Exterior finishing system and building wall containing a corrosion-resistant enhanced thickness fabric and method of constructing same

• US 7,902,092 B2
• Filed: 06/01/2009
• Issued: 03/08/2011
• Est. Priority Date: 12/19/2003
• Status: Expired due to Term

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Construction Chemicals LLC (BASF SE)
• Inventors: Newton, Mark, Egan, William F., Tucker, Mark W.
• Primary Examiner(s): Ortiz; Angela
• Assistant Examiner(s): STEELE, JENNIFER A
• Application Number:
  US12/475,652
• Publication Number:
  US 20090239430A1
• Time in Patent Office: 645 Days
• Field of Search: 442/181, 442/203, 442205-209, 442/218, 442/219, 442/2, 442/20, 442/42, 442/43, 524/08, 525/060.1
• US Class Current: 442/42
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 19/00 Gauze or leno-woven fabrics
• CPC Class Codes: D10B 2503/04 Floor or wall coverings; Carpets
• CPC Class Codes: E04F 13/04 Bases for plaster sub-ceilings with plaster-carrying means E04B9/06
• CPC Class Codes: E04F 13/047 Plaster carrying meshes
• CPC Class Codes: Y10T 428/249925 Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/102 Woven scrim
• CPC Class Codes: Y10T 442/133 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/171 Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/172 Coated or impregnated
• CPC Class Codes: Y10T 442/176 Three or more layers
• CPC Class Codes: Y10T 442/178 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/181 Bitumen coating or impregnation
• CPC Class Codes: Y10T 442/184 Nonwoven scrim
• CPC Class Codes: Y10T 442/191 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/198 Coated or impregnated
• CPC Class Codes: Y10T 442/3179 Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
• CPC Class Codes: Y10T 442/3195 Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/322 Warp differs from weft

Abstract

A corrosion-resistant lath is provided for use in exterior finishing systems, such as stucco systems and exterior insulation and finish systems (“EIFS”). The lath includes in a first embodiment an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, such as glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making an exterior finish system and building wall including an exterior finish system using such a lath.

Claims

1. A building wall comprising:

a building wall substrate;

a corrosion-resistant woven lath attached to said substrate, said lath comprising warp and weft yarns comprising non-metallic fibers, wherein at least a portion of said weft yarns are undulated when viewed in the plane of the fabric and wherein said lath has a thickness of at least about 0.125 inches (3.175 mm); and

a stucco matrix applied to said lath.

2. The building wall of claim 1, wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers, or combinations thereof.

3. The building wall of claim 2, wherein said non-metallic fibers comprise glass fibers.

4. The building wall of claim 3, wherein said glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, AR-glass fibers and combinations thereof.

5. The building wall of claim 4, wherein said glass fiber comprise AR-glass fibers.

6. The building wall of claim 5, wherein said fabric comprises a leno weave.

7. The building wall of claim 5, wherein said undulated weft yarns are fixed by a coating.

8. The building wall of claim 7, wherein said coating comprises a polymeric coating.

9. The building wall of claim 8, wherein said a polymeric coating is disposed over at least a portion of said yarns for substantially fixing said weft yarns in said undulated condition.

10. The building wall of claim 9, wherein at least a portion of said weft yarns are fixed is a substantially sinusoidal pattern when view in the plane of the lath.

11. The building wall of claim 9, wherein said polymeric coating comprises an alkaline resistant coating.

12. The building wall of claim 1, wherein said warp yarns have a combined weight which is greater than the combined weight of the weft yarns.

13. The building wall of claim 1, wherein a portion of said warp yarns are heavier than a portion of said weft yarns and said warp yarns are fewer in number than said weft yarns.

14. The building wall of claim 1, wherein said weft and warp yarns are spaced apart to provide openings of about 0.02-4.0 square inches (0.5-102 mm²).

15. The building wall of claim 1, said lath retains and supports the weight of a wet stucco matrix applied thereto.

16. The building wall of claim 1, including a weather barrier attached over said substrate.

17. A method of constructing a building wall comprising:

(a) affixing a substrate to a frame;

(b) optionally disposing a secondary weather barrier over said substrate;

(c) optionally disposing a layer of insulation over said weather barrier or said substrate;

(d) affixing a corrosion resistant lath over said substrate, or secondary weather barrier, if present, or said insulation layer, if present, said lath comprising a corrosion-resistant woven fabric comprising warp and well yarns comprising non-metallic fibers, wherein at least a portion of said weft yarns are undulated when viewed in the plane of the fabric and wherein said lath has a thickness of at least about 0.125 inches (3.175 mm);

(e) applying at least a first stucco layer to said lath; and

(f) permitting said stucco layer to set to form a hard protective finish.

18. A building wall comprising:

a building wall substrate;

an insulation board attached to the substrate;

a base coat applied to the insulation board;

a reinforcing mesh comprising warp and weft yarns comprising non-metallic fibers, wherein at least a portion of said well yarns are undulated when viewed in the plane of the mesh fabric and wherein said lath has a thickness of at least about 0.125 inches (3.175 mm); and

a finish coat applied to said reinforcing mesh, wherein the reinforcing mesh is substantially embedded within the base coat and the finish coat.