Adjustable cross-tie for construction of walls
The invention is a cross-tie used to connect two walls made of multiple bricks or blocks together so that concrete or other material can be poured into the cavity between the walls to form a single strong, dense wall. The cross-tie can also be used to attach decorative veneers to a wall. One embodiment of the cross-tie of the invention includes an inserting portion, a sleeve portion, and a wedge that is used to link the inserting portion and the sleeve portion. Another embodiment of the cross-tie includes an inserting portion and a sleeve portion that are linked by being glued together.
1. Field of the Invention
The invention relates to devices used in construction to build walls. In particular, the invention is a cross-tie that is used to connect two walls so that concrete or a similar material can be poured into the cavity between the two walls to create a single wall. The invention also relates to devices to attach masonry or other veneers to a wall.
2. Description of the Related Art
Walls Made by Filling Cavities With Concrete
Current construction methods utilize several different techniques to create a cavity between two parallel walls into which concrete or a similar material can be poured to create a single rigid wall. Because concrete is a high-density fluid, when it is poured into a cavity, it creates lateral pressures that force the opposing walls outward. Several techniques are used to create cavities that have adequate strength to withstand the lateral hydrostatic pressures of the concrete.
One technique utilizes concrete blocks. The blocks have relatively thin sides and a large cavity within each block, and may have webs extending across the cavity. First, a wall is constructed using the concrete blocks and mortar, resulting in multiple vertical cavities. Next, concrete grout is poured into the cavity, which creates a dense and strong wall. The lateral pressures of the fluid concrete are contained by the inherent tensile strength of the concrete blocks.
Another technique utilizes insulated concrete forms. This more modern method uses hollow blocks made of synthetic foam with webs or ties. The external sides of the blocks are secured to each other with ties or connectors that are bound to the sides via slots, holes, or by passing through the foam (see U.S. Pat. Nos. 6,363,683; 6,314,696; 5,625,9894; 6,321,49; and 7,889,310). The insulated concrete foam blocks interlock to create walls with cavities into which concrete grout is poured, creating a dense and strong wall. The lateral pressures of the fluid concrete are contained by the webs or ties.
Another technique utilizes formwork. Forms, or walls are made of plywood, wood planks, or steel, creating a continuous planer cavity into which fluid concrete is poured. The lateral pressures of the fluid concrete are contained by passing ties or connectors through the cavity and the form and then containing the outwood lateral pressures from the outside. Methods to connect the opposing walls include a variety of ties that cross the cavity and protrude to the outside of the forms with wedges inserted into slots in the tie outside of the form walls (see U.S. Pat. Nos. 1,755,960; 1,875,136; 3,288,428; and 5,547,163). The wedges provide a very limited means of adjustability. An alternative method of providing tension across form walls is to securely fasten wires to the outside of the wall and then either twist the wires between the walls to create tension (see U.S. Pat. Nos. 1,692,166 and 3,728,836) or twist the wires outside of the cavity (see U.S. Pat. No. 1,800,802). A rigid two-piece tie that uses pegs on one piece to lock into holes on an opposing piece has also been disclosed (see U.S. Pat. No. 4,765,109). This device provides only limited adjustability defined by the distance between the pegs or between the holes. Ties can be installed into the form walls that cross the cavity and provide a rigid tensional tie (see U.S. Pat. No. 4,698,947).
The existing methods have several disadvantages. Most of the devices cannot be easily adjusted to fit variations in the distance between the walls, and, if they are adjustable, it is only to a limited extent. Another disadvantage is that most of the devices must be attached to the outside of the walls and, therefore, the exterior portion of the device must be either removed after the concrete hardens or left intact on the exterior of the wall. Yet another disadvantage is that many of the devices are made of metal, and therefore, will have a limited lifespan due to rust. Additional disadvantages are that the existing materials are typically costly and are not environmentally “friendly.”
Attachment of Veneers to a Wall
Veneers (masonry or other materials) must be securely fastened to any wall to prevent failure of the veneer in the event of seismic activity, high winds, or other adverse conditions. Existing methods of fastening masonry veneers to concrete walls involve placing metal fasteners into the mortar between masonry courses of the veneer that fastens to parts incorporated into a previously-poured concrete wall (see U.S. Pat. No. 3,377,764). Fasteners can be mechanically bound to brick or block units by inserting parts of the fastener or dowels into cavities in the masonry units (see U.S. Pat. No. 779,268).
The disadvantages of the existing methods are that the form-work must be removed and the veneer wall constructed later, which increases the cost of construction. In addition, the metal fasteners rust and weaken over time.
Thus, there is a need for a device that connects two walls together that will have sufficient tensile strength to withstand the lateral pressures of the fluid concrete or other materials used to create walls. There is also a need for a device that can be easily adjusted during the construction of a wall to fit walls of different widths or thicknesses. Further, there is a need for devices using materials that do not rust, and are long-lasting, cost-effective, and environmentally“friendly”.
SUMMARY OF THE INVENTIONThe invention is a cross-tie used to connect two walls made of multiple bricks or blocks together so that concrete or other material can be poured into the cavity between the walls to form a single strong, dense wall. The cross-tie can also be used to attach decorative veneers to a wall. One embodiment of the cross-tie of the invention includes an inserting portion, a sleeve portion, and a wedge that is used to link the inserting portion and the sleeve portion. Another embodiment of the cross-tie includes an inserting portion and a sleeve portion that are linked by being glued together.
One advantage of the cross-tie of the invention is that it allows two walls to be fastened together with sufficient tensile strength to withstand lateral pressure, so that concrete or other similar materials can be poured into the cavity between the two walls without outward failure of the walls during the pouring of the concrete. Another advantage of the invention is that it is easily adjusted to fit walls of different thicknesses and can also be made in different dimensions. The invention is also advantageous in that it provides a platform to which wire, reinforcing steel, or other building materials can be attached as necessary in the construction of walls. A further advantage of the invention is that it can be used to fasten veneers securely to a wall. Other advantages of the invention are that it can be made of a variety of materials, including plastics, recycled materials, and others that are more cost-effective, durable, and environmentally “friendly” than are those used to make existing ties and fasteners.
BRIEF DESCRIPTION OF THE FIGURES
Cross-Tie With Wedge
As shown in
As shown in
The center portion 18 is linear and has an upper surface 24 and a lower surface 26. The center portion 18 is contiguous with the outer end 20 at one end and the inner end 22 at the other end. The center portion 18 has slots 28 in it along its length. The length L, width W, and number of slots 28 may vary, depending on the ultimate tensile strength required for the cross-tie 10 and the strength of the material used to make the cross-tie 10. The slots 28 may be cut so that one side of the slot is tapered from the upper surface 24 to the lower surface 26, so as to provide closer contact and a stronger connection with the wedge 16 which has tapered side 84. Preferably, the slots 28 are tapered on side 100, the side closest to the inner end 22, at the same angle as the angle of the tapered side 84 of the wedge 16, as shown in
The center portion 18 may optionally have tabs 30 projecting horizontally outward from one of its sides. The tabs 30 may vary in dimensions and spacing depending on the structural requirements of the walls. The purpose of the tabs 30 is to provide additional texture that will aid in forming a mechanical bond with the concrete.
The outer end 20 of the inserting portion 12 is that end of the inserting portion 12 that, when the cross-tie 10 is in use, is placed on the blocks 90 of the wall 88. The outer end 20 has a lip portion 32 and a dowel portion 34.
The lip portion 32 of the outer end 20 is essentially circular. It is the same thickness as the center portion 18. It is larger in diameter than the openings or recesses 94 in the tops of the blocks 90 comprising the walls 88, such that when the cross-tie 10 is in use, the lip portion 32 rests on top of an opening 94 in a block 90. The lip portion 32 preferably has openings 36 and grooves 37 in it, some of which may extend all the way through the dowel portion 34, for fastening additional items to the cross-tie 10, such as pins 38 as shown in
The dowel portion 34 of the outer end 20 projects downward from the lip portion 32. It is cylindrical and may be of virtually any length and diameter, but should be smaller in diameter than the lip portion 32 and approximately the same diameter as the openings 94 in the tops of the blocks 90 comprising the two walls 88, such that it fits snugly within the opening 94 of a block 90. The dowel portion 34 preferably has openings and recesses in it, that may extend vertically through all or part of it, so as to allow pins 38 or other items to be placed through the lip portion 32 and the dowel portion 34 into the opening 94 in a block 90 to provide, with mortar, a mechanical tie for other objects or to the overlying blocks. (See
The inner end 22 of the inserting portion 12 is that end of the inserting portion 12 that, when the cross-tie 10 is in use, extends into the cavity 92 between the walls 88. The inner end 22 is preferably squared off, although it can be shaped in other ways as well.
As shown in
The center portion 40 is a linear, double-pronged piece, having an upper prong 48, a lower prong 50, and a connecting portion 52. The center portion 40 is contiguous with the middle portion 42 at one end. The other end of the center portion 40 consists of the ends 54 and 56 of the two prongs 48 and 50, both of which comprise the inner end 46 of the sleeve portion 14. The two prongs 48 and 50 are preferably the same length, width, and thickness. The two prongs 48 and 50 are joined together via the connecting portion 52 that also joins the center portion 40 to the middle portion 42. The connecting portion 40 is preferably at right angles to the two prongs 48 and 50 and to the middle portion 42, although other angles will work as well. The two prongs 48 and 50 are parallel to each other with the upper prong 48 overlying the lower prong 50, forming a center space 58 in between the two prongs 48 and 50. The upper prong 48 and the lower prong 50 each have an interior surface 60 and an exterior surface 62. Each interior surface 60 is adjacent to the center space 58, such that the center space 58 is bounded by the interior surface 60 of each prong. Each exterior surface 62 is adjacent to the cavity 92 between the walls 88. The distance between the two prongs 48 and 50 is approximately the same as the thickness of the inserting portion 12. The upper prong 48 and the lower prong 50 are connected to each other. They are shown as connected at various points along their lengths by projections 64 that extend from the upper prong 48 to the lower prong 50, although they could be connected by solid sides such that the sleeve portion 14 is tubular. If projections 64 are used, they are preferably only along one side of the prongs. These projections 64 help maintain the center space 58 between the upper and lower prongs 48 and 50. The prongs 48 and 50 preferably are not connected on their other sides, although projections could be utilized on the other sides if desired. The exterior surface 62 of the upper prong 48 may optionally include raised ribs 66 that extend across the upper prong 48, perpendicular to the linear axis of the upper prong 48. The purpose of the raised ribs 66 is to provide a mechanical bond with the concrete.
The center portion 40 has slots 68 in it along its length, in both the upper prong 48 and the lower prong 50. The length L′, width W′, number of slots 68, and distance between the slots 68 may vary depending on the ultimate tensile strength required for the cross-tie 10 and the strength of the material used to make the cross-tie 10; however, these dimensions are the same for both the upper prong 48 and the lower prong 50. The width W′ of the slots 68 in the sleeve portion 14 is the same as the width W of the slots 28 in the inserting portion 12. The length L′ of the slots in the sleeve portion 14 may be the same as, or different from, the length L of the slots in the inserting portion 12. In the embodiment illustrated here, the length L is greater than the length L′. Preferably, the distance between the slots 68 in the sleeve portion 14 is different from the distance between the slots 28 in the inserting portion 12. The ratio of the number of slots 28 located along a given distance in the inserting portion 12 to the number of slots 68 located along the same distance in the sleeve portion 14 is preferably about 3:4, although ratios of 4:5, 5:6, and other ratios will also work well. The ratio can also be reversed, such that 4:3, 5:4, and 6:5 will also work. This arrangement of slots 28 and 68 is referred to herein as a vernier offset, as illustrated in
The middle portion 42 of the sleeve portion 14 is contiguous with the connecting portion 52 of the center portion 40 and the outer end 44. The middle portion 42 is a flat piece that is continguous with, and the same thickness as, the lip portion 70 of the outer end 44.
The outer end 44 of the sleeve portion 14 is that end of the sleeve portion 14 that, when the cross-tie 10 is in use, is placed on the blocks 90 of the wall 88. The outer end 44 has a lip portion 70 and a dowel portion 72. The outer end 44 is preferably the same shape and dimensions as the outer end 20 of the inserting portion 12.
The lip portion 70 of the outer end 44 is essentially circular. It is the same thickness as the middle portion 42. It is larger in diameter than the openings or recesses 94 in the tops of the blocks 90 of the walls 88, such that when the cross-tie 10 is in use, the lip portion 70 rests on top of an opening 94 in a block 90. The lip portion 70 preferably has openings 74 and grooves 76 in it, some of which may extend all the way through the dowel portion 72, for fastening additional items to the cross-tie 10, such as pins 38 as shown in
The dowel portion 72 of the outer end 44 projects downward from the lip portion 70. It is cylindrical and may be of virtually any length and diameter, but should be smaller in diameter than the lip portion 70 and approximately the same diameter as the openings or recesses 94 in the tops of the blocks 90 of the two walls 88, such that it fits snugly within the opening 94 of a block 90. The dowel portion 72 preferably has openings and recesses in it, that may extend vertically through all or part of it, so as to allow pins 38 or other items to be placed through the lip portion 70 and dowel portion 72 into the opening 94 in a block 90 to provide, with mortar, a mechanical tie for other objects or to the overlying blocks 90. (See
The inner end 46 of the sleeve portion 14 is that end of the sleeve portion 14 that, when the cross-tie 10 is in use, extends into the cavity 92 between the walls 88. The inner end 46 consists of the ends 54 and 56 of the two prongs 48 and 50. The inner end 46 is preferably squared off, although it can be shaped in other ways as well.
As shown in
The cross-tie 10 is preferably made of ABS (acrylonitrile butadiene styrene) plastic because of its low cost, glue-ability, high strength, and the availability of both pure and recycled feedstock for molding. Other moldable plastics such as polyethylene, polypropylene, PVC, polystyrene, and nylon may also be used. The cross-tie 10 may also be made of stamped metal or other ductile material, or other materials.
As shown in
After the inserting portion 12 is placed into the sleeve portion 14, because of the vernier offset arrangement of the slots 28 of the inserting portion 12 and the slots 68 of the sleeve portion 14, at least one pair of the slots 68 in the two prongs 48 and 50 of the sleeve portion 14 should be at least partially aligned with at least one slot 28 in the center portion 18 of the inserting portion 12. In most cases, it will be possible to place the wedge 16 in more than one set of slots 28 and 68. Placing the wedge 16 in certain sets of slots will cause the dowel portion 34 of the inserting portion 12 and the dowel portion 72 of the sleeve portion 14 to pull apart, while placing the wedge 16 in other sets of slots will cause the two dowel portions 34 and 72 to pull towards each other, creating tension. When using the cross-tie 10 to connect two walls 88 to withstand the lateral pressure created by concrete or other material poured into the cavity 92 between the walls 88, it is desirable to create tension. Thus, the wedge 16 should be placed in a set of slots 28 and 68 that will create such tension. In most cases, due to the vernier offset of the slots 28 and 68, there will be more than one set of slots through which the wedge 16 can be placed to create the desired tension. (See
The wedge 16 is placed through the chosen slots 28 and 68 by inserting the tip 86 of the body 80 into the upper prong 48, through the inserting portion 12, through the lower prong 50, and down into the cavity 92 between the walls 88. The head 78 of the wedge 16 is then pushed down until the body 80 extends far enough through the slots 28 and 68 to create the desired tension between the dowel portion 34 of the inserting portion 12 and the dowel portion 72 of the sleeve portion 14. The head 78 will be located on or above the cross-tie 10, depending on how far the body 80 is pushed in. Once the cross-tie 10 is installed in two blocks 90 with the wedge 16 inserted, a positive tensional lock is created between the blocks.
The difference in spacing of the slots 28 and 68 in the inserting portion 12 and the sleeve portion 14, respectively (the arrangement of the slots in a vernier offset) allows the wedge 16 to be placed in a number of different positions along the length of the cross-tie 10, which permits minute adjustments to be made in the length of the cross-tie 10. (See
Other building materials, including but not limited to, reinforcing steel, insulation, conduit for electrical wires, and pipe for plumbing can be installed in the cavity 92 between the two walls 88 before the concrete is poured. After the cross-ties 10 are installed, the concrete or other material is poured into the cavity 92 covering the cross-ties 10 in the lower courses and up to the cross-ties 10 in the top course.
Glueable Cross-Tie
As shown in
Instead of utilizing wedge 16, this cross-tie 96 utilizes glue 98 to link the inserting portion 12 and the sleeve portion 14 together. The glue 98 that is used should be compatible with the particular plastic used to construct the inserting portion 12 and the sleeve portion 14. For example, if ABS plastic is used, the preferable glue 98 is ABS glue.
To use the gluable cross-tie 96, the inserting portion 12 is placed within the sleeve portion 14. In the embodiment shown, the inserting portion 12 is slipped between the two prongs 48 and 50 of the sleeve portion 14 in the same fashion as with the cross-tie 10 when it is used with the wedge 16. Before placing the inserting portion 12, however, glue 98 is applied to either or both the inserting portion 12 and the sleeve portion 14 as desired. Glue 98 may be applied to the interior surfaces 60 of the two prongs 48 and 50 of the sleeve portion 14 and/or along the upper surface 24 and the lower surface 26 of the inserting portion 12.
Although the wedge 16 is not necessary when glue 98 is used, the wedge 16 may be used with the glueable cross-tie 96 in the same fashion as it is used with the cross-tie 10 without the glue 98. In that case, the inserting portion 12 and the sleeve portion 14 must be made with slots 28 and 68, respectively, as they are when used with the wedge 16. The wedge 16 creates a positive mechanical lock between the inserting portion 12 and the sleeve portion 14. The wedge 16 also creates tension between the two walls 88 to counteract the outward lateral forces of the poured concrete.
The invention has been described above with the reference to the preferred embodiments. Those skilled in the art may envision other embodiments and variations of the invention that fall within the scope of the claims.
Claims
1. A cross-tie, comprising:
- (a) an inserting portion having an outer end for placing into an opening in a block of a first wall, an inner end, and a center portion with slots;
- (b) a sleeve portion having an outer end for placing into an opening in a block of a second wall, an inner end, and a center portion with slots; and
- (c) a wedge;
- (d) wherein said center portion of said inserting portion is placed within said sleeve portion such that said cross-tie extends across a cavity between the first and second walls, and further, wherein said wedge is placed through said slots in said inserting portion and said slots in said sleeve portion to link said inserting portion and said sleeve portion.
2. The cross-tie of claim 1, wherein said slots in said inserting portion and said slots in said sleeve portion are arranged in a vernier offset, such that at least one pair of said slots in said sleeve portion is at least partially aligned with at least one slot in said inserting portion.
3. The cross-tie of claim 1, wherein said center portion of said sleeve portion includes an upper prong and a lower prong; wherein said slots are located in both said upper prong and said lower prong; and further, wherein said wedge is placed through a slot in said upper prong, a slot in said inserting portion, and a slot in said lower prong.
4. The cross-tie of claim 1, wherein said wedge includes a head, a body having a straight side and a tapered side, and a tip.
5. The cross-tie of claim 1, wherein said cross-tie is used to connect the first wall and the second wall, and concrete or other material is poured into the cavity between the first and second walls to create a single wall.
6. A cross-tie, comprising:
- (a) an inserting portion having an outer end for placing into an opening in a block of a first wall, an inner end, and a center portion;
- (b) a sleeve portion having an outer end for placing into an opening in a block of a second wall, an inner end, and a center portion, wherein said center portion of said inserting portion is placed within said sleeve portion; and
- (c) glue that is applied to link said inserting portion and said sleeve portion.
Type: Application
Filed: Mar 31, 2006
Publication Date: Oct 25, 2007
Inventor: Doug Bonelli (Nevada City, CA)
Application Number: 11/396,008
International Classification: E04B 1/38 (20060101);