This specification relates to structural materials for use in the construction of buildings, and, in one particular context, to support structure external veneer components.
In former times, brick walls were load bearing structures. In contemporary building structures bricks, or other masonry elements, or other visible finished surface elements, are rarely load-bearing and tend more often to be employed as surface cladding on the exterior face of load-bearing structure.
When mounting face brick or stone veneer on the face of a wall structure, it is common to support the first row of bricks or stone, or veneer on a steel support. The steel support may be termed a shelf angle, and may extend outward from the wall structure, and may run along, or have a major dimension extending in, a direction that is generally horizontal and cross-wise to the wall. The steel support is mounted to the wall before brick-laying commences. The steel support may be welded to a steel anchoring system embedded in the wall. Alternatively, the steel support may be carried in spaced apart brackets that have themselves been mounted to the load bearing wall structure.
In an aspect of the invention there is a veneer mounting bracket for mounting to a beam. The veneer mounting bracket has a beam engagement extending rearwardly of an upper region thereof. The beam engagement defines a vertical load output interface of the mounting bracket. A forwardly facing shelf angle seat is located in a lower region of the mounting bracket. It defines a vertical load input interface. The lower region has a rearwardly facing moment reaction member for engaging a lower region of the beam.
In a feature of that aspect of the invention there is a lateral securement fitting by which to discourage lateral engagement of the mounting bracket from a beam. In another feature the arm has a mounting in which to accommodate mechanical fastening hardware. In another feature, the bracket has a vertical reach having a depth greater than the beam. In still another feature, the moment reaction member defines a horizontal load interface for engagement with a side facing portion of the beam. In still another feature the arm defines a fitting for engaging an upper surface of an upper flange of the beam, and the reaction member defines an engagement interface for engaging a side-facing toe of a lower flange of the beam. In a further feature, the mounting bracket includes a web that, as installed on a beam, stands outwardly away from the beam, the seat being located in a lower portion of the web outwardly distant from the beam. In an additional feature, the bracket has a first leg and a second leg, the first leg, as installed, lying against the beam, and the second leg defining the web that extends outwardly away from the beam. In a further additional feature, a tang is formed in the first leg, the tang extending rearwardly of the first leg to define the arm. In yet another additional feature, there is a combination of the mounting bracket of any of the aspects or features, and the beam, wherein the beam has an upper flange, a lower flange, and a web extending between the upper flange and the lower flange.
In another aspect of the invention there is a mounting bracket for securement to a beam. It has a stretcher having a shelf angle seat and a hanger. The shelf angle seat defines a vertical load input interface. The hanger defines a vertical load output interface. The seat faces forwardly away from the hanger. The hanger faces rearwardly away from the seat. The hanger is located upwardly of the seat. The stretcher has a moment reaction interface located distant from the vertical load output interface and facing away from the shelf angle seat.
In a feature of that aspect of the invention, the beam has a depth, and the stretcher has a height exceeding the depth. In a further feature, there is a combination of the mounting bracket and the beam, wherein the beam has an upper flange, a lower flange, and a web extending between the upper and lower flanges; the hanger engages the upper flange, and the moment reaction interface engages the lower flange. In an additional feature, the second member is a shelf angle having a flange and a web, the flange defining an upwardly facing external veneer load receiving interface; the web having the accommodation for the protrusion formed therein. In another feature the web is an upstanding web; and the upstanding web has a greater vertical extent than the seat. In an additional feature, the web includes an aperture formed therein at a medial height location thereof, the aperture permitting introduction of the protruding toe therethrough, and the aperture defining the accommodation. In a still further feature, on assembly, the flange is located one of (a) flush with a lowermost portion of the protruding toe; and (b) downwardly proud of the protruding toe. In another feature, the seat engagement extends rearwardly and upwardly of the carrier. In a still further feature, the first member is a channel member, having a back and two spaced apart legs extending away from the back to form a channel, the back of the channel having the mounting fitting, and each of the legs of the channel having one of the seats.
In yet another feature the protrusion has an upwardly facing shoulder defining the shear load transmission interface. The seat includes an upwardly extending slot and an over-hanging finger. The second member seat engagement includes a web having an upwardly extending extremity that, on assembly, seats in the slot. The over-hanging finger defines one portion of the moment-couple reaction interface. In still yet further feature, the slot is oversized to admit at least partial angular rotation of the web of the second member on installation. The slot has a relieved first wall portion angled on a first angle relative to vertical. The overhanging finger has a downwardly distal tip, the downwardly distal tip being relieved to accommodate insertion of the web on assembly; the downwardly distal tip having a chamfer on a second angle relative to vertical; and the second angle is greater than the first angle.
In still another aspect of the invention, there is a wall mounting bracket having a seat in which to install a shelf angle for supporting external veneer. The wall mounting bracket has at least one rearwardly protruding tab by which to transmit vertical loading into a load-bearing beam structure. The bracket has at least one moment couple reaction interface oriented to engage the beam and to discourage rotation of the bracket relative to the beam when installed; and a forwardly facing seat defining an accommodation in which to receive a shelf angle.
In a feature of that aspect of the invention, a horizontal projection of the seat toward the load-bearing wall structure projects downwardly clear of the fitting.
In another aspect of the invention there is a face brick support assembly having a wall mounting bracket and a shelf angle that seats on the wall mounting bracket. The wall mounting bracket has a protrusion. The shelf angle has an accommodation that, on assembly, admits the protrusion.
The foregoing aspects and features of the invention may be explained and understood with the aid of the accompanying illustrations, in which:
The description that follows, and the embodiments described therein, are provided by way of illustration of an example, or examples, of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the invention. In the description, like parts are marked throughout the specification and the drawings with the same respective reference numerals. The drawings may be taken as being to scale, or generally proportionate, unless indicated otherwise.
The terminology used in this specification is thought to be consistent with the customary and ordinary meanings of those terms as they would be understood by a person of ordinary skill in the art in North America. Following from the decision of the Court of Appeal for the Federal Circuit in Phillips v. AWH Corp., the Applicant expressly excludes all interpretations that are inconsistent with this specification, and, in particular, expressly excludes any interpretation of the claims or the language used in this specification such as may be made in the USPTO, or in any other Patent Office, other than those interpretations for which express support can be demonstrated in this specification or in objective evidence of record in accordance with In re Lee, (for example, earlier publications by persons not employed by the USPTO or any other Patent Office), demonstrating how the terms are used and understood by persons of ordinary skill in the art, or by way of expert evidence of a person or persons of experience in the art.
Referring to the general arrangement of
In this description, reference is made to load-bearing structure, and load-bearing wall structure. The description pertains to mounting bracket assemblies that support external facing veneer components, such as face brick, spaced away from the supporting structure. The mounting brackets are anchored to load-bearing structure. Whether that load bearing structure is a structural wall or a concrete floor slab carried by framework, by a poured wall, by a block wall, or other load bearing members, in the context of this description whether it is a wall, a floor, or a ceiling, within the meaning of this specification it is a load-bearing wall structure to which the veneer supporting members may be mounted.
Wall assembly 20 may include load-bearing structure, indicated generally as 22, and externally visible facing elements, indicated generally as 24. The externally visible facing elements are mated to, or linked to, or stabilised by, load bearing structure 22. The linking, or positioning of the facing elements with the load-bearing structural elements may be achieved by the use of interface elements such as supports, or support assemblies, 26, and tying members 28. Support assemblies 26 and tying members 28 may be taken as being made of mild steel unless otherwise noted. Combinations of load bearing frame or wall assemblies, such as 22, facing elements 24, support assemblies 26 and tying assemblies 28 may be assembled as indicated in
Load-bearing structure 22 may have several different forms. First, it may include a foundation, which may be a poured concrete foundation 32. There may be a floor structure, such as a poured concrete floor slab 34. Floor slab 34 may carry a wall structure 36 which may have the form of laid blocks 38, or which may in other embodiments include a framed structure, such as may be a wood or steel framed structure.
Visible facing elements 24 may include brickwork 40, or stonework, be it rough stone or finished stone, or other cladding. The anchor system described may be used for supporting masonry veneer, thin granite veneer, large stone panels or pre-cast concrete in place of the bricks. In the example shown, facing elements 24 are shown as bricks 42 laid in successive courses. As suggested by
There may typically be at least first and second such second support members 50 spaced laterally apart. For example, there may be several such supports on, for example, 24″ centers, indicated as spacing Li, which may correspond to the spacing, or double the spacing of wall studs in standard framing (see
Second members 50 are secured to load bearing wall 22. The securement may be by suitable means. For example mechanical securements in the nature of threaded fasteners 54. In the case of securement to a poured concrete wall or floor slab (as shown) the fasteners may be concrete anchors. Fasteners 54 may be concrete anchor fittings, as shown in
Second members 50 have a depth (in the y-direction) that may correspond to, or may be greater than, the thickness of insulation panels 56 such as may be mounted to the front (or outside) face of the structural load-bearing wall assembly 22. There may also be a drainage shield, or flashing, 58 such as may encourage moisture to drain outwardly of and away from structural wall assembly 26. A vapour barrier membrane 59 may be captured behind insulation panels 56 upwardly of the floor slab, may traverse insulation 56 at the level of flashing 58, and may lay overtop of flashing 58 with its lowermost margin draining over angle iron 46, such that any moisture draining over vapour barrier 59 is drained away. That is, a continuous metal flashing 58 is supported on or above shelf angle 46. It may connect to a continuous flexible flashing which extends over the brick supports and that may connect to a vapour barrier membrane on the outer face of the wall. Sheets of rigid insulation are mounted over top of the membrane on the outer face of the wall. The anchor system allows cavity insulation to be continuous behind the brick support. The rigid insulation may be of a thickness that allows an air space between the insulation and the external veneer brick facing mounted on shelf angle 46. The anchor brackets 52 may be made in a variety of sizes each corresponding to a desired thickness of the rigid insulation and air space. In this arrangement, a standard size of brick support shelf angle 46 may be used without regard to the spacing between the brick facing and the face of the wall desired for insulation.
In some embodiments, tying members 28 may be located upwardly of support assembly 26. Tying members 28 may have the form of brick tie assembly 60, in which there is an anchor 62 and a brick tie 64. As may be noted, anchor 62 has a body 66 such as may have the form of a stamped steel plate. The distal portion of body 66 may be termed a tail 68. Tail 68 may have a length in the y-direction (i.e., into the wall) corresponding to the through thickness of cinder blocks 38, and such as may be located between adjacent blocks of a block wall, and embedded in the mortar therebetween. To that end, tail 68 may have perforations such as may permit mortar to flow therethrough. Body 66 may also have a proximal portion 70 of a depth in the y-direction corresponding to the thickness of insulation panel 56. Proximal portion 70 may be perforated to reduce thermal conduction in the y-direction. Proximal portion 70 may have a step, or abutment, or indexing or locating feature, such as a shoulder, by which the correct depth position in the y-direction is obtained relative to the cinder block and the insulation. Body 66 may also have an outermost end portion 74 having an array of tie location apertures, or seats or positions 76. A faceplate 78 seats on the outside face of the insulation, and may be used on installation where the positioning of anchor 62 is set prior to installation of tail 68 in a poured concrete form. Brick tie 64 is then located in one or another of the seat positions 76. When the successive courses of bricks 42 are laid, the outermost ends of brick tie 64 are embedded in the mortar between courses, as suggested in
Considering the enlarged detail of the embodiment of
Back 82 may have a mounting, a seat, or an attachment fitting 90 such as shown in
The side plates defined by legs 84, 86 are arranged to receive and to carry the brick support defined by bracket 46. Looking at leg 84 as being representative also of leg 86, and considering the profile shown in
Seat 94 includes a vertical reaction interface, indicated at 96, and a moment restraint, indicated at 98. Moment restraint 98 includes an upper reaction member 100 and a lower reaction member 102. Leg 84 (or 86) may have an overhanging member, or finger 104 that, in use, over-reaches, and depends in front of, the uppermost margin of first member 44. The space between finger 104 and the upper leading edge of the body of leg 84 (or 86) more generally defines a receiving slot 107 as, or at, the upper portion of seat 94. Slot 107 extends upward, and has a rearward edge (i.e., at edge or wall 114) at a top end of the recessed, generally channel-shaped profile of seat 94. The inside face of the downward or distal tip of finger 104 may have the form of an abutment, or stop, or restraint that faces wholly, substantially, or predominantly in the −y direction, defining upper reaction member 100.
Vertical reaction interface 96 may be defined as the upper face of the toe, edge, or side of an extending portion or member or dog or toe 108, such as may be or define a protruding extension or protrusion in the y-direction of the lower margin of leg 84. That is, in the embodiment illustrated the recessed channel shape of seat 94 includes a shoulder at a bottom end. That shoulder defines vertical reaction interface 96, and it carries the shelf angle, such that the brick supporting flange extends laterally outward from the wall.
Lower reaction member 102 extends upwardly and away from the root of toe 108, and has the form of a wall or edge that faces wholly, substantially or predominantly in the +y direction. A fatigue detail, or stress relief detail, in the form of a finite radius relief 110 is provided at the root of the intersection of vertical reaction interface 96 and lower reaction member 102. The upper and lower stops (i.e., 100 and 102) constrain the translational degree of freedom of corresponding upper and lower regions of angle iron 46, and thus define a moment-couple reaction inhibiting motion in the rotational degree of freedom about the x-axis of angle iron 46 in the counter-clockwise direction.
Upwardly of an inflection point 112, wall 114 of seat 94, (being the back or rearward margin of slot 107) is relieved in the −y direction such that seat 94 may include, and slot 107 may be, a slanted slot or accommodation such as to permit entry of the upper leg of angle iron 46 into the accommodation on installation. The angle of inclination α107 may be in the range of 10-20 degrees in some embodiments. The lowermost extremity of the inside tip of finger 104 may also be trimmed, or tapered, or chamfered as at 115. The angle or size of the chamfer or relief at 115, designated as α115, is steeper, i.e., smaller, than the size of angle α107 of the chamfer or relief of wall 114. That is, whereas wall 114 may be angled at 10-20 degrees, from vertical, the relief at 115 may be more than 20 degrees, and may be about 24 or 25 degrees. Lower reaction member 102 may extend in a vertical plane, P102. Upper reaction member 100 may extend in a vertical plane P100. Planes P102 and P100 may be parallel and spaced apart, with upper reaction member 100 being more distant from back 82 than is lower reaction member 102. They may be spaced apart by a distance corresponding to the through thickness of the upstanding leg of angle iron 46.
The overall height of seat 94 may be taken from the vertical shear transfer receiving interface of shoulder 96 to the uppermost extremity of slot 107, and is indicated as h94 in
The brick support defined by angle iron 46 may include a mounting flange which engages anchor bracket 50, and a supporting flange arranged to carry bricks. The mounting flange and the supporting flange may typically be mounted at right angles to form an L-shaped angle iron, typically made of steel. As in
In the embodiment of
In the engagement of toe or dog 108 in accommodation or relief 120 or 122, as may be, it may be that the lowermost margin of leg 84 (or 86) does not extend lower than (i.e., downwardly proud of) the bottom of horizontal leg 116, such that no additional vertical clearance allowance is required for toe 108, meaning that the toe is concealed behind the external veneer and the bottom edge of the lowest course of bricks may be lower than otherwise. Expressed differently, in terms of a seating arrangement of structural members, second member 50 may be considered to be the receiving member, and first member 44 may be considered to be the received member. In the arrangement of
The receiving slot 107 slidably receives an edge portion of the mounting flange of leg 118 therein such that the brick support remains secured to the anchoring bracket 46 when a weight of bricks is stacked on the supporting flange of leg 116. The rearward edge 114 of receiving slot 107 extends upward at a slight rearward incline for accommodating the edge portion of the mounting flange of leg 118 as it is inserted therein. A wedge shaped shim may then be inserted between the distal tip of leg 118 and the rearward edge 114 such as to lock the assembly in tight engagement.
The received member, such as the shelf angle identified as angle iron 46, is itself a receiving member, or accommodation, for the externally visible facing elements, and as the facing elements are received, rearward structure such as bracket 52 is obscured from view. The received member need not be an angle iron, and whether or not it is an angle iron, is need not have a 90 degree angle. In more general terms, the received member has a first portion that defines a seat or bench, or accommodation, or support, or platform or under-girding, or shelf, for the externally visible facing members, hence the term “shelf angle”. It is a form of sill. The received member also has a second portion that engages the receiving member such that vertical load from the received member is transmitted or carried into the receiving member and thence into the load-bearing supporting structure. In that sense the second portion can be thought of as an engagement fitting, or key, or inter-locking feature, or indexing feature, that mates with the receiving member. It happens that an L-shaped angle iron may be a convenient form having these properties.
In the embodiment shown in
In the alternate embodiment of
Support assemblies 26 need not be located only at the lowermost course of facing elements. As seen in
Considering
Second member 164 may be the receiving member with which it co-operates, and may be a channel-shaped bracket 170. As before, the receiving member 164 is rigidly secured to the load bearing wall structure, namely wall assembly 150. On installation, the back of bracket 170 lies in facing abutment against the load bearing wall structure in the same manner, or substantially the same manner, as member 50 described above, and where the wall is vertical, bracket 170 is correspondingly vertical. The load output interface of vertical load transfer assembly 160, namely the connection to the load bearing wall, is located at a first height, identified as H164. The load input interface of assembly 160, at which the vertical load of the external veneer or cladding is received at leg 166, is identified as a second height, H166 and passed into the vertical load input interface of bracket 170 at the upper shoulder of toe 174, indicated as being at height H162. The first height is substantially higher than the second height. That is, H166 lies at a level that is below the height of the bottom margin of the floor slab, and at a height that is more than two brick courses (i.e., more than 6″) below H164. Side web or leg 172 of channel or bracket 170 is much deeper in the z-direction (see H172) than is the depth of the accommodation for the shelf angle, i.e., first member 162, identified as H168.
In the embodiment of
In the embodiment of
In the embodiment of
The embodiment of
In each of
In each of the embodiments of
In each case the general description of installation and use is substantially the same. That is, a brick support in the form of a standard size shelf angle is mounted across the wall on the anchoring brackets. The anchoring brackets are first bolted to the wall by securing the bolts loosely by hand. The brick support is then mounted on the anchoring brackets by inserting a edge portion of the mounting flange 118 upward into the receiving slot 92 of each anchoring bracket 52 (or as may be) at an incline and then by pivoting the supporting flange inward until the mounting flange engages the rearward edge of seat 94. The rearward edge at 102 prevents the brick support from being further pivoted within the recessed channel under the increasing moment couple as the weight of the bricks is applied to the brick support. The bolts are then tightened snugly and the wedge shaped shims may be inserted to suit.
Until the nuts on the respective bolts are tightened, the relative height of each anchoring bracket is adjustable by sliding the anchoring bracket laterally along the brick support as the anchoring bracket is moved upward or downward relative to the bolt extending from the wall. This lateral movement of the anchoring bracket relative to the brick support with the adjustment in height is due to the inclination of the fastener slot from the vertical.
Once the nuts are tightened on the bolts the brick support is secured to the load-bearing wall structure, and bricks may be supported thereon. The inclination of the fastener slot from the vertical acts to inhibit vertical displacement of the anchoring bracket along the mounting bolt through the resistance of the lateral movement of the anchoring bracket along the brick support. Having anchoring brackets of opposing orientation mounted adjacent to each other further restricts the entire brick anchor system from shifting positions relative to the wall once the bolts are tightened.
The relative location of the anchoring brackets remains adjustable as the brick support is mounted thereon for accommodating irregularities in the wall or misalignment between adjacent anchoring brackets. Once the brick support is securely fastened to the wall further vertical displacement of the anchoring brackets is inhibited by the resistance of lateral movement of the anchoring brackets relative to the brick support due to the arrangement of the fastener slot.
A shim plate which is substantially similar in size to the anchoring bracket, mounts between each anchoring bracket and the outer face of the wall for evenly engaging the concrete surface and for spacing each anchoring bracket from the wall as desired to accommodate for irregularities in the outer face of the wall.
In the embodiment of
Support apparatus 220 may be termed, or may include a hanger bracket, or support bracket for mounting to beam 210. Assembly 220 may include a first member 222 and a second member 224. Unless otherwise noted, members 222 and 224 may be taken as being made of steel, as with the various support brackets and assemblies described hereinabove. First member 222 may be termed a hanger, or a hanger bracket. Second member 224 may be an external veneer supporting member, or support, or carrier, and may for convenience have the form of, and may be referred to as, a shelf angle, such as shelf angle 46 described above.
In one embodiment, first member 222 may have a first portion or wing or leg 226 and a second portion or wing or leg 228. First portion 226 and second portion 228 may be legs of a structural section, such as an angle iron, a channel, or a steel tube. In the embodiment of
An accommodation or seat 250 may be defined in a lower region of first member 222, for example in second portion 228 and third portion 232, such as may be suitable for receiving second member 224. Seat 250 has elements defining a vertical load input interface, as at 244, and a moment couple reaction interface as at 246 and 248 Second member 224 may have the form of any of the shelf angles identified or described above, and seat 250 may have the form of any of the corresponding seats or accommodations identified above. Legs 238 and 240 may be solid or may be perforated as indicated in other embodiments noted above.
First member 222 may also have an upper region distant from the lower region. The upper region of first member 222 may have a first portion, or member that defines a vertical load output interface 252. That first portion may have the form of an extending member, or protrusion, or abutment, or tang, or tab, or dog, or stop, or arm 254 that extends rearwardly of the main back plane P242, such as to be able to engage upper surface 206 of beam 210. When so engaged, arm 254 may transmit vertical load into beam 210. Arm 254 may be formed from a tongue of back 236 that has been bent outward, leaving an aperture in back 236. The aperture may have a downwardly extending U-shaped profile, as seen in
First member 222 may also have a first moment couple reaction, or horizontal reaction, engagement interface 256 which may be in the nature of a stop or abutment, as at 258. In the embodiment shown, abutment 258 may be the lower end, or a lower region, of first member 222 such as may encounter the end or tip of toe 218.
First member 222 may also have a second moment couple reaction, or horizontal reaction, engagement interface 260. That is, first member 222 may have a fitting 262 at which first member 222 is secured against rotation, or local lateral displacement, relative to beam 210. That fitting may include a free hole or bore 266. Bore 266 defines an accommodation that admits mechanical fastening hardware, such as a screw or bolt, or threaded rod, or rivet, or Huck™ bolt. Interface 260 is separated from interface 256 by a moment arm. In the embodiment of
When fastener 264 is in place, the lateral load in arm 254, which may include a component in tension in the y-direction (i.e., forwardly away from beam 210 in the frame of reference of the wall structure generally), retains arm 254 and prevents first member 222 (and therefore assembly 220) from rotating in the counter-clockwise direction as seen looking into the page in respect of
First member 222 may define an extending member or spanning member or stretcher 270, that reaches from the root of arm 254 to the bottom reaction at abutment 256. In effect, stretcher 270 defines the potential span of the moment arm in the vertical direction (i.e., as projected horizontally) as measured over the flanges of beam 210. Stretcher 270 has a length measured from the horizontal plane of the underside of arm 254 to the lowermost extremity of back 236. That length may be intended to be at least as great as the depth of beam 210 measured over the flanges. Where beam 210 is not an I-beam, or a wide flange beam, but rather a flat-sided beam such as a square or rectangular tube or a laminated beam, stretcher 270 need not be as long. In the embodiment of
In the embodiment of
In the embodiment of
Various embodiments of the invention have been described in detail. Since changes in and or additions to the above-described best mode may be made without departing from the nature, spirit or scope of the invention, the invention is not to be limited to those details but only by the appended claims.
This application claims the benefit of priority as a continuation of U.S. Ser. No. 15/626,474, filed Jun. 19, 2017, which is a continuation of U.S. Ser. No. 14/688,477 filed Apr. 16, 2015, and as a continuation-in-part of U.S. Ser. No. 15/075,682 filed Mar. 21, 2016, which is a continuation of U.S. Ser. No. 14/556,824 filed Dec. 1, 2014 now issued as U.S. Pat. No. 9,316,004; and a continuation of U.S. Ser. No. 14/556,947 filed Dec. 1, 2014 now issued as U.S. Pat. No. 9,447,585, the specifications and drawings of all of the foregoing being incorporated in their entirety herein by reference.
Number | Date | Country | |
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Parent | 15626474 | Jun 2017 | US |
Child | 16137177 | US | |
Parent | 14688477 | Apr 2015 | US |
Child | 15626474 | US | |
Parent | 14556824 | Dec 2014 | US |
Child | 15075682 | US | |
Parent | 14556947 | Dec 2014 | US |
Child | 14556824 | US |
Number | Date | Country | |
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Parent | 15075682 | Mar 2016 | US |
Child | 14688477 | US |