Embodiments of the presently-disclosed invention relate generally to systems and methods for reinforcing structural elements, such as walls, including a composite anchor comprising an anchoring pin at least partially encased or encircled by a bottom portion of a carbon fiber strap (CFS), wherein the composite anchor may be secured within a hole extending into a portion of a foundation. Embodiments of the presently-disclosed invention also relate to kits including the anchoring pin and the CFS as well as methods of stabilizing a wall structure.
Walls and other structural elements are generally capable of supporting residential and light commercial structures for a reasonable period of time. However, such walls and structural elements can begin to crack, tilt, bow, or otherwise deform due to a variety of reasons For example, walls and structural elements may begin to deform and/or structurally decay due to inherent weaknesses attributable to particular structural and/or due to exposure to sustained and/or increased hydrostatic pressure from an outside environment. When the soil adjacent an exterior surface of the wall of a building, for example, becomes saturated with water, it forces the soil to expand and press against the wall (e.g., basement wall or foundation). Deformation, such as cracking, tilting, and bowing, if left untreated, can become progressively greater and eventually facilitate collapse of an entire structural element with resultant damage to the structure supported thereon.
Certain embodiments according to the invention provide a wall reinforcement system, comprising a carbon fiber strap (CFS) adhered to over at least a portion of a wall structure, which may have a top end and a bottom end, and the CFS includes a first end located below the bottom end of the wall structure. The system also includes an anchoring pin including a first pin-end and a second pin-end, and a hole located at or proximate the bottom end of the wall structure and extending into a foundation portion, such as of a building. The hole may be configured to receive at least a portion of a composite anchor, wherein the composite anchor comprises (a) a first portion of the CFS that terminates at the first end, and (b) at least a portion of the anchoring pin. The first portion of the CFS may at least partially encase or encircle the portion of the anchoring pin, and the composite anchor may be secured within the hole, such as by an adhesive.
In another aspect, the present invention provides a method of reinforcing a wall structure having a top end and a bottom end, comprising the following steps: (i) adhering a carbon fiber strap (CFS) to the wall structure between the top end and the bottom end, the CFS having a first end, a second end, and an intermediate portion disposed between the first end and the second end; (ii) providing or forming a hole at or proximate the bottom end of the wall structure, the hole extending into a foundation portion located below the bottom end of the wall structure; (iii) providing an anchoring pin including a first pin-end and a second pin-end; (iv) forming a composite anchor via folding a first portion of the CFS that terminates at the first end at least partially around at least a portion of the anchoring pin; and (v) securing the composite anchor within the hole.
In yet another aspect, the present invention provides a kit for reinforcing a wall structure comprising at least one anchoring pin and at least one carbon fiber strap (CFS). The kit may also include an adhesive, such as an epoxy-based adhesive. In accordance with certain embodiments of the invention, the kit may include a top anchor system including a top bracket configured for attachment to a lower portion of a building.
The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout, and wherein:
Embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
When an element or feature is referred to as being “on”, “adjacent”, “clamped”, or “coupled” to another element or feature, it may be directly on, engaged, clamped or coupled to the other element or layer, or indirectly in which intervening elements or features may be present. For example, when an element is referred to as being “directly clamped between” two other elements or features, there may be no intervening elements or features present. To the contrary, for example, when an element is referred to as being “indirectly clamped between” two other elements or features, there may be intervening elements or features present.
Embodiments of the present invention relate generally to wall reinforcement systems and methods of reinforcing wall structures. The systems and methods, in accordance with certain embodiments, may include a carbon fiber strap (CFS) adhered to the wall structure, which may include a top end and a bottom end, over at least a portion of the wall structure. The CFS may include a first end located below the bottom end of the wall structure. The system also includes an anchoring pin including a first pin-end and a second pin-end, and a hole located at or proximate the bottom end of the wall structure and extending into a foundation portion, such as of a building. The hole may be configured to receive at least a portion of a composite anchor, wherein the composite anchor comprises (a) a first portion of the CFS that terminates at the first end, and (b) at least a portion of the anchoring pin. The first portion of the CFS may at least partially encase or encircle the portion of the anchoring pin, and the composite anchor may be secured within the hole, such as by an adhesive. In this regard, the composite anchor provides a structural mechanism to anchor the CFS into the foundation of the wall or other structure being stabilized, which provides structural support to the wall structure even at the bottommost portion of the wall structure (e.g., at or adjacent the floor) and facilitates the transfer of forces exerted on the wall structure by external forces throughout the CFS and into the foundation to provide improved wall stabilization.
Additionally or alternatively, the one or more CFSs may comprise a first end and a second end that define a length of the CFS along an x-y plane, a thickness defined by the shortest dimension of the CFS (e.g., the z-direction being perpendicular to the x-y plane), and a width defined as the shortest dimension in the x-y plane. In accordance with certain embodiments of the invention, the average width of the CFSs may comprise from about 2 inches to about 12 inches, such as at least about any of the following: 2, 4, 6, and 8 inches, and/or at most about any of the following: 12, 10, and 8 inches.
In accordance with certain embodiments of the invention, the one or more CFSs may comprise a unidirectional CFS or a bidirectional CFS. Additionally or alternatively, the one or more CFSs may have a basis weight from about 200 to about 600 grams-per-square meter (gsm), such as at least about any of the following: 200, 250, 300, 350, and 400 gsm, and/or at most about any of the following: 600, 550, 500, 450, and 400 gsm. Additionally or alternatively, the one or more CFSs may comprise a plurality of tows having on average from about 3000 filaments per tow to about 20,000 filaments per tow, such as at least about any of the following: 3,000, 5,000, 6,000, 8,000, 10,000, and 12,000 filaments per tow, and/or at most about any of the following: 20,000, 18,000, 16,000, 15,000, and 12,000 filaments per tow.
In accordance with certain embodiments of the invention, the one or more CFSs may be adhesively bonded to the inside surface of face of the wall structure. The particular adhesive is not necessarily limited in accordance with certain embodiments of the invention. In accordance with certain embodiments of the invention, the adhesive may comprise an epoxy-based adhesive, such as a single of multi-component epoxy. The adhesive may be disposed on portions of the inside face or surface of the wall structure where the one or more CFSs are located or intended to be located. The application pattern of the adhesive in not particularly limited (e.g., continuous or discontinuous segments of applied adhesive, or complete coverage of the location of interest). In accordance with certain embodiments of the invention, the one or more CFSs may be adhesively bonded to the wall structure and additional adhesive may be applied to the outer-facing surface of the one or more CFSs and pushed into and at least partially fill any void volume (e.g., porous cavities formed between the woven components of the CFS) to at least partially saturate the one or more CFSs with the adhesive.
With reference to
As referenced above, the first portion of the CFS may be folded upon itself and define a sleeve component that at least partially encases the portion of the anchoring pin. In accordance with certain embodiments of the invention, the sleeve component may include from 1 to 4 fold axes, such as 1, 2, 3, or 4 fold axes.
In accordance with certain embodiments of the invention, the anchoring pin has a pin-length extending from the first pin-end to the second pin-end, and the sleeve component at least partially encases from about 20 to about 100% of the pin-length, such as at least about any of the following: 20, 25, 30, 35, 40 45, and 50% of the length, and/or at most about any of the following: 100, 98, 95, 90, 85, 80, 75, 70, 60, and 50% of the pin-length. Additionally or alternatively, the CFS has an original width at the first end prior to being folded upon itself, and a first width after being folded upon itself to define the sleeve component, wherein the first width is from about 10 to about 65% of the original width, such as at least about any of the following: 10, 15, 20, 25, 30, and 35%, and/or at most about any of the following: 65, 60, 55, 50, 45, 40, and 35%. In accordance with certain embodiments of the invention, the sleeve component may have a variable width along a sleeve-length of the sleeve component, and wherein the first width has the smallest value.
In accordance with certain embodiments of the invention, the hole may have a first diameter and the anchoring pin may have a second diameter, in which the second diameter is from about 50% to about 98% of the first diameter, such as at least about any of the following: 50, 55, 60, 65, 70, and 75% of the first diameter, and/or at most about any of the following: 98, 95, 90, 85, 80, and 75% of the first diameter. Additionally or alternatively, the hole has a hole-depth and the anchoring pin has a pin-length, and wherein the pin-length is from about 50% to about 150% of the hole-depth, such as at least about any of the following: 50, 55, 60, 65, 70, and 75% of the hole-depth, and/or at most about any of the following: 150, 125, 100, 95, 90, 85, 80, and 75% of the hole-depth. Accordingly, the anchoring pin may fill a large proportion of the volume defined by the hole.
In accordance with certain embodiments of the invention, the anchoring pin may comprise one or more deformations formed in one or more outer surfaces of the anchoring pin. For example, the one or more deformations may comprise one or more ridges and/or valleys formed in a first outermost surface of the anchoring pin extending from the first pin-end and a second pin-end. The one or more ridges and/or valleys extend perpendicular to the pin-length or +45°, 35°, 35°, 20°, 10°, or 5°. Additionally or alternatively, the deformations may account for about 0.1 to about 20% of second diameter of the anchoring pin, such as at least about any of the following: 0.1, 1, 2, 3, 5, 8, and 10%, and/or at most about any of the following: 20, 18, 15, 12, and 10%.
In accordance with certain embodiments of the invention, the CFS includes a second end diametrically opposed the first end, in which the second end is located above the end of the wall structure. For example, the second end of the CFS is secured to a lower portion of a building, such as a floor joist, a rim joist, or a sill plate. In accordance with certain embodiments of the invention, the second end of the CFS may be secured to a lower portion of a building by a variety of means. In this regard, the second end of the CFS may be secured to the lower portion of the building via a top anchor system including, for example, a top bracket, such as those disclosed in U.S. Pat. Nos. 10,858,850, 8,584,431, and co-owned and co-pending application Ser. No. 17/670,950 filed on Feb. 14, 2022; the contents of each are hereby incorporated in their entirety by reference.
By way of example only,
In another aspect, the present invention provides a method of reinforcing a wall structure having a top end and a bottom end, comprising the following steps: (i) adhering a carbon fiber strap (CFS) to the wall structure between the top end and the bottom end, the CFS having a first end, a second end, and an intermediate portion disposed between the first end and the second end; (ii) providing or forming a hole at or proximate the bottom end of the wall structure, the hole extending into a foundation portion located below the bottom end of the wall structure; (iii) providing an anchoring pin including a first pin-end and a second pin-end; (iv) forming a composite anchor via folding a first portion of the CFS that terminates at the first end at least partially around at least a portion of the anchoring pin; and (v) securing the composite anchor within the hole. In accordance with certain embodiments of the invention, the step of securing the composite anchor within the hole may comprise at least partially filling a void space defined by the hole and the composite anchor with an adhesive, such as an epoxy-based adhesive.
In accordance with certain embodiments of the invention, the method may comprise folding the first part of the CFS to define a sleeve component, followed by inserting the sleeve component into the hole, followed by inserting at least a portion of the anchoring pin into and/or through the sleeve component to form the composite anchor, followed by at least partially filling the void space defined by the hole and the composite anchor with an adhesive, such as an epoxy-based adhesive. Alternatively, the method may comprise folding the first part of the CFS around at least a portion of the anchoring pin to define a sleeve component at least partially encasing the anchoring pin to form the composite anchor, followed by inserting at least a portion of the composite anchor into the hole, followed by at least partially filling the void space defined by the hole and the composite anchor with an adhesive, such as an epoxy-based adhesive.
In accordance with certain embodiments of the invention, the method may comprise
a step of securing the second end of the CFS to a lower portion of a building, such as a building is a floor joist, a rim joist, or a sill plate. For example, the second end of the CFS may be secured to the lower portion of the building via a top anchor system including a top bracket that directly or indirectly attaches the CFS to the lower portion of a building.
In yet another aspect, the present invention provides a kit for reinforcing a wall structure comprising at least one anchoring pin and at least one carbon fiber strap (CFS). The kit may also include an adhesive, such as an epoxy-based adhesive. In accordance with certain embodiments of the invention, the kit may include a top anchor system including a top bracket configured for attachment to a lower portion of a building.
In yet another aspect, the present invention provides a kit for reinforcing a wall structure comprising at least one anchoring pin and at least one carbon fiber strap (CFS). The kit may also include an adhesive, such as an epoxy-based adhesive. In accordance with certain embodiments of the invention, the kit may include a top anchor system including a top bracket configured for attachment to a lower portion of a building. The kit may include installation instructions, mounting hardware (e.g., bolts, nuts, etc.), and safety equipment (e.g., goggles, gloves, disposable wipes, etc.)
These and other modifications and variations to embodiments of the invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and it is not intended to limit the invention as further described in such appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.
This application claims the benefit of U.S. Provisional Application No. 63/470,593, filed on Jun. 2, 2023, which is hereby incorporated by reference.
Number | Date | Country | |
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63470593 | Jun 2023 | US |