Patent Application
20210301521
Not applicable.
Not applicable.
Not applicable.
The present invention relates to the field of anchoring systems for cavity walls, and more specifically, to the field of thermally insulated wall anchors for preventing the flow of thermal energy between conductive materials within a wall assembly.
Minimizing the use of energy and natural resources are vital components of the global strategy to protect the environment and mitigate climate change. Buildings and the construction sector represent a large portion of total global energy and resource consumption. One significant aspect of energy loss from a building is conductive heat transfer through the building envelope. The building envelope is a layer of the building enclosure system that resists heat flow between the interior conditioned environment and the exterior unconditioned environment. The thermal performance of the building envelope can be greatly affected by thermal bridging. Thermal bridges are localized elements or assemblies that penetrate insulated portions of the building envelope with thermally conductive materials that result in high levels of heat loss.
Determining and preventing potential thermal bridges within a cavity wall is essential for constructing a comfortable and energy efficiency building. Thermal bridging typically occurs near highly conductive materials like wood studs, metal studs, steel, and concrete. Thermal bridging can result in increased energy required to heat or cool a conditioned space due to winter heat loss and summer heat gain. For example, in a climate where the interior temperatures are greater than the exterior, heat from a room will eventually transfer through the interior drywall and to the highly conductive flanges of a stud, routing to the fastener of a brick tie, to the tie itself, and eventually exiting the brick at the exterior, resulting in a reduction of thermal performance of the wall assembly.
Additionally, when the temperature difference between indoor and outdoor space is large, and there is warm and humid air indoors, such as the conditions experienced in the winter, there is a risk of condensation in the building envelope due to the cooler temperature on the interior surface at thermal bridge locations. Condensation may ultimately result in mold growth with consequent poor indoor air quality and insulation degradation, reducing the insulation performance and causing the insulation to perform inconsistently throughout the thermal envelope.
Although traditional methods to reduce thermal bridging, such as limiting the number of wall anchors that span from unconditioned to conditioned space and utilizing wall anchors coated with non-conductive materials improve energy efficiency, the inability to completely eliminate the metal components of a wall anchor from within the cavity wall continues to cause heating and cooling losses. Therefore, a need exists to improve over the prior art and, more particularly, for an insulated wall anchor that eliminates metal components within a cavity wall for preventing the flow of thermal energy while also conserving structural integrity.
A thermally insulated wall anchor for use in a cavity wall to connect to a veneer tie that joins an inner wythe and an outer wythe of the cavity wall is disclosed. This Summary is provided to introduce a selection of disclosed concepts in a simplified form that are further described below in the Detailed Description, including the drawings provided. This Summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this Summary intended to be used to limit the claimed subject matter's scope.
In one embodiment, a wall anchor for use in a cavity wall to connect to a veneer tie that joins an inner wythe and an outer wythe of the cavity wall is disclosed. The wall anchor includes an elongated shaft and a receiving section configured to be in attachment with the elongated shaft. The receiving section defines at least one aperture configured to receive a portion of the veneer tie. The receiving section defines a thermal insulating member comprising non-metallic material. The receiving section has no metallic material surrounding the at least one aperture and is configured such that no metallic material is exposed out of the receiving section to an air cavity between the inner wythe and outer wythe when the wall anchor is in an installed state.
In one embodiment, a wall anchor for use in a cavity wall to connect to a veneer tie that joins an inner wythe and an outer wythe of the cavity wall is disclosed. The wall anchor includes an elongated shaft and a receiving section configured to be in attachment with the elongated shaft. The receiving section defines at least one aperture configured to receive a portion of the veneer tie. The receiving section defines a thermal insulating member comprising non-metallic material. The receiving section is configured such that no metallic material of the receiving section is between the inner wythe and outer wythe when the wall anchor is in an installed state.
In one embodiment, a method of anchoring a veneer wall to an inner wythe for horizontal load transfer is disclosed. The method includes securing an anchoring end of an anchor shaft of a wall anchor to an inner wythe such that a receiving end of the wall anchor protrudes into a space between the inner wythe and the outer wythe such that no metallic material is exposed out of the receiving section to an air cavity between the inner wythe and outer wythe when the wall anchor is in an installed state.
Additional aspects of the disclosed embodiment will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the disclosed embodiments. The aspects of the disclosed embodiments will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed embodiments, as claimed.
The accompanying drawings, which are incorporated in and constitute part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of the disclosed embodiments. The embodiments illustrated herein are presently preferred, it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown, wherein:
The following detailed description refers to the accompanying drawings. Whenever possible, the same reference numbers are used in the drawings and the following description to refer to the same or similar elements. While disclosed embodiments may be described, modifications, adaptations, and other implementations are possible. For example, substitutions, additions, or modifications may be made to the elements illustrated in the drawings, and the methods described herein may be modified by substituting reordering or adding additional stages or components to the disclosed methods and devices. Accordingly, the following detailed description does not limit the disclosed embodiments. Instead, the proper scope of the disclosed embodiments is defined by the appended claims.
The present invention improves upon the prior art by providing a wall anchor for use in a cavity wall to connect to a veneer tie that joins an inner wythe and an outer wythe of the cavity wall. The wall anchor includes an elongated shaft and a receiving section configured to be in attachment with the elongated shaft. The receiving section defines a thermal insulating member that is comprised of a non-metallic material and is coated with a high temperature coating. The receiving section is configured such that no metallic material is exposed out of the receiving section to an air cavity between the inner wythe and outer wythe when the wall anchor is in an installed state. The present invention further improves upon the prior art because the receiving section is configured such that no metallic material of the receiving section is between the inner wythe and outer wythe when the wall anchor is in an installed state.
Referring now to the Figures,
In one embodiment, the second end 124 of the elongated shaft 120 includes a sharp tapered tip 126 configured for attachment to materials such as sheet metal, wood, and drywall. In one embodiment, as best illustrated in
It should be appreciated that depending on the method and application of the wall anchor, the elongated shaft may comprise a broad range of diameters, lengths, drive styles, threads, and finishes, and such variations are within the spirit and scope of the claimed invention. It should also be appreciated that the elongated shaft 120 may be made of any suitable material, such as stainless steel or zinc-plated steel, or combination of materials, and may vary in accordance with the present invention. As further discussed below, the elongated shaft 120 may further include a high temperature coating to reduce thermal conductivity.
The wall anchor 100 further includes a receiving section 130 that is configured to be in attachment with the elongated shaft 120. The receiving section includes an outward facing end 132 and an inward facing end 133. In one embodiment, the outward facing end 132 of the receiving section includes an outwardly extending tab 181 comprising a substantially planar rectangular shaped body. The outward facing end 132 of the receiving section further includes at least one aperture 180 that is configured to receive a portion of the veneer tie 104. In one embodiment, the aperture is defined by an oval shaped opening formed on the outwardly extending tab of the receiving section. The inner diameter of the aperture is sized and shaped according to the outer diameter of the veneer tie 104.
In operation, as best shown in
The inward facing end 233 of the receiving section includes a collared section 140. The collared section 140 is configured to be in attachment with the first end 122 of the elongated shaft 120. In one embodiment, the collared section 140 is a hollow cylindrical shaped body having a circular shaped opening 141. The collared section 140 includes an inner diameter that is larger than an outer diameter of the elongated shaft such that the first end 122 of the elongated shaft 120 may be inserted into the circular shaped opening 141 of the collared section. It should be appreciated that the collared section 140 may have include different shapes, dimensions, and configurations, and such variations are within the spirit and scope of the claimed invention.
The wall anchor 100 further includes a flanged section 150 located between the collared section 140 and the receiving section 130. The flanged section 150 defines a shape that is configured to engage with a tool that provides a driving force to drive the second end 124 of the elongated shaft 120 into the inner wythe 106 such that the aperture is not damaged during installation. It should be appreciated that the flanged section 150 may have various shapes and dimensions, and such variations are within the spirit and scope of the claimed invention.
For example, in one embodiment, as best shown in
The wall anchor 100 further includes a washer 160 that abuts an inward facing surface of the flanged section 150. The washer 160 is configured to completely seal the opening into the inner wythe 106. The washer 160 includes an outward facing surface 161 and an inward facing surface 162. In one embodiment, the washer 160 comprises a substantially planar circular shaped body that extends beyond the flange of the wall anchor. The washer 160 may be comprised of a stabilizing neoprene fitting, or a bonded sealing washer, such as a sealing washer having a backing (e.g., nylon) with a bonded sealant (e.g., EPDM rubber, neoprene, silicone), or any other suitable material known in the art. It should be appreciated that the washer 160 may be omitted from the wall anchor or may have other shapes and dimensions, and such variations are within the spirit and scope of the claimed invention.
As discussed in greater detail below, the receiving section 130 of the wall anchor defines a thermal insulating member comprising non-metallic material for preventing the flow of thermal energy. The receiving section 130 of the wall anchor is made from a high temperature material comprising at least one of an ablative material, a boron fiber material, a carbon fiber material, a ceramic matrix composite material, a composite material, an epoxy matrix composite, a fatigue composite material, a fiber composite, a fiber-matrix interface, a filament material, a filament wound structures composite material, a filament-matrix material, a flammability composite materials, a glass fiber reinforced plastic material, a honeycomb material, an insulation composite material, a laminate material, a metal filament system, a metal matrix composite (MMC), a nanocomposite, an off-gassing/out-gassing composite material, a polymer matrix composite, a reinforcing fibers composite material, a stacking sequence composite material, a surface property composite material, whisker composite, a woven composite material, or any combination of the foregoing materials.
The receiving section 130 of the wall anchor further includes a high temperature coating selected from thermoplastics, thermosets, natural fibers, rubbers, resins, asphalts, ethylene propylene diene monomers, and admixtures thereof and may be applied in layers. The high temperature coating optionally contains an isotropic polymer, which includes, but is not limited to, acrylics, nylons, epoxies, silicones, polyesters, polyvinyl chlorides, polyethylene, and chlorosulfonated polyethylene. Alternatively, the high temperature coating may be a ceramic or ceramic-based coating including materials selected from lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, indium, scandium, yttrium, zirconium, hafnium, titanium, silica, zirconia, magnesium zirconate, yttria-stabilized zirconia, and derivatives and admixtures thereof. An initial layer of the high temperature coating may be cured to provide a pre-coat, and the layers of the high temperature coating may be cross-linked to provide high-strength adhesion to the wall anchor to resist chipping or wearing of the high temperature coating. The high temperature coating may be applied through any number of methods, including fluidized bed production, thermal spraying, hot dip processing, heat-assisted fluid coating, or extrusion, and includes both powder and fluid coating to form a reasonably uniform coating.
The present invention improves upon the prior art by removing contact with metal components within a cavity wall to prevent the flow of thermal energy. In operation, as best shown in the embodiment of
In one embodiment, as best shown in
In one embodiment, the second end 224 of the elongated shaft 220 includes a sharp tapered tip 226 configured for attachment to materials such as sheet metal, wood, and drywall. In one embodiment, as best illustrated in
It should be appreciated that depending on the method and application of the wall anchor, the elongated shafted may comprise a broad range of diameters, lengths, drive styles, threads, and finishes, and such variations are within the spirit and scope of the claimed invention. It should also be appreciated that the elongated shaft 220 may be made of any suitable material, such as stainless steel or zinc-plated steel, or combination of materials, and may vary in accordance with the present invention. As further discussed below, the elongated shaft 220 may further include a high temperature coating to reduce thermal conductivity.
The wall anchor 200 further includes a receiving section 230 that is configured to be in attachment with the elongated shaft 220. The receiving section includes an outward facing end 232 and an inward facing end 233. The outward facing end 232 of the receiving section is configured to engage with a tool that provides a driving force to drive the second end 224 of the elongated shaft 220 into the inner wythe 206. For example, in one embodiment, the outward facing end 232 of the receiving section is defined by at least one hexagonally shaped recess 278. In one embodiment, as best shown in
The inward facing end 233 of the receiving section includes a collared section 240. The collared section 240 is configured to be in attachment with the first end 222 of the elongated shaft 220. In one embodiment, the collared section 240 is a hollow cylindrical shaped body having a circular shaped opening 241. The collared section 240 includes an inner diameter that is larger than an outer diameter of the elongated shaft such that the first end 222 of the elongated shaft 220 may be inserted into the circular shaped opening 241 of the collared section. It should be appreciated that the collared section 240 may have include different shapes, dimensions, and configurations, and such variations are within the spirit and scope of the claimed invention.
The wall anchor 200 further includes a flanged section 250 located between the collared section 240 section and the receiving section 230. In one embodiment, the flanged section 250 is defined by a wing nut. The flanged section 250 further includes at least one aperture 280 that is configured to receive a portion of the veneer tie 204. In one embodiment, the aperture is defined by a circular shaped opening (two are shown) formed on the flanged section. The inner diameter of the aperture is sized and shaped according to the outer diameter of the veneer tie 204.
In operation, as best shown in
The wall anchor 200 further includes a washer 260 that abuts an inward facing surface of the flanged section 250. The washer 260 is configured to completely seal the opening into the inner wythe 206. The washer 260 includes an outward facing surface 261 and an inward facing surface 262. In one embodiment, the washer 260 comprises a substantially planar circular shaped body that extends beyond the flange of the wall anchor. The washer 260 may be comprised of a stabilizing neoprene fitting, or a bonded sealing washer, such as a sealing washer having a backing (e.g., nylon) with a bonded sealant (e.g., EPDM rubber, neoprene, silicone), or any other suitable material known in the art. It should be appreciated that the washer 260 may be omitted from the wall anchor or may have other shapes and dimensions, and such variations are within the spirit and scope of the claimed invention.
As discussed above, the receiving section 230 of the wall anchor defines a thermal insulating member comprising non-metallic material for preventing the flow of thermal energy. The receiving section 230 of the wall anchor is made from a high temperature material comprising at least one of an ablative material, a boron fiber material, a carbon fiber material, a ceramic matrix composite material, a composite material, an epoxy matrix composite, a fatigue composite material, a fiber composite, a fiber-matrix interface, a filament material, a filament wound structures composite material, a filament-matrix material, a flammability composite materials, a glass fiber reinforced plastic material, a honeycomb material, an insulation composite material, a laminate material, a metal filament system, a metal matrix composite (MMC), a nanocomposite, an off-gassing/out-gassing composite material, a polymer matrix composite, a reinforcing fibers composite material, a stacking sequence composite material, a surface property composite material, whisker composite, a woven composite material, or any combination of the foregoing materials.
The receiving section 230 of the wall anchor further includes a high temperature coating selected from thermoplastics, thermosets, natural fibers, rubbers, resins, asphalts, ethylene propylene diene monomers, and admixtures thereof and may be applied in layers. The high temperature coating optionally contains an isotropic polymer, which includes, but is not limited to, acrylics, nylons, epoxies, silicones, polyesters, polyvinyl chlorides, polyethylene, and chlorosulfonated polyethylene. Alternatively, the high temperature coating may be a ceramic or ceramic-based coating including materials selected from lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, indium, scandium, yttrium, zirconium, hafnium, titanium, silica, zirconia, magnesium zirconate, yttria-stabilized zirconia, and derivatives and admixtures thereof. An initial layer of the high temperature coating may be cured to provide a pre-coat, and the layers of the high temperature coating may be cross-linked to provide high-strength adhesion to the wall anchor to resist chipping or wearing of the high temperature coating. The high temperature coating may be applied through any number of methods, including fluidized bed production, thermal spraying, hot dip processing, heat-assisted fluid coating, or extrusion, and includes both powder and fluid coating to form a reasonably uniform coating.
The present invention improves upon the prior art by removing contact with metal components within a cavity wall to prevent the flow of thermal energy. In operation, as best shown in the embodiment of
In one embodiment, as best shown in
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing the claims.
