US20180051470A1

US20180051470A1 - Metal lath accessory with metal lath attachment feature

Info

Publication number: US20180051470A1
Application number: US15/680,367
Authority: US
Inventors: Jeremy Ryan Smith; Nick Joseph Apanovich; Erenio Reyes; Christopher K. Little; Hernando Garcia
Original assignee: Clarkwestern Dietrich Building Systems LLC
Current assignee: Clarkwestern Dietrich Building Systems LLC
Priority date: 2016-08-19
Filing date: 2017-08-18
Publication date: 2018-02-22

Abstract

A metal lath accessory comprising a metal lath attachment feature that includes a side wall, a first flange extending from the side wall, and a second flange extending from the side wall. The first flange comprises at least one barb that projects from the first flange towards the second flange. In some embodiments, the second flange comprises at least one barb that projects from the second flange toward the first flange. The barbs may be configured to engage a piece of metal lath that is inserted between the first flange and the second flange.

Description

PRIORITY

This application claims priority to U.S. Provisional Patent Application Ser. No. 62/377,067, filed Aug. 19, 2017, entitled “METAL LATH ACCESSORY WITH METAL LATH ENGAGEMENT FEATURE,” the disclosure of which is incorporated by reference herein.

BACKGROUND

In typical building construction, metal lath is installed against a substrate to provide reinforcement to a finishing material, such as portland-based cement, or stucco. Metal lath accessories are used to ensure proper alignment of the metal lath during application of the finishing material. Various types of metal lath accessories can include, but are not limited to, casing beads, control joints, expansion joints, and reveals. These metal lath accessories may be manufactured from steel, vinyl, zinc, and other materials. The metal lath is typically attached to the metal lath accessory with metal tie wires at a spacing of about every 7 inches. To provide more consistency in construction, reduce labor costs, and reduce material costs, it may be desirable to provide a metal lath accessory that comprises an attachment feature for the metal lath in a single component to replace multiple components or materials.
While a variety of metal lath accessories have been made and used, it is believed that no one prior to the inventors has made or used an invention as described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

It is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements and in which:

FIG. 1 depicts a top perspective view of an embodiment of a metal lath accessory that includes a metal lath attachment feature;

FIG. 2 depicts a front elevational view of the metal lath accessory of FIG. 1;

FIG. 3 depicts a right side elevational view of the metal lath accessory of FIG. 1;

FIG. 4 depicts a left side elevational view of the metal lath accessory of FIG. 1;

FIG. 5 depicts a top plan view of the metal lath accessory of FIG. 1;

FIG. 6 depicts a bottom plan view of the metal lath accessory of FIG. 1;

FIG. 7 depicts a top perspective view of the metal lath accessory of FIG. 1 coupled with a piece of metal lath;

FIG. 8 depicts a top view of the metal lath accessory of FIG. 1 coupled with two pieces of metal lath (shown schematically) and attached to a substrate;

FIG. 9 depicts a front elevational view of the assembly of FIG. 8 with a coating of a finishing material partially applied thereto.

FIG. 10 depicts a top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature;

FIG. 11 depicts a front elevational view of the metal lath accessory of FIG. 10;

FIG. 12 depicts a top plan view of the metal lath accessory of FIG. 10;

FIG. 13 depicts a bottom plan view of the metal lath accessory of FIG. 10;

FIG. 14 depicts a left side elevational view of the metal lath accessory of FIG. 10;

FIG. 14A depicts a detailed view of the portion of the metal lath accessory, as indicated in FIG. 14;

FIG. 15 depicts a right side elevational view of the metal lath accessory of FIG. 10;

FIG. 16 depicts a top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature;

FIG. 17 depicts a front elevational view of the metal lath accessory of FIG. 16;

FIG. 18 depicts a top plan view of the metal lath accessory of FIG. 16;

FIG. 19 depicts a bottom plan view of the metal lath accessory of FIG. 16;

FIG. 20 depicts a left side elevational view of the metal lath accessory of FIG. 16;

FIG. 21 depicts a right side elevational view of the metal lath accessory of FIG. 16;

FIG. 22 depicts a top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature;

FIG. 23 depicts a front elevational view of the metal lath accessory of FIG. 22;

FIG. 24 depicts a top plan view of the metal lath accessory of FIG. 22;

FIG. 25 depicts a bottom plan view of the metal lath accessory of FIG. 22;

FIG. 26 depicts a left side elevational view of the metal lath accessory of FIG. 22;

FIG. 27 depicts a right side elevational view of the metal lath accessory of FIG. 22;

FIG. 28 depicts a top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature and a removable leg;

FIG. 29 depicts a front elevational view of the metal lath accessory of FIG. 28;

FIG. 30 depicts a top perspective view of the metal lath accessory of FIG. 28 with the removable leg in the process of being separated from the metal lath accessory;

FIG. 31 depicts a front elevational view of the metal lath accessory of FIG. 28 with the removable leg in the process of being separated from the metal lath accessory;

FIG. 32 depicts a top plan view of the metal lath accessory of FIG. 28 with the removable leg in the process of being separated from the metal lath accessory;

FIG. 33 depicts a bottom plan view of the metal lath accessory of FIG. 28;

FIG. 34 depicts a left side elevational view of the metal lath accessory of FIG. 28 with the removable leg in the process of being separated from the metal lath accessory;

FIG. 35 depicts a right side elevational view of the metal lath accessory of FIG. 28 with the removable leg in the process of being separated from the metal lath accessory;

FIG. 36 depicts an exploded top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature, wherein the metal lath accessory comprises a lath clip and a solid-flange metal lath accessory;

FIG. 37 depicts a front elevational view of the lath clip of FIG. 36;

FIG. 38 depicts a front elevational view of the sold-flange metal lath accessory of FIG. 36;

FIG. 39 depicts an exploded, top plan view of the lath clip and solid-flange metal lath accessory of FIG. 36;

FIG. 40 depicts an exploded, left side elevational view of the lath clip and solid-flange metal lath accessory of FIG. 36;

FIG. 41 depicts a top perspective view of the assembled metal lath accessory of FIG. 36;

FIG. 42 depicts a front elevational view of the assembled metal lath accessory of FIG. 41;

FIG. 43 depicts a top plan view of the assembled metal lath accessory of FIG. 41;

FIG. 44 depicts a left side elevational view of the assembled metal lath accessory of FIG. 41;

FIG. 45 depicts a top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature;

FIG. 46 depicts a front elevational view of the metal lath accessory of FIG. 45;

FIG. 47 depicts a right side elevation view of the metal lath accessory of FIG. 45;

FIG. 48 depicts a left side elevation view of the metal lath accessory of FIG. 45;

FIG. 49 depicts a top plan view of the metal lath accessory of FIG. 45;

FIG. 50 depicts a bottom plan elevational view of the metal lath accessory of FIG. 45;

FIG. 51 depicts a top perspective view of another embodiment of a metal lath accessory that includes a metal lath attachment feature;

FIG. 52 depicts a front elevational view of the metal lath accessory of FIG. 51;

FIG. 53 depicts a left side elevational view of the metal lath accessory of FIG. 51;

FIG. 54 depicts a right side elevational view of the metal lath accessory of FIG. 51;

FIG. 55 depicts a top plan view of the metal lath accessory of FIG. 51;

FIG. 56 depicts a bottom plan view of the metal lath accessory of FIG. 51; and

FIG. 57 depicts a front elevational view of another embodiment of a metal lath accessory that includes a metal lath attachment feature.

The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.
There is a desire for metal lath accessories that comprise a metal lath attachment feature. By including the metal lath attachment feature in the metal lath accessory, the need for additional components to attach the metal lath to the metal lath accessory, such as metal ties or other fasteners, may be eliminated. The combining of these functions may also reduce installation time and total material cost.
FIGS. 1-9 show a metal lath accessory (10) that can be used to attach metal lath to a substrate, such as a wall. In the illustrated embodiment, the metal lath accessory (10) comprises a control joint having a central portion (14) positioned between a pair of side walls (12). The metal lath accessory (10) can comprise other suitable accessory configurations in addition to a control joint, including but not limited to casing beads, expansion joints, reveals, reveal control joints, reveal expansion joints, intersections, crosses, outside corners, inside corners, T's, and connectors. As shown in FIG. 2, the central portion (14) comprises a recess to form a V-shape, but other suitable shapes for central portion (14) can be used.
As shown in FIGS. 1-9, the metal lath accessory (10) comprises a lower flange (20) extending outwardly from a bottom portion of each side wall (12). The metal lath accessory (10) further comprises an upper flange (22) extending outwardly from each side wall (12) at a position above the lower flange (20). In some embodiments, one or more of the central portion (14), side walls (12), lower flanges (20), and upper flanges (22) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the central portion (14), side walls (12), lower flanges (20), and upper flanges (22) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the central portion (14), side walls (12), lower flanges (20), and upper flanges (22) may comprise non-integral, separate components that are attached to each other. In the illustrated embodiment, each upper flange (22) is substantially parallel to the corresponding lower flange (20). In some embodiments, one or both of the upper flange (22) and the lower flange (20) may extend substantially perpendicularly relative to the respective side wall (12), while in other embodiments, one or both of the upper flange (22) and the lower flange (20) may extend obliquely relative to the respective side wall (12). Lower and upper flanges (20, 22) thereby form a channel to receive the metal lath (30) within the metal lath accessory (10), as shown in FIGS. 7 and 8. Accordingly, the upper flange (22) may be spaced apart from the lower flange (20) any distance suitable to allow the metal lath accessory (10) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (22) may be spaced apart from the lower flange (20) about 0.230 inches and the tip of the barbs (26, 28) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (22) may extend obliquely relative to the lower flange (20). For example, in some embodiments, the upper flange (22) may extend downwardly toward the lower flange (20) such that the height of the channel defined, at least in part, by the upper flange (22) and the lower flange (20) is larger at the fixed end of the upper flange (22) than the height of the channel at the free end of the upper flange (22).
The metal lath accessory (10) further comprises a pair of metal lath attachment features configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (10) are attached to each other. In the illustrated embodiment, each metal lath attachment feature comprises an upper flange (22), a corresponding lower flange (20), and at least one barb (26, 28) positioned on each of the upper flange (22) and the lower flange (20). As shown in FIG. 2, each lower flange (20) comprises at least one barb (26) extending upwardly from the lower flange (20) toward the upper flange (22). Each upper flange (22) comprises at least one barb (28) extending downwardly from the upper flange (20) toward the lower flange (20). As shown, the barbs (26, 28) are sized and shaped to substantially fit within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) to the metal lath accessory (10). Each lower and upper flange (20, 22) comprises a plurality of barbs (26, 28) along a length of the flanges (20, 22), as shown in FIGS. 3 and 4. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (10) along the length of the metal lath accessory (10). As shown, adjacent barbs (26) on the lower flange (20) are separated by openings (16) in the lower flange (20). Similarly, in this embodiment, adjacent barbs (28) on the upper flange (22) are separated by openings (16) in the upper flange (22). Of course, any suitable number of barbs (26, 28) can be used to sufficiently secure the metal lath (30) to the metal lath accessory (10). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (26, 28), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIG. 2, each barb (26, 28) comprises a ramped surface (26 a, 28 a) facing the opening of the channel between the lower and upper flanges (20, 22) and a shoulder surface (26 b, 28 b) facing the respective side wall (12). In some embodiments, the shoulder surface (26 b, 28 b) may be substantially perpendicular relative to the respective flange (20, 22) the barb (26, 28) projects from. This may allow the metal lath (30) to slide along the ramped surface (26 a, 28 a) of each barb (26, 28) when the metal lath (30) is inserted within the metal lath accessory (10) such that the metal lath accessory (10) is more easily able to receive the metal lath (30). As shown, after the metal lath (30) has been received within the channel between the lower and upper flanges (20, 22), the shoulder surface (26 b, 28 b) of each of the barbs (26, 28) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (10). In the illustrated embodiment, barbs (26, 28) have a substantially triangular cross-section. In other embodiments, barbs (26, 28) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (20, 22). As shown, the barbs (26) on the lower flange (20) and the barbs (28) on the upper flange (22) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs (26, 28) on the same flange (20, 22) may have different cross-sections.
In the embodiment shown in FIGS. 1-9, each upper flange (22) further comprises an angled portion (24) at the free end of each upper flange (22). Angled portion (24) may be positioned at about a 45 degree angle relative to the upper flange (22), but any other suitable configuration may be used. This may help guide the metal lath (30) into the channel between the lower flange (20) and the upper flange (22) when the metal lath (30) is inserted into the metal lath accessory (10). It should be noted that angled portion (24) of the upper flange (22) is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (10), the upper flange (22) may be sufficiently resilient such that the upper flange (22) flexes slightly upwardly to allow the metal lath (30) to slide between the upper flange (22) and the lower flange (20), past the barbs (26, 28), and adjacent to the side wall (12). Once the metal lath (30) is inserted between the lower and upper flanges (20, 22), the upper flange (22) can flex downwardly to its original position such that at least one of the barbs (26, 28) engages the metal lath (30). Barbs (26, 28) thus hold the metal lath (30) within the metal lath accessory (10) and prevent the metal lath (30) from pulling away from the metal lath accessory (10). Barbs (26, 28) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (20, 22). In some embodiments, barbs (26, 28) may be positioned in corresponding pairs, while in other embodiments barbs (26, 28) may be staggered between the upper flange (22) and the lower flange (20) along the length of the metal latch accessory (10).
Either before or after the metal lath (30) is inserted within the metal lath accessory (10), the lower flange (20) of the metal lath accessory (10) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). The substrate (5) may be any suitable structure, such as a wall comprising any suitable material, such as plywood, cinder blocks, or any other similar material. As shown in FIG. 9, once the metal lath (30) is inserted within the metal lath accessory (10) and metal lath accessory (10) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material, can then be applied over the lower and upper flanges (20, 22) of the metal lath accessory (10) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (20, 22) of the metal lath accessory (10) comprise a plurality of openings (16) that may allow the finishing material to better bond to the metal lath accessory (10), but these openings (16) are merely optional and may be sized, shaped and arranged in any suitable configuration. By way of example only, FIGS. 45-50 depict another embodiment of a metal lath accessory (710) that comprises a control joint that is substantially similar to metal lath accessory (10) shown in FIGS. 1-9, except that metal lath accessory (710) has an alternate hole pattern and configuration and upper flange (722) is wider than upper flange (22). As shown in FIGS. 1-9, openings (16) are substantially circular and vary in size, while openings (716) shown in FIGS. 45-50 include a plurality of circular openings (716 a, 716 c), a plurality of substantially trapezoidal openings (716 b), and a plurality of substantially triangular openings (716 d). In the illustrated embodiment of metal lath accessory (10), the openings (16) located in the upper flange (22) are positioned directly above openings (16) in the lower flange (20) that correspond in size and shape to the openings (16) in the upper flange (22). The embodiment illustrated in FIGS. 1-9 also includes a pair of angled members (25) extending from a respective side wall (12) adjacent to the juncture of each upper flange (22) and the respective side wall (12). The angled members (25) are merely optional and may be arranged at any suitable angle and positioned at any suitable position along the side wall (12) or omitted entirely. Of course, other suitable profiles and configurations for the metal lath accessory (10) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIGS. 10-15 show another embodiment of a metal lath accessory (110) that is configured as a casing bead that comprises a side wall (112) extending upwardly from an end of a lower flange (120). An upper flange (122) extends outwardly from the side wall (112) at a position spaced above the lower flange (120). In the illustrated embodiment, the upper flange (122) is substantially parallel to the lower flange (120). In some embodiments, one or both of the upper flange (122) and the lower flange (120) may extend substantially perpendicularly relative to the side wall (112), while in other embodiments, one or both of the upper flange (122) and the lower flange (120) may extend obliquely relative to the side wall (112). Lower and upper flanges (120, 122) thereby form a channel to receive the metal lath (30) within the metal lath accessory (110). Accordingly, the upper flange (122) may be spaced apart from the lower flange (120) any distance suitable to allow the metal lath accessory (110) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (122) may be spaced apart from the lower flange (120) about 0.230 inches and the tip of the barbs (126, 128) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (122) may extend obliquely relative to the lower flange (120). For example, in some embodiments, the upper flange (122) may extend downwardly toward the lower flange (120) such that the height of the channel defined, at least in part, by the upper flange (122) and the lower flange (120) is larger at the fixed end of the upper flange (122) than the height of the channel at the free end of the upper flange (122). At an upper end of the side wall (112), a lip (114) extends outwardly from the side wall (112) having a first portion that extends substantially parallel to the upper flange (122) and a second portion that extends downward towards the upper flange (122). In some embodiments, one or more of the side wall (112), lip (114), lower flange (120), and upper flange (122) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the side wall (112), lip (114), lower flange (120), and upper flange (122) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the side wall (112), lip (114), lower flange (120), and upper flange (122) may comprise non-integral, separate components that are attached to each other.
The metal lath accessory (110) further comprises a metal lath attachment feature configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (110) are attached to each other. In the illustrated embodiment, the metal lath attachment feature comprises the upper flange (122), the lower flange (120), and at least one barb (126, 128) positioned on each of the upper flange (122) and the lower flange (120). As shown in FIG. 11, the lower flange (120) comprises a barb (126) extending upwardly from the lower flange (120) toward the upper flange (122). The upper flange (122) comprises a barb (128) extending downwardly from the upper flange (120) toward the lower flange (120). As shown, the barbs (126, 128) are sized and shaped to fit substantially within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) with the metal lath accessory (110). Each lower and upper flange (120, 122) comprises a plurality of barbs (126, 128) along a length of the flanges (120, 122), as shown in FIG. 14. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (110) along the length of the metal lath accessory (110). As shown, adjacent barbs (126) on the lower flange (120) are separated by openings (116) in the lower flange (120). Similarly, in this embodiment, adjacent barbs (128) on the upper flange (122) are separated by openings (116) in the upper flange (122). Of course, any suitable number of barbs (126, 128) can be used to sufficiently secure the metal lath (30) to the metal lath accessory (110). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (126, 128), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIG. 11, each barb (126, 128) comprises a ramped surface (126 a, 128 a) facing the opening of the channel between lower and upper flanges (120, 122) and a shoulder surface (126 b, 128 b) facing the respective side wall (112). In some embodiments, the shoulder surface (126 b, 128 b) may be substantially perpendicular relative to the respective flange (120, 122) the barb (126, 128) projects from. This may allow the metal lath (30) to slide along the ramped surface of each barb (126, 128) when the metal lath (30) is inserted within the metal lath accessory (110) such that the metal lath accessory (110) is more easily able to receive the metal lath (30). After the metal lath (30) has been received within the channel between the lower and upper flanges (120, 122), the shoulder surface (126 b, 128 b) of each of the barbs (126, 128) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (110). In the illustrated embodiment, barbs (126, 128) have a substantially triangular cross-section. In other embodiments, barbs (126, 128) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (120, 122). As shown, the barbs (126) on the lower flange (120) and the barbs (128) on the upper flange (122) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs on the same flange may have different cross-sections.
Similar to the angled portion (24) described above, in some embodiments, the upper flange (122) may comprise an angled portion at the free end of the upper flange (122). This may help guide the metal lath (30) into the channel between the lower flange (120) and the upper flange (122) when the metal lath (30) is inserted within the metal lath accessory (110). Of course, any such angled portion is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (110), the upper flange (122) may be sufficiently resilient such that the upper flange (122) flexes upwardly to allow the metal lath (30) to slide between the upper flange (122) and the lower flange (120), past the barbs (126, 128), and adjacent to the side wall (112). Once the metal lath (30) is inserted between the lower and upper flanges (120, 122), the upper flange (122) can flex downwardly to its original position such that at least one of the barbs (126, 128) engages the metal lath (30). Barbs (126, 128) thus hold the metal lath (30) within the metal lath accessory (110) and prevent the metal lath (30) from pulling away from the metal lath accessory (110). Barbs (126, 128) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (120, 122). In some embodiments, barbs (126, 128) may be positioned in corresponding pairs, while in other embodiments barbs (126,128) may be staggered between the upper flange (122) and the lower flange (120) along the length of the metal latch accessory (110).
Either before or after the metal lath (30) is inserted within the metal lath accessory (110), the lower flange (120) of the metal lath accessory (110) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). Once the metal lath (30) is inserted within the metal lath accessory (110) and metal lath accessory (110) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material, can then be applied over the lower and upper flanges (120, 122) of the metal lath accessory (110) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (120, 122) of the metal lath accessory (110) comprise a plurality of openings (116) that may allow the finishing material to better bond to the metal lath accessory (110), but these openings (116) are merely optional and may be sized, shaped and arranged in any suitable configuration. As shown, the openings (116) located in the upper flange (122) are positioned directly above openings (116) in the lower flange (120) that correspond in size and shape to the openings (116) in the upper flange (122). Of course, other suitable profiles and configurations for the metal lath accessory (110) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIGS. 16-21 show another embodiment of a metal lath accessory (210) that is configured as a casing bead similar to the metal lath accessory (110), except that the metal lath accessory (210) comprises a second side wall (218) that is spaced away from the first side wall (212) along the width of the lower flange (220). As shown, the first side wall (212) extends upwardly from an end of the lower flange (220), and the second side wall (218) is positioned to extend upwardly from an intermediate portion of the lower flange (220). The upper flange (222) extends outwardly from an upper end of the second side wall (218) such that the upper flange (222) is spaced apart from and above the lower flange (220). In the illustrated embodiment, the upper flange (222) is substantially parallel to the lower flange (220). In some embodiments, one or both of the upper flange (222) and the lower flange (220) may extend substantially perpendicularly relative to the second side wall (218), while in other embodiments, one or both of the upper flange (222) and the lower flange (220) may extend obliquely relative to the second side wall (218). Lower and upper flanges (220, 222) thereby form a channel to receive the metal lath (30) within the metal lath accessory (210). Accordingly, the upper flange (222) may be spaced apart from the lower flange (220) any distance suitable to allow the metal lath accessory (210) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (222) may be spaced apart from the lower flange 2(20) about 0.230 inches and the tip of the barbs (226, 228) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (222) may extend obliquely relative to the lower flange (220). For example, in some embodiments, the upper flange (222) may extend downwardly toward the lower flange (220) such that the height of the channel defined, at least in part, by the upper flange (222) and the lower flange (220) is larger at the fixed end of the upper flange (222) than the height of the channel at the free end of the upper flange (222). At an upper end of the first side wall (212), a lip (214) extends outwardly from the side wall (212) having a first portion that extends substantially parallel to the lower flange (220) and a second portion that extends downward towards the lower flange (220). In some embodiments, one or more of the first side wall (212), second side wall (218), lip (214), lower flange (220), and upper flange (222) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the first side wall (212), second side wall (218), lip (214), lower flange (220), and upper flange (222) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the first side wall (212), second side wall (218), lip (214), lower flange (220), and upper flange (222) may comprise non-integral, separate components that are attached to each other.
The metal lath accessory (210) further comprises a metal lath attachment feature configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (210) are attached to each other. In the illustrated embodiment, the metal lath attachment feature comprises the upper flange (222), the lower flange (220), and at least one barb (226, 228) positioned on each of the upper flange (222) and the lower flange (220). As shown in FIG. 17, the lower flange (220) comprises at least one barb (226) extending upwardly from the lower flange (220) toward the upper flange (222). The upper flange (222) comprises at least one barb (228) extending downwardly from the upper flange (220) toward the lower flange (220). As shown, the barbs (226, 228) are sized and shaped to substantially fit within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) to the metal lath accessory (210). The lower and upper flanges (220, 222) comprise a plurality of barbs (226, 228) along a length of the flanges (220, 222), as shown in FIG. 20. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (210) along the length of the metal lath accessory (210). As shown, adjacent barbs (226) on the lower flange (220) are separated by openings (216) in the lower flange (220). Similarly, in this embodiment, adjacent barbs (228) on the upper flange (222) are separated by openings (216) in the upper flange (222). Of course, any suitable number of barbs (226, 228) can be used to sufficiently secure the metal lath (30) with the metal lath accessory (210). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (226, 228), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIG. 17, each barb (226, 228) comprises a ramped surface (226 a, 228 a) facing the opening of the channel between lower and upper flanges (220, 222) and a shoulder surface (226 b, 228 b) facing the second side wall (218). In some embodiments, the shoulder surface (226 b, 228 b) may be substantially perpendicular relative to the respective flange (220, 222) the barb (226, 228) projects from. This may allow the metal lath (30) to slide along the ramped surface (226 a, 228 a) of each barb (226, 228) when the metal lath (30) is inserted within the metal lath accessory (210) such that the metal lath accessory (210) is more easily able to receive the metal lath (30). After the metal lath (30) has been received within the channel between the lower and upper flanges (220, 222), the shoulder surface (226 b, 228 b) of each of the barbs (226, 228) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (210). In the illustrated embodiment, barbs (226, 228) have a substantially triangular cross-section. In other embodiments, barbs (226, 228) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (220, 222). As shown, the barbs (226) on the lower flange (220) and the barbs (228) on the upper flange (222) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs on the same flange may have different cross-sections.
In the illustrated embodiment, the upper flange (222) further comprises an angled portion (224) at the free end of the upper flange (222). Angled portion (224) may be positioned at about a 45 degree angle relative to the upper flange (222), but any other suitable configuration may be used. This may help guide the metal lath (30) into the channel between the lower flange (220) and the upper flange (222) when the metal lath (30) is inserted into the metal lath accessory (210). It should be noted that angled portion (224) of the upper flange (222) is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (210), the upper flange (222) may be sufficiently resilient such that the upper flange (222) flexes slightly upwardly to allow the metal lath (30) to slide between the upper flange (222) and the lower flange (220), past the barbs (226, 228), and adjacent to the side wall (218). Once the metal lath (30) is inserted between the lower and upper flanges (220, 222), the upper flange (222) can flex downwardly to its original position such that at least one of the barbs (226, 228) engages the metal lath (30). Barbs (226, 228) thus hold the metal lath (30) within the metal lath accessory (210) and prevent the metal lath (30) from pulling away from the metal lath accessory (210). Barbs (226, 228) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (220, 222). In some embodiments, barbs (226, 228) may be positioned in corresponding pairs, while in other embodiments barbs (226, 228) may be staggered between the upper flange (222) and the lower flange (220) along the length of the metal latch accessory (210).
Either before or after the metal lath (30) is inserted within the metal lath accessory (210), the lower flange (220) of the metal lath accessory (210) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). The substrate (5) may be any suitable structure, such as a wall comprising any suitable material, such as plywood, cinder blocks, or any other similar material. Once the metal lath (30) is inserted within the metal lath accessory (210) and metal lath accessory (210) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material can then be applied over the lower and upper flanges (220, 222) of the metal lath accessory (210) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (220, 222) of the metal lath accessory (210) comprise a plurality of openings (216) that may allow the finishing material to better bond to the metal lath accessory (210), but these openings (216) are merely optional and may be sized, shaped and arranged in any suitable configuration. As shown, the openings (216) located in the upper flange (222) are positioned directly above openings (216) in the lower flange (220) that correspond in size and shape to the openings (216) in the upper flange (222). Of course, other suitable configurations for the metal lath accessory (210) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIGS. 22-27 show another embodiment of a metal lath accessory (310) that can be used to attach metal lath to a substrate. In the illustrated embodiment, the metal lath accessory (310) comprises a connector having a central portion (314) positioned between a pair of side walls (312). As shown in FIG. 23, the central portion (314) comprises a recess to form a U-shape in combination with the side walls (312), but other suitable shapes for central portion (314) can be used. In the illustrated embodiment, the metal lath accessory (310) comprises a lower flange (320) extending outwardly from a bottom portion of each side wall (312). The metal lath accessory (310) further comprises an upper flange (322) extending outwardly from each side wall (312) at a position above the lower flange (320). As shown, the upper flanges (322) each extend from an upper end of a respective side wall (312), although in other embodiments, the side walls (312) may extend above the respective upper flange (322). In the illustrated embodiment, each upper flange (322) is substantially parallel to the corresponding lower flange (320). In some embodiments, one or both of the upper flange (322) and the lower flange (320) may extend substantially perpendicularly relative to the respective side wall (312), while in other embodiments, one or both of the upper flange (322) and the lower flange (320) may extend obliquely relative to the respective side wall (312). Lower and upper flanges (320, 322) thereby form a channel to receive the metal lath (30) within the metal lath accessory (310). Accordingly, the upper flange (322) may be spaced apart from the lower flange (320) any distance suitable to allow the metal lath accessory (310) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (322) may be spaced apart from the lower flange (320) about 0.230 inches and the tip of the barbs (326, 328) may be spaced apart from each other about 0.140 inches. In some embodiments, one or both of the upper flanges (322) may extend obliquely relative to a corresponding lower flange (320). For example, in some embodiments, one or both of the upper flanges (322) may extend downwardly toward a corresponding lower flange (320) such that the height of the channel defined, at least in part, by the upper flange (322) and the lower flange (320) is larger at the fixed end of the upper flange (322) than the height of the channel at the free end of the upper flange (322). In some embodiments, one or more of the side walls (312), central portion (314), lower flanges (320) and upper flanges (322) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the side walls (312), central portion (314), lower flanges (320) and upper flanges (322) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of side walls (312), central portion (314), lower flanges (320) and upper flanges (322) may comprise non-integral, separate components that are attached to each other.
The metal lath accessory (310) further comprises a pair of metal lath attachment features configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (310) are attached to each other. In the illustrated embodiment, each metal lath attachment feature comprises an upper flange (322), a corresponding lower flange (320), and at least one barb (326, 328) positioned on each of the upper flange (322) and the lower flange (320). As shown in FIG. 23, each lower flange (320) comprises at least one barb (326) extending upwardly from the lower flange (320) toward the upper flange (322). Each upper flange (322) comprises at least one barb (328) extending downwardly from the upper flange (320) toward the lower flange (320). As shown, the barbs (326, 328) are sized and shaped to substantially fit within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) to the metal lath accessory (310). Each lower and upper flange (320, 322) comprises a plurality of barbs (326, 328) along a length of the flanges (320, 322), as shown in FIGS. 26 and 27. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (310) along the length of the metal lath accessory (10). As shown, adjacent barbs (326) on the lower flange 3(20) are separated by openings (316) in the lower flange (320). Similarly, in this embodiment, adjacent barbs (328) on the upper flange (322) are separated by openings (16) in the upper flange (322). Of course, any suitable number of barbs (326, 328) can be used to sufficiently secure the metal lath (30) to the metal lath accessory (310). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (326, 328), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIG. 23, each barb (326, 328) comprises a ramped surface (326 a, 328 a) facing the opening of the channel between lower and upper flanges (320, 322) and a shoulder surface (326 b, 328 b) facing the respective side wall (312). In some embodiments, the shoulder surface (326 b, 328 b) may be substantially perpendicular relative to the respective flange (320, 322) the barb (326, 328) projects from. This may allow the metal lath (30) to slide along the ramped surface (326 a, 328 a) of each barb (326, 328) when the metal lath (30) is inserted within the metal lath accessory (310) such that the metal lath accessory (310) is more easily able to receive the metal lath (30). After the metal lath (30) has been received within the channel between the lower and upper flanges (320, 322), the shoulder surface (326 b, 328 b) of each of the barbs (326, 328) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (310). In the illustrated embodiment, barbs (326, 328) have a substantially triangular cross-section. In other embodiments, barbs (326, 328) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (320, 322).
As shown, the barbs (326) on the lower flange (320) and the barbs (328) on the upper flange (322) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs on the same flange may have different cross-sections.
In the illustrated embodiment, each upper flange (322) further comprises an angled portion (324) at the free end of each upper flange (322). Angled portion (324) may be positioned at about a 45 degree angle relative to the upper flange (322), but any other suitable configuration may be used. This may help guide the metal lath (30) into the channel between the lower flange (320) and the upper flange (322) when the metal lath (30) is inserted into the metal lath accessory (310). It should be noted that angled portion (324) of the upper flange (322) is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (310), the upper flange (322) may be sufficiently resilient such that the upper flange (322) flexes slightly upwardly to allow the metal lath (30) to slide between the upper flange (322) and the lower flange (320), past the barbs (326, 328), and adjacent to the side wall (312). Once the metal lath (30) is inserted between the lower and upper flanges (320, 322), the upper flange (322) can flex downwardly to its original position such that at least one of the barbs (326, 328) engages the metal lath (30). Barbs (326, 328) thus hold the metal lath (30) within the metal lath accessory (310) and prevent the metal lath (30) from pulling away from the metal lath accessory (310). Barbs (326, 328) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (320, 322). In some embodiments, barbs (326, 328) may be positioned in corresponding pairs, while in other embodiments barbs (326, 328) may be staggered between the upper flange (322) and the lower flange (320) along the length of the metal latch accessory (310).
Either before or after the metal lath (30) is inserted within the metal lath accessory (310), the lower flange (320) of the metal lath accessory (310) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). The substrate (5) may be any suitable structure, such as a wall comprising any suitable material, such as plywood, cinder blocks, or any other similar material. Once the metal lath (30) is inserted within the metal lath accessory (310) and metal lath accessory (310) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material can then be applied over the lower and upper flanges (320, 322) of the metal lath accessory (310) and the metal lath (30). By inserting a piece of metal lath (30) between each pair of upper and lower flanges (320, 322) of the metal lath accessory (310), two pieces of metal lath (30) can be positioned adjacent to each other without overlapping. Typically, when two pieces of metal lath (30) are positioned adjacent to each other, the pieces of metal lath (30) are positioned to overlap, which can cause an uneven application of the finishing material. However, the metal lath accessory (310) allows two pieces of metal lath (30) to be positioned adjacent to each other without overlapping to prevent uneven application of the finishing material.
In the illustrated embodiment, the lower and upper flanges (320, 322) of the metal lath accessory (310) comprise a plurality of openings (316) that may allow the stucco to better bond to the metal lath accessory (310), but these openings (316) are merely optional and may be sized, shaped and arranged in any suitable configuration. As shown, the openings (316) located in the upper flange (322) are positioned directly above openings (316) in the lower flange (320) that correspond in size and shape to the openings (316) in the upper flange (322). Of course, other suitable profiles and configurations for the metal lath accessory (310) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIGS. 28-35 show another embodiment of a metal lath accessory (410) that is configured as a casing bead that comprises a side wall (412) extending upwardly from an end of a lower flange (420), a backing strip (418) attached to a rear surface of the side wall (412), and a removable leg (430) that is removably attached to the rear surface of the side wall (412). An upper flange (422) extends outwardly from the side wall (412) at a position spaced above the lower flange (420). In the illustrated embodiment, the upper flange (422) is substantially parallel to the lower flange (420). In some embodiments, one or both of the upper flange (422) and the lower flange (420) may extend substantially perpendicularly relative to the side wall (412), while in other embodiments, one or both of the upper flange (422) and the lower flange (420) may extend obliquely relative to the side wall (412). Lower and upper flanges (420, 422) thereby form a channel to receive the metal lath (30) within the metal lath accessory (410). Accordingly, the upper flange (422) may be spaced apart from the lower flange (420) any distance suitable to allow the metal lath accessory (410) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (422) may be spaced apart from the lower flange (420) about 0.230 inches and the tip of the barbs (426, 428) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (422) may extend obliquely relative to the lower flange (420). For example, in some embodiments, the upper flange (422) may extend downwardly toward the lower flange (420) such that the height of the channel defined, at least in part, by the upper flange (422) and the lower flange (420) is larger at the fixed end of the upper flange (422) than the height of the channel at the free end of the upper flange (422). At an upper end of the side wall (412), a lip (414) extends outwardly from the side wall (412) having a first portion that extends substantially parallel to the upper flange (422) and a second portion that extends downward towards the upper flange (422).
In some embodiments, one or more of the lower flange (420), upper flange (422), side wall (412), lip (414), and removable leg (430) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the lower flange (420), upper flange (422), side wall (412), lip (414), and removable leg (430) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the lower flange (420), upper flange (422), side wall (412), lip (414), and removable leg (430) may comprise non-integral, separate components that are attached to each other. Metal lath accessory (410) is configured to be installed on a wall structure adjacent to a window frame or door jamb. In some applications, metal lath accessory (410) can be installed such that the outer surface of backing strip (418) abuts or engages the edge of the window frame or door jamb. Metal lath accessory (410) can be installed by mounting metal lath accessory (410) onto a wall structure that includes a backing wall, such as plywood or other similar material. It will be appreciated that other materials, such as felt, galvanized wire or lathe may also be attached to the backing wall (and possibly between metal lath accessory (410) and the backing wall in some applications). One or more coats (e.g., a scratch coat and a finishing coat) of a finishing material, such as stucco, plaster or other similar material, may then be applied to the wall structure. Side wall (412) and lip (414) of metal lath accessory (410) are configured to substantially contain the finishing material and prevent the finishing material from contacting the window frame or door jamb.
In the illustrated embodiment, removable leg (430) is removably attached to side wall (412). As shown, removable leg (430) is positioned adjacent to the upper end of side wall (412) near the junction between side wall (412) and lip (414). In other embodiments, the removable leg (430) may be positioned in another location along the side wall (412) suitable to prevent finishing material from contacting the backing strip (418). Removable leg (430) may be integrally attached to side wall (412).
The junction between removable leg (430) and side wall (412) may comprise a thin or weakened section of material configured to allow a user to separate removable leg (430) by grasping removable leg (430) and applying force to removable leg (430) in a direction away from side wall (412) (e.g., an upward force, a downward force, an outward force, or an angled force generally away from side wall (412)). FIGS. 28-29 depict removable leg (430) fully attached to side wall (412), while FIGS. 30-35 depict removable leg (430) in the process of being removed or separated from side wall (412). In some embodiments, removable leg (430) may include one or more openings or perforations along the junction between removable leg (430) and side wall (412) to facilitate removal of removable leg (430), although this is not required. The user may use his or her hand to separate removable leg (430) from side wall (412) or the user may use a tool, such as a pair of pliers or other similar gripping device, to grasp removable leg (430) and apply the necessary force. Other methods for separating removable leg (430) from side wall (412), including but not limited to slicing removable leg (430) at its junction with side wall (412) with a pocket knife or other sharp object, may also be used.
As shown, removable leg (430) comprises a t-shaped cross-section. Specifically, in this embodiment removable leg (430) includes a base member (432) that extends substantially perpendicular from side wall (412) and a gripping member (434) that extends substantially perpendicular from base member (432). Gripping member (434) is configured to facilitate the gripping of removable leg (430) by a user, which may subsequently facilitate separation of removable leg (430) from side wall (412). In other embodiments, removable leg (430) may comprise other cross-sections, including but not limited to round, rectangular, or square cross-sections, configured to facilitate the gripping of removable leg (430) by a user, and in some embodiments, gripping member (434) may be omitted entirely. In still other embodiments, the entire removable leg (430) may be omitted entirely.
The illustrated embodiment of metal lath accessory (410) includes backing strip (418), which is a separate component attached to side wall (412). Backing strip (418) may be attached to side wall (412) using an adhesive or any other conventional fasteners or attachment methods. In some alternate embodiments, backing strip (418) may be integral with side wall (412) instead of being a separate component that is attached to side wall (412). Backing strip (418) is configured to abut a window frame or door jamb once metal lath accessory (410) is installed on the desired wall structure. Once removable leg (430) is removed or separated from side wall (412), then a user may apply a bead of caulk or other similar sealant or material in the gap created by side wall (412), backing strip (418) and the adjacent window frame or door jamb to substantially seal the joint between metal lath accessory (410) and the window frame or door jamb. Backing strip (418) may comprise a resilient or compressible material, including but not limited to closed cell foam. In some embodiments, backing strip (418) may comprise a material substantially similar to the material used for conventional backer rod. In some embodiments, backing strip (418) may comprise a material that does not bond very well, if at all, with conventional caulk and other sealants. As a result, in these embodiments, the caulk or other sealants may have a stronger bond with side wall (412) of metal lath accessory (410) and the outer surface of the adjacent window frame or door jamb. In some embodiments, the backing strip (418) may be omitted entirely and a backer rod or other similar material may be inserted between the metal lath accessory (410) and the adjacent window frame or doorjamb.
The metal lath accessory (410) further comprises a metal lath attachment feature configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (410) are attached to each other. In the illustrated embodiment, the metal lath attachment feature comprises the upper flange (422), the lower flange (420), and at least one barb (426, 428) positioned on each of the upper flange (422) and the lower flange (420). As shown in FIG. 31, the lower flange (420) comprises a barb (426) extending upwardly from the lower flange (420) toward the upper flange (422). The upper flange (422) comprises a barb (428) extending downwardly from the upper flange (420) toward the lower flange (420). As shown, the barbs (426, 428) are sized and shaped to fit substantially within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) with the metal lath accessory (410). Each lower and upper flange (420, 422) comprises a plurality of barbs (426, 428) along a length of the flanges (420, 422), as shown in FIG. 34. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (410) along the length of the metal lath accessory (410). As shown, adjacent barbs (426) on the lower flange (420) are separated by openings (416) in the lower flange (420). Similarly, in this embodiment, adjacent barbs (428) on the upper flange (422) are separated by openings (416) in the upper flange (422). Of course, any suitable number of barbs (426, 428) can be used to sufficiently secure the metal lath (30) to the metal lath accessory (410). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (426, 428), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIGS. 29 and 31, each barb (426, 428) comprises a ramped surface (426 a, 428 a) facing the opening of the channel between lower and upper flanges (420, 422) and a shoulder surface (426 b, 428 b) facing the side wall (412). In some embodiments, the shoulder surface (426 b, 428 b) may be substantially perpendicular relative to the respective flange (420, 422) the barb (426, 428) projects from. This may allow the metal lath (30) to slide along the ramped surface of each barb (426, 428) when the metal lath (30) is inserted within the metal lath accessory (410) such that the metal lath accessory (410) is more easily able to receive the metal lath (30). After the metal lath (30) has been received within the channel between the lower and upper flanges (420, 422), the shoulder surface (426 b, 428 b) of each of the barbs (426, 428) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (410). In the illustrated embodiment, barbs (426, 428) have a substantially triangular cross-section. In other embodiments, barbs (426, 428) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (420, 422). As shown, the barbs (426) on the lower flange (420) and the barbs (428) on the upper flange (422) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs on the same flange may have different cross-sections.
Similar to the angled portion (24) described above, in some embodiments, the upper flange (422) may comprise an angled portion at the free end of the upper flange (422). This may help guide the metal lath (30) into the channel between the lower flange (420) and the upper flange (422) when the metal lath (30) is inserted within the metal lath accessory (410). Of course, any such angled portion is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (410), the upper flange (422) may be sufficiently resilient such that the upper flange (422) flexes upwardly to allow the metal lath (30) to slide between the upper flange (422) and the lower flange (420), past the barbs (426, 428), and adjacent to the side wall (412). Once the metal lath (30) is inserted between the lower and upper flanges (420, 122), the upper flange (422) can flex downwardly to its original position such that at least one of the barbs (426, 428) engages the metal lath (30). Barbs (426, 428) thus hold the metal lath (30) within the metal lath accessory (410) and prevent the metal lath (30) from pulling away from the metal lath accessory (410). Barbs (426, 428) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (420, 122). In some embodiments, barbs (426, 428) may be positioned in corresponding pairs, while in other embodiments barbs (426,428) may be staggered between the upper flange (422) and the lower flange (420) along the length of the metal latch accessory (410).
Either before or after the metal lath (30) is inserted within the metal lath accessory (410), the lower flange (420) of the metal lath accessory (410) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). The substrate (5) may be any suitable structure, such as a wall comprising any suitable material, such as plywood, cinder blocks, or any other similar material. Once the metal lath (30) is inserted within the metal lath accessory (410) and metal lath accessory (410) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material can then be applied over the lower and upper flanges (420, 422) of the metal lath accessory (410) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (420, 422) of the metal lath accessory (410) comprise a plurality of openings (416) that may allow the stucco to better bond to the metal lath accessory (410), but these openings (416) are merely optional and may be sized, shaped and arranged in any suitable configuration. As shown, the openings (416) located in the upper flange (422) are positioned directly above openings (416) in the lower flange (420) that correspond in size and shape to the openings (416) in the upper flange (422). Of course, other suitable profiles and configurations for the metal lath accessory (410) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIGS. 36-44 show an embodiment of a lath clip (510) that is configured to be used in conjunction with a typical solid flange metal lath accessory. A typical solid flange metal lath accessory may comprise a typical metal lath accessory that comprises a lower flange that is substantially solid (i.e., substantially unperforated or substantially free of any openings), including but not limited to a weep screed, an expansion joint, a casing bead, a corner bead, or a control joint, such as the mid-wall control joint (610) shown in FIGS. 36 and 38-44 and described below. The lath clip (510) can be combined with a typical solid flange metal lath accessory to provide a resulting metal lath accessory (505) that includes a metal lath attachment feature. As shown, the lath clip (510) comprises a side wall (512) extending upwardly from a lower flange (520). An upper flange (522) extends outwardly from the side wall (512) at a position spaced above the lower flange (520). In this embodiment, the upper flange (522) extends from an upper end of the side wall (512), although in other embodiments, the upper flange (522) may extend from side wall (512) at an intermediate position below the upper end of the side wall (512). In the illustrated embodiment, the upper flange (522) is substantially parallel to the lower flange (520). In some embodiments, one or both of the upper flange (522) and the lower flange (520) may extend substantially perpendicularly relative to the side wall (512), while in other embodiments, one or both of the upper flange (522) and the lower flange (520) may extend obliquely relative to the side wall (512). Lower and upper flanges (520, 522) thereby form a channel to receive the metal lath (30) within the lath clip (510). Accordingly, the upper flange (522) may be spaced apart from the lower flange (520) any distance suitable to allow the lath clip (510) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (522) may be spaced apart from the lower flange (520) about 0.230 inches and the tip of the barbs (526, 528) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (522) may extend obliquely relative to the lower flange (520). For example, in some embodiments, the upper flange (522) may extend downwardly toward the lower flange (520) such that the height of the channel defined, at least in part, by the upper flange (522) and the lower flange (520) is larger at the fixed end of the upper flange (522) than the height of the channel at the free end of the upper flange (522). In some embodiments, one or more of the side wall (512), lower flange (520), and upper flange (522) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the side wall (512), lower flange (520), and upper flange (522) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the side wall (512), lower flange (520), and upper flange (522) may comprise non-integral, separate components that are attached to each other.
The lath clip (510) further comprises a metal lath attachment feature configured to receive and engage the metal lath (30) so that the metal lath (30) and the lath clip (510) (and the metal lath (30) and the combined lath clip (510) and associated metal lath accessory (610)) are attached to each other. In the illustrated embodiment, the metal lath attachment feature comprises the upper flange (522), the lower flange (520), and at least one barb (526, 528) positioned on each of the upper flange (522) and the lower flange (520). As shown in FIGS. 37 and 42, the lower flange (520) comprises a barb (526) extending upwardly from the lower flange (520) toward the upper flange (522). The upper flange (522) comprises a barb (528) extending downwardly from the upper flange (520) toward the lower flange (520). As shown, the barbs (526, 528) are sized and shaped to fit substantially within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) with the lath clip (510). Each lower and upper flange (520, 522) comprises a plurality of barbs (526, 528) along a length of the flanges (520, 522), as shown in FIGS. 40 and 44. This can provide a plurality of attachment points between the metal lath (30) and the lath clip (510) along the length of the lath clip (510). As shown, adjacent barbs (526) on the lower flange (520) are separated by openings (516) in the lower flange (520). Similarly, in this embodiment, adjacent barbs (528) on the upper flange (522) are separated by openings (516) in the upper flange (522). Of course, any suitable number of barbs (526, 528) can be used to sufficiently secure the metal lath (30) to the lath clip (510). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (526, 528), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIGS. 37 and 42, each barb (526, 528) comprises a ramped surface (526 a, 528 a) facing the opening of the channel between lower and upper flanges (520, 522) and a shoulder surface (526 b, 528 b) facing the side wall (512). In some embodiments, the shoulder surface (526 b, 528 b) may be substantially perpendicular relative to the respective flange (520, 522) the barb (526, 528) projects from. This may allow the metal lath (30) to slide along the ramped surface of each barb (526, 528) when the metal lath (30) is inserted within the lath clip (510) such that the lath clip (510) is more easily able to receive the metal lath (30). After the metal lath (30) has been received within the channel between the lower and upper flanges (520, 522), the shoulder surface (526 b, 528 b) of each of the barbs (526, 528) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (510). In the illustrated embodiment, barbs (526, 528) have a substantially triangular cross-section. In other embodiments, barbs (526, 528) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (520, 522). As shown, the barbs (526) on the lower flange (520) and the barbs (528) on the upper flange (522) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs on the same flange may have different cross-sections.
Similar to the angled portion (24) described above, in some embodiments, the upper flange (522) may comprise an angled portion at the free end of the upper flange (522). This may help guide the metal lath (30) into the channel between the lower flange (520) and the upper flange (522) when the metal lath (30) is inserted within the lath clip (510). Of course, any such angled portion is merely optional.
When the metal lath (30) is inserted within the lath clip (510), the upper flange (522) may be sufficiently resilient such that the upper flange (522) flexes upwardly to allow the metal lath (30) to slide between the upper flange (522) and the lower flange (520), past the barbs (526, 528), and adjacent to the side wall (512). Once the metal lath (30) is inserted between the lower and upper flanges (520, 522), the upper flange (522) can flex downwardly to its original position such that at least one of the barbs (526, 528) engages the metal lath (30). Barbs (526, 528) thus hold the metal lath (30) within the lath clip (510) and prevent the metal lath (30) from pulling away from the lath clip (510). Barbs (526, 528) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (520, 522). In some embodiments, barbs (526, 528) may be positioned in corresponding pairs, while in other embodiments barbs (526,528) may be staggered between the upper flange (522) and the lower flange (520) along the length of the metal latch accessory (510).
In some embodiments, it may be desirable to couple the lath clip (510) with a typical solid flange metal lath accessory (610). In the illustrated embodiment, the solid flange metal lath accessory (610) is shown as a mid-wall control joint that comprises a first flange (620) and a second flange (618) joined by a V-shaped joint that is formed by sidewalls (612, 614) and a top portion (616). The lath clip (510) can be coupled with the solid flange metal lath accessory (610) by joining a top surface of the first flange (620) of the solid flange metal lath accessory (610) to a bottom surface of the lower flange (520) of the lath clip (510). Alternatively, or additionally, the lath clip (510) can be coupled with the solid flange metal lath accessory (610) at other areas of the lath clip (510) and/or solid flange metal lath accessory (610). The lath clip (510) and solid flange metal lath accessory (610) can be joined together by ultrasonic welding, welding, fasteners, adhesives, etc. The lath clip (510) may comprise one or more substantially solid or substantially unperforated portions that can serve as weld points and/or used for fasteners or adhesives to couple the lath clip (510) and the solid flange metal lath accessory (610). Once the lath clip (510) is coupled to the solid flange metal lath accessory (610), then the solid flange metal lath accessory (610) can be secured to a substrate using standard fasteners and/or fastening methods well known within the art. In other embodiments, the solid flange metal lath accessory (610) may be secured to a substrate before the lath clip (510) is coupled to the solid flange metal lath accessory (610).
For instance, either before or after the metal lath (30) is inserted within the lath clip (510), the flange (620) of the solid flange metal lath accessory (610) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). The substrate (5) may be any suitable structure, such as a wall comprising any suitable material, such as plywood, cinder blocks, or any other similar material. Once the metal lath (30) is inserted within the metal lath accessory (510) and metal lath accessory (510) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material can then be applied over the lower and upper flanges (520, 522) of the metal lath accessory (510) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (520, 522) of the lath clip (510) comprise a plurality of openings (516) that may allow the stucco to better bond to the lath clip (510), but these openings (516) are merely optional and may be sized, shaped and arranged in any suitable configuration. As shown, the openings (516) located in the upper flange (522) are positioned directly above openings (516) in the lower flange (520) that correspond in size and shape to the openings (516) in the upper flange (522). Of course, other suitable profiles and configurations for the lath clip (510) will be apparent to one of ordinary skill in the art in view of the teachings herein.
While the illustrated embodiment shows the solid flange metal lath accessory (610) as a mid-wall control joint, other suitable types of accessories can be used, such as weep screeds, control joints, expansion joints, casing beads, corner beads, etc. Accordingly, by coupling the lath clip (510) to the solid flange metal lath accessory (610), any type of accessory can be assembled with a piece of metal lath such that the need for additional components to attach the metal lath to the accessory, such as metal ties or other fasteners, may be eliminated. The lath clip (510) can be manufactured as a separate component configured to be joined with the solid flange metal lath accessory (610), as described above, or the lath clip (510) and the solid flange metal lath accessory (610) can be manufactured together as a unitary component. Other suitable configurations for the lath clip (510) and/or the solid flange metal lath accessory (610) will be apparent to one with ordinary skill in the art in view of the teachings herein.
FIGS. 45-50 show another embodiment of a metal lath accessory (710) that is configured as a control joint and is substantially similar to the metal lath accessory (10), except that metal lath accessory (710) has an alternate hole pattern and configuration and upper flange (722) is wider than upper flange (22). As shown, metal lath accessory (710) comprises a central portion (714) positioned between a pair of side walls (12). As shown in FIG. 46, the central portion (714) comprises a recess to form a V-shape, but other suitable shapes for central portion (714) can be used.
As shown in FIGS. 45-50, the metal lath accessory (710) comprises a lower flange (720) extending outwardly from a bottom portion of each side wall (712). The metal lath accessory (710) further comprises an upper flange (722) extending outwardly from each side wall (712) at a position above the lower flange (720). In some embodiments, one or more of the central portion (714), side walls (712), lower flanges (720), and upper flanges (722) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the central portion (714), side walls (712), lower flanges (720), and upper flanges (722) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the central portion (714), side walls (712), lower flanges (720), and upper flanges (722) may comprise non-integral, separate components that are attached to each other. In the illustrated embodiment, each upper flange (722) is substantially parallel to the corresponding lower flange (720). In some embodiments, one or both of the upper flange (722) and the lower flange (720) may extend substantially perpendicularly relative to the respective side wall (712), while in other embodiments, one or both of the upper flange (722) and the lower flange (720) may extend obliquely relative to the respective side wall (712). Lower and upper flanges (720, 722) thereby form a channel to receive the metal lath (30) within the metal lath accessory (710). Accordingly, the upper flange (722) may be spaced apart from the lower flange (720) any distance suitable to allow the metal lath accessory (710) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (722) may be spaced apart from the lower flange (720) about 0.230 inches and the tip of the barbs (726, 728) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (722) may extend obliquely relative to the lower flange (720). For example, in some embodiments, the upper flange (722) may extend downwardly toward the lower flange (720) such that the height of the channel defined, at least in part, by the upper flange (722) and the lower flange (720) is larger at the fixed end of the upper flange (722) than the height of the channel at the free end of the upper flange (722).
The metal lath accessory (710) further comprises a pair of metal lath attachment features configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (710) are attached to each other. In the illustrated embodiment, each metal lath attachment feature comprises an upper flange (722), a corresponding lower flange (720), and at least one barb (726, 728) positioned on each of the upper flange (722) and the lower flange (720). As shown in FIG. 46, each lower flange (720) comprises at least one barb (726) extending upwardly from the lower flange (720) toward the upper flange (722). Each upper flange (722) comprises at least one barb (728) extending downwardly from the upper flange (720) toward the lower flange (720). As shown, the barbs (726, 728) are sized and shaped to substantially fit within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) to the metal lath accessory (710). Each lower and upper flange (720, 722) comprises a plurality of barbs (726, 728) along a length of the flanges (720, 722), as shown in FIGS. 47 and 48. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (710) along the length of the metal lath accessory (710). As shown, adjacent barbs (726) on the lower flange (720) are separated by openings (716) in the lower flange (720). Similarly, in this embodiment, adjacent barbs (728) on the upper flange (722) are separated by openings (716) in the upper flange (722). Of course, any suitable number of barbs (726, 728) can be used to sufficiently secure the metal lath (30) to the metal lath accessory (710). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (726, 728), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIG. 46, each barb (726, 728) comprises a ramped surface (726 a, 728 a) facing the opening of the channel between the lower and upper flanges (720, 722) and a shoulder surface (726 b, 728 b) facing the respective side wall (712). In some embodiments, the shoulder surface (726 b, 728 b) may be substantially perpendicular relative to the respective flange (720, 722) the barb (726, 728) projects from. This may allow the metal lath (30) to slide along the ramped surface (726 a, 728 a) of each barb (726, 728) when the metal lath (30) is inserted within the metal lath accessory (710) such that the metal lath accessory (710) is more easily able to receive the metal lath (30). As shown, after the metal lath (30) has been received within the channel between the lower and upper flanges (720, 722), the shoulder surface (726 b, 728 b) of each of the barbs (726, 728) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (710). In the illustrated embodiment, barbs (726, 728) have a substantially triangular cross-section. In other embodiments, barbs (726, 728) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (720, 722). As shown, the barbs (726) on the lower flange (720) and the barbs (728) on the upper flange (722) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs (726, 728) on the same flange (720, 722) may have different cross-sections.
In the embodiment shown in FIGS. 45-50, each upper flange (722) further comprises an angled portion (724) at the free end of each upper flange (722). Angled portion (724) may be positioned at about a 45 degree angle relative to the upper flange (722), but any other suitable configuration may be used. This may help guide the metal lath (30) into the channel between the lower flange (720) and the upper flange (722) when the metal lath (30) is inserted into the metal lath accessory (710). It should be noted that angled portion (724) of the upper flange (722) is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (710), the upper flange (722) may be sufficiently resilient such that the upper flange (722) flexes slightly upwardly to allow the metal lath (30) to slide between the upper flange (722) and the lower flange (720), past the barbs (726, 728), and adjacent to the side wall (712). Once the metal lath (30) is inserted between the lower and upper flanges (720, 722), the upper flange (722) can flex downwardly to its original position such that at least one of the barbs (726, 728) engages the metal lath (30). Barbs (726, 728) thus hold the metal lath (30) within the metal lath accessory (710) and prevent the metal lath (30) from pulling away from the metal lath accessory (710). Barbs (726, 728) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (720, 722). In some embodiments, barbs (726, 728) may be positioned in corresponding pairs, while in other embodiments barbs (726, 728) may be staggered between the upper flange (722) and the lower flange (720) along the length of the metal latch accessory (710).
Either before or after the metal lath (30) is inserted within the metal lath accessory (710), the lower flange (720) of the metal lath accessory (710) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). The substrate (5) may be any suitable structure, such as a wall comprising any suitable material, such as plywood, cinder blocks, or any other similar material. Once the metal lath (30) is inserted within the metal lath accessory (710) and metal lath accessory (710) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material, can then be applied over the lower and upper flanges (720, 722) of the metal lath accessory (710) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (720, 722) of the metal lath accessory (710) comprise a plurality of openings (716) that may allow the finishing material to better bond to the metal lath accessory (710), but these openings (716) are merely optional and may be sized, shaped and arranged in any suitable configuration. As shown, the openings (716) located in the upper flange (722) are positioned directly above openings (716) in the lower flange (720) that correspond in size and shape to the openings (716) in the upper flange (722).
As shown in FIGS. 45-50, the plurality of openings (716) includes a plurality of exterior circular openings (716 a), a plurality of trapezoidal openings (716 b), a plurality of interior circular openings (716 c) and a plurality of triangular openings (716 d). In this embodiment, the exterior circular openings (716 a) are positioned in a row adjacent to the free end of upper flange (722) and lower flange (720). The trapezoidal openings (716 b) are positioned between the row of exterior circular openings (716 a) and the row of interior circular openings (716 c). The triangular openings (716 d) are arranged in repeating groups of three openings between adjacent trapezoidal openings (716 b) and adjacent interior circular openings (716 c). Relative to the opening patterns illustrated in FIGS. 1-44, the opening pattern illustrated in FIGS. 45-50 may be configured to provide an increased amount of open space in upper flange (722) and lower flange (720) and, thus, allow an increased amount of finishing material (35) into the channel defined, at least in part, by the upper flange (722) and the lower flange (720) and to contact the substrate (5) beneath lower flange (720). As a result, the opening pattern illustrated in FIGS. 45-50 may result in a stronger bond between the finishing material (35), the metal lath (30), finishing accessory (710) and the substrate (5).
The embodiment illustrated in FIGS. 45-50 also includes a pair of angled members (725) extending from a respective side wall (712) adjacent to the juncture of each upper flange (722) and the respective side wall (712). The angled members (725) are merely optional and may be arranged at any suitable angle and positioned at any suitable position along the side wall (712) or omitted entirely. Of course, other suitable profiles and configurations for the metal lath accessory (710) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIGS. 51-56 show another embodiment of a metal lath accessory (810) that is configured as a control joint and is substantially similar to the metal lath accessory (110), except that metal lath accessory (810) has an alternate hole pattern and configuration and upper flange (822) is wider than upper flange (122).
In this embodiment, metal lath accessory (810) comprises a side wall (812) extending upwardly from an end of a lower flange (820). An upper flange (822) extends outwardly from the side wall (812) at a position spaced above the lower flange (820). In the illustrated embodiment, the upper flange (822) is substantially parallel to the lower flange (820). In some embodiments, one or both of the upper flange (822) and the lower flange (820) may extend substantially perpendicularly relative to the side wall (812), while in other embodiments, one or both of the upper flange (822) and the lower flange (820) may extend obliquely relative to the side wall (812). Lower and upper flanges (820, 822) thereby form a channel to receive the metal lath (30) within the metal lath accessory (110). Accordingly, the upper flange (822) may be spaced apart from the lower flange (820) any distance suitable to allow the metal lath accessory (810) to receive and engage various thicknesses of metal lath (30). By way of example only, in some embodiments the upper flange (822) may be spaced apart from the lower flange (820) about 0.230 inches and the tip of the barbs (826, 828) may be spaced apart from each other about 0.140 inches. In some embodiments, the upper flange (822) may extend obliquely relative to the lower flange (820). For example, in some embodiments, the upper flange (822) may extend downwardly toward the lower flange (820) such that the height of the channel defined, at least in part, by the upper flange (822) and the lower flange (820) is larger at the fixed end of the upper flange (822) than the height of the channel at the free end of the upper flange (822). At an upper end of the side wall (812), a lip (814) extends outwardly from the side wall (812) having a first portion that extends substantially parallel to the upper flange (822) and a second portion that extends downward towards the upper flange (822). In some embodiments, one or more of the side wall (812), lip (814), lower flange (820), and upper flange (822) may comprise a single, integral piece that is of unitary construction. In some embodiments, one or more of the side wall (812), lip (814), lower flange (820), and upper flange (822) may be extruded or co-extruded together to form a product of unitary construction. In other embodiments, one or more of the side wall (812), lip (814), lower flange (820), and upper flange (822) may comprise non-integral, separate components that are attached to each other.
The metal lath accessory (810) further comprises a metal lath attachment feature configured to receive and engage the metal lath (30) so that the metal lath (30) and the metal lath accessory (810) are attached to each other. In the illustrated embodiment, the metal lath attachment feature comprises the upper flange (822), the lower flange (820), and at least one barb (826, 828) positioned on each of the upper flange (822) and the lower flange (820). As shown in FIG. 11, the lower flange (820) comprises a barb (826) extending upwardly from the lower flange (820) toward the upper flange (822). The upper flange (822) comprises a barb (828) extending downwardly from the upper flange (820) toward the lower flange (820). As shown, the barbs (826, 828) are sized and shaped to fit substantially within or otherwise engage an opening of the metal lath (30) to secure the metal lath (30) with the metal lath accessory (810). Each lower and upper flange (820, 82) comprises a plurality of barbs (826, 828) along a length of the flanges (820, 822), as shown in FIG. 53. This can provide a plurality of attachment points between the metal lath (30) and the metal lath accessory (810) along the length of the metal lath accessory (810). As shown, adjacent barbs (826) on the lower flange (820) are separated by openings (816) in the lower flange (820). Similarly, in this embodiment, adjacent barbs (828) on the upper flange (822) are separated by openings (816) in the upper flange (822). Of course, any suitable number of barbs (826, 828) can be used to sufficiently secure the metal lath (30) to the metal lath accessory (810). In other embodiments, the metal lath attachment feature may comprise one or more different structures instead of or in addition to the barbs (826, 828), including but not limited to a flange, a snap-down leg, and a channel.
As shown in FIG. 52, each barb (826, 828) comprises a ramped surface (826 a, 828 a) facing the opening of the channel between lower and upper flanges (820, 822) and a shoulder surface (826 b, 828 b) facing the respective side wall (812). In some embodiments, the shoulder surface (826 b, 828 b) may be substantially perpendicular relative to the respective flange (820, 822) the barb (826, 828) projects from. This may allow the metal lath (30) to slide along the ramped surface of each barb (826, 828) when the metal lath (30) is inserted within the metal lath accessory (810) such that the metal lath accessory (810) is more easily able to receive the metal lath (30). After the metal lath (30) has been received within the channel between the lower and upper flanges (820, 822), the shoulder surface (826 b, 828 b) of each of the barbs (826, 828) is configured to engage the metal lath (30) to prevent the metal lath (30) from being easily removed from the metal lath accessory (810). In the illustrated embodiment, barbs (826, 828) have a substantially triangular cross-section. In other embodiments, barbs (826, 828) may have a different cross-sectional shape suitable to sufficiently engage the metal lath while still allowing the metal lath to be received within the channel between the lower and upper flanges (820, 822). As shown, the barbs (826) on the lower flange (820) and the barbs (828) on the upper flange (822) have identical cross-sections. In other embodiments, the barbs on the lower flange and the barbs on the upper flange may have different cross-sections. In still other embodiments, barbs on the same flange may have different cross-sections.
Similar to the angled portion (24) described above, in some embodiments, the upper flange (822) may comprise an angled portion at the free end of the upper flange (822). This may help guide the metal lath (30) into the channel between the lower flange (820) and the upper flange (822) when the metal lath (30) is inserted within the metal lath accessory (810). Of course, any such angled portion is merely optional.
When the metal lath (30) is inserted within the metal lath accessory (810), the upper flange (822) may be sufficiently resilient such that the upper flange (822) flexes upwardly to allow the metal lath (30) to slide between the upper flange (822) and the lower flange (820), past the barbs (826, 828), and adjacent to the side wall (812). Once the metal lath (30) is inserted between the lower and upper flanges (820, 822), the upper flange (822) can flex downwardly to its original position such that at least one of the barbs (826, 828) engages the metal lath (30). Barbs (826, 828) thus hold the metal lath (30) within the metal lath accessory (810) and prevent the metal lath (30) from pulling away from the metal lath accessory (810). Barbs (826, 828) may be substantially aligned opposite each other, or, alternatively, they may be offset from each other along the width of the lower and upper flanges (820, 822). In some embodiments, barbs (826, 828) may be positioned in corresponding pairs, while in other embodiments barbs (826,828) may be staggered between the upper flange (822) and the lower flange (820) along the length of the metal latch accessory (810).
Either before or after the metal lath (30) is inserted within the metal lath accessory (810), the lower flange (820) of the metal lath accessory (810) can be secured to a substrate (5) to thereby couple the metal lath (30) to the substrate (5). Once the metal lath (30) is inserted within the metal lath accessory (810) and metal lath accessory (810) is secured to the substrate (5), one or more coats (e.g., a scratch coat and a finishing coat) of a finishing material (35), such as stucco, plaster or other similar material, can then be applied over the lower and upper flanges (820, 822) of the metal lath accessory (810) and the metal lath (30).
In the illustrated embodiment, the lower and upper flanges (820, 822) of the metal lath accessory (810) comprise a plurality of openings (816) that may allow the finishing material to better bond to the metal lath accessory (810), but these openings (816) are merely optional and may be sized, shaped and arranged in any suitable configuration. The openings (816) in metal lath accessory (810) are substantially similar to those in metal lath accessory (710) described above. As shown, the openings (816) located in the upper flange (822) are positioned directly above openings (816) in the lower flange (820) that correspond in size and shape to the openings (816) in the upper flange (822). Of course, other suitable profiles and configurations for the metal lath accessory (810) will be apparent to one of ordinary skill in the art in view of the teachings herein.
FIG. 57 shows another embodiment of a metal lath accessory (810′) that is configured as a casing bead and is substantially similar to the metal lath accessory (810), except that upper flange (822′) extends obliquely relative to lower flange (820′). Specifically, the upper flange (822′) extends downwardly toward the lower flange (820′) such that the height of the channel defined, at least in part, by the upper flange (822′) and the lower flange (820′) is larger at the fixed end of the upper flange (822′) than the height of the channel at the free end of the upper flange (822′).
In some embodiments, the upper flange of the metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810) can be resiliently biased such that the upper flange is positioned in an upward, open position with the metal lath (30) is inserted into the metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810), and then the upper flange can be pivoted downward to a closed position to attach the metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810) to the metal lath (30). In some other embodiments, the metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810) comprises a plurality of rows of barbs positioned between the lower and upper flanges of the metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810).
The upper flange of the metal lath accessory (10, 110, 210, 310, 410, 505, 710, 810) may comprise any suitable width. In some embodiments, including but not limited to those shown in FIGS. 1-44, the lower flange may be wider than the upper flange. In other embodiments, including but not limited to those shown in FIGS. 45-56, the upper flange and the lower flange may comprise substantially the same width. In still other embodiments, the upper flange may be wider than the lower flange.
The metal lath accessories and lath clip described herein may comprise a plastic material, including but not limited to rigid polyvinyl chloride (PVC) or chlorinated polyvinyl chloride (CPVC), a metal material, including but not limited to zinc alloy (99% pure zinc), galvanized (zinc coated) steel, or anodized aluminum alloy, or any other suitable material. In some embodiments, the metal lath accessory or lath clip may be produced using an extrusion or co-extrusion process.
Based on the teachings herein, embodiments of the metal lath attachment features and the lath clip described herein, including the inclusion of an upper flange and one or more barbs on an upper and/or lower flange, may be incorporated into and/or used in conjunction with any metal lath accessory that includes a lower flange that is attached to a substrate, including but not limited to casing beads, control joints, expansion joints, reveals, corner beads, and screeds.
Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of any claims that may be presented and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

Claims

What is claimed is:

1. A metal lath accessory comprising:

a. a side wall;

b. a first flange, wherein the first flange extends from the sidewall in a first direction;

c. a second flange, wherein the second flange extends from the sidewall in the first direction such that the first flange and the second flange are spaced apart from each other; and

d. a first barb, wherein the first barb projects from the first flange toward the second flange.

2. The metal lath accessory of claim 1, wherein the first barb comprises a first ramped portion.

3. The metal lath accessory of claim 2, wherein the side wall, the first flange, and the second flange at least partially define a channel comprising an opening, and wherein the first ramped portion is facing the opening of the channel.

4. The metal lath accessory of claim 2, wherein the first barb further comprises a first shoulder portion.

5. The metal lath accessory of claim 4, wherein the first shoulder portion is facing the side wall.

6. The metal lath accessory of claim 1 further comprising a second barb, wherein the second barb projects from the second flange toward the first flange.

7. The metal lath accessory of claim 1, wherein the first flange is substantially parallel to the second flange.

8. The metal lath accessory of claim 1, wherein the first flange comprises a first plurality of openings.

9. The metal lath accessory of claim 8, wherein the second flange comprises a second plurality of openings.

10. The metal lath accessory of claim 9, wherein each of the first plurality of openings in the first flange is aligned with a corresponding one of the second plurality of openings in the second flange.

11. The metal lath accessory of claim 1, wherein the first flange further comprises an angled portion located at a free end of the first flange.

12. The metal lath accessory of claim 1, wherein the first barb comprises a substantially triangular cross-section.

13. The metal lath accessory of claim 1, wherein the side wall, the first flange, the second flange and the first barb are of unitary construction.

14. A metal lath accessory comprising:

a. a side wall;

b. a first flange comprising a first plurality of openings, wherein the first flange extends from the sidewall in a first direction;

c. a second flange, wherein the second flange extends from the sidewall in the first direction such that the first flange and the second flange are spaced apart from each other;

d. a first plurality of barbs, wherein the first plurality of barbs project from the first flange toward the second flange, wherein at least one of the first plurality of openings is positioned between a pair of adjacent barbs of the first plurality of barbs.

15. The metal lath accessory of claim 14, wherein the second flange comprises a second plurality of openings.

16. The metal lath accessory of claim 15 further comprising a second plurality of barbs, wherein the second plurality of barbs project from the second flange toward the first flange, wherein at least one of the second plurality of openings is positioned between a pair of adjacent barbs of the second plurality of barbs.

17. The metal lath accessory of claim 14, wherein at least one of the first plurality of openings comprises a substantially triangular opening.

18. The metal lath accessory of claim 14, wherein at least one of the first plurality of openings comprises a substantially trapezoidal opening.

19. An assembly comprising

a. a metal lath accessory, wherein the metal lath accessory comprises

i. a side wall,

ii. a first flange, wherein the first flange is connected to the side wall,

iii. a second flange, wherein the second flange is connected to the side wall,

iv. a channel, wherein the channel is at least partially defined by the side wall, the first flange and the second flange, and

v. a first barb, wherein the first barb projects from the first flange into the channel;

b. a piece of metal lath, wherein the piece of metal lath comprises a plurality of openings, wherein the piece of metal lath is inserted into the channel such that the first barb engages the piece of metal lath via one of the plurality of openings in the piece of metal lath.

20. The assembly of claim 20, wherein the metal lath accessory further comprises a second barb, wherein the second barb projects from the second flange into the channel, and wherein the piece of metal lath is inserted into the channel such that the second barb engages the piece of metal lath via one of the plurality of openings in the piece of metal lath.