THERMALLY INSULATED WALL ANCHOR

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 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.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

TECHNICAL FIELD

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.

BACKGROUND

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.

SUMMARY

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.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 is a front view of a wall anchor for use in a cavity wall, according to a first example embodiment of the present invention;

FIG. 2 is a right-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 3 is a left-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 4 is a perspective right-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 5 is a perspective left-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 6 is a front view of a wall anchor for use in a cavity wall, wherein a second end of the elongated shaft includes a self-drilling point that is configured for use with metal, according to an example embodiment of the present invention;

FIG. 7 is a perspective view of a receiving section, wherein a flange of the receiving section is defined by an oval shape, according to an example embodiment of the present invention;

FIG. 8 is a perspective view of a receiving section, wherein a flange of the receiving section is defined by a 12-point star-shaped pattern, according to an example embodiment of the present invention;

FIG. 9 is a perspective view of a receiving section, wherein a flange of the receiving section is defined by at least one recess, according to an example embodiment of the present invention;

FIG. 10 is a cross sectional view of a wall anchor in an installed state, wherein the receiving section is configured such that no metallic material of the receiving section is exposed to an air cavity between the inner wythe and outer wythe, according to an example embodiment of the present invention;

FIG. 11 is a cross sectional view of a wall anchor in an installed state, wherein the receiving section is configured such that no metallic material of the receiving section is between the inner wythe and outer wythe, according to an example embodiment of the present invention;

FIG. 12 is a top view of a veneer tie attached to a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 13 is a side view of a veneer tie attached to a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 14 is a perspective right-side view of a veneer tie attached to a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 15 is a front view of a wall anchor for use in a cavity wall, according to a second example embodiment of the present invention;

FIG. 16 is a right-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 17 is a left-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 18 is a perspective right-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 19 is a perspective left-side view of a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 20 is a front view of a wall anchor for use in a cavity wall, wherein a second end of the elongated shaft includes a self-drilling point that is configured for use with metal, according to an example embodiment of the present invention;

FIG. 21 is a right-side view of a receiving section, wherein an outward facing end of the receiving section includes a hexagon-shaped protrusion, according to an example embodiment of the present invention;

FIG. 22 is a front view of a receiving section, wherein an outward facing end of the receiving section includes a hexagon shaped protrusion, according to an example embodiment of the present invention;

FIG. 23 is a right-side view of a receiving section, wherein an outward facing end of the receiving section includes two recesses, according to an example embodiment of the present invention;

FIG. 24 is a front view of a receiving section, wherein an outward facing end of the receiving section includes two recesses, according to an example embodiment of the present invention;

FIG. 25 is a right-side view of a receiving section, wherein an outward facing end of the receiving section includes four recesses, according to an example embodiment of the present invention;

FIG. 26 is a front view of a receiving section, wherein an outward facing end of the receiving section includes four recesses, according to an example embodiment of the present invention;

FIG. 27 is a cross sectional view of a wall anchor in an installed state, wherein the receiving section is configured such that no metallic material of the receiving section is exposed to an air cavity between the inner wythe and outer wythe, according to an example embodiment of the present invention;

FIG. 28 is a cross sectional view of a wall anchor in an installed state, wherein the receiving section is configured such that no metallic material of the receiving section is between the inner wythe and outer wythe, according to an example embodiment of the present invention;

FIG. 29 is a top view of a veneer tie attached to a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 30 is a side view of a veneer tie attached to a wall anchor for use in a cavity wall, according to an example embodiment of the present invention;

FIG. 31 is a perspective right-side view of a veneer tie attached to a wall anchor for use in a cavity wall, according to an example embodiment of the present invention; and

FIG. 32 is a flowchart describing the steps of the process for preparing a cooked food item, according to an example embodiment of the present invention.

 DETAILED DESCRIPTION

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, FIGS. 1-5 illustrate a wall anchor 100 for use in a cavity wall 102 to connect to a veneer tie 104 that joins an inner wythe 106 and an outer wythe 108 of the cavity wall 102, according to a first embodiment of the present invention and will be discussed together for ease of reference. The wall anchor 100 includes an elongated shaft 120 defining a fully threaded cylindrical shape that extends from a first end 122 to a second end 124. The first end 122 of the elongated shaft 120 is configured to be in attachment with a receiving section 130, as further discussed below. The second end 124 of the elongated shaft 120 is configured to be driven into the inner wythe 106 of the cavity wall 102. The elongated shaft may be attached to the receiving section in a variety of manners including an extrusion process, forging a mold, welding, shearing, punching welding, folding etc. However, other types of processes may also be used and are within the spirit and scope of the present invention.

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 FIG. 6, the second end 124 of the elongated shaft 120 includes a self-drilling tip 127 configured for attachment to materials such as metal and wood. In operation, the self-drilling tip acts as a drill bit for the elongated shaft. Specifically, a notch 128 on the self-drilling tip functions as a reservoir to receive wood chips or metal filings to create the space necessary to drive the elongated shaft 120 into the inner wythe 106 of the cavity wall 102.

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 FIGS. 12-14, the veneer tie 104 is inserted into the aperture of the receiving section to secure the veneer tie to the wall anchor 100. The veneer tie is configured to resist compressive and tensile loads that arise from lateral loads, such as from wind or seismic excitation. It should be appreciated that the aperture may have a variety of cross-sectional shapes and configurations, and such variations are within the spirit and scope of the claimed invention. The aperture on the receiving section may be manufactured from a variety of different processes such as punching, stamping, scissoring, flame cutting, laser cutting, sawing, drilling, milling, or turning.

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 FIG. 2, the flanged section 150 is defined by a hexagonal shape. In one embodiment, as best shown in FIG. 7, the flanged section 150 is defined by an oval shape. In one embodiment, as best shown in FIG. 8, the flanged section 150 is defined by a 12-point star-shaped pattern. In one embodiment, as best shown in FIG. 9, the flanged section 150 is defined by at least one recess 178 (three are shown) located on the outward facing end 132 of the receiving section 130. It should be appreciated that the recess may have a variety of cross-sectional shapes and configurations, and such variations are within the spirit and scope of the claimed invention. In one embodiment, the wall anchor is part of a kit that includes a tool that is configured to engage with a shape of the flanged section 150 to provide a driving force to drive the second end 124 of the elongated shaft 120 into the inner wythe 106.

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 FIG. 10, the receiving section 130 is configured such that no metallic material is exposed out of the receiving section to an air cavity 109 between the inner wythe and outer wythe when the wall anchor is in an installed state. Specifically, the receiving section enclosed in the dashed area 182 is comprised of non-metallic material to prevent the flow of thermal energy. Thus, unlike the prior art, the receiving section has no metallic material surrounding the aperture. Therefore, although the first end 122 of the elongated shaft 120 is located between the inner wythe and outer wythe, no metallic material is exposed out of the receiving section to the air cavity 109 between the inner wythe and outer wythe because the receiving section 130 of the wall anchor includes the thermal insulating member that prevents the flow of thermal energy.

In one embodiment, as best shown in FIG. 11, the receiving section 130 is configured such that there is no metallic material located between the inner wythe and outer wythe when the wall anchor is in an installed state. As discussed above, the receiving section enclosed in the dashed area 182 (including the body 183 surrounding the aperture 180) is comprised of non-metallic material to prevent the flow of thermal energy. In addition to the thermal insulating member preventing the flow of thermal energy, the first end 122 of the elongated shaft 120 is further confined to a portion of the collared section such that it is completely removed from between the inner wythe and outer wythe.

FIGS. 15-19 illustrate a wall anchor 200 for use in a cavity wall 202 to connect to a veneer tie 204 that joins an inner wythe 206 and an outer wythe 208 of the cavity wall 202, according to a second embodiment of the present invention and will be discussed together for ease of reference. The wall anchor 200 includes an elongated shaft 220 defining a fully threaded cylindrical shape that extends from a first end 222 to a second end 224. The first end 222 of the elongated shaft 220 is configured to be in attachment with a receiving section 230, as further discussed below. The second end 224 of the elongated shaft 220 is configured to be driven into the inner wythe 206 of the cavity wall 202.

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 FIG. 20, the second end 224 of the elongated shaft 220 includes a self-drilling tip 227 configured for attachment to materials such as metal and wood. In operation, the self-drilling tip acts as a drill bit for the elongated shaft. Specifically, a notch 228 on the self-drilling tip functions as a reservoir to receive wood chips or metal filings to create the space necessary to drive the elongated shaft 220 into the inner wythe 206 of the cavity wall 202.

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 FIGS. 21 and 22, the outward facing end 232 of the receiving section is defined by at least one outwardly extending hexagonally shaped bolt. In one embodiment, as best shown in FIGS. 23 and 24, the outward facing end 232 of the receiving section is defined by two circular shaped recesses 278. In one embodiment, as best shown in FIGS. 25 and 26, the outward facing end 232 of the receiving section is defined by four circular shaped recesses 278. It should be appreciated that the recess may have a variety of cross-sectional shapes and configurations, and such variations are within the spirit and scope of the claimed invention. In one embodiment, the wall anchor is part of a kit that includes a tool that is configured to provide a driving force to drive the second end 224 of the elongated shaft 220 into the inner wythe 206. The tool may be configured to engage with the outward facing end of the receiving section. For example, in certain embodiments, the tool is configured to engage with the recesses on the receiving section. In other embodiments, the tool is configured to engage with the hexagonal head of the receiving section, however it is understood that other embodiments may be used and are within the spirit and scope of the present invention.

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 FIGS. 29-31, the veneer tie 204 is inserted into the aperture to secure the veneer tie to the wall anchor 200. The veneer tie is configured to resist compressive and tensile loads that arise from lateral loads, such as from wind or seismic excitation. It should be appreciated that the aperture may have a variety of cross-sectional shapes and configurations, and such variations are within the spirit and scope of the claimed invention. The aperture may be manufactured from a variety of different processes such as punching, stamping, scissoring, flame cutting, laser cutting, sawing, drilling, milling, or turning.

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 FIG. 27, the receiving section 230 illustrated in FIGS. 21 and 22 is configured such that no metallic material is exposed out of the receiving section to an air cavity 209 between the inner wythe and outer wythe when the wall anchor is in an installed state. Specifically, the receiving section enclosed in the dashed area 282 (including outward facing end 232) is comprised of non-metallic material to prevent the flow of thermal energy. Therefore, unlike the prior art, the receiving section has no metallic material surrounding the aperture. In the prior art, there may be devices that have a metallic material coated by a non-metallic material, which results in the aperture being surrounded by metallic material and coated by non-metallic material. In the present invention, therefore, although the first end 222 of the elongated shaft 220 is located between the inner wythe and outer wythe, no metallic material is exposed out of the receiving section to the air cavity 209 between the inner wythe and outer wythe because the receiving section 230 of the wall anchor includes the thermal insulating member that prevents the flow of thermal energy.

In one embodiment, as best shown in FIG. 28, the receiving section 230 is configured such that there is no metallic material located between the inner wythe and outer wythe when the wall anchor is in an installed state. As discussed above, the receiving section enclosed in the dashed area 282 is comprised of non-metallic material to prevent the flow of thermal energy. In addition to the thermal insulating member preventing the flow of thermal energy, the first end 222 of the elongated shaft 220 is further confined to a portion of the collared section such that it is completely removed from between the inner wythe and outer wythe.

FIG. 32 is a flowchart describing the steps of the process 300 of anchoring a veneer wall to an inner wythe for horizontal load transfer, according to an example embodiment of the present invention. The sequence of steps depicted is for illustrative purposes only and is not meant to limit the method in any way as it is understood that the steps may proceed in a different logical order, additional or intervening steps may be included, or described steps may be divided into multiple steps, without detracting from the invention. As described above with respect to FIGS. 10 and 11, step 305 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. In step 310, the process includes placing a portion of a veneer tie into at least one aperture of the wall anchor, as shown in FIGS. 13-15. Alternatively, step 305 may be substituted with step 315, wherein the process includes securing the receiving end of the wall anchor into the inner wythe such that no metallic material of the receiving section is in the space between the inner wythe and outer wythe.

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.

Claims

1. 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 comprising:

an elongated shaft;
a receiving section configured to be in attachment with the elongated shaft;
wherein the receiving section defines at least one aperture configured to receive a portion of the veneer tie and an abutting section configured to abut an outward facing surface of the inner wythe;
wherein the receiving section defines a thermal insulating member comprising non-metallic material;
wherein the receiving section has no metallic material surrounding the at least one aperture; and
wherein the receiving section is free of metallic material up to at least the abutting section.

2. (canceled)

3. The wall anchor of claim 2, wherein the receiving section further comprises a collared section and wherein a first end of the elongated shaft is in attachment with the collared section.

4. The wall anchor of claim 1, wherein the receiving section further defines a shape configured to engage with a tool that provides a driving force to drive a second end of the elongated shaft into the inner wythe.

5. The wall anchor of claim 4, wherein the shape is defined by at least one recess within an outward facing end of the receiving section.

6. The wall anchor of claim 3, wherein the wall anchor further includes a flanged section between the collared section and receiving section.

7. The wall anchor of claim 6, wherein the abutting section also abuts an inward facing surface of the flanged section.

8. The wall anchor of claim 1, wherein the receiving section comprises a high temperature material.

9. The wall anchor of claim 1, wherein the receiving section comprises a high temperature coating.

10. The wall anchor of claim 8, wherein the high temperature material comprises 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 and any combination of the foregoing material.

11. The wall anchor of claim 9, wherein the high temperature coating comprises 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 and any combination of the foregoing material.

12. 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 comprising:

an elongated shaft;
a receiving section configured to be in attachment with the elongated shaft;
wherein the receiving section defines at least one aperture configured to receive a portion of the veneer tie, and a washer configured to abut an outward facing surface of the inner wythe;
wherein the receiving section defines a thermal insulating member comprising non-metallic material; and
wherein the receiving section is free of metallic material up to at least the washer.

13. The wall anchor of claim 12, wherein the receiving section further comprises a collared section and wherein a first end of the elongated shaft is in attachment with the collared section.

14. The wall anchor of claim 12, wherein the receiving section further defines at least one recess within an outward facing end of the receiving section that is configured to engage with a tool wherein the tool provides a driving force to drive a second end of the elongated shaft into the inner wythe.

15. The wall anchor of claim 13, wherein the wall anchor further includes a flanged section between the collared section and receiving section.

16. The wall anchor of claim 12, wherein the washer abuts an inward facing surface of the flanged section.

17. The wall anchor of claim 12, wherein the receiving section comprises at least one of a high temperature material and a high temperature coating.

18. A method of anchoring a veneer wall to an inner wythe for horizontal load transfer, the method comprising the steps of:

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 an outer wythe such that the space between the inner wythe and the outer wythe is free of metallic material when the wall anchor is in an installed state; and
placing a portion of a veneer tie into at least one aperture of the wall anchor.

19. (canceled)

Patent History
Publication number: 20210301521
Type: Application
Filed: Mar 27, 2020
Publication Date: Sep 30, 2021
Inventor: Ronald Hohmann, JR. (Parkland, FL)
Application Number: 16/832,420
Classifications
International Classification: E04B 1/41 (20060101); E04B 1/76 (20060101);