Abstract:
A fail-safe wall anchor for cavity walls includes a wingnut including receptors for receiving pintles of a veneer tie. Thermally insulative material is provided to inhibit transfer of heat from the veneer tie to the wall anchor. Back up structure is provided in the event the thermally insulative material fails to maintain the structural connection between the wall anchor and the veneer tie.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to fail-safe anchoring systems for cavity walls. At the inner wythe, the anchoring systems provide a stud-type wall anchor with a hybrid connector portion for interlocking with a veneer anchor. The hybrid connector portion has two elements, namely, a thermoplastic portion and a metal stamping portion. Upon being subjected to a extreme heat or a fire, the thermoplastic portion is fail-prone and melts and the metal stamping portion is fail-safe and retains the veneer anchor. Under normal conditions, the thermoplastic portion provides a thermal break between the metal veneer anchor and the stud-type wall anchor. 
         [0003]    2. Description of the Prior Art 
         [0004]    In the past, anchoring systems have taken a variety of configurations. Where the applications included masonry backup walls, wall anchors were commonly incorporated into ladder- or truss-type reinforcements and provided wire-to-wire connections with box ties or pintle-receiving designs on the veneer side. 
         [0005]    In the late 1980&#39;s, surface-mounted wall anchors were developed by Hohmann &amp; Barnard, Inc., patented under U.S. Pat. No. 4,598,518 (&#39;518). The invention was commercialized under trademarks DW-10®, DW-10-X®, and DW-10-HS®. These widely accepted building specialty products were designed primarily for drywall construction, but were also used with masonry backup walls. For seismic applications, it was common practice to use these wall anchors as part of the DW-10 Seismiclip® interlock system which added a Byna-Tie® wire formative, a Seismiclip® snap-in device—described in U.S. Pat. No. 4,875,319 (&#39;319), and a continuous wire reinforcement. 
         [0006]    In the dry wall application, the surface-mounted wall anchor of the above-described system has pronged legs that pierce the insulation and the wall board and rest against the metal stud to provide mechanical stability in a four-point landing arrangement. The vertical slot of the wall anchor enables the mason to have the wire tie adjustably positioned along a pathway of up to 3.625-inch (max). The interlock system served well and received high scores in testing and engineering evaluations which examined the effects of various forces, particularly lateral forces, upon brick veneer masonry construction. However, under certain conditions, the system did not sufficiently maintain the integrity of the insulation. 
         [0007]    The engineering evaluations further described the advantages of having a continuous wire embedded in the mortar joint of anchored veneer wythes. The seismic aspects of these investigations were reported in the inventor&#39;s &#39;319 patent. Besides earthquake protection, the failure of several high-rise buildings to withstand wind and other lateral forces resulted in the incorporation of a continuous wire reinforcement requirement in the Uniform Building Code provisions. The use of a continuous wire in masonry veneer walls has also been found to provide protection against problems arising from thermal expansion and contraction and to improve the uniformity of the distribution of lateral forces in the structure. 
         [0008]    Shortly after the introduction of the pronged wall anchor, a seismic veneer anchor, which incorporated an L-shaped backplate, was introduced. This was formed from either 12- or 14-gauge sheetmetal and provided horizontally disposed openings in the arms thereof for pintle legs of the veneer anchor. In general, the pintle-receiving sheetmetal version of the Seismiclip® interlock system served well, but in addition to the insulation integrity problem, installations were hampered by mortar buildup interfering with pintle leg insertion. 
         [0009]    In the late 1980&#39;s, an anchor for masonry veneer walls was developed and described in U.S. Pat. No. 4,764,069 by Reinwall et al., which patent is an improvement of the masonry veneer anchor of Lopez, U.S. Pat. No. 4,473,984. Here the anchors are keyed to elements that are installed using power-rotated drivers to deposit a mounting stud in a cementitious or masonry backup wall. Fittings are then attached to the stud which include an elongated eye and a wire tie therethrough for disposition in a bed joint of the outer wythe. It is instructive to note that pin-point loading—that is forces concentrated at substantially a single point—developed from this design configuration. Upon experiencing lateral forces over time, this resulted in the loosening of the stud. 
         [0010]    Exemplary of the public sector building specification is that of the Energy Code Requirement, Boston, Mass. (See Chapter 13 of 780 CMR, Seventh Edition). This Code sets forth insulation R—values well in excess of prior editions and evokes an engineering response opting for thicker insulation and correspondingly larger cavities. 
         [0011]    As insulation became thicker, the tearing of insulation during installation of the pronged DW-10X® wall anchor, see supra, became more prevalent. This occurred as the installer would fully insert one side of the wall anchor before seating the other side. The tearing would occur during the arcuate path of the insertion of the second leg. The gapping caused in the insulation permitted air and moisture to infiltrate through the insulation along the pathway formed by the tear. While the gapping was largely resolved by placing a self-sealing, dual-barrier polymeric membrane at the site of the legs and the mounting hardware, with increasing thickness in insulation, this patchwork became less desirable. The improvements hereinbelow in surface mounted wall anchors look toward greater retention of insulation integrity and less reliance on a patch. 
         [0012]    In the past, the use of wire formatives have been limited by the mortar layer thickness which, in turn, are dictated either by the new building specifications or by pre-existing conditions, e.g. matching during renovations or additions to the existing mortar layer thickness. While arguments have been made for increasing the number of the fine-wire anchors per unit area of the facing layer, architects and architectural engineers have favored wire formative anchors of sturdier wire. 
         [0013]    Contractors found that heavy wire anchors, with diameters approaching the mortar layer height specification, frequently result in misalignment. This led to the low-profile wall anchors of the inventors hereof as described in U.S. Pat. No. 6,279,283. However, the above-described technology did not fully address the adaption thereof to insulated inner wythes utilizing stabilized stud-type devices. 
         [0014]    Another prior art development occurred shortly after that of Reinwall/Lopez when Hatzinikolas and Pacholok of Fero Holding Ltd. introduced their sheetmetal masonry connector for a cavity wall. This device is described in U.S. Pat. Nos. 5,392,581 and 4,869,043. Here a sheetmetal plate connects to the side of a dry wall column and protrudes through the insulation into the cavity. A wire tie is threaded through a slot in the leading edge of the plate capturing an insulative plate thereunder and extending into a bed joint of the veneer. The underlying sheetmetal plate is highly thermally conductive, and the &#39;581 patent describes lowering the thermal conductivity by foraminously structuring the plate. However, as there is no thermal break or barrier, a concomitant loss of the insulative integrity results. 
         [0015]    The construction of a steel-framed inner wythe of a commercial 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 wythe to the inner wythe by screwing or bolting an anchor to a steel stud. Although steel offers many benefits, it does not provide the high insulation efficiency of timber framing and can cause the effective R-value of fiberglass batt insulation between the steel studs to fall 50 to 60%. 
         [0016]    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. In order to maintain high insulation values, a thermal break or barrier is needed between the steel framing and the outer wythe. This is achieved by the present invention through the use of high-strength polymeric components which have low thermal conductivity. Removing the steel portions of the anchor at specific locations and replacing the steel with a high-strength polymeric material with a lower thermal conductivity than steel, causes a thermal break and significantly reduces the transfer of heat. 
         [0017]    In the course of prosecution, wall anchor patents indicated by an asterisk on the tabulation below, came to the attention of the inventor and are believed to be relevant in this discussion of the prior art. A more extensive list of patents known to the inventor is included in the Information Disclosure Statement. Thereafter and in preparing for this disclosure, the additional patents which became known to the inventors are discussed further: 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Pat. 
                 Inventor 
                 Issue Date 
               
               
                   
                   
               
             
             
               
                   
                 2,058,148* 
                 Hard 
                 Oct. 20, 1936 
               
               
                   
                 2,966,705* 
                 Massey 
                 Jan. 3, 1961 
               
               
                   
                 3,377,764 
                 Storch 
                 Apr. 16, 1968 
               
               
                   
                 4,021,990* 
                 Schwalberg 
                 May 10, 1977 
               
               
                   
                 4,305,239* 
                 Geraghty 
                 Dec. 15, 1981 
               
               
                   
                 4,373,314 
                 Allan 
                 Feb. 15, 1983 
               
               
                   
                 4,438,611* 
                 Bryant 
                 Mar. 27, 1984 
               
               
                   
                 4,473,984 
                 Lopez 
                 Oct. 2, 1984 
               
               
                   
                 4,598,518 
                 Hohmann 
                 Jul. 8, 1986 
               
               
                   
                 4,869,038 
                 Catani 
                 Sep. 26, 1989 
               
               
                   
                 4,875,319 
                 Hohmann 
                 Oct. 24, 1989 
               
               
                   
                 5,392,581 
                 Hatzinikolas, et. al. 
                 Feb. 28, 1995 
               
               
                   
                 5,408,798 
                 Hohmann 
                 Apr. 25, 1995 
               
               
                   
                 5,456,052 
                 Anderson et al. 
                 Oct. 10, 1995 
               
               
                   
                 5,816,008 
                 Hohmann 
                 Oct. 6, 1998 
               
               
                   
                 6,209,281 
                 Rice 
                 Apr. 3, 2001 
               
               
                   
                 6,279,283 
                 Hohmann et al. 
                 Aug. 28, 2001 
               
               
                   
                 7,415,803 
                 Bronner 
                 Aug. 26, 2008 
               
               
                   
                 8,037,653 
                 Hohmann, Jr. 
                 Oct. 18, 2011 
               
               
                   
                   
               
             
          
         
       
     
         [0018]    It is noted that with some exceptions these devices are generally descriptive of wire-to-wire anchors and wall ties and have various cooperative functional relationships with straight wire runs embedded in the inner and/or outer wythe. 
         [0019]    U.S. Pat. No. 3,337,764—D. Storch—Issued Apr. 16, 1968 discloses a bent wire, tie-type anchor for embedment in a facing exterior wythe engaging with a loop attached to a straight wire run in a backup interior wythe. 
         [0020]    U.S. Pat. No. 4,021,990—B. J. Schwalberg—Issued May 10, 1977 discloses a dry wall construction system for anchoring a facing veneer to wallboard/metal stud construction with a pronged sheetmetal anchor. Like Storch &#39;764, the wall tie is embedded in the exterior wythe and is not attached to a straight wire run. 
         [0021]    U.S. Pat. No. 4,373,314—J. A. Allan—Issued Feb. 15, 1983 discloses a vertical angle iron with one leg adapted for attachment to a stud and the other having elongated slots to accommodate wall ties. Insulation is applied between projecting vertical legs of adjacent angle irons with slots being spaced away from the stud to avoid the insulation. 
         [0022]    U.S. Pat. No. 4,473,984—Lopez—Issued Oct. 2, 1984 discloses a curtain-wall masonry anchor system wherein a wall tie is attached to the inner wythe by a self-tapping screw to a metal stud and to the outer wythe by embedment in a corresponding bed joint. The stud is applied through a hole cut into the insulation. 
         [0023]    U.S. Pat. No. 4,869,038—M. J. Catani—Issued Sep. 26, 1989 discloses a veneer wall anchor system having in the interior wythe a truss-type anchor, similar to Hala et al. &#39;226, supra, but with horizontal sheetmetal extensions. The extensions are interlocked with bent wire pintle-type wall ties that are embedded within the exterior wythe. 
         [0024]    U.S. Pat. No. 4,875,319—R. Hohmann—Issued Oct. 24, 1989 discloses a seismic construction system for anchoring a facing veneer to wallboard/metal stud construction with a pronged sheetmetal anchor. Wall tie is distinguished over that of Schwalberg &#39;990 and is clipped onto a straight wire run. 
         [0025]    U.S. Pat. No. 5,392,581—Hatzinikolas et al.—Issued Feb. 28, 1995 discloses a cavity-wall anchor having a conventional tie wire for mounting in the brick veneer and an L-shaped sheetmetal bracket for mounting vertically between side-by-side blocks and horizontally atop a course of blocks. The bracket has a slit which is vertically disposed and protrudes into the cavity. The slit provides for a vertically adjustable anchor. 
         [0026]    U.S. Pat. No. 5,408,798—Hohmann—Issued Apr. 25, 1995 discloses a seismic construction system for a cavity wall having a masonry anchor, a wall tie, and a facing anchor. Sealed eye wires extend into the cavity and wire wall ties are threaded therethrough with the open ends thereof embedded with a Hohmann &#39;319 (see supra) clip in the mortar layer of the brick veneer. 
         [0027]    U.S. Pat. No. 5,456,052—Anderson et al.—Issued Oct. 10, 1995 discloses a two-part masonry brick tie, the first part being designed to be installed in the inner wythe and then, later when the brick veneer is erected to be interconnected by the second part. Both parts are constructed from sheetmetal and are arranged on substantially the same horizontal plane. 
         [0028]    U.S. Pat. No. 5,816,008—Hohmann—Issued Oct. 6, 1998 discloses a brick veneer anchor primarily for use with a cavity wall with a drywall inner wythe. The device combines an L-shaped plate for mounting on the metal stud of the drywall and extending into the cavity with a T-head bent stay. After interengagement with the L-shaped plate the free end of the bent stay is embedded in the corresponding bed joint of the veneer. 
         [0029]    U.S. Pat. No. 6,209,281—Rice—Issued Apr. 3, 2001 discloses a masonry anchor having a conventional tie wire for mounting in the brick veneer and sheetmetal bracket for mounting on the metal-stud-supported drywall. The bracket has a slit which is vertically disposed when the bracket is mounted on the metal stud and, in application, protrudes through the drywall into the cavity. The slit provides for a vertically adjustable anchor. 
         [0030]    U.S. Pat. No. 6,279,283—Hohmann et al.—Issued Aug. 28, 2001 discloses a low-profile wall tie primarily for use in renovation construction where in order to match existing mortar height in the facing wythe a compressed wall tie is embedded in the bed joint of the brick veneer. 
         [0031]    U.S. Pat. No. 7,415,803—Bronner—Issued Aug. 26, 2008 discloses a double-wingnut anchor system and method for connecting an anchor shaft extending from the backup wall to a wire tie extending from a veneer wall. The wingnut houses the wire tie legs and is independently rotatable to obtain the desired angular position. 
         [0032]    U.S. Pat. No. 8,037,653—Hohmann, Jr.—Issued Oct. 18, 2011 discloses a dual seal anchoring system for insulated cavity walls. The stud anchor has a dual-diameter barrel with thermally-isolating seals. 
         [0033]    None of the above provide the high-strength, supported stud-type wall anchor or anchoring systems utilizing these devices of this invention. As will become clear in reviewing the disclosure which follows, the cavity wall structures benefit from the recent developments described herein that lead to solving the problems of thermal conductivity by providing an in-cavity thermal break and of anchor integrity by having a hybrid wall anchor with both a failure-prone and a fail-safe receptor portions. The anchoring systems hereof combine various wall anchors for self-leveling installation and include reinforcement for seismic protection. 
       SUMMARY 
       [0034]    In general terms, an embodiment of the invention disclosed hereby is an anchoring system for use in a cavity wall. The anchoring system has a steel stud-type wall anchor and a wire formative veneer tie. The steel stud has an elongated dual-diameter barrel body with a driven self-drilling tip and a receptor-bearing hybrid wing nut. 
         [0035]    The wing nut has both a failure-prone portion and a fail-safe portion. The failure-prone portion is a thermoplastic structure formed by overmolding or undermolding a metal armature. When, in the event of a fire, the temperature exceeds the melting point of the thermoplastic, the veneer tie remains interlocked with the metal armature which becomes a fail-safe wall anchor. In normal use and under normal conditions, the hybrid wing nut provides an in-cavity thermal break between the veneer and the backup wall. 
         [0036]    In the molding process, the overmolded embodiment is first discussed. Here exemplary of the device, the armature has a shaftway the central axis of which is co-extensive with that of the stud-type wall anchor and has wings normal to central axis with receptors therethrough to accommodate pintles of the veneer tie. Projections on the armature position the armature during molding so that the receptors are coated with thermoplastic material and so that there is no metal-to-metal contact. 
         [0037]    In the molding process, the undermolded product is next discussed. Here the metal receptor portions is banded or surrounds the thermoplastic material and only makes metal-to-metal contact in the fail-safe mode of operation. 
         [0038]    The structure taught by this invention overcomes both the problems of thermal conductivity by providing an in-cavity thermal break and of failure under extreme temperature conditions. The pin-point loading as described in the Background of the Invention, supra, is overcome by full body support throughout the drywall, the air/vapor barrier, and the insulation. The vapor seal, when the stud-type anchor is fully driven into place provides a seal over the insertion point into the air/vapor barrier. The insulation seal, when the stud-type anchor is fully driven into place, provides a seal over the opening of an anchor-receiving channel and thereby preserves the insulation integrity. Similarly, the insertion seal, when the anchor is fully driven into place, provides a seal at the insertion point in the inner wythe. The polymeric seals provide a thermal break between the inner and outer wythe and thereby maintain insulation R-values. The vapor seal and the larger barrel of the anchor, when installed, completely fill the anchor receiving channel and stabilize the wall anchor. The wall anchor is clamped in place by the seals. The anchor includes either two or three seals. 
         [0039]    The stud-type anchor is disclosed as operating with a variety of veneer ties and drivers, each providing for different applications. A modified Byna-Tie® wire formative with a swaged side leg in the insertion portion expands the utility of the system to seismic applications and accommodates a wire reinforcement in the outer wythe. a tie with a U-shaped rear leg provides for accommodating the driver head at whatever angle it is at when fully driven into place. A tie with an angled rear leg provides for self-leveling as between the stud position and the bed joint height. A wingnut driver accommodates a tie with pintle side legs and provides for angular adjustment. 
         [0040]    It is an object of the present invention to provide new and novel anchoring systems for cavity walls, which systems provide a fail-safe mode under extreme conditions and an in-cavity thermal break under normal conditions. 
         [0041]    It is yet another object of the present invention to provide adjustability of the veneer anchor to compensate for slight angular and height misalignments. 
         [0042]    It is a further object of the present invention to provide an anchoring system which precludes disengagement under seismic and other severe environmental conditions. 
         [0043]    It is another object of the present invention to provide an anchoring system that maintains high insulation values. 
         [0044]    It is a feature of the present invention that the wall anchor has a dual-diameter barrel with a self-drilling screw tip which facilitates installation. 
         [0045]    It is another feature of the present invention that the wall anchor has high-strength polymeric components that provide for a thermal break in the cavity. 
         [0046]    It is yet another feature of the present invention that the anchor system has a hybrid wingnut with receptors for the pintles of a veneer tie. 
         [0047]    It is still yet another feature of the present invention that the hybrid wingnut is readily fabricated by overmolding or undermolding. 
         [0048]    Other objects and features of the present invention will become apparent upon reviewing the drawing and reading the detailed description which follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0049]    In the following drawings, the same parts in the various views are afforded the same reference designators. 
           [0050]      FIG. 1  shows a first embodiment of this invention and is a perspective view of an anchoring system as applied to a cavity wall with an inner wythe of an insulated dry wall construction and an outer wythe of brick; 
           [0051]      FIG. 2  is a cross-sectional view of  FIG. 1  taken along an xz-plane including the longitudinal axis of the wall anchor, and showing the hybrid wingnut of the wall anchor; 
           [0052]      FIG. 3  is an exploded view of the wall anchor showing the dual-barrel configuration and the overmolded hybrid wingnut of this invention; 
           [0053]      FIG. 4  is a side elevational view of the metal stamping used to form the wall anchor armature shown prior to overmolding; 
           [0054]      FIG. 5  is a top plan view of the wall anchor armature utilizing two metal stampings shown in  FIG. 4  and providing a fail-safe wall anchor; 
           [0055]      FIG. 6  is a perspective view of the hybrid wingnut wherein a thermoplastic is molded over the fail-safe wall anchor of  FIG. 5  and is partially broken away to show the fail-safe wall anchor; 
           [0056]      FIG. 7  is a perspective view of an anchoring system similar to  FIG. 1 , but utilizing an undermolded hybrid wingnut and a unitary stud-type wall anchor; 
           [0057]      FIG. 8  is a cross-sectional view of the anchoring system of  FIG. 7 ; 
           [0058]      FIG. 9  is a perspective view of a fail-safe metal band for an undermolded hybrid wingnut; and, 
           [0059]      FIG. 10  is a perspective view of the hybrid wingnut wherein a thermoplastic is molded under the fail-safe anchor of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION 
       [0060]    Before entering into the Detailed Description, several terms which will be revisited later are defined. These terms are relevant to discussions of innovations introduced by the improvements of this disclosure that overcome the deficits of the prior art devices. 
         [0061]    In the embodiments described hereinbelow, the inner wythe is provided with insulation. In the dry wall construction, shown herein, the insulation is applied to the outer surface thereof. Recently, building codes have required that after the anchoring system is installed and, prior to the inner wythe being closed up, that an inspection be made for insulation integrity to ensure that the insulation prevents infiltration of air and moisture. The term as used herein is defined in the same sense as the building code in that, “insulation integrity” means that, after the installation of the anchoring system, there is no change or interference with the insulative properties and concomitantly that there is substantially no change in the air and moisture infiltration characteristics. 
         [0062]    Anchoring systems for cavity walls are used to secure veneer facings to a buildings and overcome extreme temperature conditions, seismic and other forces, i.e. fire, wind shear, etc. In the past, some systems have experienced failure. Here, the term “hybrid wingnut” is defined as a two anchor component wherein each component has a specific function. The insulative function is produced using an anchor of nonthermally conductive material such as a thermoplastic and further the fail-safe function is achieved using a metal anchor. When the hybrid wingnut is produced by overmolding, the metal portion acts as an “armature” defined for our purposes as an underlying element around or upon which the mold is structured. When the hybrid wingnut is produced by undermolding, the metal anchor forms a framework or a band within which the molded portion resides. 
         [0063]    In general terms, the dual function of the hybrid wingnut creates a desirable redundancy and, when the thermoplastic anchor melts at high temperatures, the veneer—in this case a brick veneer—is left safely attached to the backup wall by the metal anchor. 
         [0064]    In the detailed description which follows, the veneer ties and reinforcements are wire formatives. The hybrid wingnut of the wall anchor provides an in-cavity thermal break attributable to the use of high-strength polymeric material. 
         [0065]    Referring now to  FIGS. 1 through 6 , the first embodiment shows an anchoring system suitable for seismic zone applications. This anchoring system, discussed in detail hereinbelow, has a wall anchor, an interengaging veneer tie, and a veneer (outer wythe) reinforcement. For the first embodiment, a cavity wall having an insulative layer of 4.0 inches (approx.) and a total span or 4.75 inches (approx.) is chosen as exemplary. 
         [0066]    The anchoring system for cavity walls is referred to generally by numeral  10 . A cavity wall structure  12  is shown having an inner wythe or drywall backup  14  with sheetrock or wallboard  16  mounted on metal studs or columns  17  and an outer wythe or facing wall  18  of brick  20  construction. Inner wythes constructed of masonry materials or wood framing (not shown) are also applicable. Between the inner wythe  14  and the outer wythe  18 , a cavity  22  is formed. The cavity  22  has attached to the exterior surface  24  of the inner wythe  14  an air or air-vapor barrier  25  and insulation  26 . The air or air-vapor  25  and the wallboard  16  together form the exterior layer  28  of the inner wythe  14 , which exterior layer  28  has the insulation  26  disposed thereon. 
         [0067]    Successive bed joints  30  and  32  are substantially planar and horizontally disposed and, in accord with current building standards, are 0.375-inch (approx.) in height. Selective ones of bed joints  30  and  32 , which are formed between courses of bricks  20 , are constructed to receive therewithin the insertion portion of the veneer anchor hereof. Being threadedly mounted in the inner wythe, the wall anchor is supported thereby and, as described in greater detail herein below, is configured to minimize air and moisture penetration around the wall anchor/inner wythe interface. 
         [0068]    For purposes of discussion, the cavity surface  24  of the inner wythe  14  contains a horizontal line of x-axis  34  intersecting vertical line or y-axis  36 . A horizontal line or z-axis  38 , normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes. A wall anchor  40  is shown with a hybrid wingnut component  53 . The hybrid component  53  is constructed of a thermoplastic overmold consisting of an insulative high-strength polymeric material, such as polyvinyl chloride, that provides a nonconductive pathway through the cavity wall  12 . The nonconductive material is essential in maintaining maximum insulation R-values by providing an in-cavity thermal break between the metal studs  17  and the outer wythe  18 . A steel armature  61 , shown in  FIGS. 4 ,  5 , and  6 , is a pair of metal stamping  63  constructed from stainless steel, carbon steel, galvanized steel, zinc cast steel, or the like. The armature  61 , upon a fire melting away the thermoplastic covering  65  acts as a backup, fail-safe wall anchor and may also be referred to herein as an armature-anchor  61 . 
         [0069]    The wall anchor  40 , while shown as an assemblage of several distinct parts, may be manufactured as a unitary structure. The veneer tie  44  is a box Byna-Tie® device manufactured by Hohmann &amp; Barnard, Inc., Hauppauge, N.Y. 11788. The veneer tie  44  is a wire formative with pintle connectors  43  and  45  that engage the apertures or receptors  55  and  57  in the wingnut  53  of the anchor  40 . The veneer tie  44  is shown in  FIG. 1  as being emplaced on a course of bricks  20  in preparation for embedment in the mortar of bed joint  30 . In this embodiment, the system includes a wire or outer wythe reinforcement  46 , a wall anchor  40  and a veneer tie  44 . The wire reinforcement  46  is constructed of a wire formative. 
         [0070]    In the overmolding process, molten thermoplastic flows though receptors  67 ,  FIG. 4 , to form the receptors  55  and  57  and apertures  69  to form interior thread  71 . Projections  73  properly position armature  61  within the mold to create the hybrid wingnut component  53 . 
         [0071]    At intervals along a horizontal surface  24 , wall anchors  40  are positioned on surface  24  so that the longitudinal axis of wall anchor  40  extends from a driven end  52  to a driver end  54 . The driven end  52  is constructed with a self-drilling screw portion  56 . 
         [0072]    Contiguous with screw portion  56  is a dual-diameter barrel with a smaller diameter barrel or shaft portion  58  toward the driven end  52  and a larger diameter barrel or shaft portion  60  toward the driver end  54 . At the juncture of barrel portions  58  and  60 , a flange  62  is formed and a stabilizing neoprene fitting or internal seal  64  is emplaced thereat. When fully driven into column  17  the screw  56  and barrel portion  58  wall anchor  40  pierces sheetrock or wallboard  16  and air or air-vapor barrier  25 . The channel seal  64  covers the insertion point or installation channel precluding air and moisture penetration therethrough and maintaining the integrity barrier  25 . 
         [0073]    At the driving end  54 , a driver portion  66  adjoins larger diameter barrel or shaft portion  60  forming a flange  68  therebetween and another stabilizing neoprene fitting or external seal  70  is emplaced threat. Upon installation into rigid insulation, the larger barrel portion  60  is forced into a press fit relationship with anchor-receiving channel  48 . Stabilization of this stud-type wall anchor  40  is attained by barrel portion  60  and neoprene fitting  64  completely filling the channel  48  with external neoprene fitting  70  capping the opening  72  of channel  48  into cavity  22  and clamping wall anchor  40  in place. This arrangement does not leave any end play or wiggle room for pin-point loading of the wall anchor and therefore does not loosen over time. With stabilizing fitting or external seal  70  in place, the insulation integrity within the cavity wall is maintained. The driver portion  66  is capable of being driven using a conventional chuck and, after being rotated to align with the bed joint  30 , the wingnut  53  is locked in place. The wingnut  53  has two apertures  55  and  57  for accommodating the veneer tie and has the effect of spreading stresses experienced during use and further reducing pin-point loading as opposite force vectors cancel one another. In producing wall anchor  48 , the length of the smaller diameter barrel  58  less the internal seal  64  height is dimensioned to match the external layer  28  thickness. Similarly, the length of the larger diameter barrel  60  plus the internal seal  64  height is dimensioned to match the insulation thickness. 
         [0074]    In this embodiment, the driver portion  66  is a bolt  51  and a washer  59  that secures a wingnut  53 . The two apertured ends  55  and  57  of the wingnut  53  receive the veneer tie  44 . The wingnut  53  is angularly adjusted to ensure proper alignment of the veneer tie  44 . The veneer tie  44  is a wire formative having two pintle leg portions  43  and  45 . The leg portions  43  and  45  are inserted into the apertured ends  55  and  57  of the wingnut  53  and extend to and, at the front portion thereof, are part of insertion portion  80  which is shown installed into bed joint  30 . The insertion portion  80  is constructed with two parallel front legs  82  and  84  adjoining leg portions  43  and  45 , respectively, and housing therebetween wire reinforcement  46 . At the juncture of side leg  43  and front leg  82 , a swaged area  86  is shown for further accommodating wire reinforcement  46 . 
         [0075]    Referring now to  FIGS. 7 through 10 , the second embodiment shows an anchoring system suitable for seismic zone applications. This anchoring system, discussed in detail hereinbelow, has a wall anchor, an interengaging veneer tie, and a veneer (outer wythe) reinforcement. Similar to the first embodiment, the second embodiment has a cavity wall having an insulative layer of 4.0 inches (approx.) and a total span or 4.75 inches (approx.) is chosen as exemplary; however, here the undermolded hybrid wingnut is employed. In the description which follows, reference designators used for similar parts to those in the first embodiment are “100” digits higher. For example, metal studs  17  in the first embodiment find similar columns  117  in the second embodiment. 
         [0076]    The anchoring system for cavity walls is referred to generally by numeral  110 . A cavity wall structure  112  is shown having an inner wythe or drywall backup  114  with sheetrock or wallboard  116  mounted on metal studs or columns  117  and an outer wythe or facing wall  118  of brick  120  construction. Inner wythes constructed of masonry materials or wood framing (not shown) are also applicable. Between the inner wythe  114  and the outer wythe  118 , a cavity  122  is formed. The cavity  122  has attached to the exterior surface  124  of the inner wythe  114  an air or air-vapor barrier  125  and insulation  126 . The air or air-vapor  125  and the wallboard  116  together form the exterior layer  128  of the inner wythe  114 , which exterior layer  128  has the insulation  126  disposed thereon. 
         [0077]    Successive bed joints  130  and  132  are substantially planar and horizontally disposed and, in accord with current building standards, are 0.375-inch (approx.) in height. Selective ones of bed joints  130  and  132 , which are formed between courses of bricks  120 , are constructed to receive therewithin the insertion portion of the veneer anchor hereof. Being threadedly mounted in the inner wythe, the wall anchor is supported thereby and, as described in greater detail herein below, is configured to minimize air and moisture penetration around the wall anchor/inner wythe interface. 
         [0078]    A wall anchor  140  is shown with a hybrid wingnut component  153 . The hybrid component  153  is constructed of a thermoplastic undermold consisting of an insulative high-strength polymeric material, such as polyvinyl chloride, that provides an in-cavity thermal break interrupting the prior conductive pathway through the cavity wall  112 . The nonconductive material is in essence maintains the maximum insulation R-values through this in-cavity thermal break between the metal studs  117  and the outer wythe  118 . A steel anchor band  161 , shown in  FIGS. 8 ,  9 , and  10 , is a pair of snap-fit metal stampings  163  constructed from stainless steel, carbon steel, galvanized steel, zinc cast steel, or the like. The steel anchor band  161 , upon a fire melting away the undermolded thermoplastic anchor  165  acts as a backup, fail-safe wall anchor and may also be referred to herein as an exterior anchor  161 . The wall anchor  140 , while shown as a unitary structure  160  may be an assemblage of several distinct parts. 
         [0079]    The veneer tie  144  is a box Byna-Tie® device manufactured by Hohmann &amp; Barnard, Inc., Hauppauge, N.Y. 11788. The veneer tie  144  is a wire formative with pintle connectors  143  and  145  that engage the apertures or receptors  155  and  157  in the wingnut  153  of the anchor  140 . The veneer tie  144  is shown in  FIG. 7  as being emplaced on a course of bricks  120  in preparation for embedment in the mortar of bed joint  130 . In this embodiment, the system includes a wire or outer wythe reinforcement  146 , a wall anchor  140  and a veneer tie  144 . The wire reinforcement  146  is constructed of a wire formative. 
         [0080]    In the undermolding process, molten thermoplastic flows though receptors  167  to form the receptors  155  and  157  and apertures  169  to form interior thread  171 . Projections  173  properly position the metal anchor band  161  to form the hybrid wingnut component  153 . While the fail-safe band  161  is described as part of this process, the component may be assembled to the thermoplastic anchor  165  apart from the molding process. 
         [0081]    In this embodiment, the wingnut  153  is secured to the driver portion  166  of the stud-type anchor body by a bolt  151  and a washer  159 . The two apertured ends  155  and  157  of the wingnut  153  receive the veneer tie  144 . The wingnut  153  is angularly adjusted to ensure proper alignment of the veneer tie  144 . The metal band or framework  163  surrounding the thermoplastic molded portion  165  enhances the tension and compression rating of the hybrid wingnut  153 . The veneer tie  144  is a wire formative having two pintle leg portions  143  and  145 . The leg portions  143  and  145  are inserted into the thermoplastic apertured ends  155  and  157  of the wingnut  153 . The veneer tie  144  extends to and, at the front portion thereof, are part of insertion portion  180  which is shown installed into bed joint  130 . The insertion portion  180  is constructed with two parallel front legs  182  and  184  adjoining leg portions  143  and  145 , respectively, and housing therebetween wire reinforcement  146 . At the juncture of side leg  143  and front leg  182 , a swaged area  186  is shown for further accommodating wire reinforcement  146 . 
         [0082]    The following attributes of the anchoring system hereof have been described in related applications and are re-iterated here for purposes of clarity and completeness. At intervals along a horizontal surface  24 , wall anchors  40  are positioned on surface  24  so that the longitudinal axis of wall anchor  40  extends from a driven end  52  to a driver end  54 . The driven end  52  is constructed with a self-drilling screw portion  56 . 
         [0083]    Contiguous with screw portion  56  is a dual-diameter barrel with a smaller diameter barrel or shaft portion  58  toward the driven end  52  and a larger diameter barrel or shaft portion  60  toward the driver end  54 . At the juncture of barrel portions  58  and  60 , a flange  62  is formed and a stabilizing neoprene fitting or internal seal  64  is emplaced thereat. When fully driven into column  17  the screw  56  and barrel portion  58  wall anchor  40  pierces sheetrock or wallboard  16  and air or air-vapor barrier  25 . The channel seal  64  covers the insertion point or installation channel precluding air and moisture penetration therethrough and maintaining the integrity barrier  25 . 
         [0084]    At the driving end  54 , a driver portion  66  adjoins larger diameter barrel or shaft portion  60  forming a flange  68  therebetween and another stabilizing neoprene fitting or external seal  70  is emplaced threat. Upon installation into rigid insulation, the larger barrel portion  60  is forced into a press fit relationship with anchor-receiving channel  48 . Stabilization of this stud-type wall anchor  40  is attained by barrel portion  60  and neoprene fitting  64  completely filling the channel  48  with external neoprene fitting  70  capping the opening  72  of channel  48  into cavity  22  and clamping wall anchor  40  in place. This arrangement does not leave any end play or wiggle room for pin-point loading of the wall anchor and therefore does not loosen over time. With stabilizing fitting or external seal  70  in place, the insulation integrity within the cavity wall is maintained. The driver portion  66  is capable of being driven using a conventional chuck and, after being rotated to align with the bed joint  30 , the wingnut  53  is locked in place. The wingnut  53  has two apertures  55  and  57  for accommodating the veneer tie and has the effect of spreading stresses experienced during use and further reducing pin-point loading as opposite force vectors cancel one another. In producing wall anchor  48 , the length of the smaller diameter barrel  58  less the internal seal  64  height is dimensioned to match the external layer  28  thickness. Similarly, the length of the larger diameter barrel  60  plus the internal seal  64  height is dimensioned to match the insulation thickness. 
         [0085]    In the above description of fail-safe anchoring systems for cavity walls of this invention various configurations are described and applications thereof in corresponding settings are provided. Because varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. Thus minor changes may be made without departing from the spirit of the invention.