Composite thermal isolating masonry tie fastener

Cavity walls include fasteners that provide a thermal break. A cavity wall assembly includes a support structure, insulation, and an outer wythe. The insulation is mounted on the support structure. The outer wythe is spaced apart from the insulation, such that a cavity is formed between the insulation and the outer wythe. A tie is attached to the outer wythe. A fastener extends through a portion of the tie, through the insulation, and into the support structure to attach the tie to the support structure. The fastener provides a thermal break between the support structure and the tie. At least a portion of the thermal break is disposed within a width of the insulation.

FIELD OF THE INVENTION

The present inventions relate to thermally isolated anchoring systems for insulated walls. In particular, the present invention relates to anchoring systems that minimize heat transfer through a fastener that extends through an insulation material.

BACKGROUND OF THE INVENTION

Published US Patent Application Pub. No. 2011/0047919 provides a background of anchoring systems. Portions of US Patent Application Pub. No. 2011/0047919 are incorporated below. US Patent Application No. 2011/0047919 is incorporated herein by reference in its entirety.

In the past, anchoring systems have taken a variety of configurations. The construction of a steel frame of a commercial or residential building, to which masonry veneer is attached, uses steel studs with insulation installed outboard of the steel stud framing. Steel anchors and ties attach the outer masonry wythe to the inner steel stud framing by screwing or bolting an anchor to a steel stud. Steel is an extremely good conductor of heat. The use of steel anchors attached to steel framing draws heat from the inside of a building through the exterior sheathing and insulation, towards the exterior of the masonry wall. US Patent Application No. 2011/0047919 recognizes that in order to maintain high insulation values, a thermal break or barrier is needed between the steel framing and the outer wythe.

SUMMARY

The present application discloses fasteners that provide a thermal break in cavity walls. In one exemplary embodiment, a cavity wall assembly includes a support structure, insulation, and an outer wythe. The insulation is mounted on the support structure. The outer wythe is spaced apart from the insulation, such that a cavity is formed between the insulation and the outer wythe. A tie is attached to the outer wythe. A fastener extends through a portion of the tie, through the insulation, and into the support structure to attach the tie to the support structure. The fastener provides a thermal break between the support structure and the tie. For example, in one exemplary embodiment, at least a portion of the thermal break is disposed within a width of the insulation.

DETAILED DESCRIPTION

As described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements.

In the embodiments described herein, the inner wythe is provided with insulation. In exemplary embodiments disclosed herein, the insulation is applied to the outer surface thereof of sheathing and/or drywall. Anchoring systems for cavity wall assemblies are used to secure veneer facings to a building and overcome seismic and other forces, i.e. wind shear, etc.

Exemplary embodiments of wall anchoring systems110are disclosed in the present application. Each of the wall anchoring systems include a fastener10. The fastener10can take a wide variety of different forms. In the examples illustrated byFIGS. 1, 1A, and 1B, the fastener10includes a thermal break12or the fastener can be made from a material having a low thermal conductivity, such as plastic (SeeFIGS. 1Can1D) that provide a thermal break. The thermal break12can take a wide variety of different forms. Referring toFIG. 3, in one exemplary embodiment, the thermal break12is positioned on the fastener10, such that the thermal break is positioned within the width W of the insulation126. In one exemplary embodiment, the thermal break is provided across the entire width W of the insulation126. For example, the fasteners10illustrated byFIGS. 1C and 1Dthat are made from plastic provide a thermal break across the entire width of the insulation. In another embodiment, the entire portion of the fastener10that is within the width W of the insulation126provides a thermal break, while one or more other portions of the fastener are conductive.

In the exemplary embodiments illustrated byFIGS. 1, 1A, 1B, 1C, and 1D, the fastener10includes a head14, a threaded portion16, and an optional unthreaded shank18. In another exemplary embodiment, the entire length of the fastener10is threaded. In the examples illustrated byFIGS. 1, 1A, and 1B, the fastener10includes a thermal break. One or more thermal breaks12can be positioned anywhere along the threaded portion16and/or the unthreaded shank18. The thermal breaks can take a wide variety of different forms. In one exemplary embodiment, the thermal break12is between 0.010 and 0.500 inches wide (i.e. along the axis of the fastener).

In the examples illustrated byFIGS. 1C and 1D, the entire head14and/or the entire optional shank18are made from a non-thermally conductive material, such as plastic, such that the entire unthreaded shank18provides a thermal break. In one exemplary embodiment, the entire head14, the entire optional shank18, and the entire threaded portion are made from a non-thermally conductive material, such as plastic, such that the entire fastener provides a thermal break.

The head14can take a wide variety of different forms. For example, the head14can be a head that is configured to be driven by a conventional driver, such that a special tool is not required. For example, the illustrated head14has a hexagonal configuration for driving with a wrench or socket. The head could also be configured to accept a bit, such as a blade bit, a Phillips head bit, a hex bit, a torqx bit, etc. In another exemplary embodiment, the head14is configured for attachment to a veneer tie (See, for example, FIG. 6 of US Patent No. 2011/0047919). Referring toFIG. 1C, in one exemplary embodiment the head14includes an integral large washer15. The integral large washer15may be included on any of the fasteners10illustrated byFIGS. 1, 1A, 1B, and 1D. Incorporating the large washer15directly on the fastener makes the fastener easier to install, since there are fewer steps and pieces. In one exemplary embodiment, the integral large washer15can include any of the features of the tie retaining devices440,540or the composite tie840described below. In one exemplary embodiment, the diameters of the washers disclosed by this application are at least twice as large as the largest diameter of the hexagonal (or other shape) of the driven portion of the head. For example, the washers disclosed by this application can be between 1″ and 3″ in diameter. The large washer15(or the washers of the retaining devices440,540or the composite tie840) distribute load when a pressure differential is present on the foam (i.e. wind load).

The threaded portion16can take a wide variety of different forms. In the examples illustrated byFIGS. 1, 1A, and 1B, the threaded portion16has a cutting end20that is configured to cut through a metal stud117(SeeFIG. 3) and threads22that are configured to secure the fastener10to the metal stud. In another exemplary embodiment, the threaded portion16is configured to cut into wood, for example a wood stud or panel, or masonry, for example cinder block or poured concrete. However, the threaded portion can take any form that secures the fastener10to the metal stud. For example, in one exemplary embodiment, the cutting end20can be omitted.

The unthreaded shank18can take a wide variety of different forms. In the example illustrated byFIG. 1, the unthreaded shank18includes a large diameter portion160and a small diameter portion158. In the example illustrated byFIG. 1A, the unthreaded shank18includes only a large diameter portion160. In the example illustrated byFIG. 1B, the unthreaded portion18includes only a small diameter portion158, such that a portion that is approximately the same diameter as the major or maximum diameter of the threaded portion16. However, when included, the unthreaded shank18can take any form.

FIGS. 2 and 3illustrate an exemplary embodiment of an anchoring system110. This anchoring system110includes a fastener10, and a veneer tie140. A cavity wall assembly112is shown as having an inner wythe114constructed from one or more panels116or layers, which may be sheetrock, drywall, particle board, oriented strand board, fiberglass mats on the front and back of a fiberglass reinforced gypsum core, and/or any other wall construction panel or facing material, mounted on a support structure117, such as a metal stud or column, a wood support structure, such as a wood stud or panel, and/or a masonry support structure, such as a cinder block or poured concrete. The illustrated support structure117is a metal stud, but inner wythes constructed of masonry materials and/or wood framing (not shown) are also applicable. The cavity wall assembly also includes an outer wythe or facing wall118of brick120construction. Between the inner wythe114and the outer wythe118, a cavity122is formed. The cavity122has attached to the exterior surface124of the inner wythe114an optional air or air-vapor barrier125and insulation126. The barrier125may be an air barrier, an air and vapor barrier, and/or an air barrier and vapor retarder with some vapor permeance, such as about 1 perm. The air or air-vapor barrier125and/or the panel116form an exterior layer of the inner wythe114, which exterior layer has the insulation126disposed thereon. The insulation126can take a wide variety of different forms. Rigid foam insulation boards are illustrated, but the insulation126can take any form.

Successive bed joints130and132may be substantially planar and horizontally disposed, in accord with current building standards. For example, the bed joints may be 0.375-inch (approx.) in height. Selective ones of bed joints130and132, which are formed between courses of bricks120, are constructed to receive a veneer anchor140. The veneer anchor can take a wide variety of different forms. In the example illustrated byFIG. 2, any veneer anchor140capable of being mounted to the inner wythe114and insulation126with a conventional fastener or can be mounted with one of the fasteners10having a thermal break12illustrated byFIGS. 1, 1A, and1B. In the exemplary embodiment illustrated byFIG. 2, the veneer anchor140is a simple “L” shaped metal bracket or strap. Being threadedly mounted in the inner wythe, the fastener10and tie or anchor140is supported. Referring toFIGS. 2 and 3, at intervals along a horizontal surface124, fasteners10and ties or anchors140are driven into place in holes148in the insulation. The ties140are positioned on surface124so that the longitudinal axis of the fastener10is normal to an xy-plane and taps into column117.

For purposes of discussion, the cavity surface124of the inner wythe114contains a horizontal line or x-axis134and intersecting vertical line or y-axis136. A horizontal line or z-axis138, normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes.FIG. 3is a sectional view taken through this xz plane. As can be seen inFIG. 3, the location of the thermal break12is inside the width W of the insulation126in an exemplary embodiment. This positioning of the thermal break12inside the insulation significantly reduces heat transfer from one side of the insulation to the other side of the insulation. For example, in the winter the temperature inside a building and thus the temperature of the support structure117may be a room temperature between 65 and 75 degrees F., while the temperature of the outer wythe118and the cavity122may be below freezing. If a conventional metal fastener that does not have a thermal break within the width of the insulation126, heat will conduct from the support structure117, such as a metal stud, directly through the fastener, to the head of the fastener, and be lost in the cavity122that is much colder than the support structure117. By providing a fastener10with a thermal break12within the width of the insulation126, heat will conduct from the support structure117, such as a metal stud and into the fastener, but the thermal break substantially prevents heat from passing to the head of the fastener, and from being lost in the colder cavity122.

In an exemplary embodiment, one or more thermal breaks12can be positioned anywhere in the insulation126. In the example illustrated byFIG. 3, thermal break(s) can be positioned as indicated by reference numbers12,12′ and/or12″. Any number of thermal breaks can be provided. In the illustrated embodiment, the fastener10includes a metallic portion30that extends into the insulation126from the outside32and a metallic portion34that extends into the insulation126from the inside, with one or more thermal breaks12,12′, and/or12″ disposed completely in the insulation.

The thermal break12can take a wide variety of different forms. For example, two or more parts of the fastener10can be connected by a material having a low thermal conductivity to form the thermal break12. For example, the two or more parts can be connected together by an epoxy or other adhesive having a low thermal conductivity, mechanically connected together, for example by one or more threaded connectors having a low thermal conductivity, and the like. Any manner for providing a thermal break can be implemented. In another exemplary embodiment, the entire fastener10is made from a material having a low thermal conductivity, rather than providing a thermal break.

FIGS. 4A and 4Billustrate an exemplary embodiment of a tie retaining device440that can be used with a conventional fastener, such as a threaded fastener, or any of the fasteners10disclosed by the present application and a conventional tie. The illustrated tie retaining device comprises a disk402and a tie retainer404. In an exemplary embodiment, the disk402is made from a material that is substantially non-conductive, such as plastic. The disk402includes a central hole406that is sized to accept threaded portion16and shank18of the fastener and such that the head14engages the disk402. The tie retainer404extends away from the disk402to provide an opening408for an end (See the strap tie140illustrated byFIG. 2) or legs610of a tie (SeeFIG. 6).

If a conventional metal fastener is used directly with the metal tie strap140illustrated byFIGS. 2 and 3, heat will conduct from the support structure117, such as a metal stud, directly through the fastener and the metal strap140, and be lost in the cavity122and the outer wythe118that are much colder than the support structure117. By using the retaining device440with a conventional fastener or a fastener10and a metal tie140, a thermal break is provided between the metal tie140and the conventional fastener or a fastener10. The plastic material of the disk402provides the thermal break.

FIGS. 5A and 5Billustrate another exemplary embodiment of a tie retaining device540that can be used with a conventional fastener, such as a threaded fastener, or any of the fasteners10disclosed by the present application and a conventional tie. The illustrated tie retaining device comprises a disk502and a tie retainer504. In an exemplary embodiment, the disk502and the tie retainer504are made from a material that is substantially non-conductive, such as plastic. The disk502includes a central hole506that is sized to accept the threaded portion16and shank18of the fastener10, such that the head14engages the disk402. The tie retainer504extends away from the disk502to provide an opening508for an end of a strap tie140(SeeFIG. 2) or legs (SeeFIG. 6) of a tie140.

If a conventional metal fastener is used directly with the metal tie strap140illustrated byFIGS. 2 and 3, heat will conduct from the support structure117, such as a metal stud, directly through the fastener and the metal strap, and be lost in the cavity122and the outer wythe118that are much colder than the support structure117. By using the retaining device540with a conventional fastener or a fastener10and a metal tie140, a thermal break is provided between the metal tie140and the conventional fastener or a fastener10. The plastic material of the disk502and the tie retainer504provide the thermal break.

FIGS. 6 and 7illustrate a wall anchoring system610that uses fasteners10shown inFIGS. 1, 1A and/or 1Band the tie retaining device540illustrated byFIG. 5. A cavity wall assembly112is shown as having an inner wythe114constructed from one or more panels116or layers, which may be sheetrock, drywall, particle board, oriented strand board, fiberglass mats on the front and back of a fiberglass reinforced gypsum core, and/or any other wall construction panel or facing material, mounted on a support structure117, such as metal studs-117. Inner wythes constructed of masonry materials and/or wood framing (not shown) are also applicable. The cavity wall assembly also includes an outer wythe or facing wall118of brick120construction. Between the inner wythe114and the outer wythe118, a cavity122is formed. The cavity122has attached to the exterior surface124of the inner wythe114an optional air or air-vapor barrier125and insulation126. The air or air-vapor barrier125and/or the panel116form an exterior layer of the inner wythe114, which exterior layer has the insulation126disposed thereon.

Successive bed joints130and132may be substantially planar and horizontally disposed, in accord with current building standards. For example, the bed joints may be 0.375-inch (approx.) in height. Selective ones of bed joints130and132, which are formed between courses of bricks120, are constructed to receive a veneer anchor or tie140. The veneer anchor or tie can take a wide variety of different forms. In the example illustrated byFIG. 6, any veneer anchor140capable of being mounted to the inner wythe114and insulation126with a conventional fastener or can be mounted with one of the fasteners10having a thermal break12illustrated byFIGS. 1, 1A, and 1Bcan be used. In the exemplary embodiment illustrated byFIG. 6, the veneer tie140is a formed from wire with legs610that fit in the opening508. The veneer tie140is shown inFIG. 1on a course of bricks120in preparation for embedment in the mortar of a bed joint130.

Referring toFIGS. 6 and 7, at intervals along a horizontal surface124, fasteners10are driven into place in holes148in the insulation. The ties140are positioned on surface124so that the longitudinal axis of wall anchor140is normal to an xy-plane and the fastener10taps into column117. For purposes of discussion, the cavity surface124of the inner wythe114contains a horizontal line or x-axis134and intersecting vertical line or y-axis136. A horizontal line or z-axis138, normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes.FIG. 7is a sectional view taken through this xz plane. As can be seen inFIG. 7, the location of the thermal break12is inside the width W of the insulation126in an exemplary embodiment. This positioning of the thermal break12inside the insulation significantly reduces heat transfer from one side of the insulation to the other side of the insulation. For example, in the winter the temperature inside a building and thus the temperature of the support structure117, such as a metal stud, may be a room temperature between 65 and 75 degrees F., while the temperature of the outer wythe118and the cavity122may be below freezing. If a conventional metal fastener that does not have a thermal break within the width of the insulation126, heat will conduct from the support structure117, such as a metal stud, directly through the fastener, to the head of the fastener, and be lost in the cavity122that is much colder than the support structure117. By providing a fastener10with a thermal break12within the width of the insulation126, heat will conduct from the support structure117, such as a metal stud and into the fastener, but the thermal break substantially prevents heat from passing to the head of the fastener, and from being lost in the colder cavity122.

In an exemplary embodiment, one or more thermal breaks12can be positioned anywhere in the insulation126. In the example illustrated byFIG. 7, thermal break(s) can be positioned as indicated by reference numbers12,12′ and/or12″. Any number of thermal breaks can be provided. In the illustrated embodiment, the fastener10includes a metallic portion30that extends into the insulation126from the outside32and a metallic portion34that extends into the insulation126from the inside, with one or more thermal breaks12,12′, and/or12″ disposed completely in the insulation.

The thermal break12can take a wide variety of different forms. For example, two or more parts of the fastener10can be connected by a material having a low thermal conductivity to form the thermal break12. For example, the two or more parts can be connected together by an epoxy or other adhesive having a low thermal conductivity, mechanically connected together, for example by one or more threaded connectors having a low thermal conductivity, and the like. Any manner for providing a thermal break can be implemented. In another exemplary embodiment, the entire fastener10is made from a material having a low thermal conductivity, rather than providing a thermal break.

FIGS. 8A and 8Billustrate an exemplary embodiment of a composite tie840that can be used with a conventional fastener, such as a threaded fastener, or any of the fasteners10disclosed by the present application. The illustrated composite tie840comprises a disk802and a wire loop804. In an exemplary embodiment, the disk802is made from a material that is substantially non-conductive, such as plastic. The disk802includes a central hole806that is sized to accept the threaded portion16and shank18of the fastener10, such that the head14engages the disk802. The tie retainer wire loop804extends away from the disk802. The disk802provides a thermal break between the fastener10or a conventional fastener and the tie retainer wire loop804.

FIGS. 9 and 10illustrate a wall anchoring system910that uses fasteners10shown inFIGS. 1, 1A and/or 1Band the composite tie840illustrated byFIGS. 8A and 8B. A cavity wall assembly112is shown as having an inner wythe114constructed from one or more panels116or layers, which may be sheetrock, drywall, particle board, oriented strand board, fiberglass mats on the front and back of a fiberglass reinforced gypsum core, and/or any other wall construction panel or facing material, mounted on a support structure117, such as metal studs or columns, wood studs or panels, or a masonry wall. Metal studs are illustrated, but inner wythes constructed of masonry materials and/or wood framing (not shown) are also applicable. The cavity wall assembly also includes an outer wythe or facing wall118of brick120construction. Between the inner wythe114and the outer wythe118, a cavity122is formed. The cavity122has attached to the exterior surface124of the inner wythe114an optional air or air-vapor barrier125and insulation126. The air or air-vapor barrier125and/or the panel116form an exterior layer of the inner wythe114, which exterior layer has the insulation126disposed thereon.

Successive bed joints130and132may be substantially planar and horizontally disposed, in accord with current building standards. For example, the bed joints may be 0.375-inch (approx.) in height. Selective ones of bed joints130and132, which are formed between courses of bricks120, are constructed to receive a veneer anchor140. The veneer anchor can take a wide variety of different forms. In the example illustrated byFIG. 2, any veneer anchor140capable of being mounted to the inner wythe114and insulation126with a conventional fastener can be mounted with one of the fasteners10having a thermal break12illustrated byFIGS. 1, 1A, and1B. The tie retainer wire loop804is disposed on a course of bricks120in preparation for embedment in the mortar of bed joint130.

Referring toFIGS. 9 and 10, at intervals along a horizontal surface124, fasteners10are driven into place in holes148in the insulation. The ties140are positioned on surface124so that the longitudinal axis of wall anchor140is normal to an xy-plane and the fastener10taps into column117.

For purposes of discussion, the cavity surface124of the inner wythe114contains a horizontal line or x-axis134and intersecting vertical line or y-axis136. A horizontal line or z-axis138, normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes.FIG. 10is a sectional view taken through this xz plane. As can be seen inFIG. 10, the location of the thermal break12is inside the width W of the insulation126in an exemplary embodiment. This positioning of the thermal break12inside the insulation significantly reduces heat transfer from one side of the insulation to the other side of the insulation. For example, in the winter the temperature inside a building and thus the temperature of the support structure117, such as a metal stud, may be a room temperature between 65 and 75 degrees F., while the temperature of the outer wythe118and the cavity122may be below freezing. If a conventional metal fastener that does not have a thermal break within the width of the insulation126, heat will conduct from the support structure117, such as a metal stud, directly through the fastener, to the head of the fastener, and be lost in the cavity122that is much colder than the support structure117, By providing a fastener10with a thermal break12within the width of the insulation126, heat will conduct from the support structure117, such as a metal stud and into the fastener, but the thermal break substantially prevents heat from passing to the head of the fastener, and from being lost in the colder cavity122.

In an exemplary embodiment, one or more thermal breaks12can be positioned anywhere in the insulation126. In the example illustrated byFIG. 10, thermal break(s) can be positioned as indicated by reference numbers12,12′ and/or12″. Any number of thermal breaks can be provided. In the illustrated embodiment, the fastener10includes a metallic portion30that extends into the insulation126from the outside32and a metallic portion34that extends into the insulation126from the inside, with one or more thermal breaks12,12′, and/or12″ disposed completely in the insulation.

The thermal break12can take a wide variety of different forms. For example, two or more parts of the fastener10can be connected by a material having a low thermal conductivity to form the thermal break12. For example, the two or more parts can be connected together by an epoxy or other adhesive having a low thermal conductivity, mechanically connected together, for example by one or more threaded connectors having a low thermal conductivity, and the like. Any manner for providing a thermal break can be implemented. In another exemplary embodiment, the entire fastener10is made from a material having a low thermal conductivity, rather than providing a thermal break.

FIG. 11is a graph that represents results of a test that was run on a fastener10used in the anchoring systems110illustrated byFIGS. 3, 7, and 10. In the test, a metal stud117is made from steel and is heated. The line1102on the graph represents the temperature of the steel stud. Two fasteners are attached to the metal stud. The first fastener is made from steel and does not include a thermal break. The second fastener is also made from steel, but has a thermal break about midway through the thickness of the insulation. The line1104on the graph represents the temperature of the head of the steel fastener without a thermal break. The line1106on the graph represents the temperature of the head of the steel fastener with a thermal break positioned in the insulation126. As can be seen inFIG. 11, the drop in temperature from the stud to the fastener head is much greater when the fastener includes a thermal break inside the thickness of the insulation. In the example illustrated byFIG. 11, the temperature drop from the steel stud117to the fastener head14doubles, at least doubles, or approximately doubles when a thermal break inside the insulation is included. In the example illustrated byFIG. 11, the temperature drop for a steel fastener without a thermal break is about 20 degrees F. (About 130 degrees F. minus about 110 degrees F.) and the temperature drop for a steel fastener with a thermal break is about 40 degrees (About 130 degrees minus about 90 degrees). As such, the inclusion of a thermal break in a steel fastener inside the width of the insulation significantly reduces the thermal conductivity of the fastener10.

While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the invention to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, the specific locations of the component connections and interplacements can be modified. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of the applicant's general inventive concept.