Composite building material
An integral composite building material is provided that includes a three-dimensional, corrosion-resistant fabric that is pre-attached to a weather barrier. The invention also provides a building wall and exterior finishing system including the composite building material. The invention further includes a method for constructing a building wall including the exterior finishing system.
1 . An integral composite building material comprising:
a weather barrier; and
a corrosion-resistant, three-dimensional lath of non-metal fibers attached to said weather barrier.
2 . The composite building material of claim 1 , wherein said lath comprises a corrosion-resistant, woven, three-dimensional fabric of non-metal fibers.
3 . The composite building material of claim 1 , wherein said lath is attached to said weather barrier by a securement means.
4 . The composite building material of claim 3 , wherein said securement means is selected from the group consisting of adhesives and heat lamination.
5 . The composite building material of claim 4 , wherein said securement means is an adhesive.
6 . The composite building material of claim 5 , wherein said adhesive is a plurality of adhesive spots.
7 . The composite building material of claim 5 , wherein said adhesive comprises a least one strip of adhesive.
8 . The composite building material of claim 5 , wherein said adhesive is selected from the group consisting of acrylic adhesives, styrene-acrylic adhesives, and aliphatic resin adhesives.
9 . The composite building material of claim 1 , wherein said lath has fibers undulating in at least one of the (i) longitudinal and (ii) transverse directions.
10 . The composite building material of claim 1 , wherein said weather barrier is selected from the group consisting of building papers and polymeric sheets.
11 . The composite building material of claim 10 , wherein said building papers are selected from the group consisting of kraft paper and asphalt impregnated building paper.
12 . The composite building material of claim 10 , wherein said polymeric sheets are selected from the group consisting of woven polyolefin sheets and spun-bonded polyolefin sheets.
13 . The composite building material of claim 12 , wherein said polymeric sheet comprises a non-woven sheet of spun-bonded polyolefin fibers.
14 . The composite building material of claim 13 , wherein said spun-bonded polyolefin fibers are selected from the group consisting of polyethylene fibers, polypropylene fibers, and mixtures thereof.
15 . The composite building material of claim 1 , wherein said fibers of said lath are selected from the group consisting of glass fibers, polymer fibers, and combinations thereof.
16 . The composite building material of claim 15 , wherein said polymer fibers are nylon fibers.
17 . The composite building material of claim 15 , wherein said glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.
18 . The composite building material of claim 17 , wherein said glass fibers are E-glass fibers.
19 . The composite building material of claim 17 , wherein said glass fibers are AR-glass fibers.
20 . The composite building material of claim 19 , wherein said lath is alkaline resistant.
21 . The composite building material of claim 1 , wherein said lath has a crush resistance sufficient to support exterior finish materials.
22 . The composite building material of claim 1 , wherein said weather barrier and lath are selectively detachable from one another without causing damage to either.
23 . The composite building material of claim 1 , wherein said composite building material is supplied in a roll or sheet form.
24 . A building wall comprising:
a substrate; and
an integral composite building material attached to said substrate, said composite building material comprising a weather barrier and a corrosion-resistant, three-dimensional lath of non-metal fibers attached to said weather barrier.
25 . The building wall of claim 24 , wherein said lath comprises a corrosion-resistant, woven, three-dimensional fabric of non-metal fibers.
26 . The building wall of claim 24 , wherein said lath is attached to said weather barrier by a securement means.
27 . The building wall of claim 26 , wherein said securement means is selected from the group consisting of adhesives and a heat lamination.
28 . The building wall of claim 27 , wherein said securement means is an adhesive.
29 . The building wall of claim 28 , wherein said adhesive is a plurality of adhesive spots.
30 . The building wall of claim 28 , wherein said adhesive comprises a least one strip of adhesive.
31 . The building wall of claim 28 , wherein said adhesive is selected from the group consisting of acrylic adhesives, styrene-acrylic adhesives, and aliphatic resin adhesives.
32 . The building wall of claim 26 , wherein said lath has fibers undulating in at least one of the (i) longitudinal and (ii) transverse directions.
33 . The building wall of claim 24 , wherein said weather barrier is selected from the group consisting of building papers and polymeric sheets.
34 . The building wall of claim 33 , wherein said building paper is selected from the group consisting of kraft paper and asphalt impregnated building paper.
35 . The building wall of claim 34 , wherein said polymeric sheet is selected from the group consisting of woven polyolefin sheets and spun-bonded polyolefin sheets.
36 . The building wall of claim 35 , wherein said polymeric sheet comprises a non-woven sheet of spun-bonded polyolefin fibers.
37 . The building wall of claim 36 , wherein said spun-bonded olefin fibers are selected from the group consisting of polyethylene fibers, polypropylene fibers, and mixtures thereof.
38 . The building wall of claim 26 , wherein said fibers of said lath are selected from the group consisting of glass fibers, polymer fibers, and combinations thereof.
39 . The building wall of claim 38 , wherein said polymer fibers are nylon.
40 . The building wall of claim 38 , wherein said glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.
41 . The building wall of claim 40 , wherein said glass fibers are E-glass fibers.
42 . The building wall of claim 40 , wherein said glass fibers are AR-glass fibers.
43 . The building wall of claim 26 , wherein said lath is alkaline resistant.
44 . The building wall of claim 26 , wherein said lath has a crush resistance sufficient to support exterior finishing materials.
45 . The building wall of claim 26 , wherein said weather barrier and lath are selectively detachable from one another without causing damage to either.
46 . The building wall of claim 26 , comprising an exterior covering installed over the composite building material.
47 . The building wall of claim 46 , wherein said exterior covering is stucco.
48 . The building wall of claim 26 , wherein said substrate is selected from the group consisting of a wood frame, metal frame, plywood sheathing, cement board, gypsum board, oriented strand board, wafer board, insulation board, masonry, and concrete masonry units.
49 . The building wall of claim 26 , wherein an insulation layer is disposed between said substrate and said composite building material.
50 . A method of constructing a building wall comprising:
attaching an integral composite building material comprising a weather barrier and a corrosion-resistant, three-dimensional lath of non-metal fibers attached to said weather barrier.
51 . The method of claim 50 , wherein said lath comprises a corrosion-resistant, woven, three-dimensional fabric of non-metal fibers.
52 . The method of claim 50 , wherein said composite building material is an elongated strip having a greater length than width and having a longitudinal axis, and including attaching said composite building material to extend lengthwise along said substrate.
53 . The method of claim 50 , including overlapping vertical and longitudinal edges of adjacent strips of said composite building material, wherein a portion of an upper weather barrier overlaps a portion of an adjacent lower weather barrier.
54 . The method of claim 50 , including providing an elongated edge of said composite building material that is free of said woven fabric.
55 . The method of claim 50 , wherein said composite building material is provided in roll form, and the method includes unrolling said composite building material before or while attaching to said building wall substrate.
56 . The method of claim 50 , including disposing an exterior covering over said woven fabric of said composite building material.
57 . The method of claim 55 , wherein said exterior covering is at least one layer of stucco.
58 . An exterior finishing system comprising:
an integral composite building material comprising a weather barrier and a corrosion-resistant, three-dimensional lath of non-metal fibers attached to said weather barrier; and
an exterior covering applied over said composite building material.
59 . The exterior finishing system of claim 58 , wherein said lath comprises a corrosion-resistant, woven, three-dimensional fabric of non-metal fibers.
60 . The exterior finishing system of claim 58 , wherein said lath is attached to said weather barrier by a securement means.
61 . The exterior finishing system of claim 60 , wherein said securement means is selected from the group consisting of adhesives and a heat lamination.
62 . The exterior finishing system of claim 61 , wherein said securement means is an adhesive.
63 . The exterior finishing system of claim 62 , wherein said adhesive is a plurality of adhesive spots.
64 . The exterior finishing system of claim 62 , wherein said adhesive comprises a least one strip of adhesive.
65 . The exterior finishing system of claim 60 , wherein said adhesive is selected from the group consisting of acrylic adhesives, styrene-acrylic adhesives, and aliphatic resin adhesives.
66 . The exterior finishing system of claim 58 , wherein said lath has fibers undulating in at least one of the (i) longitudinal and the (ii) transverse directions.
67 . The exterior finishing system of claim 58 , wherein said weather barrier is selected from the group consisting of building papers and polymeric sheets.
68 . The exterior finishing system of claim 67 , wherein said building paper is selected from the group consisting of kraft paper and asphalt impregnated building paper.
69 . The exterior finishing system of claim 66 , wherein said polymeric sheet is selected from the group consisting of woven polyolefin fiber sheets and spun-bonded polyolefin fiber sheets.
70 . The exterior finishing system of claim 69 , wherein said polymeric sheet comprises a non-woven sheet of spun-bonded polyolefin fibers.
71 . The exterior finishing system of claim 70 , wherein said spun-bonded polyolefin fibers are selected from the group consisting of polyethylene fibers, polypropylene fibers, and mixtures thereof.
72 . The exterior finishing system of claim 58 , wherein said fibers of said lath are selected from the group consisting of glass fibers, polymer fibers, and combinations thereof.
73 . The exterior finishing system of claim 72 , wherein said polymer fibers are nylon.
74 . The exterior finishing system of claim 73 , wherein said glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.
75 . The exterior finishing system of claim 74 , wherein said glass fibers are E-glass fibers.
76 . The exterior finishing system of claim 74 , wherein said glass fibers are AR-glass fibers.
77 . The exterior finishing system of claim 76 , wherein said lath is alkaline resistant.
78 . The exterior finishing system of claim 58 , wherein said weather barrier and lath are selectively detachable from one another without causing damage to either.
79 . A method of constructing a stucco system comprising:
optionally disposing insulation over said a building wall substrate;
attaching an integral composite building material over said substrate or over said insulation, if insulation is present, said composite building material comprising a weather barrier and a corrosion-resistant, three-dimensional lath of non-metal fibers attached to said weather barrier; and
applying at least one stucco layer over said composite building material.
80 . The method of claim 79 , wherein said lath comprises a corrosion-resistant, woven, three-dimensional fabric of non-metal fibers.
81 . The method of claim 79 , comprising applying at least one finish layer over said at least one stucco layer.
82 . The method of claim 79 , wherein said lath is capable of retaining and supporting the weight of a wet stucco applied thereto.