  420  such that the heads of the applied staples are on the top surface of the water channel layer  410  and the ends of the applied staples are clinched such as to engage the lath  405 . The stapling frame  420  may then slide horizontally to its original starting position so that the attached rectangular portions of water channel layer  410  and lath  405  may be removed and new, separate rectangular portions of water channel layer  410  and lath  405  may be inserted atop the flat surface  415 . The staplers may optionally be pneumatically operated by cooperatively engaging the staplers  425  with pneumatic mechanism  435 . 
         [0030]    In one alternative to the foregoing, a more open frame could be used for mounting the staplers, as described with the first embodiment. In another alternative to the foregoing, the stapling system may be engaged for use with fiberglass lath, which is typically supplied in continuous rolls, such that the water channel layer would be delivered to the flat surface  415  in a roll to roll process rather than sheets. 
         [0031]      FIG. 5  shows a lath  505  and water channel layer  510  combined into an integrated unit via staples  515 . The staples  515  are generally evenly spaced along the width of the integrated unit, as shown by the spacing  525  between each staple  515 . Further, the staples  515  begin at predetermined distance  520  from inward from the long edge of the water channel layer  510 . Similarly, the staples  515  are generally evenly spaced along the length of the integrated unit, as shown by the spacing  535  between each staple  515 . Further, the staples  515  begin at predetermined distance  530  from inward from the short edge of the water channel layer  510 . 
         [0032]    While the present invention has been described with respect to certain embodiments, numerous changes and modifications will be apparent to those of skill in the art, and such changes and modifications are intended to be encompassed within the spirit of the invention, as defined by the claims.