Abstract:
A device and method for mounting structures to masonry. The device has a cover plate with a plurality of extendable and retractable straps and is used to cover a hole in a masonry wall, while providing temporary support to various structural items to be attached to the masonry wall. Each strap also engages the inner surface of the masonry wall. The straps preferably have a series of ridges that engage the cover plate such that sufficient resistance is provided to temporarily affix various objects to be embedded in the masonry wall. The straps position the plate on the front surface of the masonry wall such that it is generally concentric with the masonry hole. Grout is then poured into the hollow cavity behind the masonry wall, thus securing the embedded material permanently. The cover plate is preferably transparent to allow the user to determine that the wall and hole are property grouted.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of application Ser. No. 09/728,875, filed Dec. 4, 2000, which claims the benefit of provisional application Ser. No. 60/234,908, filed Sep. 25, 2000. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is directed generally to securing and anchoring devices and more particularly to a universal mounting plate particularly adapted for use in securing bolts, studs and other objects in masonry units. 
     2. Description of the Related Art 
     In construction of a building, there are many instances where masonry and other types of material, such as wood or steel, meet or intersect. Since masonry cannot easily be nailed or bolted to without expectation of breakage, various techniques and devices have been developed to allow masonry to be secured to such other materials. However, until the present invention, methods and devices for connecting to masonry elements generally have exhibited particular problems or disadvantages. 
     For example, one current method involves drilling a hole into the masonry item, placing a strap of metal in the hole and packing paper around the hole. When grout or cement is poured into the masonry, usually through the hollow middle in the case of concrete block, the paper, at least in part, limits grout leaking out of the hole. However, a significant amount of grout tends to leak during this procedure. If one tries to place more paper in the hole, this results in less room for grout to surround and support the strap, which results in a weaker connection. 
     Another method involves placing a threaded bolt into a hole drilled in the masonry, while attached to a suitably large piece of scrap wood, such as plywood. The machine bolt, all thread nuts and washer have to be installed on the bolt in the plywood at the time the plywood is temporarily secured to the masonry, such as by nails. After the grout or concrete dries, it is necessary to remove the nuts to remove the plywood and reinstall the nuts. In a typical construction, many bolts are installed. Accordingly, the steps involved in preparation and removal of the plywood requires significant time, resulting in additional labor costs. 
     Previous attempts to simplify and improve these processes include the use of a piece of flat sheet metal with several wire hooks for engaging the inside surface of a masonry wall, for example, as described in U.S. Pat. No. 5,794,394. The plate includes a hole for supporting an anchor bolt. While there are several clear advantages to this design over previous procedures, it still suffers some disadvantages. This design does not provide a way to visually inspect the connection among the masonry wall, the bolt and the grout. Additionally, this device is specifically tailored to attaching an anchor bolt to a masonry wall. This device would require significant alteration to accommodate other embedded items common to the industry such as a weld plate or a purlin anchor (PA) strap. 
     Also in using these devices, one could never be sure that the hole was adequately grouted and that air pockets, which inevitably initially exist, are sufficiently removed. This is because the plywood, metal plate or paper covering the hole and cannot be seen through. Accordingly, it would be beneficial to have a device that is used to secure bolts and other structures to masonry while allowing visual inspection of the grout filling process to ensure that the hole is completely grouted, that the bolt is centered in the hole, and that air pockets are removed. 
     Accordingly, there exists a need for a device which will easily center various items to be embedded within a hollow masonry wall structure, while providing assurance that the hole has been sufficiently grouted as desired. In addition, there is a need for a device that is adaptable to allow a variety of different materials to be securely connected to masonry items. The present invention satisfies these needs and provides related advantages as well. 
     SUMMARY OF THE INVENTION 
     The present invention provides a device and a method for securing a structure to masonry, and more particularly to a hollow concrete masonry unit such as a concrete building block. The wall of the masonry unit has an outer surface and an inner surface spaced apart from the outer surface, and also has a masonry hole therein. The device is made up of a plate of sufficient size to cover the masonry hole. The plate has a securing member hole therein and at least one strap mounting hole. The device also has at least one securing strap. Each strap has a first portion, and an anchor portion disposed at an angle to the first portion. The first portion of each strap is slidably engaged in the strap mounting hole and extends through the masonry hole so that the anchor portion of the securing strap contacts the inner surface so that when the securing strap is pulled through the strap mounting hole, the plate is positioned on the outer surface such that the securing member hole is concentric with the masonry hole. 
     In further embodiments of the device, each securing strap has a plurality of ridges along the first portion and each of the strap mounting holes has at least one tooth to engage the ribs of the securing strap. 
     In another embodiment, the plate of the device is transparent, the material is polyethylene, rubber or nylon and the cover plate is fluorescent or biodegradable. 
     In yet another embodiment, the securing member hole is configured to accept a machine bolt, a PA strap and a weld plate. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     The objects, advantages and features of the present invention will be more clearly understood by reference to the following detailed description, when read in conjunction with the accompanying drawing, in which: 
     FIG. 1 is a side view of a universal mounting plate representing one embodiment of the invention; 
     FIG. 2 is a partial plan view of a securing strap; 
     FIG. 3 is an outside plan view of one embodiment of a plate used in connection with the present invention; 
     FIG. 4 is an inside perspective view of an alternate embodiment of the present invention; 
     FIG. 5 is an expanded view of the engaging mechanism; 
     FIG. 6 a  shows the present invention used with a PA strap; 
     FIG. 6 b  shows the present invention used with a machine bolt; 
     FIG. 6 c  shows the present invention used with a weld plate; 
     FIG. 7 is a side view of one embodiment of the present invention into which a machine bolt is inserted; 
     FIG. 8 is a side view of another embodiment of the present invention into which a PA strap is inserted; and 
     FIG. 9 shows the present invention partially installed into a piece of masonry. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention relates to a universal mounting plate adapted for use in securing a variety of construction materials or structures to masonry items. An example of such a structure could be a wooden or steel beam. It is generally understood that masonry is a relatively brittle substance, requiring special tools and techniques for working with. In addition, when material such as wood or steel needs to be attached to a masonry wall, special challenges are faced. Using the present invention one can relatively easily attach wood or steel members to a masonry item allowing flexibility in building design and construction. 
     In a preferred embodiment, a connecting member, such as a threaded rod, a PA strap or a metal plate is secured to the masonry wall. The rod, strap or metal plate allows other structural members to be easily attached by the use of nuts, nails or welding, for example. When a rod or anchor bolt is used, it is placed in the device, inserted into about a precut hole in the masonry and then filled with grout. The objects and advantages of the invention include providing simple installation of various embedded items. The invention is particularly adapted for easy inspection and can be used with a wide variety of commonly embedded objects. Typically the device remains in the wall as a nonstructural member. The cover plate portion of the invention can also be removed after the grout has cured by simply separating the plate at a weakened joint provided therein, if additional inspection is required. 
     The present invention is a significant improvement over the prior art. The device herein provides a means for easily attaching several commonly embedded devices such as an anchor bolt, a PA Strap and a weld plate. Additionally, the device is preferably made of a transparent material so that a user has immediate feedback concerning the flow and coverage of grout. If voids are observed, a user may take immediate corrective action, unlike previous uses of plywood or sheet metal which would not be discovered until after the grout has cured. 
     In addition, the use of securing straps and a cover plate ensures that the connecting member is placed in the center of the hole drilled in the masonry, which affords maximum grout contact. It also ensures that the connecting member does not move about during grout filling and that grout does not leak from the hole that has been drilled. Since the device is preferably made of a plastic material, portions of the device protruding from the front surface of the masonry wall can be easily trimmed off after the grout has cured. This provides an unobstructed installation and a clean finished look. 
     Referring now to the drawing, and more particularly to FIG. 1, a side view of one embodiment of the invention is shown. Cover plate  20  is shown with reinforcing land  25  and securing member hole  23 . The cover plate is generally disc-shaped. Securing strap  30  is passed through a strap mounting hole  19  in boss  21 . Hole  19  is shown in FIG.  3 . Anchor portion  32  on the inside end of the strap is shown as having a generally triangular shape. However it is contemplated that anchor portion  32  can be any other suitable shape that allows the anchor portion to contact an inner surface of the masonry item such that it prevents the device from falling out. 
     In FIG. 2 more details of the securing strap are shown. For example, along the length of securing strap  30  are a plurality of ridges  31 , which serve to frictionally engage with teeth or detents in he mounting hole in boss  21 . Outside end  33  of the strap  30  is tapered to facilitate installation of the strap into the mounting hole. 
     Cover plate  20 , shown in FIG. 3, is preferably made of generally transparent plastic. It consists of several apertures including, concentric or centered securing member hole  23 , generally centered slot  22 , and four strap mounting holes  19  which are preferably evenly spaced apart from the plate&#39;s center. Also formed into the plate is weakened joint  24 , which extends from the end of one side of slot  22  to the outer dimension of plate  20 . When the weakened joint is opened it provides for ease of installation of cover plate  20  onto the stem of a weld plate, for example. In addition, opened joint  24  enables removal of cover plate  20 , if desired, after the grout has cured. In preferred embodiments of cover plate  20 , apertures are reinforced, as shown by elevated or raised portions of cover plate material surrounding the various apertures. Examples of this reinforcement is raised land  25  about securing member hole  23 , and bosses  21  through which straps  30  pass. 
     As contemplated herein, the term “securing member hole” refers to a hole or aperture in cover plate  20  into which a variety of objects can be inserted. These include, for example, anchor bolts which are commonly used in the construction trade, straps or other connecting members which are known to those skilled in the art. 
     FIG. 4 shows essentially the embodiment of FIGS. 1-3 in perspective, where ridges  52  are positioned on a side of the first portion of securing strap  30  that faces toward the center of the device. If desired, ridges  52  can be positioned on the side of the strap  30  that faces toward the outside perimeter of the device. Score lines  53  in straps  30  can be provided to enable the externally protruding ends of the straps to be cut off or snapped off after the mounting plate is installed. Note that bosses  21  are approximately tangential to the periphery of circular land  25 . These bosses project into the hole in the masonry wall and serve the additional function of centering cover plate  20  over the masonry hole. 
     FIG. 5 provides more detail of an embodiment of the slidable engagement of ridges  52  in mounting hole  19  in boss  21 , in which is ridge engagement tab  54 . It can be seen that teeth having a shape corresponding to the shape of individual ridges  52  are provided on the contact surface of tab  54 . Engaging teeth  55  of tab  54  may have a sloped saw-tooth shape as shown, or they may be simple projections. Likewise, ridges  52  may be simple projections or they may have a sloped saw-tooth shape for enhanced positive engagement. Oppositely sloped saw-tooth shapes on the engaging elements would provide a very secure position, not easily reversed, for the strap in the mounting hole. The securing strap can be referred to as a zip tie. 
     The versatility of the preferred embodiment of the invention is shown in attaching various embedded elements such as PA strap  40  in FIG. 6 a , machine bolt  43  in FIG. 6 b , and weld plate  44  in FIG. 6 c . A weld plate provides a surface to which external objects may be welded. It has stem  46  and head  47 . Cover plate  20  is fitted onto the stem by opening weakened joint  24  and sliding the cover plate onto the stem. Then the stem is inserted into the masonry hole. 
     A hole (not shown) is bored or otherwise formed in wall  11  of masonry block  10 . The hole in block  10  is equal to or slightly larger than the diameter of land  25  of plate  20 . A PA strap or a machine bolt, for example, can be placed in the hole and inserted through hole  23  in plate  20  as it projects outwardly from the inside the masonry block. Plate  20  is placed against wall  11  so that bosses  21  and land  25  project into the hole in the block and the inside surface of plate  20  is flush against the surface of wall  11 . Straps  30  may be inserted through holes  19  in bosses  21  from inside the block until anchor elements  32  engage the inside surface of wall  11 . Ridges  52  and teeth  55  are then fully engaged so that straps  30  are positively positioned. Another means of mounting is to partially insert the straps in holes  19 , then bend the anchor element ends inwardly to allow them to pass through the masonry hole as the plate is applied to the masonry wall (see FIG.  9 ). 
     Referring now to FIG. 7, this side view shows the interrelationships of cover plate  20 , securing strap  30 , and threaded bolt  43 , which has head  45 . Bolt  43  fits into the rear or inside of cover plate  20  through securing member hole  23 . Anchor portion  32  is then positioned so that it&#39;s narrowest dimension is directed away from the cover plate center. As contemplated herein, “anchor portion” refers to a structure that serves to prevent the device from falling out of the masonry hole. In a preferred embodiment, the anchor portion is triangular in shape with its narrowest dimension pointed away from the center of the securing member hole. This orientation ensures that the anchor portion will engage with the inner surface of the masonry element during installation of the device. 
     A side view of plate  20 , securing strap  30 , and PA strap  40  demonstrates their interrelationships in FIG.  8 . PA strap  40  fits into the rear of cover plate  20  through centered slot cut out  22 . Straps  30  with anchor portions  32  function as previously described. 
     FIG. 9 demonstrates a typical installation of the device of the present invention into a masonry element, such as concrete block. First, masonry hole  50  is drilled into the masonry wall. Securing straps  30  are inserted part way into the strap mounting holes in cover plate  20 . A machine bolt or PA strap can be inserted through hole  23  or slot  22 , respectively, before the cover plate is placed against the masonry surface. If a wall plate is employed it will be added after the cover plate is secured to the masonry element. The securing straps are contemplated to be resilient so they can be deformed toward the center to enable anchor portions  32  to fit through hole  50  and return to their original shape after being fully inserted through the masonry wall. The outwardly projecting ends of straps  30  are pulled outwardly so that anchor portions  32  then contact the inner surface of the masonry element, thereby preventing the device from falling out. 
     Although cover plate  20  is shown having a circular shape, its shape is not critical. It must only be larger than the masonry hole so it can be secured to the outside surface of the masonry wall by means of the securing straps and the anchor portions which engage the inside wall surface. Four mounting holes and securing straps are shown, but sufficient centering and engaging could be achieved with three, or even two securing straps. Under some circumstances only one securing strap might be used to simply hold the cover plate and the other element (PA strap, machine bolt, weld plate) in place while grout is poured and cured. On the other hand, there is no absolute limit to the number of securing straps that might be used. Under some circumstances it might be desired to employ five, or six, or even more securing straps through the cover plate. 
     A particular advantage of the present invention is that the cover plate is preferably made of a transparent material for easy visual inspection of grout flow. This further helps to detect and eliminate any incompletely grouted areas. If there are any voids or ungrouted areas, this can be detected through the transparent cover plate, giving the user the opportunity to take remedial action before the grout dries. This visual feedback is not appreciated or provided in the prior art devices, which are typically constructed of plywood and plate or sheet metal. In addition, if desired, various dyes or fluorescent materials can be added to the cover plate material during its manufacture to allow quick and easy location of the device on a masonry wall when, for example, construction work is being done in a dimly lit location, or after dark. Further, if desired, the cover plate can be made of a biodegradable plastic so that over time the cover plate disintegrates, leaving behind the embedded material. Various forms of biodegradable plastic material are well known to those skilled in the art. 
     While the present invention has been illustrated and described by means of specific embodiments and alternatives, it is to be understood that numerous changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it should be understood that the invention is not to be limited in any way except in accordance with the appended claims and their equivalents.