Note: Descriptions are shown in the official language in which they were submitted.
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L-BEAD: A LEAK PREVENTION SYSTEM FOR STUCCO SURFACES
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to the application of stucco or plaster in homes or
other
buildings and specifically to the stop system used between the edge of the
stucco or plaster
surface and the adjoining frame for windows and doors or where stucco or
plaster meets any
material dissimilar from the stucco or plaster.
2. BACKGROUND OF THE PRIOR ART
Stucco and/or plaster are typically used for both interior and exterior
surfaces in home or
commercial building construction. Stucco or plaster is routinely applied to a
galvanized wire
mesh over felt paper which has been attached to underlying plywood or other
sheathing
material. (See Figure 1.) In order to provide a smooth edge where the stucco
or plaster meets a
door or window jamb or frame, plastic stop strips are installed along the
desired edge of the
stucco or plaster to contain it and provide for an even finish.
The plastic stop often used for this purpose is presented in Figure 2. The
plaster stop
generally consists of a perforated plastic strip approximately 2 inches wide
with a plastic lip or
edge acting to contain the stucco or plaster away from the jamb or frame. The
plaster stop is
typically installed approximately 1/4 inch away from the jamb or frame,
leaving a gap between
the stop and the backing surface. In order to provide a complete finish, the
worker must install
a backer rod into the gap and then apply a finishing layer of caulk. This
process that is used by
some builders to prevent leaks is very time consuming.
This method of stucco installation has often resulted in leaking problems
between
CA 02666118 2009-05-19
the stucco or plaster surface and the adjacent jamb, thereby causing
significant additional
repair costs and frustration to both home owners and construction companies.
In addition, the
extra time and materials necessary for installation of the backer rod and
finishing caulk layer
can add considerably to the costs and duration of the construction. The L-Bead
eliminates the
need for installation of a backer rod - saving considerable time and money -
and significantly
cuts down on the potential for leaks around windows and doors.
BRIEF SUMMARY OF THE INVENTION
The present invention, L-Bead system, provides a system for quick, efficient
and lower
cost installation of stucco and or plaster which cuts down on the potential
for leaks around
windows and doors. The L-Bead is used as a stop between the edge of the stucco
or plaster
surface and the adjacent jamb or window/door frame. Proper installation of
existing plaster
stop requires a 1/4 inch gap between the stop and the jamb, mandating the
installation of a
backer rod and supplemental caulking. The L-Bead system eliminates this need
by adding an
extra plastic strip or "lip" along the edge of existing plaster stop which
abuts directly to the
jamb, thereby simplifying a smooth finish and minimizing the potential for
leaks.
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BRIEF DESCRIPTION OF THE FIGURES
Figure 1
Figure 1 shows the typical manner in which stucco or plaster will be applied
and
installed in homes or other buildings around window or door frames or adjacent
to other
surfaces such as aluminum siding using the L-Bead system. Such construction
occurs in layers,
with each layer given a number in order of installation. A wire mesh layer of
galvanized wire
(#3) is anchored over felt paper (# 1) to the backing wall (usually plywood or
a similar
material). Scratch and finish coats of plaster or stucco (#4 and #5) are
applied to the wire layer.
Where the stucco or plaster meets a window or door jamb or another surface,
plastic L-Bead
stopping strips (#2) are nailed to the backing wall behind or adjacent to the
galvanized wire
layer. The edge of the stop closest to the jamb is raised to contain the
stucco or plaster and
keep it away from the jamb or frame. The key to the L-bead is the separate
backing "lip" along
the plastic stop which directly abuts the jamb or other surface. No backing
rod is necessary. A
fmal small layer of caulk (#6) is applied.to finish the job.
Figure I A
Figure IA is a view in cross-section taken along the lines and arrows 1 A -
IA, illustrating
the inventive stop or stop bead 2 mounted along a jamb 10 of a window 11.
Figure 2
Figure 2 is a drawing showing an enlarged view of existing plaster stop. The
perforated portion of the plaster stop is nailed or otherwise attached to the
backing wall. The
lip on the edge of the plaster stop acts to contain the plaster or stucco and
keep it away from
the door or window jamb.
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Figure 3
Figure 3 shows the new L-Bead. As with traditional plaster stop, the
perforated portion
is nailed or otherwise attached to the backing wall. The higher lip part of
the stop contains the
stucco or plaster. The added backing lip of the L-Bead abuts directly to the
jamb and
eliminates the need for a backer rod, thereby cutting down on both leaks and
installation time.
Figure 4
Figure 4 is a view in cross-section of the prior art stop or stop bead shown
in Figure 2.
Figure 5
Figure 5 is a view in cross-section of the inventive stop or stop bead 2 shown
in Figure 3.
Figure 6
Figure 6 is a view in perspective showing a preferred alternative embodiment
of the
inventive stop bead constructed in accordance with the invention.
Figure 7
Figure 7 is a view in cross-section of the stop bead shown in Figure 6.
Figure 8
Figure 8 is a view in cross-section showing the alternative embodiment of the
stop bead
of Figure 6 installed in a wall.
DETAILED DESCRIPTION OF THE INVENTION
The L-Bead system significantly reduces the time and costs necessary to
install smooth
finishes where stucco or plaster meets window or door frames or jamb. In
ordinary house of
building construction, exterior and interior surfaces are often made of stucco
or plaster. The
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method of installation of these materials is generally consistent in the
construction business
and usually involves the installation of a felt layer over the backing wall
(plywood or similar
material), a galvanized wire (or lathe) layer, and both scratch and finish
coats of stucco or
plaster. (See Figure 1.)
Leaking and other problems often occur where the stucco or plaster finish
aligns with
other design constructs of the home or building, such as windows or doors.
Stop strips which
contain and form the outer boundaries of the stucco or plaster surfaces where
they meet
window or door jambs have been developed to improve the seal and finishes of
these
adjacencies. In particular, the use of standard plaster stop strips as shown
in Figure 2 has
become standard practice in the stucco and masonry business.
However, for traditional plaster stop to be properly installed and finished,
the worker
typically installs the plaster stop 1/4 inch from the edge of the door or
window jamb. The
resulting gap must be filled with a backing rod and properly caulked for the
correct finish.
Installation of this backing rod and additional caulking costs time and money,
particularly
where the architectural design calls for numerous windows, doors or other
interruptions in
stucco or plaster surfaces. In addition, this manner of construction has
unfortunately resulted
in frequent leaking problems around windows and doors.
The inventor has come up with a system which eliminates the need for
installation of a
backing rod by manufacturing an additional strip of plastic which is bound to
the existing
plaster stop and abuts directly against the jamb or other surface. The L-Bead
system
significantly modifies both the existing plaster stop unit itself and the ease
of installation.
Plaster stop strips routinely consist of a thin, 2-inch wide strip 7 of
plastic which is
perforated throughout its length and which contains an edge strip 8 of plastic
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approximately /2 inch high running along one side of the strip 7. The top '/4
inch of this
additional plastic strip 8 is then bent back over the wide, perforated portion
strip 7 forming
a "lip" which runs along the entire length of the stop. See Figure 2. When the
plaster stop
strip is nailed to the backing wall, it is installed approximately %4 inch
away from the jamb
or other surface. The lip side contains and holds the stucco or plaster in
place providing a
smooth, straight edge.
Because traditional plaster stop must be installed 1/4 inch from the jamb for
it to
perform properly, there remains a 1 /4 inch gap running the entire length of
the
adjacency between the stucco and the door or window jamb. In typical
construction,
this gap is filled with a backing rod and requires considerable caulking which
often
leads to leaking or other problems. The L-Bead system eliminates this last
step and
will greatly improve construction techniques for reducing leaks in windows or
doors.
The L-Bead system alters traditional plaster stop by adding a separate backing
strip 9 to
the existing plaster stop. The additional length of plastic stripping 9 is
attached to the outside of
the lip and runs along the entire length of the stop 2. (See Figure 3.)
Whereas the original plaster
stop contained the stucco or plaster, the L-Bead system not only contains the
stucco or plaster,
but also provides a backing strip 9 which abuts directly against the jamb 10
or other surface and
thereby eliminates the need for (and serves the purpose of) a backing rod and
additional
caulking. Because the additional backing strip 9 is located lower than the lip
containing the
stucco, it can account for variations in the jamb 10 or other surface. A
simple and thin caulking
6 over the L-Bead, where it meets the jamb 10 or other surface, makes for a
smooth, leak-proof
finish.
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The L-Bead system is a system for use as a plaster or stucco stop where the
plaster or
stucco meets a separate surface such as window or door frames or jamb. Typical
plaster stop in
the stucco masonry industry consists of a perforated strip running parallel to
the jamb with a
plastic edge acting to contain the applied plaster or stucco surface.
Traditional plaster stop is
routinely installed approximately'/4 inch away from the jamb in order to
account for differences
in the raised height of the jamb or other surface. The resulting gap or space
requires the
installation of a backer rod between the plaster stop and the edge of the
jamb. This requires
additional construction costs and can cause considerable potential for leaks.
The L-Bead system provides a stop system which eliminates the need for the
installation of a backer rod and thereby reduces the potential for leaks. The
L-Bead system adds
an additional plastic strip to the back and along the length of the stop. The
L-Bead is installed
flush against the jamb, eliminating the need for a backer rod, and requiring
only a small amount
of caulking over the area for a finished job. This new system will save time
and money and will
significantly reduce the potential for leaks in these areas.
L-Bead eliminates the need for backing rods around windows, doors or any other
place
where stucco or plaster meets a different surface. Given that a typical house
design includes
numerous windows, doors, garages, or other architectural interruptions in
stucco surfaces, the
elimination of backer rods and simplified construction associated with the L-
Bead system will
save millions of dollars in construction costs and will greatly improve such
finishes against
leaking or other problems.
Turning now to Figures 6 and 7, there is shown a preferred alternative
embodiment of the
inventive stop bead. In this preferred alternative embodiment of the
invention, a stop bead 102 is
provided for mounting on a wall having a jamb formed therein to separate the
jamb from plaster
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or stucco material 4, 5 during application of the plaster or stucco material
4, 5 to the wall. The
jamb is part of a frame for a window or door that frames an opening in the
wall, and the jamb has
a first surface facing the opening in the wall and a second surface facing
away from the opening
in the wall. Stop bead 102 has a first side end portion 113, and a second side
end portion 115, a
top end portion, and a bottom end portion 116 at the end of the stop bead 102
opposite the top
end portion. The first side end portion 113 has a leading edge 117 for
engaging the second
surface of the jamb when the stop bead 102 is mounted adjacent to the jamb.
The stop bead 102 has a base panel 107 having a front face over which plaster
or stucco
material 4, 5 is applied after the stop bead 102 is mounted adjacent to the
jamb. The base panel
107 preferably has perforations formed therein. A stop bead wall 108 is formed
on the base
panel 107 and extends outwardly above the front face of the base panel 107.
The stop bead wall
108 has a first side having an engaging surface 119 for engaging plaster or
stucco material 4, 5
after the stop bead 102 has been mounted adjacent to the jamb, and the stop
bead wall 108 has a
second side having a jamb facing surface 121 that faces the second surface of
the jamb when the
stop bead 102 is mounted adjacent to the jamb.
A spacing member 109 is formed on the stop bead 102 and extends outwardly away
from
the jamb facing surface 121 of the stop bead wall 108. The spacing member 109
preferably
comprises a strip of flexible (and also preferably resilient) material (e.g.,
a plastic or a polymer,
such as flexible vinyl (preferably a flexible exterior grade vinyl; or a
metal)), and may be formed
on the stop bead wall 108 by co-extruding the spacing member 109 with the
remainder (which
comprises a material that is compatible for co-extrusion with the material
used for the spacing
member 109, such as a rigid exterior grade vinyl which is compatible with a
flexible exterior
grade vinyl if a flexible exterior grade vinyl is used for the spacing member
109, or a rigid metal
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if a flexible metal compatible to the rigid metal is used for the spacing
member 109) of the stop
bead 102, such that the entire stop bead 102, including the spacing member
109, is extruded as
one piece. Preferably, as shown in Figures 6 and 7, the spacing member 109
forms a hollow tube
having a substantially rectangular cross-section, and four walls 123, 125,
127, and 129, with wall
129 being part of the stop bead wall 108 and walls 123, 125, and 127 being
part of the spacing
member 102. Preferably, wall 125 is somewhat concave.
The stop bead 102 preferably is two inches wide and about 3/4 inches high (at
the stop
bead wall 108), and the width of the spacing member 109 (the distance between
the stop bead
wall 108 and the jamb when the stop bead 102 is mounted adjacent to the jamb)
preferably is 1/4
inch to the 1/2 inch and more preferably 3/8 inch. Also, the distance from the
top of the spacing
member 109 to the top of the stop bead wall 108 preferably is 1/4 inch.
Typically, window units are vinyl or vinyl clad, or aluminum or aluminum clad,
and
likely to expand and contract due to changes in the weather. Further, door
units often have some
expansion and contraction due to changes in the weather. Because the spacing
member 109 is
flexible and preferably resilient, it permits movement of the jamb due to
expansion or
contraction of the window unit or door unit. Accordingly, if the jamb moves
outwardly toward
the stop bead 102 due to expansion of the window unit or the door unit it
forms a part of, the
jamb compresses the resilient, flexible spacing member 109 toward the stop
bead wall 108,
thereby accommodating for the expansion. The concave wall 125 helps facilitate
the
compression of the spacing member 109.
The spacing member 109 forms the leading edge 117 of the first side end
portion 113 of
the stop bead 102, and the leading edge 117 has a jamb engaging surface 131
that engages the
second surface of the jamb when the stop bead 102 is mounted adjacent to the
jamb. When the
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stop bead 102 is mounted adjacent to the jamb, with the jamb engaging surface
131 abutting
against the second surface of the jamb, the stop bead wall 108 is spaced a
uniform,
predetermined distance from the second surface of the jamb. Further, the
spacing member 102,
in conjunction with the jamb and the jamb facing surface of the stop bead wall
108, form a caulk
receiving area 133 above the spacing member 109 and between the second surface
of the jamb
and the jamb facing surface of the stop bead wall 108 for receiving caulk 6 to
seal between the
stop bead 102 and the jamb.
Preferably, bond-breaking tape 135 is fixed to the outer surface of wall 123
by laying it
onto the outer surface of the wall 123 as the stop bead 102 exits the
extruder. The bond-breaking
tape 135 hinders formation of a bond between the caulk 6 and the bond-breaking
tape 135.
Accordingly, the caulk 6 positioned in the caulk receiving area 133 bonds only
with the jamb and
the jamb facing surface of the stop bead wall 108, thereby creating a double-
sided joint (e.g.,
caulk 6 connected to the jamb and the jamb facing surface of the stop bead
wall 108), rather than
a triple-sided joint (e., caulk 6 connected to the jamb, the jamb facing
surface of the stop bead
wall 108, and the spacing member 109), to seal between the stop bead 102 and
the jamb.
In addition to providing means for spacing the stop bead wall 108 a uniform
and
predetermined distance from the second surface of the jamb when the stop bead
102 is mounted
adjacent to the jamb, and to creating a caulk receiving area 133 in
conjunction with the jamb and
the jamb facing surface 121 of the stop bead wall 108 when the stop bead 102
is mounted
adjacent to the jamb, the spacing member 109 provides means for accommodating
movement of
the jamb due to expansion or contraction of the window unit or door unit, of
which the jamb is a
part, due to changes in the weather.
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To assist in containing the plaster or stucco material 4, 5, the stop bead
wall 108 has a
flange 137 formed in its upper end portion, having a first portion that
extends laterally away
from the stop bead wall 108 and over the base panel 107 and a second portion
extending from the
first portion downwardly toward the base panel 107.
My invention also includes a wall having (1) a jamb formed therein, the jamb
being part
of a frame that frames an opening in the wall, and the jamb having a first
surface facing the
opening in the wall and a second surface facing away from the opening in the
wall, and (2) a stop
bead 102 mounted on the wall, with the spacing member 109 abutting against the
second surface
of the jamb, caulk 6 positioned in the caulk receiving area 133 and contacting
the stop bead 102
and the jamb to form a seal between the stop bead 102 and the jamb, and a
plaster or stucco
material applied to the wall and separated from the jamb by the stop bead 102.
Preferably, the
stop bead 102 is provided with bond-breaking tape 135 mounted on the wall 123
of the spacing
member 109. -
In use, the inventive stop bead 102 is mounted adjacent to the jamb such that
the spacing
member 109 abuts against the second surface of the jamb to create a straight
and uniform gap
between the jamb facing surface of the stop bead wall 108 and the jamb,
thereby, uniformly
spacing the stop bead wall 108 from the second surface of the jamb and forming
the caulk
receiving area 133 for receiving caulk 6 to seal between the stop bead 102 and
the jamb. To seal
against leaks between the stop bead 102 and the jamb, caulk 6 is applied to
and extends between
the stop bead 102 and the jamb in the caulk receiving area 133 to form a seal
between the stop
bead 102 and the jamb. Plaster or stucco material 4, 5 is applied to the wall
and kept separated
from the jamb by the stop bead wall 108.
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The invention provides uniform spacing of a stop bead wall from the second
surface of
the jamb, since the stop bead wall 108 of the stop bead 102 is spaced a
uniform, predetermined
distance (the width of the spacing member 109) from the jamb. The stop bead
102 separates the
jamb from the plaster or stucco material being applied to the wall by blocking
access to the jamb
with its stop bead wall 108. The stop bead 102 also provides for sealing
against leaks between
the stop bead 102 and the jamb by permitting simply caulking to obtain a seal
between the stop
bead 102 and the jamb.
For illustrative purposes, the specification set out above uses the inventive
stop bead in
conjunction with a jamb of a window unit or door unit. However, the inventive
stop bead may
be used to separate plaster or stucco material from any material dissimilar
from the plaster or
stucco material, such as where plaster or stucco is to be separated from
soffits, capping, or
siding. As used herein, a jamb is part of a frame that frames an opening in a
wall. Further, as
used herein, a jamb includes a structure, such as soffits, capping, or siding,
which is to be
separated from plaster or stucco material with a stop bead.
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