Apparatuses and Methods for an Improved Lath, Vapor Control Layer and Rain Screen Assembly

Abstract

An improved lath and rain screen assembly for fastening to an exterior building surface or the like is provided. The lath and rain screen assembly comprises a rain screen configured to encourage ventilation and drying, and a lath configured to receive at least a portion of a first mortar layer. In various embodiments, the rain screen comprises a first and a second body, defining respective co-parallel first and second planes, while the lath comprises a third body spaced apart from and substantially parallel to at least the first plane. In certain embodiments, the first body and the lath are spaced apart so as to provide a first intermediate pathway. In certain embodiments, the first intermediate pathway is at least partially defined by the second body of the rain screen. A method of applying the improved lath and rain screen assembly is also provided.

1 . A lath and rain screen assembly configured for fastening to an exterior building surface, the lath and rain screen assembly comprising:
 A) a rain screen configured to encourage ventilation and drying, said rain screen including
 1) a first substantially planar body, said first body having a nominal thickness and opposing primary planar first and second sides, said first body further defining a first plane; and 
 2) a second substantially planar body, said second body having a nominal thickness and opposing primary planar first and second sides, said first side being operably connected to said second side of said first body, said second body further defining a second plane, said second plane being substantially parallel to said first plane of said first body; and 
   B) a lath configured to receive at least a portion of a first mortar layer, said lath including a third substantially planar body having a nominal thickness, said third body being operably connected to said second side of said second body, said third body further defining a third plane spaced apart from and substantially parallel to said first plane,   such that at least said first body of said rain screen and said third body of said lath are spaced apart so as to provide a first intermediate pathway therebetween configured for permitting the passage of liquid water and water vapor.   
     
     
         2 . The lath and rain screen assembly of  claim 1 , wherein:
 said second body is formed from a permeable material; and   said permeable material of said second body substantially defines said first intermediate pathway.   
     
     
         3 . The lath and rain screen assembly of  claim 2 , wherein said permeable material of said second body has a permeability value in a range of about 15 perms to about 35 perms. 
     
     
         4 . The lath and rain screen assembly of  claim 1 , wherein said connections between said second body of said rain screen and said third body of said lath are provided by heat bonding. 
     
     
         5 . The lath and rain screen assembly of  claim 1 , wherein said first intermediate pathway has a width of from about 0.0625 inches to about 0.50 inches, said width being defined at least in part by said nominal thickness of said second body. 
     
     
         6 . The lath and rain screen assembly of  claim 1 , wherein said nominal thickness of said second body is in a range of about 0.0625 inches to about 0.50 inches. 
     
     
         7 . The lath and rain screen assembly of  claim 1 , wherein said first body of said rain screen is formed from a polymer-based material. 
     
     
         8 . The lath and rain screen assembly of  claim 7 , wherein said polymer-based material is selected from a group consisting of: polyvinyl chloride, polystyrene, polyethylene, polypropylene, or any combination thereof. 
     
     
         9 . The lath and rain screen assembly of  claim 1 , wherein said nominal thickness of said first body is in a range of about 0.005 inches to about 0.50 inches. 
     
     
         10 . The lath and rain screen assembly of  claim 1 , wherein said rain screen further comprises a fourth substantially planar body, said fourth body having a nominal thickness and opposing primary planar first and second sides, said second side being operably connected to said first side of said first body, said first side defining a fourth plane, said fourth plane being spaced apart from and substantially parallel to said first plane of said first body. 
     
     
         11 . The lath and rain screen assembly of  claim 10 , wherein:
 said fourth body is formed from a permeable material; and   said permeable material of said fourth body substantially defines a second intermediate pathway, said second pathway being located substantially between said fourth plane of said fourth body and said first plane of said first body, and said second pathway being configured for permitting the passage of liquid water and water vapor.   
     
     
         12 . The lath and rain screen assembly of  claim 11 , wherein said permeable material of said fourth body has a permeability value in a range of about 15 perms to about 35 perms. 
     
     
         13 . The lath and rain screen assembly of  claim 10 , wherein:
 said second body is formed from a permeable material; and   said permeable material of said second body substantially defines said first intermediate pathway.   
     
     
         14 . The lath and rain screen assembly of  claim 13 , wherein said permeable material of said second body has a permeability value in a range of about 15 perms to about 35 perms. 
     
     
         15 . The lath and rain screen assembly of  claim 13 , wherein said permeable material of said second body and said permeable material of said fourth body are substantially the same. 
     
     
         16 . The lath and rain screen assembly of  claim 11 , wherein said second intermediate pathway has a width of from about 0.0625 inches to about 0.50 inches, said width being defined at least in part by said nominal thickness of said fourth body. 
     
     
         17 . The lath and rain screen assembly of  claim 10 , wherein said nominal thickness of said fourth body is in a range of about 0.0625 inches to about 0.50 inches. 
     
     
         18 . The lath and rain screen assembly of  claim 1 , wherein said first body is formed from a substantially impermeable material, said impermeable material having a permeability value in a range of about 0.06 perms to about 5 perms. 
     
     
         19 . The lath and rain screen assembly of  claim 1 , wherein said connections between said rain screen and said lath are provided by heat bonding. 
     
     
         20 . The lath and rain screen assembly of  claim 1 , wherein said lath includes a plurality of spaced apart apertures configured to permit passage of the first layer of mortar substantially through the lath. 
     
     
         21 . The lath and rain screen assembly of  claim 1 , wherein the lath is formed from a fiberglass-based material. 
     
     
         22 . The lath and rain screen assembly of  claim 21 , wherein said lath is formed by weaving the fiberglass-based material into a mesh configuration. 
     
     
         23 . The lath and rain screen assembly of  claim 1 , wherein said lath and rain screen assembly is capable of being stored in a rolled-up fashion. 
     
     
         24 . The lath and rain screen assembly of  claim 1 , wherein said lath has a width of from about 1/64 inches to about 0.25 inches, said width being defined at least in part by said nominal thickness of said third body. 
     
     
         25 . A method of providing a lath and rain screen assembly configured to be attached to an exterior building surface, said method comprising the steps of:
 A) providing a rain screen configured to encourage ventilation and drying, said rain screen including:
 1) a first substantially planar body, said first body having a nominal thickness and opposing primary planar first and second sides, said first body further defining a first plane; and 
 2) a second substantially planar body, said second body having a nominal thickness and opposing primary planar first and second sides, said first side being operably connected to said second side of said first body, said second body further defining a second plane, said second plane being substantially parallel to said first plane of said first body; 
   B) providing a lath configured to receive at least a portion of a first mortar layer, said lath including a third substantially planar body having a nominal thickness, said third body being operably connected to said second side of said second body, said third body further defining a third plane spaced apart from and substantially parallel to said first plane; and   C) providing said lath and rain screen assembly by connecting said rain screen and said lath, such that at least said first body of said rain screen and said third body of said lath are spaced apart so as to provide a first intermediate pathway therebetween configured for permitting the passage of liquid water and water vapor.   
     
     
         26 . The method as claimed in  claim 25 , wherein in Step “C” said connection between said rain screen and said lath is provided by heat bonding. 
     
     
         27 . The method as claimed in  claim 25 , wherein in Step “C” said connection between said rain screen and said lath is provided by adhesive. 
     
     
         28 . The method as claimed in  claim 25 , wherein in Step “B” said lath is provided with apertures configured to permit passage of mortar therethrough. 
     
     
         29 . The method as claimed in  claim 25 , wherein in Step “A” said first body of said rain screen is provided with a permeability value in a range of about 0.06 perms to about 5 perms. 
     
     
         30 . The method as claimed in  claim 25 , wherein in Step “A” said second body of said rain screen is provided with a permeability value in a range of about 15 perms to about 35 perms. 
     
     
         31 . A method of applying a lath and rain screen assembly to an exterior building surface to facilitate the attachment of exterior cladding materials, said method comprising the steps of:
 A) providing a rain screen configured to encourage ventilation and drying, said rain screen including:
 1) a first substantially planar body, said first body having a nominal thickness and opposing primary planar first and second sides, said first body further defining a first plane; and 
 2) a second substantially planar body, said second body having a nominal thickness and opposing primary planar first and second sides, said first side being operably connected to said second side of said first body, said second body further defining a second plane, said second plane being substantially parallel to said first plane of said first body; 
   B) providing a lath configured to receive at least a portion of a first mortar layer, said lath including a third substantially planar body having a nominal thickness, said third body being operably connected to said second side of said second body, said third body further defining a third plane spaced apart from and substantially parallel to said first plane;   C) providing said lath and rain screen assembly by connecting said rain screen and said lath, such that said first body of said rain screen and said third body of said lath are spaced apart so as to provide a first intermediate pathway therebetween configured for permitting the passage of liquid water and water vapor;   D) positioning said lath and rain screen assembly adjacent said exterior building surface;   E) applying a first layer of mortar onto said lath; and   F) attaching a plurality of exterior cladding materials to said lath at least partially with the use of said mortar.   
     
     
         32 . The method as claimed in  claim 31 , wherein in Step “E” said first intermediate pathway receives at least a portion of a first layer of mortar. 
     
     
         33 . The method as claimed in  claim 31 , wherein in step “B” said lath is provided with a plurality of spaced apart apertures configured to permit passage of a portion of said first layer of mortar substantially through the lath in Step “E”, and wherein in Step “F”, said first layer of mortar, upon passing substantially through the lath, further substantially encapsulates the lath. 
     
     
         34 . The method as claimed in  claim 31 , wherein step “E” furthers comprises the step of applying a second layer of mortar onto said first layer of mortar once said first layer has been allowed to cure. 
     
     
         35 . The method as claimed in  claim 31 , wherein:
 A) said step “A” of providing a rain screen comprises a rain screen further including a fourth substantially planar body, wherein:
 1) said fourth body has opposing primary planar first and second sides, said second side being operably connected to said first side of said first body, said first side defining a fourth plane, said fourth plane being spaced apart from and substantially parallel to said first plane of said first body; and 
 2) said fourth body substantially defines a second intermediate pathway, said second pathway being located substantially between said fourth plane of said fourth body and said first plane of said first body, and said second pathway being configured for permitting the passage of liquid water and water vapor; and 
   B) said step “D” of positioning said lath and rain screen assembly adjacent said exterior building surface comprises positioning said first side of said fourth body of said rain screen in contact with the exterior building surface.   
     
     
         36 . The method as claimed in  claim 35 , wherein following Step “D” said second intermediate pathway has a width of from about 0.0625 inches to about 0.50 inches.