Flexible Fabric Lath for Plaster Wall Design
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Solution Overview
Problem
Existing methods for applying deformable materials like mortar or plaster to vertical structures are time-consuming and costly, as they require multiple laths to be individually secured, leading to inconsistent application and material wastage due to the gap between laths, and are prone to moisture issues that can cause mold or decay.
Innovation Solution
A lightweight flexible fabric or rigid board system is secured to the wall with fasteners that do not obstruct design impression, featuring a surface configuration that corresponds to the viscosity of the material and includes offset strips to create an air gap, preventing moisture trapping and allowing for efficient and consistent application of deformable materials with a preselected design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple laths are disposed in close proximity to support deformable material, then the deformable material can be secured to the vertical structure, but the application process becomes time-consuming and expensive
Solution Approach 1:
Multiple laths are merged into a single continuous mesh fabric that can be applied as one piece rather than individually installed components. The mesh fabric combines the support function of multiple laths while eliminating the need for individual installation, thereby reducing time and cost while maintaining the ability to secure deformable material.
Solution Approach 2:
The mesh fabric acts as an intermediary between the vertical structure and the deformable material, providing a continuous support surface that eliminates the need for multiple discrete laths. This intermediary structure maintains material security while streamlining the application process.
2Ease of operation
If gaps are provided between adjacent laths to allow material application, then deformable material can be applied to the structure, but material can be pressed through the gaps and wasted
Solution Approach 1:
The mesh fabric provides locally dense structure at the points where material application occurs, while maintaining overall permeability for design impression. The varying mesh densities in different regions allow material to be contained where needed while still permitting design tools to impress patterns into the material.
Solution Approach 2:
The mesh fabric functions as a flexible thin film structure that conforms to the vertical surface while providing continuous material containment. The flexible nature allows it to accommodate design impression forces without breaking, while the film structure prevents material from being pressed through to the other side.
3Strength
If laths are individually screwed or nailed into the wall structure, then the deformable material can be supported, but the process becomes time-consuming and costly
Solution Approach 1:
Multiple individual lath installations are merged into a single mesh fabric application. The mesh fabric is installed as one continuous piece rather than requiring individual screws or nails for each lath, dramatically reducing installation time and cost while maintaining the structural support function through its continuous network structure.
Solution Approach 2:
The mesh fabric serves as a temporary support structure that is installed quickly and removed after the deformable material hardens. This disposable approach eliminates the need for permanent individual lath installations, reducing both time and cost while providing sufficient support during the critical hardening period.
4Reliability
If fasteners are used to secure the fabric member to the wall structure, then the fabric can be firmly attached, but the fasteners may obstruct the design impression process
Solution Approach 1:
The mesh fabric provides locally dense structure at fastener locations to ensure firm attachment to the wall, while maintaining open areas elsewhere that allow design tools to pass through and impress patterns into the deformable material without obstruction.
Data Source
AI summary
An apparatus and method for securing a deformable material to a wall structure such that the deformable material is allowed to solidify to form a predetermined configuration upon the wall structure, includes securing a fabric member to a wall structure, the fabric member having a configuration that supports a deformable material that ultimately solidifies; a plurality of offset strips (when required) that separate the fabric member from the wall structure to provide an air gap; and fasteners that maintain the relative position of the fabric upon the wall structure throughout the application of the deformable material upon the fabric member, the configuring of a design into the deformable material, and after the deformable material has solidified.