Composite building material

Abstract

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.