Patent Abstract:
Thermally-isolating wall anchors and anchoring systems employing the same are disclosed. A thermally-isolating coating is applied to the wall anchor, which is interconnected with a wire formative veneer tie. The thermally-isolating coating is selected from a distinct grouping of materials, that are applied using a specific variety of methods, in one or more layers and cured and cross-linked to provide high-strength adhesion. The thermally-coated wall anchors provide an in-cavity thermal break that severs the thermal threads running throughout the cavity wall structure, reducing the U- and K-values of the anchoring system by thermally-isolating the metal components.

Full Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to thermally-coated wall anchors and associated veneer ties and anchoring systems for cavity walls. More particularly, the invention relates to anchoring systems with thermally-isolating coated wall anchors and associated components made largely of thermally conductive metals. The system has application to seismic-resistant structures and to cavity walls requiring thermal isolation. 
     2. Description of the Prior Art 
     The move toward more energy-efficient insulated cavity wall structures has led to the need to create a thermally isolated building envelope which separates the interior environment and the exterior environment of a cavity wall structure. The building envelope is designed to control temperature, thermal transfer between the wythes and moisture development, while maintaining structural integrity. Thermal insulation is used within the building envelope to maintain temperature and therefore restrict the formation of condensation within the cavity. The integrity of the thermal insulation is compromised when used in conjunction with the prior art metal anchoring systems, which are constructed from thermally conductive metals that facilitate thermal transfer between and through the wythes. The use of the specially designed and thermally-protected wall anchors of the present invention lowers the underlying metal thermal conductivities and thereby reducing thermal transfer. 
     When a cavity wall is constructed and a thermal envelope created, hundreds, if not thousands, of wall anchors and associated ties are inserted throughout the cavity wall. Each anchor and tie combination form a thermal bridge perforating the insulation and moisture barriers within the cavity wall structure. While seals at the insertion locations deter water and vapor entry, thermal transfer and loss still result. Further, when each individual anchoring system is interconnected veneer-tie-to-wall-anchor, a thermal thread results stretching across the cavity and extending between the inner wythe to the outer wythe. Failure to isolate the steel components and break the thermal transfer, results in heating and cooling losses and potentially damaging condensation buildup within the cavity wall structure. Such buildups provide a medium for corrosion and mold growth. The use of thermally-isolating coated wall anchors removes the thermal bridges and breaks the thermal thread causing a thermally isolated anchoring system with a resulting lower heat loss within the building envelope. 
     The present invention provides a thermally-isolating coated wall anchor specially-suited for use within a cavity wall. Anchoring systems within cavity walls are subject to varied outside forces such as earthquakes and wind shear that cause abrupt movement within the cavity wall, requiring high-strength anchoring materials. Additionally, any materials placed within the cavity wall require the characteristics of low flammability and, upon combustion, the release of combustion products with low toxicity. The present invention provides a coating suited to such requirements, which, besides meeting the flammability/toxicity standards, includes characteristics such as shock resistance, non-frangibility, low thermal conductivity and transmissivity, and a non-porous resilient finish. This unique combination of characteristics provides a wall anchor well-suited for installation within a cavity wall anchoring system. 
     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. 
     In the late 1980&#39;s, surface-mounted wall anchors were developed by Hohmann &amp; Barnard, Inc., now a MiTek-Berkshire Hathaway Company, and patented under U.S. Pat. No. 4,598,518. 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 dry-wall 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 (319), and a continuous wire reinforcement. 
     In an insulated dry wall application, the surface-mounted wall anchor of the above-described system has pronged legs that pierce the insulation and the wallboard 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 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. Also, upon the promulgation of more rigorous specifications by which tension and compression characteristics were raised, a different structure—such as one of those described in detail below—became necessary. 
     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. 
     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. 
     In the 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 deposition 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. This resulted, upon experiencing lateral forces over time, in the loosening of the stud. 
     There have been significant shifts in public sector building specifications, such as 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. Here, the emphasis is upon creating a building envelope that is designed and constructed with a continuous air barrier to control air leakage into or out of conditioned space adjacent the inner wythe, which have resulted in architects and architectural engineers requiring larger and larger cavities in the exterior cavity walls of public buildings. These requirements are imposed without corresponding decreases in wind shear and seismic resistance levels or increases in mortar bed joint height. Thus, wall anchors are needed to occupy the same ⅜ inch high space in the inner wythe and tie down a veneer facing material of an outer wythe at a span of two or more times that which had previously been experienced. 
     As insulation became thicker, the tearing of insulation during installation of the pronged DW-10X® wall anchor, see infra, 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 at two times, namely, during the arcuate path of the insertion of the second leg and separately upon installation of the attaching hardware. 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 insulation integrity and less reliance on a patch. 
     As concerns for thermal transfer and resulting heat loss/gain and the buildup of condensation within the cavity wall grew, focus turned to thermal isolation and breaks. Another prior art development occurred in an attempt to address thermal transfer 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, a concomitant loss of the insulative integrity results. Further reductions in thermal transfer were accomplished through the Byna-Tie® system (&#39;319) which provides a bail handle with pointed legs and a dual sealing arrangement as described, U.S. Pat. No. 8,037,653. While each prior art invention reduced thermal transfer, neither development provided more complete thermal protection through the use of a specialized thermally-isolating coated wall anchor, which removes thermal bridging and improves thermal insulation through the use of a thermal barrier. 
     Focus on the thermal characteristics of cavity wall construction is important to ensuring minimized heat transfer through the walls, both for comfort and for energy efficiency of heating and air conditioning. When the exterior is cold relative to the interior of a heated structure, heat from the interior should be prevented from passing through the outside. Similarly, when the exterior is hot relative to the interior of an air conditioned structure, heat from the exterior should be prevented from passing through to the interior. The main cause of thermal transfer is the use of anchoring systems made largely of metal, either steel, wire formatives, or metal plate components, that are thermally conductive. While providing the required high-strength within the cavity wall system, the use of steel components results in heat transfer. 
     Another application for anchoring systems is in the evolving technology of self-cooling buildings. Here, the cavity wall serves additionally as a plenum for delivering air from one area to another. The ability to size cavities to match air moving requirements for naturally ventilated buildings enable the architectural engineer to now consider cavity walls when designing structures in this environmentally favorable form. 
     Building thermal stability within a cavity wall system requires the ability to hold the internal temperature of the cavity wall within a certain interval. This ability helps to prevent the development of cold spots, which act as gathering points for condensation. Through the use of a thermally-isolating coating, the underlying steel wall anchor obtains a lower transmission (U-value) and thermal conductive value (K-value) and provides non-corrosive benefits. The present invention maintains the strength of the steel and further provides the benefits of a thermal break in the cavity. 
     In the past, the use of wire formatives have been limited by the mortar layer thicknesses which, in turn are dictated either by the new building specifications or by pre-existing conditions, e.g., matching during renovations or additions 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. On the other hand, contractors find 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 address the adaption thereof to surface mounted devices. The combination of each individual wall anchor and tie combination linked together in a cavity wall setting creates a thermal thread throughout the structure thereby raising thermal conductivity and reducing the effectiveness of the insulation. The present invention provides a thermal break which interrupts and restricts thermal transfer. 
     In the course of preparing this Application, several patents, became known to the inventors hereof and are acknowledged hereby: 
     
       
         
               
               
               
             
               
               
               
             
               
             
               
               
               
             
           
               
                   
               
               
                 Pat. No. 
                 Inventor 
                 Issue Date 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 2,058,148 
                 Hard 
                 October, 1936 
               
               
                 2,966,705 
                 Massey 
                 January, 1961 
               
               
                 3,377,764 
                 Storch 
                 April, 1968 
               
               
                 4,021,990 
                 Schwalberg 
                 May, 1977 
               
               
                 4,305,239 
                 Geraghty 
                 December, 1981 
               
               
                 4,373,314 
                 Allan 
                 February, 1983 
               
               
                 4,438,611 
                 Bryant 
                 March, 1984 
               
               
                 4,473,984 
                 Lopez 
                 October, 1984 
               
               
                 4,598,518 
                 Hohmann 
                 July, 1986 
               
               
                 4,869,038 
                 Catani 
                 September, 1989 
               
               
                 4,875,319 
                 Hohmann 
                 October, 1989 
               
               
                 5,063,722 
                 Hohmann 
                 November, 1991 
               
               
                 5,392,581 
                 Hatzinikolas et al. 
                 February, 1995 
               
               
                 5,408,798 
                 Hohmann 
                 April, 1995 
               
               
                 5,456,052 
                 Anderson et al. 
                 October, 1995 
               
               
                 5,816,008 
                 Hohmann 
                 October, 1998 
               
               
                 6,125,608 
                 Charlson 
                 October, 2000 
               
               
                 6,209,281 
                 Rice 
                 April, 2001 
               
               
                 6,279,283 
                 Hohmann et al. 
                 August, 2001 
               
               
                 8,109,706 
                 Richards 
                 February, 2012 
               
             
          
           
               
                 Foreign Patent Documents 
               
             
          
           
               
                 279,209 
                 CH 
                 March, 1952 
               
               
                 2,069,024 
                 GB 
                 August, 1981 
               
               
                   
               
             
          
         
       
     
     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. 
     U.S. Pat. No. 3,377,764—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. 
     U.S. Pat. No. 4,021,990—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. 
     U.S. Pat. No. 4,373,314—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. 
     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. 
     U.S. Pat. No. 4,869,038—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. 
     U.S. Pat. No. 4,875,319—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. The wall tie is distinguished over that of Schwalberg &#39;990 and is clipped onto a straight wire run. 
     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 on 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. 
     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. 
     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. 
     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. 
     U.S. Pat. No. 6,125,608—Charlson—Issued Oct. 3, 2000 Discloses a composite insulated framing system within a structural building system. The Charlson system includes an insulator adhered to the structural support through the use of adhesives, frictional forces or mechanical fasteners to disrupt thermal activity. 
     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. 
     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. 
     U.S. Pat. No. 8,109,706—Richards—Issued Feb. 7, 2012 Discloses a composite fastener, belly nut and tie system for use in a building envelope. The composite fastener includes a fiber reinforced polymer. The fastener has a low thermal conductive value and non-corrosive properties. 
     None of the above provide a thermally-isolating coated anchoring system that maintains the thermal isolation of a building envelope. 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 insulation and heat transfer within the cavity wall. The wall anchor assembly is modifiable for use on various style wall anchors allowing for interconnection with veneer ties in varied cavity wall structures. The prior art does not provide the present novel cavity wall construction system as described herein below. 
     SUMMARY 
     In general terms, the invention disclosed hereby is a high-strength thermally-isolating surface-mounted anchoring system for use in a cavity wall structure. The wall anchor is thermally-coated and interconnected with varied veneer ties. The veneer ties are wire formatives configured for insertion within the wall anchor and the bed joints of the outer wythe. The veneer ties are optionally compressed forming a low profile construct and swaged for interconnection with a reinforcement wire to form a seismic construct. 
     The first embodiment of the thermally-isolated wall anchor is a sheetmetal device with a bail type receptor for interconnection with a veneer tie. The wall anchor provides a sealing effect precluding the penetration of air, moisture, and water vapor into the inner wythe structure. The cavity portion and aperture receptor portion and optionally, the attachment portion, the wall anchor mounting surface, the outer surface and the pair of legs receive a thermally-isolating coating. The thermally-isolating coating is selected from a distinct grouping of materials, which are applied using a specific variety of methods, in one or more layers which are cured and cross-linked to provide high-strength adhesion. A matte finish is provided to form a high-strength interconnection. The thermally-coated wall anchors provide an in-cavity thermal break that interrupts the thermal conduction in the anchoring system threads running throughout the cavity wall structure. The thermal coating reduces the U- and K-values of the anchoring system by thermally-isolating the metal components. 
     The second embodiment of the thermally-isolated anchoring system includes a sheetmetal wall anchor with an L-shaped design having an attachment portion, at least one cavity portion with a receptor portion and a receiving aperture in the receptor portion. A pintle-type veneer tie is interconnected with the wall anchor. The receiving aperture and optionally, the attachment portion and the cavity portion receive a thermally-isolating coating. 
     It is an object of the present invention to provide new and novel anchoring systems for cavity walls, which systems are thermally isolating. 
     It is another object of the present invention to provide a new and novel high-strength metal wall anchor which is thermally coated with a thermally-isolating compound that reduces the U- and K-values of the anchoring system. 
     It is yet another object of the present invention to provide in an anchoring system having an inner wythe and an outer wythe, a high-strength wall anchor that interengages a veneer tie. 
     It is still yet another object of the present invention to provide an anchoring system which is constructed to maintain insulation integrity within the building envelope by providing a thermal break. 
     It is a feature of the present invention that the wall anchor hereof provides thermal isolation of the anchoring system. 
     It is another feature of the present invention that the wall anchor is utilizable with a dry wall construct that secures to a metal stud and is interconnected with a veneer tie. 
     It is another feature of the present invention that the thermally-coated wall anchor provides an in cavity thermal break. 
     It is a further feature of the present invention that the wall anchor coating is shock resistant, resilient and noncombustible. 
     Other objects and features of the invention will become apparent upon review of the drawings and the detailed description which follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       In the following drawing, the same parts in the various views are afforded the same reference designators. 
         FIG. 1  shows a first embodiment of this invention and is a perspective view of a surface-mounted anchoring system with a thermally isolating wall anchor, as applied to a cavity wall with an inner wythe of dry wall construction with insulation disposed on the cavity-side thereof and an outer wythe of brick interconnected with a veneer tie; 
         FIG. 2  is a perspective view of the surface-mounted anchoring system of  FIG. 1  shown with a thermally-isolating folded wall anchor and a veneer tie threaded therethrough; 
         FIG. 3  is a perspective view of an alternative design thermally-isolating wall anchor and a veneer tie threaded therethrough; 
         FIG. 4  is a perspective view of an alternative design thermally-isolating wall anchor with notched tubular legs and a veneer tie threaded therethrough with an interconnected reinforcement wire; 
         FIG. 5  is a perspective view of a second embodiment of this invention showing a surface-mounted anchoring system with a thermally isolating wall anchor, as applied to a cavity wall with an inner wythe of dry wall construction with insulation disposed on the cavity-side thereof and an outer wythe of brick interconnected with a pintle veneer tie; 
         FIG. 6  is a perspective view of the anchoring system of  FIG. 5  with a low profile pintle veneer tie interconnected therewith; and, 
         FIG. 7  is a perspective view of an alternative design thermally-isolating wall anchor interconnected with a veneer tie and reinforcement wire, forming a seismic system. 
     
    
    
     DETAILED DESCRIPTION 
     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 technical shortcoming of the prior art devices. 
     In the embodiments described hereinbelow, the inner wythe is optionally provided with insulation and/or a waterproofing membrane. In the cavity wall construction shown in the embodiments hereof, this takes the form of exterior insulation disposed on the outer surface of the inner wythe. 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. Here the term insulation integrity is used in the same sense as the building code in that, after the installation of the anchoring system, there is no change or interference with the insulative properties and concomitantly substantially no change in the air and moisture infiltration characteristics. 
     In a related sense, prior art sheetmetal anchors and anchoring systems have formed a conductive bridge between the wall cavity and the interior of the building. Here the terms thermal conductivity and thermal conductivity analysis are used to examine this phenomenon and the metal-to-metal contacts across the inner wythe. The present anchoring system serves to sever the conductive bridge and interrupt the thermal pathway created throughout the cavity wall by the metal components, including a reinforcement wire which provides a seismic structure. Failure to isolate the metal components of the anchoring system and break the thermal transfer, results in heating and cooling losses and in potentially damaging condensation buildup within the cavity wall structure. 
     In addition to that which occurs at the outer or facing wythe, attention is further drawn to the construction at the exterior surface of the inner or backup wythe. Here there are two concerns. namely, maximizing the strength of the securement of the surface-mounted wall anchor to the backup wall and, as previously discussed minimizing the interference of the anchoring system with the insulation and the waterproofing. The first concern is addressed using appropriate fasteners such as, for mounting to metal, dry-wall studs, self-tapping screws. The latter concern is addressed by the flatness of the base of the surface-mounted wall anchor and its thermally-isolating characteristics. 
     In the detailed description, the veneer reinforcements and the veneer ties are wire formatives. The wire used in the fabrication of veneer joint reinforcement conforms to the requirements of ASTM Standard Specification A951-00, Table 1. For the purpose of this application tensile strength tests and yield tests of veneer joint reinforcements are, where applicable, those denominated in ASTM A-951-00 Standard Specification for Masonry Joint Reinforcement. 
     The thermal stability within the cavity wall maintains the internal temperature of the cavity wall within a certain interval. Through the use of the presently described thermal-isolating coating, the underlying metal wall anchor, obtains a lower transmission (U-value) and thermal conductive value (K-value) providing a high strength anchor with the benefits of thermal isolation. The term K-value is used to describe the measure of heat conductivity of a particular material, i.e., the measure of the amount of heat, in BTUs per hour, that will be transmitted through one square foot of material that is one inch thick to cause a temperature change of one degree Fahrenheit from one side of the material to the other. The lower the K-value, the better the performance of the material as an insulator. The metal comprising the components of the anchoring systems generally have a K-value range of 16 to 116 W/m K. The thermal coating disposed on the wall anchor of this invention greatly reduces such K-values to a low thermal conductive (K-value) not to exceed 1 W/m K. Similar to the K-value, a low thermal transmission value (U-value) is important to the thermal integrity of the cavity wall. The term U-value is used to describe a measure of heat loss in a building component. It can also be referred to as an overall heat transfer co-efficient and measures how well parts of a building transfer heat. The higher the U-value, the worse the thermal performance of the building envelope. Low thermal transmission or U-value is defined as not to exceed 0.35 W/m 2 K for walls. The U-value is calculated from the reciprocal of the combined thermal resistances of the materials in the cavity wall, taking into account the effect of thermal bridges, air gaps and fixings. 
     Referring now to  FIGS. 1 through 4 , the first embodiment shows an anchoring system with a thermally isolating wall anchor that provides an in-cavity thermal break. This system is suitable for recently promulgated standards and, in addition, has lower thermal transmission and conductivity values than the prior art anchoring systems. The system discussed in detail hereinbelow, has a thermally-isolating wall anchor with a bail opening for interengagement with a veneer tie. The wall anchor is surface mounted onto an externally insulated dry wall structure with an optional waterproofing membrane (not shown) between the wallboard and the insulation. For the first embodiment, a cavity wall having an insulative layer of 2.5 inches (approx.) and a total span of 3.5 inches (approx.) is chosen as exemplary. 
     The surface-mounted anchoring system for cavity walls is referred to generally by the numeral  10 . A cavity wall structure  12  is shown having an inner wythe or dry wall backup  14 . Sheetrock or wallboard  16  is mounted on metal studs or columns  17 , and an outer wythe or facing wall  18  of brick  20  construction. Between the inner wythe  14  and the outer wythe  18 , a cavity  22  is formed. The wallboard  16  has attached insulation  26 . 
     Successive bed joints  30  and  32  in the outer wythe  14  are substantially planar and horizontally disposed and in accord with building standards are a predetermined 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  68  of the veneer tie  44  of the anchoring system hereof. Being surface mounted onto the inner wythe  14 , the anchoring system  10  is constructed cooperatively therewith and is configured to minimize air and moisture penetration around the wall anchor system/inner wythe juncture. 
     For purposes of discussion, the cavity surface  24  of the inner wythe  14  contains a horizontal line or x-axis  34  and an 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 folded wall anchor  40  as shown in  FIGS. 1 and 2 , is constructed from a sheetmetal plate-like body. Alternative design wall anchors  40  are shown in  FIGS. 3 and 4 . The wall anchor  40  has an attachment portion  39  for surface mounting on the inner wythe  14 . The attachment portion  39  is comprised of a mounting face or surface  41  and an outer face or surface  43 . A cavity portion  67  having a receptor or apertured receptor portion  63  is contiguous with the attachment portion  39 . The wall anchor  40  is affixed (as shown in  FIGS. 1 ,  2 , and  4 ) with a pair of legs  42  extending from the mounting surface  41  which penetrate the inner wythe  14 . The pair of legs  42  have longitudinal axes  45  that are substantially normal to the mounting surface  41  and outer surface  43 . Optionally, as shown in  FIG. 3 , the wall anchor  40  is constructed without the pair of legs  42 . The wall anchor  40  is a stamped metal construct which is constructed for surface mounting on inner wythe  14  and for interconnection with veneer tie  44  and affixed to the inner wythe  14  with a pair of fasteners  48 . The receptor  63  is adjacent the outer surface  43  and dimensioned to interlock with the veneer tie  44 . 
     The veneer tie  44  is a wire formative and 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 wall anchor  40 , a veneer tie  44 , and optionally a reinforcement wire  71 . 
     At intervals along a horizontal line on the outer surface of insulation  26 , the wall anchors  40  are surface mounted. In this structure, where applicable, the pair of legs  42  sheathe the pair of fasteners or mounting hardware  48 . The wall anchors  40  are positioned on the outer surface of insulation  26  so that the longitudinal axis of a column  17  lies within the yz-plane formed by the longitudinal axes  45  of the pair of legs  42 . Upon insertion in the inner wythe  14 , the mounting surface  41  rests snugly against the opening formed thereby and serves to cover the opening, precluding the passage of air and moisture therethrough. This construct maintains the insulation integrity. In  FIGS. 1 ,  2 , and  4 , the pair of legs  42  have the lower portion removed thereby forming notches which draw off moisture, condensate or water from the associated leg or hardware which serves to relieve any pressure which would drive toward wallboard  16 . This construct maintains the waterproofing integrity. 
     Optional strengthening ribs  84  are impressed in the wall anchor  40 . The ribs  84  are substantially parallel to the receptor  63  and, when mounting hardware  48  is fully seated so that the wall anchor  40  rests against the insulation  26 , the ribs  84  are then pressed into the surface of the insulation  26 . This provides additional sealing. While the ribs  84  are shown as protruding toward the insulation, it is within the contemplation of this invention that ribs  84  could be raised in the opposite direction. The alternative structure would be used in applications wherein the outer layer of the inner wythe is noncompressible and does not conform to the rib contour. The ribs  84  strengthen the wall anchor  40  and achieve an anchor with a tension and compression rating of 100 lbf. 
     A thermally-isolating coating or thermal coating  85  is applied to the receptor  63  to provide a thermal break in the cavity. The thermal coating  85  is optionally applied to the cavity portion  67 , the mounting surface  41 , the outer surface  43  and/or the pair of legs  42  to provide ease of coating and additional thermal protection. The thermal coating  85  is selected from thermoplastics, thermosets, natural fibers, rubbers, resins, asphalts, ethylene propylene diene monomers, and admixtures thereof and applied in layers. The thermal coating  85  optionally contains an isotropic polymer which includes, but is not limited to, acrylics, nylons, epoxies, silicones, polyesters, polyvinyl chlorides, and chlorosulfonated polyethelenes. The initial layer of the thermal coating  85  is cured to provide a precoat and the layers of the thermal coating  85  are cross-linked to provide high-strength adhesion to the veneer tie to resist chipping or wearing of the thermal coating  85 . 
     The thermal coating  85  reduces the K-value and the U-value of the underlying metal components which include, but are not limited to, mill galvanized, hot galvanized, and stainless steel. Such components have K-values that range from 16 to 116 W/m K. The thermal coating  85  reduces the K-value of the veneer tie  44  to not exceed 1.0 W/m K and the associated U-value to not exceed 0.35 W/m 2 K. The thermal coating  85  is not combustible and gives off no toxic smoke in the event of a fire. Additionally, the thermal coating  85  provides corrosion protection which protects against deterioration of the anchoring system  10  over time. 
     The thermal coating  85  is applied through any number of methods including fluidized bed production, thermal spraying, hot dip processing, heat-assisted fluid coating, or extrusion, and includes both powder and fluid coating to form a reasonably uniform coating. A coating  85  having a thickness of at least about 5 micrometers is optimally applied. The thermal coating  85  is applied in layers in a manner that provides strong adhesion to the veneer tie  44 . The thermal coating  85  is cured to achieve good cross-linking of the layers. Appropriate examples of the nature of the coating and application process are set forth in U.S. Pat. Nos. 6,284,311 and 6,612,343. 
     The dimensional relationship between wall anchor  40  and veneer tie  44  limits the axial movement of the construct. The veneer tie  44  is a wire formative. Each veneer tie  44  has an attachment portion  64  that interlocks with the receptor  63 . The receptor  63  is constructed, in accordance with the building code requirements, to be within the predetermined dimensions to limit the z-axis  38  movement and permit y-axis  36  adjustment of the veneer tie  44 . The dimensional relationship of the attachment portion  64  to the receptor  63  limits the x-axis movement of the construct. Contiguous with the attachment portion  64  of the veneer tie  44  are two cavity portions  66 . An insertion portion  68  is contiguous with the cavity portions  66  and opposite the attachment portion  64 . 
     The insertion portion  68  is optionally ( FIG. 4 ) compressively reduced in height to a combined height substantially less than the predetermined height of the bed joint  30  ensuring a secure hold in the bed joint  30  and an increase in the strength and pullout resistance of the veneer tie  44 . Further to provide for a seismic construct, an optional compression or swaged indentation  69  is provided in the insertion portion  68  to interlock in a snap-fit relationship with a reinforcement wire  71  (as shown in  FIG. 4 ). 
     The description which follows is a second embodiment of the thermally-isolating wall anchor and anchoring system that provides an in-cavity thermal break in cavity walls. For ease of comprehension, wherever possible similar parts use reference designators  100  units higher than those above. Thus, the veneer tie  144  of the second embodiment is analogous to the veneer tie  44  of the first embodiment. Referring now to  FIGS. 5 through 7 , the second embodiment of the surface-mounted anchoring system is shown and is referred to generally by the numeral  110 . As in the first embodiment, a wall structure  112  is shown. The second embodiment has an inner wythe or backup wall  114  of a dry wall construction with an optional waterproofing membrane (not shown) disposed thereon. Wallboard  116  is attached to columns or studs  117  and an outer wythe or veneer  118  of facing brick  120 . The inner wythe  114  and the outer wythe  118  have a cavity  122  therebetween. Here, the anchoring system has a surface-mounted wall anchor  140  for interconnection with varied veneer ties  144 . 
     The anchoring system  110  is surface mounted to the inner wythe  114 . In this embodiment like the previous one, insulation  126  is disposed on the wallboard  116 . Successive bed joints  130  and  132  are substantially planar and horizontally disposed and in accord with building standards set at a predetermined 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  168  of the veneer tie  144  of the anchoring system  110  construct hereof. Being surface mounted onto the inner wythe, the anchoring system  110  is constructed cooperatively therewith. 
     For purposes of discussion, the insulation surface  124  of the inner wythe  114  contains a horizontal line or x-axis  134  and an intersecting vertical line or y-axis  136 . A horizontal line or z-axis  138 , normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes. A wall anchor  140  constructed from a metal plate-like body is shown which has an attachment portion  143  that is substantially planar in form and surface mounted on the inner wythe  114 . A cavity portion  145  is contiguous with the attachment portion  143  and extends from the inner wythe  114  into the cavity  122 . The cavity portion  145  contains a receptor portion  163  with a receiving aperture  165  therewithin disposed horizontally in the cavity  122  for interconnection with a veneer tie  144 . A pair of fasteners  148  secures the wall anchor  140  to the inner wythe  114 . In  FIGS. 5 and 6 , the wall anchor  140  contains a single receiving aperture  165  for interconnection with a veneer tie  144 .  FIG. 7  provides a variation of the wall anchor  140  having a split cavity portion  145  with two receptor portions  163  for interconnection with a veneer tie. 
     At intervals along the inner wythe  114 , wall anchors  140  are surface mounted. The wall anchors  140  rest snugly against the inner wythe  114 . Optional strengthening ribs  184  are impressed in wall anchor  140 . The ribs  184  are substantially normal to the apertured receptor portion  163  and when mounting hardware  148  is fully seated, so that the wall anchor  140  rests against the insulation  126 , the ribs  184  strengthen the wall anchor  140  and achieve an anchor with a tension and compression rating of 100 lbf. 
     The veneer tie  144  is shown in  FIG. 5  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 wall anchor  140  and a veneer tie  144  with an optional reinforcement wire  171  to form a seismic construct. 
     The dimensional relationship between wall anchor  140  and veneer tie  144  limits the axial movement of the construct. The veneer tie  144  is a wire formative. Each veneer tie  144  has an attachment portion  164  that interengages with the apertured receptor portion  163 . As shown in  FIGS. 5 through 7 , the attachment portion  164  of the veneer tie  144  is a pintle construct. To further protect against veneer tie  144  pullout, securement portions  181  are formed from the pintle. The apertured receptor portion  163  is constructed, in accordance with the building code requirements, to be within the predetermined dimensions to limit the z-axis  138  movement and permit y-axis  136  adjustment of the veneer tie  144 . The dimensional relationship of the attachment portion  164  to the apertured receptor portion  163  limits the x-axis movement of the construct and prevents disengagement from the anchoring system. Contiguous with the attachment portion  164  of the veneer tie  144  are cavity portions  166 . An insertion portion  168  is contiguous with the cavity portions  166  and opposite the attachment portion  164 . 
     The insertion portion  168  is (as shown in  FIGS. 5 and 6 ) optionally compressively reduced in height to a combined height substantially less than the predetermined height of the bed joint  130  ensuring a secure hold in the bed joint  130  and an increase in the strength and pullout resistance of the veneer tie  144 . Further to provide for a seismic construct, a compression or swaged indentation  169  is provided in the insertion portion  168  (as shown in  FIG. 7 ) to interlock in a snap-fit relationship with a reinforcement wire  171 . 
     A thermally-isolating coating or thermal coating  185  is applied to the receiving aperture  165  to provide a thermal break in the cavity  122 . The thermal coating  185  is optionally applied to the attachment portion  143 , the cavity portion  145  and the receptor portion  163  to provide ease of coating and additional thermal protection. The thermal coating  185  is selected from thermoplastics, thermosets, natural fibers, rubbers, resins, asphalts, ethylene propylene diene monomers, and admixtures thereof and applied in layers. The thermal coating  185  optionally contains an isotropic polymer which includes, but is not limited to, acrylics, nylons, epoxies, silicones, polyesters, polyvinyl chlorides, and chlorosulfonated polyethelenes. The initial layer of the thermal coating  185  is cured to provide a precoat and the layers of the thermal coating  185  are cross-linked to provide high-strength adhesion to the veneer tie to resist chipping or wearing of the thermal coating  185 . 
     The thermal coating  185  reduces the K-value and the U-value of the underlying metal components which include, but are not limited to, mill galvanized, hot galvanized, and stainless steel. Such components have K-values that range from 16 to 116 W/m K. The thermal coating  185  reduces the K-value of the veneer tie  144  to not exceed 1.0 W/m K and the associated U-value to not exceed 0.35 W/m 2 K. The thermal coating  185  is not combustible and gives off no toxic smoke in the event of a fire. Additionally, the thermal coating  185  provides corrosion protection which protects against deterioration of the anchoring system  110  over time. 
     The thermal coating  185  is applied through any number of methods including fluidized bed production, thermal spraying, hot dip processing, heat-assisted fluid coating, or extrusion, and includes both powder and fluid coating to form a reasonably uniform coating. A coating  185  having a thickness of at least about 5 micrometers is optimally applied. The thermal coating  185  is applied in layers in a manner that provides strong adhesion to the veneer tie  144 . The thermal coating  185  is cured to achieve good cross-linking of the layers. Appropriate examples of the nature of the coating and application process are set forth in U.S. Pat. Nos. 6,284,311 and 6,612,343. 
     As shown in the description and drawings, the present invention serves to thermally isolate the components of the anchoring system reducing the thermal transmission and conductivity values of the anchoring system to low levels. The novel coating provides an insulating effect that is high-strength and provides an in cavity thermal break, severing the thermal threads created from the interlocking anchoring system components. 
     In the above description of the anchoring systems of this invention various configurations are described and applications thereof in corresponding anchoring systems are provided. Because many 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.

Technology Classification (CPC): 4