Patent Abstract:
A connector for coupling a veneer panel to a back-up comprises a support member comprising a mounting flange adapted for securing the support member to said back-up wall, and first and second support member side walls extending outwardly from the mounting flange. The first and second support member side walls define at least one generally horizontal slot when the support member is secured to the back-up wall. The connector further comprises a veneer connector configured for non-rotational sliding receipt in the generally horizontal slot and adapted to support a generally horizontal edge of said veneer panel when the veneer connector is received in the generally horizontal slot and when the support member is secured to the back-up wall.

Full Description:
[0001]    This application is a continuation of U.S. patent application Ser. No. 11/217,688, filed Sep. 2, 2005, which is a continuation in part of U.S. patent application Ser. No. 10/430,298, filed on May 7, 2003 (now U.S. Pat. No. 6,973,756), both of which are incorporated herein by reference in their entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to a connector for securing veneer to back-up walls. 
       BACKGROUND OF THE INVENTION 
       [0003]    Many construction techniques have been developed for commercial buildings utilizing a back-up wall and a set of thin walled veneer panels that are supported on the back-up wall. Typically, there is a cavity between the veneer panels and the back-up wall to allow for the insertion of insulation and other materials. The veneer panels are connected to the back up wall using any of several different styles of connectors that are currently available. In addition to supporting the veneer panels, these connectors typically withstand various other loads, such as shear and wind loads. 
         [0004]    Typically prior art connectors are relatively expensive to manufacture, and offer relatively poor load-bearing capacity for their weight and cost. One such prior art connector consists of an L-shaped member, and a veneer connector plate. The vertical portion of the L-shaped member is mounted to the back-up wall, and the horizontal portion extends outwardly therefrom. The horizontal portion typically includes slotted holes therethrough, for the mounting of the veneer connector plate thereon. The veneer connector plate extends outwards and supports at its outwardmost edge, a portion of a veneer panel. 
         [0005]    For several reasons, these connectors are typically relatively expensive, and can add to the overall cost of erecting a building. One reason for their cost is that, to support the required loads during use, such connectors are typically required to be made from relatively thick materials. For example, for some applications, the L-shaped member is made from angle having a ⅜″ wall thickness. Furthermore, many building codes require such connectors to be made from stainless steel, to resist corrosion and subsequent weakening or failure. Because of this materials requirement, the cost of the L-shaped member is increased substantially. 
         [0006]    Furthermore, in order to cut ⅜″ thick angle when making the L-shaped member, a sophisticated cutting device may be required, such as, for example, a plasma cutter. Plasma cutters are typically more expensive to operate than other cutting devices, and also, plasma cutter operators are more expensive than other cutting machine operators due to their relatively uncommon expertise. 
         [0007]    A further issue driving the cost of prior art connectors is that, typically, they include at least two stainless steel bolts in their assembly, for example, to attach the veneer connector to the L-shaped piece. Stainless steel bolts are relatively expensive and can add significantly to the overall cost of the connector. 
         [0008]    Accordingly, there is a need for a connector that is relatively inexpensive to manufacture, for use in supporting veneer panels. 
       SUMMARY OF THE INVENTION 
       [0009]    According to one aspect, a connector for retaining at least one veneer panel on a back up wall is provided. The veneer panel may have a top edge and a bottom edge. The connector comprises a veneer connector and a support member. The support member comprises a mounting flange adapted for securing the support member to the back-up wall, and first and second support member side walls extending outwardly from the mounting flange. The first and second support member side walls define at least one generally horizontal surface when the support member is secured to the back-up wall. The veneer connector is securable to the horizontal surface by a mechanical fastener and is adapted to support a generally horizontal edge of the at least one veneer panel when the support member is secured to the back-up wall and when the veneer connected is supported by the generally horizontal surface. The connector is mountable on the back up wall such that the veneer connector supports one of the top and bottom edges of the at least one veneer panel. 
         [0010]    The mounting flange may have an adjustment aperture therethrough. The adjustment aperture may be elongate and may be adapted to adjustably receive a fastener therethrough for mounting the support member to the back-up wall. The adjustment aperture may be generally vertical. 
         [0011]    The generally horizontal surface may be provided by an upper surface of the first and second support member side walls. 
         [0012]    The connector may further comprise a separate fastener for securing the veneer connector to the generally horizontally extending surface. 
         [0013]    The veneer connector may comprise a section that abuts the veneer panel and is adapted to receive fasteners that engage the veneer panel. 
         [0014]    According to another aspect, a connector for coupling a veneer panel to a back-up wall is provided. The connector comprises a support member comprising a mounting flange adapted for securing the support member to said back-up wall, and first and second support member side walls extending outwardly from the mounting flange. The first and second support member side walls define at least one generally horizontal slot when the support member is secured to the back-up wall. The connector further comprises a veneer connector configured for non-rotational sliding receipt in the generally horizontal slot and adapted to support a generally horizontal edge of said veneer panel when the veneer connector is received in the generally horizontal slot and when the support member is secured to the back-up wall. 
         [0015]    The veneer connector may have a load transfer region for supporting the veneer panel, and the first and second support member side walls may extend outward from the mounting flange sufficiently to support the veneer connector proximate the load transfer region. 
         [0016]    The veneer connector may have at least one veneer connector side wall. The veneer connector side wall may be generally vertical and may extend at least along a portion of the veneer connector that is unsupported by the support member. 
         [0017]    The veneer connector may have a generally horizontal load transfer region for mounting to a horizontal edge of the veneer panel. 
         [0018]    The generally horizontal slot may comprise a generally horizontal lower surface. 
         [0019]    The mounting flange may comprise a first mounting flange portion and a second mounting flange portion. Each may have an aperture therethrough for mounting the support member to the back-up wall. At least one of the apertures may be positioned above the slot. 
         [0020]    An elongate veneer connector adjustment aperture may be defined in the veneer connector. An elongate support member adjustment aperture may be defined in the support member. The support member adjustment aperture and the veneer connector adjustment aperture may extend generally perpendicularly to each other. 
         [0021]    A veneer connector aperture may be defined in the veneer connector. A support member aperture may be defined in the support member. The support member aperture and the veneer connector aperture may be alignable with respect to each other for the pass through of a single mechanical fastener for securing the veneer connector to the support member. 
         [0022]    The first and second side walls may be connected to each other by a side wall connecting portion. The first and second side walls may be joined together by a horizontal load support wall. The horizontal load support wall may be positioned at the top of the side walls. 
         [0023]    The veneer connector may comprise a section that abuts the veneer panel and is adapted to receive fasteners that engage the veneer panel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    For a better understanding of the present invention and to show clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which: 
           [0025]      FIG. 1  is a perspective view of a system of connectors in accordance with a first embodiment of the present invention, supporting panels of veneer on a back up wall; 
           [0026]      FIG. 2  is a magnified plan view of a veneer connector shown in  FIG. 1 ; 
           [0027]      FIG. 2   a  is a plan view of a variant of the veneer connector shown in  FIG. 2 ; 
           [0028]      FIG. 3  is a perspective view of a portion of the veneer connector shown in  FIG. 2 , supporting a panel of veneer; 
           [0029]      FIG. 4  is a magnified perspective view of a support member shown in  FIG. 1 ; 
           [0030]      FIG. 5  is a magnified perspective view of the connector shown in  FIG. 1 ; 
           [0031]      FIG. 5   a  is an end view of the connector shown in  FIG. 5 , partially sectioned for greater clarity, with a variant to the fastener shown in  FIG. 5 ; 
           [0032]      FIG. 6   a  is a magnified plan view of the support member shown in  FIG. 1 , in a partial state of manufacture; 
           [0033]      FIG. 6   b  is a perspective view of the support member shown in  FIG. 6   a  in a further state of manufacture; 
           [0034]      FIG. 7  is a magnified perspective view of an alternative veneer connector to that which is shown in  FIG. 1 ; 
           [0035]      FIG. 8  is a perspective view of a variant of the support member shown in  FIG. 4 ; 
           [0036]      FIG. 8   a  is an end view the support member variant shown in  FIG. 8 , supporting a veneer panel; 
           [0037]      FIG. 9  is an end view of another variant of the support member shown in  FIG. 4 ; 
           [0038]      FIG. 10  is an end view of yet another variant of the support member shown in  FIG. 4 ; 
           [0039]      FIG. 11  is a plan view of a work piece that is in a partial state of manufacture, which can be made into either of the support members shown in  FIGS. 9 and 10 ; 
           [0040]      FIGS. 12   a  and  12   b  are perspective views of the work piece shown in  FIG. 11 , in a further state of manufacture; 
           [0041]      FIG. 13  is a plan view of a system, made up of the connectors shown in  FIGS. 9 and 10 , supporting veneer panels to a back-up wall; 
           [0042]      FIG. 14  is a top view of a variant of the support member shown in 
           [0043]      FIG. 4 ; 
           [0044]      FIG. 15  is an front view of another variant of the support member shown in  FIG. 4 ; 
           [0045]      FIG. 16  is a perspective view of a connector in accordance with another embodiment of the present invention; 
           [0046]      FIG. 17  is a front view of the connector shown is  FIG. 16 ; 
           [0047]      FIG. 18  is a perspective view of another variant of the support member shown in  FIG. 4 ; and 
           [0048]      FIG. 19  is a perspective view of another variant of the support member shown in  FIG. 4 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0049]    Reference is made to  FIG. 1 , which shows a system of connectors  10  in accordance with a preferred embodiment of the present invention. Each connector  10  includes a veneer connector  12  for connecting with a veneer panel  14 , and a support member  16  adapted for receiving the veneer connector  12  and for securement to a back-up wall  18 . The connectors  10  may be made of any suitable material, such as 10 or 11 gauge stainless steel. The connectors  10  are preferably free of welds and formed from a single sheet of metal manufactured into the desired shape. The veneer panel  14  is may be a natural stone material, such as marble or granite. The veneer panel  14  may be a thin-walled panel, which is typically known as a thin masonry veneer panel, which many building codes require to be individually supported (i.e., each panel must be supported individually). It will be noted that the mortar that would typically exist between adjacent veneer panels  14  has been removed from the Figures for greater clarity. 
         [0050]    The back-up wall  18  may be of form-poured concrete construction. Alternatively, the back-up wall  18  may be constructed of any suitable material, such as, for example, metallic studs, or block masonry. The veneer panels  14  may be spaced from the back-up wall  18  to provide a cavity  20  therebetween. Optionally, an insulation material  24  and a vapor barrier  26  may be installed in the cavity  20 . 
         [0051]    Reference is made to  FIG. 2 , which shows the veneer connector  12  in plan view. The veneer connector  12  may have a generally rectangular shape and has a first edge  28  and a second edge  30 . An adjustment aperture  32  may be positioned adjacent the first edge  28 . Referring to  FIG. 5 , the adjustment aperture  32  is used to receive a fastener  65  to join the veneer connector  12  to the support member  16 . Referring to  FIG. 2 , the adjustment aperture  32  may be generally elongate to permit adjustment of the position of the veneer connector  12  within the support member  16 , as will be discussed further below. 
         [0052]    The veneer connector  12  includes a plurality of veneer connection apertures  34 , which may be positioned proximate the second edge  30 . The veneer connector  12  may include any suitable number of veneer connection apertures  34 , such as, for example, three apertures  34 , as shown in  FIG. 2 . Referring to  FIG. 3 , the veneer connection apertures  34  permit the pass-through of fastening ties  36  that extend from the edge of the veneer panel  14 . The veneer connection apertures  34  may be generally circular, and may be sized to permit easy pass-through of the fastening ties  36 , but are not required to be so large as to facilitate substantial adjustment of the veneer  14  relative to the veneer connector  12 . 
         [0053]    The veneer connection apertures  34  are positioned proximate the second edge  30  of the veneer connector  12  to prevent the unwanted protrusion of the second edge  30  past the outer face of the veneer  14 . Thus, the second edge  30  can be buried in the mortar between vertically adjacent panels of veneer  14 . 
         [0054]    Referring to  FIG. 2   a , an alternative veneer connector  12 ′ is shown, which has a plurality of veneer connection apertures  34 ′ which are elongate to provide further adjustability of the veneer connector  12  with respect to the fastening ties  36 . 
         [0055]    Referring to  FIG. 3 , a securing means  40  prevents veneer  14  from disengaging from veneer connector  12 . Securing means  40  may be any suitable means, such as, for example, a mechanical fastener or a weld. 
         [0056]    The veneer connector  12  supports the veneer panel  14  ( FIG. 1 ) during use generally in the region of the veneer connection apertures  34 . The load imparted to the veneer connector  12  from the weight of the veneer panel  14  is shown at F. 
         [0057]    Reference is made to  FIG. 4 , which shows the support member  16  in more detail. The support member  16  includes a mounting flange  42  and a support portion  44 . The mounting flange  42  is adapted for mounting the support member  16  to the back-up wall  18  ( FIG. 1 ). As shown, the mounting flange  42  is formed by a first mounting flange and a second mounting flange  48  (shown in  FIG. 4 ) 
         [0058]    The mounting flange  42  has an adjustment aperture  50  therethrough, which is adapted to receive a fastener  52 , for fastening the support member  16  to the back-up wall  18  ( FIG. 1 ). The adjustment aperture  50  may be generally elongate, as shown in  FIG. 4 , to permit adjustment of the support member  16  in the vertical direction. Such vertical adjustment capability facilitates aligning the support members  16  in a row on the back-up wall  18  ( FIG. 1 ). 
         [0059]    The mounting flange  42  also includes a securing aperture  54  therethrough, may be positioned on the second mounting flange  48 , generally opposite the adjustment aperture  50 . The securing aperture  54  is adapted for receiving a fastener  56  therethrough to further retain the support member  16  on the back-up wall  18  ( FIG. 1 ), and to fix the position of the support member  16  therewith. Once the desired adjustment to the position of the support member  16  has been made using the fastener  52  and the adjustment aperture  50 , the fastener  56  may be passed through the aperture  54  and into the back up wall  18  ( FIG. 1 ), to fix the position of the support member  16 . 
         [0060]    Reference is made to  FIG. 5 , which shows the support portion  44  of the support member  16  more clearly. The support portion  44  extends from the mounting flange  42 , and specifically, extends from the first mounting flange  46  and the second mounting flange  48 , in a generally vertical plane denoted by the axes (y) and (z), and joins the first mounting flange  46  and second mounting flange  48  along two generally vertical lines which extend generally in the vertical (y) direction. By extending in a generally vertical plane, the support portion  44  is provided with a generally greater resistance to vertical bending forces, which result from the load F, that arise when the connector  10  supports a veneer panel  14  ( FIG. 1 ). In other words, the configuration of the support portion  44  provides the support member  16  with a relatively high moment of inertia in the vertical (y) direction, compared to a typical L-shaped member used in connectors of the prior art. 
         [0061]    The support portion  44  is made up of two spaced apart side walls  58 , which are connected at their respective upper ends by a top portion  59 . The top portion  59  and the spaced configuration of the side walls  58  provide resistance to bending loads that can occur in the lateral (x) direction during use. It is expected that any lateral loads will be smaller than the vertical loads incurred from the weight of the veneer  14  ( FIG. 1 ). As a result, the moment of inertia in the lateral (x) direction may be smaller than that in the vertical (y) direction. 
         [0062]    The top portion  59  can thus be referred to as a horizontal load support wall  59 . As such it is not necessary for the horizontal load support wall  59  to be positioned at the top of the support member  16 . For example, referring to  FIG. 18 , a support member  16 ″″″ is shown, having a horizontal load support wall  132  positioned at the bottom of the two side walls  58 . The support member  16 ″″″ may otherwise be similar to the support member  16  ( FIG. 5 ). 
         [0063]    In the embodiments in  FIG. 5 , the horizontal load support wall  59  may be made contiguous such that the adjustment aperture  62  is not provided thereon. Instead the opposing end (ie. the bottom end) of the side walls  58 , which is not covered, may act as the adjustment aperture in the Z direction. Thus, the fastener  65  could mount between the open bottom end of the side walls  58  and the veneer connector  14 . Similarly, in the embodiment in  FIG. 18 , horizontal support wall  132  may be made contiguous such that the adjustment aperture  62  is not provided thereon. Instead the opposing end (ie. the top end) of the side walls  58 , which is not covered, may act as the adjustment aperture in the Z direction. Thus, the fastener  65  (not shown in  FIG. 18 )  65  could mount between the open top end of the side walls  58  and the veneer connector  14 . 
         [0064]    Referring to  FIG. 5 , the side walls  58  are advantageously joined together by the horizontal load support wall  59 . However, the horizontal load support wall  59  could be omitted, as shown in the embodiment shown  FIG. 19 .  FIG. 19  shows a support member  16 ″″″ that has a contiguous flange portion  136 . The side walls  138  extend outwards from the flange portion  136  and are joined to the flange portion along generally vertical, spaced apart lines. The side walls  138  could be joined to the flange portion by any suitable means, such as, for example, welding. 
         [0065]    Referring to  FIG. 5 , the side walls  58  together define a slot portion  60 , which may extend in a generally horizontal (x-z) plane, for receiving and supporting the veneer connector  12 . The slot  60  permits the lateral adjustment of the veneer connector  12  in both the (x) direction and in the z direction. The slot  60  is made sufficiently deep so that the veneer connector  12  is supported along a substantial portion of its length. More particularly, the support portion  44  extends outwards to support the veneer connector  12  proximate its load supporting region, ie. the region about the apertures  34  where the load F is imparted to the veneer connector  12  by the veneer panel  14  ( FIG. 1 ). This reduces bending stresses on the veneer connector  12  in use when supporting a veneer panel  14  ( FIG. 1 ). 
         [0066]    The slot  60  is preferably positioned proximate the upper ends of the side walls  58 , to reduce its impact on the overall moment of inertia of the support portion  44  in the vertical (y) direction. It will be noted that the slot  60  may extend in a plane that is other than horizontal. For example the slot  60  may be angled generally downwards towards its blind end, so that the veneer connector  12  may be retained in place temporarily without the use of a fastener. 
         [0067]    An adjustment aperture  62  may be defined in the upper portion  59 , for receiving the fastener  65  therethrough. The fastener  65  may pass through the adjustment aperture  62  and the adjustment aperture  32  in the veneer connector  12  for fixedly retaining the veneer connector  12  in place in the support member  16 . The adjustment aperture  62  may be generally elongate, and may extend in a direction that is generally perpendicular the aperture  32  in the veneer connector  12 . In this way, the apertures  62  and  32  cooperate to provide adjustment for the veneer connector  12  within the slot  60  in both the (x) and (z) directions. 
         [0068]    The fastener  65  may be any suitable type of fastener. For example, the fastener  65  may be made up of a stainless steel hex-head bolt  65   a , a washer  65   b , and a nut  65   c . The hex head bolt  65   a  extends upwards from under the veneer connector  12 , and is sized so that the side walls  58  capture the head of the bolt  65   a  and prevent it from rotating. The threaded end of the bolt  65   a  passes up and through the adjustment aperture  62  on the support member  16 . The washer  65   b  and nut  65   c  are positioned on the exposed end of the bolt  65   a  and are tightened to provide a secure connection between the support member  16  and the veneer connector  12 . By having captured the bolt  65   a  between the side walls  58 , the task of installing the fastener  65  is facilitated. It will be noted that other types of bolts and other types of fasteners altogether could alternatively be used to connect the support member  16  and the veneer connector  12 . 
         [0069]    Reference is made to  FIG. 5   a , which shows an alternative washer  65   b ′ that can be used as part of the connector  65 . The washer  65   b ′ may have a generally arcuate shape in side view and extends downwards to capture the side walls  58  of the support member  16 . When the nut  65   c  is tightened, the washer  65   b ′ captures and pushes together the side walls  58 , further strengthening their capture of the head of the bolt  65   a . Thus, as the tightening force on the nut  65   c  is increased, the capturing force of the side walls  58  on the bolt  65   a  is increased, inhibiting the bolt  65   a  from rotating as a result of the increased tightening force. 
         [0070]    It will be noted that the washer  65   b ′ may have any suitable shape for pushing the side walls  58  together. For example, the washer  65   b ′ may alternatively have an inverted V-shape in side view instead of an arcuate shape. Furthermore, the washer  65   b ′ may have any shape in plan view. For example, the washer  65   b ′ may have a generally circular shape or may alternatively have a rectangular shape so that it better captures the side walls  58 . 
         [0071]    Reference is made to  FIG. 6   a , which shows a plate  70  which may be used to manufacture the support member  16  ( FIG. 1 ). The plate  70  may be machined with a plurality of apertures and slots which will ultimately form the slot  60 , the aperture  62  and the mounting apertures  50  and  54 . Furthermore, a slot  72  may be machined into the plates  70 , to remove unnecessary material. Once the plate  70  is machined with the appropriate slots and apertures, it may be bent into the shape of the support member  16  by two primary bending operations. The first bending operation bends the two tabs shown at  74  and  76  along a bend line  78 , resulting in the structure  79  shown in  FIG. 6   b . The tabs  74  and  76  will ultimately form the mounting flange  42  ( FIG. 4 ). The second bending operation involves folding the plate  70  generally about a fold line. The folding of the plate  70  may be performed on a radiused surface thereby forming the upper portion  59  and the spaced apart side walls  58 . Manufacturing the support member  16  in this way saves cost and manufacturing time while providing a relatively strong resulting structure. It will be noted that the order of operations described is preferable, but may alternatively be rearranged in any suitable way. 
         [0072]    By making the support member  16  by appropriately machining and by applying two simple bends to the single, integral plate  70 , the cost of manufacture for the support member  16  are reduced, relative to complex structures of the prior art which are made from multiple pieces which are welded together. 
         [0073]    Reference is made to  FIG. 1 , which shows the connector  10  in use. In use, a plurality of connectors  10  are used to support a plurality of panels of veneer  14  in a spaced relationship from the back up wall  18  of a structure such as an office tower. The support members  16  are mounted to the back-up wall, and may be spaced from each other in a generally horizontally and vertically extending array. The veneer connectors  12  are positioned in the slots  60  ( FIG. 5 ), and extend therefrom to support the veneer panels  14 . The fastening ties  36  ( FIG. 3 ) extend between vertically adjacent veneer panels  14  and pass through the veneer connection apertures  34 , which retain the panels  14  in place. Furthermore, mortar may be used to close any air gap adjacent veneer panels  14 , and to assist in retaining the panels  14  in place. The vertical load F that results from the weight of the veneer panels  14  is supported by the veneer connectors  12 , and in turn, by the support members  16 . Because the support members  16  have generally high moments of inertia in the vertical direction, they are able to be made with relatively thin gauge material for supporting the load imposed thereon by the veneer panels  14 . It will be noted that while two connectors  10  are shown along the top edge of each veneer panel  14 , any suitable number of connectors  10  may be used to support each veneer panel  14 , depending on the nature of the specific application. 
         [0074]    Reference is made to  FIG. 7 , which shows a veneer connector  12 ′″, which may be used alternatively to the veneer connector  12 . The veneer connector  12 ′″ may be similar to the veneer connector  12  ( FIG. 2 ), or the veneer connector  12 ′ ( FIG. 2   a ), except that the veneer connector  12 ′″ has a pair of side webs  84  that extend vertically from the side edges of the veneer connector  12 ′″. The side webs  84  may extend generally along substantially the entire length of the veneer connector  12 ′″, except for the portion  86  of the veneer connector  12 ′″ that will be embedded within the gap between adjacent veneer panels  14  ( FIG. 1 ). The side webs  84  provide increased bending resistance to the veneer connector  12 ′″, relative to the veneer connector  12  ( FIG. 2 ), because the side webs  84  generally increase the moment of inertia of the veneer connector  12 ′″. 
         [0075]    Reference is made to  FIG. 8 , which shows a support member  16 ′ that maybe used as an alternative to the support member  16  ( FIG. 4 ). The support member  16 ′ may be similar to the support member  16 , except that the support member  16 ′ has a slot  90  that positioned closer to the bottom of the support member  16 ′, relative to the slot  60  on the support member  16  ( FIG. 4 ). The slot  90  may otherwise be similar to the slot  60 , and is for receiving and retaining the veneer connector  12  or  12 ′″ ( FIGS. 2 and 2   a ). Referring to  FIG. 8   a , the slot  90  is positioned sufficiently low, so that, when the support member  16 ′ is being mounted to the back-up wall  18  proximate the top edge of a veneer panel  14 , the veneer panel  14  does not completely obstruct access to the adjustment aperture and the securing aperture, which are shown at  92  and  94  respectively. Thus, the relatively lower position of the slot  90  facilitates the mounting of the support member  16 ′. 
         [0076]    Reference is made to  FIG. 9 , which shows a support member  16 ″, which is another alternative to the support member  16 . The support member  16 ″ may be similar to the support member  16 , except that the support member  16 ″ has an adjustment aperture  98  that is elongate along an angle A from the vertical. The adjustment aperture  98  in the embodiment shown in  FIG. 9  provides vertical adjustability for the support member  16 ″, in a similar way to the adjustment aperture  50  on the support member  16  ( FIG. 4 ). During vertical adjustment of the support member  16 ″, however, the support member  16 ″ will be shifted by a certain amount horizontally. Preferably, the angle A from the vertical is small, to reduce the horizontal shift that occurs during vertical adjustment of the support member  16 ″. Referring to  FIG. 10 , a support member  16 ′″ may also be made which has an adjustment aperture  98 ′ that is a mirror image of the adjustment aperture  98  ( FIG. 9 ). 
         [0077]    The support member  16 , as shown in  FIG. 5 , has a support portion  44  that extends generally orthogonally outwards from the plane of the mounting flange  42 . It is, however, possible for the support portion  44  to extend outwards from the mounting flange  42 , at an angle such that it is not orthogonal to the mounting flange  42 , as shown in  FIG. 14 . In the support member  16 ″ of the variant shown in  FIG. 14 , the side walls  58  of the support portion  44  are supported along generally vertical lines by the mounting flange  42  and thus have a greater resistance to bending under a vertical load imposed thereupon, relative to a typical L-shaped member used in connectors of the prior art. This is true even though the side walls  58  extend outward from the mounting flange  42  at an angle such that they are not orthogonal to the mounting flange  42 . 
         [0078]    The side walls  58  of the support portion  44  are shown in  FIG. 5  as being supported along vertical lines by the mounting flange  42 . It is not necessary that the support be provide along strictly vertical lines however. Referring to  FIG. 15 , the support member  16 ″″ is advantageous relative to L-shaped members of the prior art, even though the side walls  58  are not strictly vertical, and are supported by the mounting flange  42  along lines that are off of vertical by some small amount. Throughout this disclosure and the accompanying claims, the term “generally vertical” is meant to include lines or planes that are strictly vertical and those that are off of vertical within a selected range. While the selected range is preferably small so that the side walls  58  are relatively close to vertical, the range could alternatively be relatively large while still providing a structure that is advantageous relative to L-shaped connectors of the prior art. For example, the range could be as large as 45 degrees off of vertical in each direction. 
         [0079]    Reference is made to  FIG. 16 , which shows a connector  110 , in accordance with another embodiment of the present invention. The connector  110  includes a support member  16 ′″″ and a veneer connector  12 ″. The support member  16 ′″″ may be similar to the support member  16  ( FIG. 4 ), except that the support member  16 ″″″ supports the veneer connector on its upper surface, shown at  116 , instead of supporting the veneer connector  12 ″ in a slot. 
         [0080]    The upper support wall  116  may be made generally planer to assist in supporting and stabilizing the veneer connector  12 ″. The adjustment aperture  62  is provided in the upper support wall  116 . The upper support wall  116  extends between the two spaced apart side walls  118 . The side walls  118  may be similar to the side walls  58 , shown in the support member  16 , shown in  FIG. 5 . The upper support wall  116 , thus acts as the horizontal support for the side walls  118 . 
         [0081]    The veneer connector  12 ″ rests on top of the upper support wall  116 . The veneer connector  12 ″ has the adjustment aperture  32  which is alignable with the adjustment aperture  62  on the support member  16 ′″″ when the veneer connector is positioned on the upper support wall  116 . The adjustment aperture  32  is generally perpendicular to the adjustment aperture  62  in order to provide adjustability for the veneer connector  12 ″ on the support member  16 ′″″ in two orthogonal directions in a horizontal plane. 
         [0082]    Referring to  FIG. 17 , the fastener  65  may be provided for joining the veneer connector  12 ″ to the support member  16 ″′″. The fastener  65  may include the hex head bolt  65   a , the washer  65   b , the nut  65   c , and a washer  65   d.    
         [0083]    The washers  65   b  and  65   d  are provided to inhibit the pulling through of the bolt  65   a  or nut  65   c  through the adjustment apertures  62  and  32  during assembly and use of the connector  110 . 
         [0084]    Referring to  FIG. 16 , the veneer connector  12 ″ includes the veneer connection apertures  34 , positioned proximate its second, or outside, edge  30 . The veneer connection apertures  34  may include a centre aperture  34   a  and two outer apertures  34   b . The centre aperture  34   a  may be generally circular while the outer apertures  34   b  may be slotted to provide flexibility in receiving imperfectly positioned fastening ties  36  ( FIG. 3 ) on the veneer panels  14  ( FIG. 3 ). 
         [0085]    The veneer connector  12 ″ may include a pair of side webs  120 , which may be similar to the side webs  84  on the veneer connector  12 ′″, as shown in  FIG. 7 . 
         [0086]    The veneer connector  12 ″ may include one or more strengthening ribs  121  on its upper surface  122 . The strengthening ribs  121  provide additional vertical bending resistance for the central region of the veneer connector  12 ″ which is spaced relatively far away from the side webs  120 . By positioning the strengthening ribs  121  on the upper surface  122 , they do not create an interference hazard when mounting the veneer connector  12 ″ on the support member  16 ″′″. Like the side webs  120 , the strengthening ribs  121  must be positioned so as not to obstruct the connection of the veneer connector  12 ″ with the veneer panel  14  that will ultimately sit above it (see  FIG. 3 ). 
         [0087]    Referring to  FIG. 11 , the support members  16 ″ and  16 ′″ may be manufactured from a common plate  100 . The common plate  100  may be similar to the plate  70  ( FIG. 6   a ), except that the common plate  100  has an aperture therein, that will ultimately become the adjustment aperture  98  ( FIG. 9 ), or the adjustment aperture  98 ′ ( FIG. 10 ), depending on which way the plate  100  is folded during manufacture. For example, referring to  FIG. 12   a , the tabs on the plate  100 , which are shown at  104  may be folded in a first direction, so that the plate  100  will ultimately form the support member  16 ″. However, referring to  FIG. 12   b , the tabs  104  may be folded in a second direction that is opposite the first direction, so that the plate  100  ultimately forms the support member  16 ′″. 
         [0088]    Reference is made to  FIG. 13 , which shows a system of connectors  106  and  108 , which cooperate in pairs to support veneer panels  14 . The connectors  106  and  108  may be similar to the connector  10  ( FIG. 1 ), and include a suitable veneer connector, such as the veneer connector  12 . However, the connectors  106  and  108  include the support members  16 ″ and  16 ′″ respectively, instead of the support member  16  ( FIG. 1 ). 
         [0089]    The top and bottom edges of the panel  14  are supported by at least one of each connector  106  and  108 . As a result, the weight of the panel  14  is prevented from dragging the connectors  106  and  108  down the wall  18 , because the adjustment apertures extend in different directions. Thus, because the adjustment apertures  98  and  98 ′ are not parallel to each other when the connectors  106  and  108  are installed on the back-up wall and are in use, the adjustment apertures  98  and  98 ′ cooperate with their respective fasteners and with each other to prevent the connectors  106  and  108  from being dragged down from their supported load. 
         [0090]    It will be noted that more than one of each connector  106  and  108  may be used to support an edge of the veneer panel  14 . For example, several of one type of connector, eg. connector  106  and one or two of the other type of connector, eg. connector  108 , may be used to support an edge of the veneer panel  14 . At least one of each connector  106  and  108  is used, however. 
         [0091]    It will be noted that the features shown in the support members disclosed herein may all be combined into a support member in accordance with the present invention in any desired way. For example, a support member may be provided that includes the basic structure of support member  16 , but that has a low-positioned slot, similar to the slot  90  of support member  16 ′ ( FIG. 8 ), and that also has a slanted adjustment aperture, similar to the adjustment aperture  98  or  98 ′ of support members  16 ″ and  16 ′″ ( FIGS. 9 and 10 ). Similarly, the features shown in the veneer connectors disclosed herein may all be combined into a veneer connector in accordance with the present invention in any desired way. 
         [0092]    In the embodiments described above, the side walls of the support members have been described and shown as extending outwardly from the mounting flanges along vertical planes. It will be noted that the vertical planes need not be strictly vertical, but are at least generally vertical. In another alternative, the side walls of the support members need not be strictly planar, and may instead be curved or may have further folds, which are preferably generally vertical. 
         [0093]    In the embodiments described above, the veneer connector mounts to the support member using a single fastener, such as a bolt. Using a single fastener instead of a plurality of fasteners can provide a significant cost savings in the overall cost of the connector, particularly in jurisdictions which require the use of stainless steel for connectors supporting veneer panels in a cavity wall. 
         [0094]    The connectors of the present invention are able to support the same loads as the L-shaped connectors of the prior art, but can be manufactured from thinner material, with fewer fasteners. As a result the connectors of the present invention can be less expensive than the L-shaped connectors of the prior art. 
         [0095]    While what has been shown and described herein constitutes the preferred embodiments of the subject invention, it will be understood that various modifications and adaptations of such embodiments can be made without departing from the present invention, the scope of which is defined in the appended claims.

Technology Classification (CPC): 8