Stucco wall structure

Abstract

Wall structures and methods for producing wall structures are described in this specification. The wall structures include a frame, a sheathing board attached to the frame, a foam layer, a bond break layer, a lath layer, and a stucco layer.

1 . A wall structure comprising:
 a frame comprising:
 a first member; 
 a second member spaced apart from the first member; and 
 two side members extending between the first member and the second member, wherein the first member, the second member, and the two side members each comprise a front surface and a rear surface that form a front frame surface and a rear frame surface; 
   a sheathing board attached to the front frame surface, wherein the sheathing board, the first and second members, and the two side members define a cavity within the frame;   a foam layer located within the cavity and adhered to a rear-facing surface of the sheathing board;   a bond break layer located adjacent to a front-facing surface of the sheathing board;   a lath layer located adjacent to the bond break layer; and   a stucco layer integrated into the lath layer,   wherein the sheathing hoard comprises an extruded polystyrene board.   
     
     
         2 . The wall structure of  claim 1 , wherein the bond break layer comprises an asphalt-impregnated kraft paper, an asphalt-impregnated felt paper, an extruded polystyrene layer, an expanded polystyrene layer, a polyiso layer a polyethylene sheet or film, a polypropylene sheet or film, a poly(vinyl chloride) sheet or film, a woven house wrap, a perforated housewrap, a nonmoven and spunbonded polyolefin sheet or film, a woven and perforated polyolefin sheet or film, a layer comprising a three-dimensional matrix of randomly-oriented extruded polymer filaments, or a fiberboard. 
     
     
         3 . The wall structure of  claim 1 , wherein the bond break layer comprises a Grade D 60-minute building paper. 
     
     
         4 . The wall structure of  claim 1 , wherein the lath layer comprises a self-furred steel wire lath. 
     
     
         5 . The wall structure of  claim 1 , wherein the bond break layer and the lath layer are pre-bonded together, and wherein the pre-bonded combination of the bond break layer and the lath layer are positioned on the front-facing surface of the sheathing board and attached to the frame with one set of fasteners that penetrate through the sheathing board. 
     
     
         6 . The wall structure of  claim 5 , wherein the pre-bonded combination of the bond break layer and the lath layer comprises a bond break layer comprising paper and a lath layer comprising metal wire lath. 
     
     
         7 - 9 . (canceled) 
     
     
         10 . The wall structure of  claim 1 , wherein the foam layer comprises polyurethane or polyisocyanurate, or mixtures thereof. 
     
     
         11 . The wall structure of  claim 1 , wherein the sheathing board is attached to the front faces of the first and second members, and to the front faces of the two side members, with fasteners. 
     
     
         12 . The wall structure of  claim 1 , wherein the sheathing board is attached to the front faces of the first and second members, and to the front faces of the two side members, with an adhesive. 
     
     
         13 . The wall structure of  claim 1 , wherein the foam layer comprises a thickness extending from the rear-facing surface of the sheathing board to a position intermediate the front frame surface and the rear frame surface such that a gap is formed within the frame between a rear-facing surface of the foam layer and the rear frame surface. 
     
     
         14 . A method for producing the wall structure of  claim 1  comprising:
 providing a wall panel, the wall panel comprising:
 a frame comprising:
 a first member; 
 a second member spaced apart from the first member; and 
 two side members extending between the first member and the second member, wherein the first member, the second member, and the two side members each comprise a front surface and a rear surface that form a front frame surface and a rear frame surface; 
 
 a sheathing board attached to the front frame surface, wherein the sheathing board, the first and second members, and the two side members define a cavity within the frame; and 
 a foam layer located within the cavity and adhered to a rear-facing surface of the sheathing board; 
 positioning a bond break layer and a lath layer adjacent to a front-facing surface of the sheathing board; 
 attaching the bond break layer and the lath layer to the frame; and 
 applying a stucco layer integrated into the lath layer, 
 wherein the sheathing board comprises an extruded polystyrene board. 
 
 
     
     
         15 . The method of  claim 14 , further comprising:
 assembling multiple wall panels into an incomplete wall structure;   positioning the bond break layer and the lath layer adjacent to the front-facing surfaces of the sheathing board and over the incomplete wall structure;   attaching the bond break layer and the lath layer to the frames of the multiple assembled panels; and   applying a stucco layer integrated into the lath layer to complete the wall structure.   
     
     
         16 . The method of  claim 14 , wherein the lath layer comprises a self-furred steel wire lath, and wherein the bond break layer comprises an asphalt-impregnated kraft paper, an asphalt-impregnated felt paper, an extruded polystyrene layer, an expanded polystyrene layer, a polyiso layer, a polyethylene sheet or film, a polypropylene sheet or film, a poly(vinyl chloride) sheet or film, a woven house wrap, a perforated housewrap, a nonmoven and spunbonded polyolefin sheet or film, a woven and perforated polyolefin sheet or film, a layer comprising a three-dimensional matrix of randomly-oriented extruded polymer filaments, or a fiberboard. 
     
     
         17 . The method of  claim 14 , wherein the bond break layer and the lath layer are pre-bonded together, and wherein the pre-bonded combination of the bond break layer and the lath layer are positioned on the front-facing surface of the sheathing board and attached to the frame with one set of fasteners that penetrate through the sheathing board. 
     
     
         18 . The method of  claim 17 , wherein the pre-bonded combination of the bond break layer and the lath layer comprises a paper-backed metal wire lath. 
     
     
         19 . The method of  claim 18 , wherein the bond break layer comprises a Grade D 60-minute building paper and the metal wire lath comprises a self-furred steel wire lath. 
     
     
         20 - 22 . (canceled) 
     
     
         23 . The method of  claim 14 , wherein the foam layer comprises polyurethane or polyisocyanate, or mixtures thereof. 
     
     
         24 . The method of  claim 14 , wherein applying the stucco layer comprises:
 applying a brown coat integrated into the lath layer; and   applying a finish coating onto the brown coat.   
     
     
         25 . The method of  claim 14 , wherein applying the stucco layer comprises:
 applying a scratch coat integrated into the lath layer;   applying a brown coat onto the scratch coat; and   applying a finish coating onto the brown coat.