Patent Document

BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to anchoring systems for insulated cavity walls. At the inner wythe, the anchoring systems provide sealing along the dual-diameter barrel of the wall anchor with a first seal covering the insertion site at the air-vapor barrier and a second seal covering the opening of the wall anchor channel at the exterior surface of the insulation. At the outer wythe, the anchoring systems provide a variety of veneer ties for angular adjustment, self-leveling, and seismic protection. Besides sealing the air-vapor barrier and the insulation, the seals provide support for the wall anchor and substantially preclude lateral movement. 
         [0003]    2. Description of the Prior Art 
         [0004]    In the past, anchoring systems have taken a variety of configurations. Where the applications included masonry backup walls, wall anchors were commonly incorporated into ladder- or truss-type reinforcements and provided wire-to-wire connections with box-ties or pintle-receiving designs on the veneer side. 
         [0005]    In the late 1980&#39;s, surface-mounted wall anchors were developed by Hohmann &amp; Barnard, Inc., patented under U.S. Pat. No. 4,598,518 (&#39;518) of the first-named inventor hereof. The invention was commercialized under trademarks DW-10®, and DW-10-HS®. These widely accepted building specialty products were designed primarily for drywall construction, but were also used with masonry backup walls. For seismic applications, it was common practice to use these wall anchors as part of the DW-10 Seismiclip® interlock system which added a Byna-Tie® wire formative, a Seismiclip® snap-in device—described in U.S. Pat. No. 4,875,319 (&#39;319), and a continuous wire reinforcement. 
         [0006]    In the dry wall application, the surface-mounted wall anchor of the above-described system has pronged legs that pierce the insulation and the 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 the effects of various forces, particularly lateral forces, upon brick veneer masonry construction. However, under certain conditions, the system did not sufficiently maintain the integrity of the insulation. 
         [0007]    The engineering evaluations further described the advantages of having a continuous wire embedded in the mortar joint of anchored veneer wythes. The seismic aspects of these investigations were reported in the inventor&#39;s &#39;319 patent. Besides earthquake protection, the failure of several high-rise buildings to withstand wind and other lateral forces resulted in the incorporation of a continuous wire reinforcement requirement in the Uniform Building Code provisions. The use of a continuous wire in masonry veneer walls has also been found to provide protection against problems arising from thermal expansion and contraction and to improve the uniformity of the distribution of lateral forces in the structure. 
         [0008]    Shortly after the introduction of the pronged wall anchor, a seismic veneer anchor, which incorporated an L-shaped backplate, was introduced. This was formed from either 12- or 14-gauge sheetmetal and provided horizontally disposed openings in the arms thereof for pintle legs of the veneer anchor. In general, the pintle-receiving sheetmetal version of the Seismiclip® interlock system served well, but in addition to the insulation integrity problem, installations were hampered by mortar buildup interfering with pintle leg insertion. 
         [0009]    In the 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 includes an elongated eye and a wire tie therethrough for disposition in a bed joint of the outer wythe. It is instructive to note that pin-point loading—that is forces concentrated at substantially a single point—developed from this design configuration. Upon experiencing lateral forces over time, this resulted in the loosening of the stud. 
         [0010]    Exemplary of the public sector building specification is that of the Energy Code Requirement, Boston, Mass. (See Chapter 13 of 780 CMR, Seventh Edition). This Code sets forth insulation R-values well in excess of prior editions and evokes an engineering response opting for thicker insulation and correspondingly larger cavities. 
         [0011]    As insulation became thicker, the tearing of insulation during installation of the pronged DW-10× wall anchor, see supra, became more prevalent. This occurred as the installer would fully insert one side of the wall anchor before seating the other side. The tearing would occur during the arcuate path of the insertion of the second leg. The gapping caused in the insulation permitted air and moisture to infiltrate through the insulation along the pathway formed by the tear. While the gapping was largely resolved by placing a self-sealing, dual-barrier polymeric membrane at the site of the legs and the mounting hardware, with increasing thickness in insulation, this patchwork became less desirable. The improvements hereinbelow in surface mounted wall anchors look toward greater retention of insulation integrity and less reliance on a patch. 
         [0012]    Another prior art development occurred shortly after that of Reinwall/Lopez when Hatzinikolas and Pacholok of Fero Holding Ltd. introduced their sheetmetal masonry connector for a cavity wall. This device is described in U.S. Pat. Nos. 5,392,581 and 4,869,043. Here a sheetmetal plate is connected 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 described lowering the thermal conductivity by foraminously structuring the plate. However, as there is no thermal break, a concomitant loss of the insulative integrity results. 
         [0013]    In recent building codes for masonry structures a trend away from eye and pintle structures is seen in that newer codes require adjustable anchors be detailed to prevent disengagement. This has led to anchoring systems in which the open end of the veneer tie is embedded in the corresponding bed joint of the veneer and precludes disengagement by vertical displacement. 
         [0014]    In the past, the use of wire formatives have been limited by the mortar layer thickness which, in turn are dictated either by the new building specifications or by pre-existing conditions, e.g. matching during renovations or additions 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. 
         [0015]    Contractors found that heavy wire anchors, with diameters approaching the mortar layer height specification, frequently result in misalignment. This led to low-profile wall anchors of the inventors hereof as described in U.S. Pat. No. 6,279,283. However, the above-described technology did not fully address the adaption thereof to insulated inner wythes utilizing stabilized stud-type devices. 
         [0016]    In the course of prosecution of U.S. Pat. No. 4,598,518 (Hohmann &#39;518) several patents indicated by an asterisk on the tabulation below, became known to the inventors hereof and are acknowledged hereby. Thereafter and in preparing for this disclosure, the additional patents which became known to the inventors are discussed further as to the significance thereof: 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
             
           
               
                   
                   
               
             
             
               
                   
                 Pat. 
                 Inventor 
                 Issue Date 
               
               
                   
                   
               
               
                   
                 2,058,148 
                 M. W. Hard 
                 Oct. 20, 1936 
               
               
                   
                 2,966,705 
                 W. Massey 
                 Jan. 3, 1961 
               
               
                   
                 3,377,764 
                 B. Storch 
                 Apr. 16, 1968 
               
               
                   
                 4,021,990 
                 Schwalberg 
                 May 10, 1977 
               
               
                   
                 4,305,239 
                 Geraghty 
                 Dec. 15, 1981 
               
               
                   
                 4,373,314 
                 Allan 
                 Feb. 15, 1983 
               
               
                   
                 4,438,611 
                 Bryant 
                 Mar. 27, 1984 
               
               
                   
                 4,473,984 
                 Lopez 
                 Oct. 2, 1984 
               
               
                   
                 4,598,518 
                 Hohmann 
                 Jul. 8, 1986 
               
               
                   
                 4,764,069 
                 Reinwall et al. 
                 Aug. 16, 1988 
               
               
                   
                 4,869,038 
                 Catani 
                 Sep. 26, 1989 
               
               
                   
                 4,875,319 
                 Hohmann 
                 Oct. 24, 1989 
               
               
                   
                 5,063,722 
                 Hohmann 
                 Nov. 12, 1991 
               
               
                   
                 5,392,581 
                 Hatzinikolas et al. 
                 Feb. 28, 1995 
               
               
                   
                 5,408,798 
                 Hohmann 
                 Apr. 25, 1995 
               
               
                   
                 5,456,052 
                 Anderson et al. 
                 Oct. 10, 1995 
               
               
                   
                 5,816,008 
                 Hohmann 
                 Oct. 6, 1998 
               
               
                   
                 6,209,281 
                 Rice 
                 Apr. 3, 2001 
               
               
                   
                 6,279,283 
                 Hohmann et al. 
                 Aug. 28, 2001 
               
               
                   
                 7,415,803 
                 Bronner 
                 Aug. 26, 2008 
               
               
                   
                 7,562,506 
                 Hohmann, Jr. 
                 Jul. 21, 2009 
               
               
                   
                 7,845,137 
                 Hohmann, Jr. 
                 Dec. 7, 2010 
               
               
                   
                   
               
             
          
           
               
                   
                 Patent App. 
                 Inventor 
                 Publication Date 
               
               
                   
                   
               
               
                   
                 2010/0037552 
                 Bronner 
                 Feb. 18, 2010 
               
               
                   
                   
               
             
          
         
       
     
         [0000]    
       
         
               
             
               
               
               
               
               
             
           
               
                   
               
               
                 FOREIGN PATENT DOCUMENTS 
               
             
          
           
               
                   
                 Patent 
                 Country 
                 O.Cl. 
                 Issue Date 
               
               
                   
                   
               
               
                   
                 279209* 
                 CH 
                 52/714 
                 Mar. 1, 1952 
               
               
                   
                 2069024* 
                 GB 
                 52/714 
                 Aug. 19, 1981 
               
               
                   
                   
               
               
                   
                 Note: 
               
               
                   
                 Original classification provided for asterisked items only. 
               
             
          
         
       
     
         [0017]    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. 
         [0018]    U.S. Pat. No. 3,377,764—D. Storch—Issued Apr. 16, 1968 discloses a bent wire, tie-type anchor for embedment in a facing exterior wythe engaging with a loop attached to a straight wire run in a backup interior wythe. 
         [0019]    U.S. Pat. No. 4,021,990—B. J. Schwalberg—Issued May 10, 1977 discloses a dry wall construction system for anchoring a facing veneer to wallboard/metal stud construction with a pronged sheetmetal anchor. Like Storch &#39;764, the wall tie is embedded in the exterior wythe and is not attached to a straight wire run. 
         [0020]    U.S. Pat. No. 4,373,314—J. A. Allan—Issued Feb. 15, 1983 discloses a vertical angle iron with one leg adapted for attachment to a stud; and the other having elongated slots to accommodate wall ties. Insulation is applied between projecting vertical legs of adjacent angle irons with slots being spaced away from the stud to avoid the insulation. 
         [0021]    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 embedment in a corresponding bed joint. The stud is applied through a hole cut into the insulation. 
         [0022]    U.S. Pat. No. 4,869,038—M. J. Catani—Issued Sep. 26, 1989 discloses a veneer wall anchor system having in the interior wythe a truss-type anchor, similar to Hala et al. &#39;226, supra, but with horizontal sheetmetal extensions. The extensions are interlocked with bent wire pintle-type wall ties that are embedded within the exterior wythe. 
         [0023]    U.S. Pat. No. 4,879,319—R. Hohmann—Issued Oct. 24, 1989 discloses a seismic construction system for anchoring a facing veneer to wallboard/metal stud construction with a pronged sheetmetal anchor. Wall tie is distinguished over that of Schwalberg &#39;990 and is clipped onto a straight wire run. 
         [0024]    U.S. Pat. No. 5,392,581—Hatzinikolas et al.—Issued Feb. 28, 1995 discloses a cavity-wall anchor having a conventional tie wire for mounting in the brick veneer and an L-shaped sheetmetal bracket for mounting vertically between side-by-side blocks and horizontally atop a course of blocks. The bracket has a slit which is vertically disposed and protrudes into the cavity. The slit provides for a vertically adjustable anchor. 
         [0025]    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. 
         [0026]    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. 
         [0027]    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. 
         [0028]    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. 
         [0029]    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. 
         [0030]    U.S. Pat. No. 7,415,803—Bronner—Issued Aug. 26, 2008 discloses a wing nut wall anchoring system for use with a two legged wire tie. The wing nut is rotatable in all directions to allow angular adjustment of the wire tie. 
         [0031]    U.S. Pat. No. 7,562,506—Hohmann, Jr.—Issued Jul. 21, 2009 discloses a notched surface-mounted wall anchor and anchoring system for use with various wire formative veneer ties. The notches, upon surface mounting of the anchor, form small wells which entrain fluids and inhibit entry of same into the wallboard. 
         [0032]    U.S. Pat. No. 7,845,137—Hohmann, Jr.—Issued Dec. 7, 2010 discloses a folded wall anchor and anchoring system for use with various wire formative veneer ties. The folded wall anchor enables sheathing of the hardware and sealing of the insertion points. 
         [0033]    U.S. Pub. No. 2010/0037552—Bronner—Filed Jun. 1, 2009 discloses a side-mounted anchoring system for veneer wall tie connection. The system transfers horizontal loads between a backup wall and a veneer wall. 
         [0034]    None of the above provide the high-strength, supported stud-type wall anchor or anchoring systems utilizing these devices of this invention. As will become clear in reviewing the disclosure which follows, the insulated cavity wall structures benefit from the recent developments described herein that lead to solving the problems of insulation and air/vapor barrier integrity, of high-span applications, and of pin-point loading. The wall anchors, when combined with various veneer tie arrangements hereof, provide for angular adjustment therebetween, self-leveling installation, and seismic level of protection. 
       SUMMARY 
       [0035]    In general terms, the invention disclosed hereby is an anchoring system for use in an insulated cavity wall. The anchoring system has a steel stud-type wall anchor and a wire formative veneer tie. The steel stud has an elongated dual-diameter barrel body with a driven self-drilling tip or alternatively with a separate fastener sheathed by a stepped cylinder body. 
         [0036]    At the juncture of the smaller diameter barrel and the larger diameter barrel, there is a flange that houses an interior seal. At the juncture of the larger diameter barrel and the driver head, there is a flange that houses an exterior seal. The wall anchor is dimensioned with the length of the smaller diameter barrel (less the height of the interior seal) to be coextensive with the drywall and the air/vapor barrier. Additionally, the wall anchor is dimensioned with the length of the larger diameter barrel (plus the height of the interior seal) to be coextensive with the rigid insulation. 
         [0037]    The structure taught by this invention overcomes both the problems of pin-point loading and of insulation integrity described in the Background of the Invention hereinabove. The pin-point loading is overcome by full body support throughout the drywall, the air/vapor barrier, and the insulation. The interior seal, when the stud-type anchor is fully driven into place provides a seal over the insertion point into the air/vapor barrier. Similarly, the exterior seal, when the stud-type anchor is fully driven into place, provides a seal over the opening of an anchor-receiving channel and thereby preserves the insulation integrity. The interior seal and the larger barrel of the anchor, when installed, completely fill the anchor receiving channel and stabilize the wall anchor. The wall anchor is clamped in place by the interior and exterior seals. 
         [0038]    The stud-type anchor is disclosed as operating with a variety of veneer ties each providing for different applications. A modified Byna-Tie® wire formative with a swaged side leg in the insertion portion expands the utility of the system to seismic applications and accommodates a wire reinforcement in the outer wythe. A tie with a U-shaped rear leg provides for accommodating the driver head at whatever angle it is at when fully driven into place. A tie with an angled rear leg provides for self-leveling as between the stud position and the bed joint height. 
       OBJECTS AND FEATURES OF THE INVENTION 
       [0039]    Accordingly, it is the primary object of the present invention to provide new and novel anchoring systems for insulated cavity walls, which systems provide high-strength connectivity with two seals—one for the insulation; and the other for the air/vapor barrier. 
         [0040]    It is another object of the present invention to prevent air infiltration and water penetration into and along the wall anchoring channel. 
         [0041]    It is yet another object of the present invention to provide adjustability of the veneer anchor to compensate for slight angular and height misalignments. 
         [0042]    It is still yet another object of the present invention to provide an anchoring system which fully supports the wall anchor along the length thereof and precludes pin-point loading and prevents disengagement under seismic and other severe environmental conditions. 
         [0043]    It is a feature of the present invention that the wall anchor has a dual-diameter barrel with a self-drilling screw tip which facilitates installation. 
         [0044]    It is another feature of the present invention that the wall anchor is convertible with an apertured collar adapter to receive a box tie veneer anchor. 
         [0045]    It is yet another feature of the present invention that the anchor system is angularly adjustable with veneer anchor having a U-shaped rear leg. 
         [0046]    It is still yet another feature of the present invention that the anchoring system is self-leveling with an infinity shaped veneer anchor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0047]    In the following drawings, the same parts in the various views are afforded the same reference designators. 
           [0048]      FIG. 1  shows a first embodiment of this invention and is a perspective view of an anchoring system as applied to a cavity wall with an inner wythe of an insulated dry wall construction and an outer wythe of brick; 
           [0049]      FIG. 2  is a partial perspective view of  FIG. 1  which shows the double sealing of the wall anchor, a wire reinforcement for seismic protection, and the angular adjustability of the veneer anchor; 
           [0050]      FIG. 3  is a perspective view of the wall anchor of  FIG. 1  showing the dual-barrel configuration, the insulation seal, the air/vapor barrier seal, and the self-drilling screw; 
           [0051]      FIG. 4  is a second embodiment of this invention and is a perspective view of an anchoring system similar to  FIG. 1 , but showing a slip-in collar with box-tie veneer anchor and an inner wythe of wood framing; 
           [0052]      FIG. 5  is a cross-sectional view of  FIG. 4  taken along an xz-plane including the longitudinal axis of the wall anchor; 
           [0053]      FIG. 6  is a cross-sectional view of  FIG. 4  taken along an yz-plane including the longitudinal axis of the wall anchor; 
           [0054]      FIG. 7  is a third embodiment of this invention and is a perspective view of an anchoring system similar to  FIG. 1 , but showing a self-leveling veneer anchor; 
           [0055]      FIG. 8  shows a perspective view of a detail of  FIG. 7  that includes the wall anchor and the self-leveling veneer anchor; 
           [0056]      FIG. 9  is a cross-sectional view of  FIG. 7  taken along a xz-plane including the longitudinal axis of the wall anchor; 
           [0057]      FIG. 10  is a cross-sectional view of  FIG. 7  taken along a yz-plane including the longitudinal axis of the wall anchor; 
           [0058]      FIG. 11  is a fourth embodiment of this invention and is an exploded view of the wall anchor similar to that of the first embodiment, but having a stepped-cylindrical body; 
           [0059]      FIG. 12  is a cross-sectional view of  FIG. 11  with the wall anchor thereof shown mounted in the inner wythe and interlocking with a veneer anchor disposed in the outer wythe; and 
           [0060]      FIG. 13  is a cross-sectional view of  FIG. 11  along line  13 - 13  showing the fastener thereof sheathed by the stepped cylinder. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0061]    Before entering into the detailed Description of the Preferred Embodiments, several terms which will be revisited later are defined. These terms are relevant to discussions of innovations introduced by the improvements of this disclosure that overcome the deficits of the prior art devices. 
         [0062]    In the embodiments described hereinbelow, the inner wythe is provided with insulation. In dry wall construction, this takes the form of exterior insulation disposed on the outer surface of the inner wythe. In the masonry block backup wall construction, insulation is applied to the outer surface of the masonry block. 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 have formed a conductive bridge between the wall cavity and the metal studs of columns of the interior of the building. Here the terms thermal conductivity, thermally-isolated and -isolating, and thermal conductivity analysis are used to examine this phenomenon and the metal-to-metal contacts across the inner wythe. 
         [0063]    The term stepped cylinder as used hereinafter refers to a cylinder having cylindrical portions with differing diameters about a common longitudinal axis and having shoulders between adjacent portions or steps. The term thermally-isolated tubule or tubule assembly for thermally isolating a surface-mounted wall anchor as used hereinafter refers to a stepped cylinder that is joined to a metal base, where the base is positioned substantially at right angles (normal) to the longitudinal axis of the stepped cylinder and where at the location that the stepped cylinder joins to the base, the base surrounds the latitudinal (cross-sectional) perimeter of the stepped cylinder with some area of cylinder material extending on all sides of this joint forming a press-fit relationship or the base is secured against a flanged end of the stepped cylinder and held in place by a retaining clip or other method. The base has two major faces, identified by the orientation presented when the veneer anchor is installed. The face oriented towards the inner wythe is identified as the base surface or mounting surface, and the face oriented towards the outer wythe is the outer surface. The stepped cylinder sheaths the mounting hardware or fastener and is thermally-isolated through the use of a series of neoprene or similar washers. 
         [0064]    Anchoring systems for cavity walls are used to secure veneer facings to a building and overcome seismic and other forces, i.e. wind shear, etc. In the past some systems have experienced failure because the forces have been concentrated at substantially a single point. Here, the term pin-point loading refers to an anchoring system wherein forces are concentrated at a single point. In the Description which follows, means for supporting the wall anchor shaft to limit lateral movement are taught. 
         [0065]    In addition to that which occurs at the 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 and ease of the securement of the wall anchor to the backup wall while, as previously discussed, maintaining the integrity of the insulation. The first concern is addressed using appropriate fasteners such as for mounting to metal, drywall studs, self-drilling screws. The latter concern is addressed by the wall anchor seal which surround the openings formed for the installation (the profile is seen in the cross-sectional drawing  FIG. 2 ). 
         [0066]    In the detailed description, the veneer reinforcements and the veneer anchors 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 test veneer joint reinforcements are, where applicable, those dominated in ASTM-A951-00 Standard Specification for Masonry Joint Reinforcement. 
         [0067]    Referring now to  FIGS. 1 through 3 , the first embodiment shows an anchoring system suitable for seismic zone applications. This anchoring system, discussed in detail hereinbelow, has a wall anchor, an interengaging veneer tie, and a veneer (outer wythe) reinforcement and is disposed in an externally insulated drywall. For the first embodiment, a cavity wall having an insulative layer of 4.0 inches (approx.) and a total span of 4.75 inches (approx.) is chosen as exemplary. 
         [0068]    The 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 drywall backup  14  with sheetrock or wall board  16  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 cavity  22  has attached to the exterior surface  24  of the inner wythe  14  an air/vapor barrier  25  and insulation  26 . 
         [0069]    The air/vapor barrier  25  and the wallboard  16  together form the exterior layer  28  of the inner wythe  14 , which exterior layer  28  has the insulation  26  disposed thereon. 
         [0070]    Successive bed joints  30  and  32  are substantially planar and horizontally disposed and, in accord with building standards, are 0.375-inch (approx.) in height. Selective ones of bed joints  30  and  32 , which are formed between courses of bricks  20 , are constructed to receive therewithin the insertion portion of the veneer anchor hereof. Being threadedly mounted in the inner wythe, the wall anchor is supported thereby and, as described in greater detail herein below, is configured to minimize air and moisture penetration around the wall anchor/inner wythe interface. 
         [0071]    For purposes of discussion, the cavity surface  24  of the inner wythe  14  contains a horizontal line or x-axis  34  and intersecting vertical line or y-axis  36 . A horizontal line or z-axis  38 , normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes. A wall anchor  40  is shown with a U-shaped rear leg portion  42 . The wall anchor  40 , while shown as a unitary structure of high-strength steel may be manufactured as an assemblage of several distinct parts. 
         [0072]    The veneer tie  44  is adapted from one shown and described in Hohmann, U.S. Pat. No. 4,875,319 which patent is incorporated herein by reference. The veneer tie  44  is shown in  FIG. 1  as being emplaced on a course of bricks  20  in preparation for embedment in the mortar of bed joint  30 . In this embodiment, the system includes a wire or outer wythe reinforcement  46 , a wall anchor  40  and a veneer tie  44 . The wire reinforcement  46  is constructed of a wire formative conforming to the joint reinforcement requirements of ASTM Standard Specification A951-00, Table 1, see supra. 
         [0073]    At intervals along a horizontal surface  24 , wall anchors  40  are driven into place in the anchor-receiving channels  48 . The wall anchors  40  are positioned on surface  24  so that the longitudinal axis  50  of wall anchor  40  is normal to an xy-plane and taps into column  17 . As best shown in  FIGS. 2 and 3 , the wall anchor  40  extends from a driven end  52  to a driver end  54 . The driven end  52  is constructed with a self-drilling screw portion  56 . 
         [0074]    Contiguous with screw portion  56  is a dual-diameter barrel with a smaller diameter barrel or shaft portion  58  toward the driven end  52  and a larger diameter barrel or shaft portion  60  toward the driver end  54 . At the juncture of barrel portions  58  and  60 , a flange  62  is formed and a stabilizing neoprene fitting or internal seal  64  is emplaced thereat. When fully driven into column  17  the screw  56  and barrel portion  58  of wall anchor  40  pierces sheetrock or wallboard  16  and air/vapor barrier  25 . The seal  64  covers the insertion point precluding air and moisture penetration therethrough and maintaining the integrity of barrier  25 . 
         [0075]    At the driving end  54 , a driver portion  66  adjoins larger diameter barrel or shaft portion  60  forming a flange  68  therebetween and another stabilizing neoprene fitting or external seal  70  is emplaced thereat. Upon installation into rigid insulation, the larger barrel portion  60  is forced into a press fit relationship with anchor-receiving channel  48 . Stabilization of this stud-type wall anchor  40  is attained by barrel portion  60  and internal neoprene fitting  64  completely filling the channel  48  with external neoprene fitting  70  capping the opening  72  of channel  48  into cavity  22  and clamping wall anchor  40  in place. This arrangement does not leave any wiggle room for pin-point loading of the wall anchor. With stabilizing fitting or external seal  70  in place, the insulation integrity within the cavity wall is maintained. 
         [0076]    In producing wall anchor  48 , the length of the smaller diameter barrel  58  less the internal seal  64  height is selected to match the external layer  28  thickness. Similarly, the length of the larger diameter barrel  60  plus the internal seal  64  height is selected to match the insulation thickness. 
         [0077]    In this embodiment, the driver portion  66  has an elongated aperture  74  for the interlacing of veneer tie  44 . The veneer tie  44  is a wire formative having a U-shaped rear leg portion  42  for angular adjustment, see supra. From the rear leg  42 , two side legs  76  and  78  extend to and, at the front portion thereof, are part of insertion portion  80  which is shown installed into bed joint  30 . The insertion portion  80  is constructed with two parallel front legs  82  and  84  adjoining side legs  76  and  78 , respectively, and housing therebetween wire reinforcement  46 . At the juncture of side leg  78  and front leg  84 , a swaged area  86  is shown for further accommodating wire reinforcement  46 . 
         [0078]    The description which follows is a second embodiment of the anchoring system for insulated cavity walls of this invention. 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. 4 ,  5  and  6 , the second embodiment of the 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 drywall or a wallboard construct  116  on wood framing or studs  117  and an outer wythe or veneer  118  of brick  120 . Between the inner wythe  114  and the outer wythe  118 , a cavity  122  is formed. The cavity  122  has attached to the exterior surface  124  of the inner wythe  114  and air/vapor barrier  125  and insulation  126 . Here, the anchoring system has a wall anchor with a clip-on, winged collar for receiving the veneer tie portion of the anchoring system. 
         [0079]    For purposes of discussion, the cavity 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 construct  140  is shown which penetrates the wallboard  116 . The wall anchor  140  is a unitary metal construct which is constructed for mounting in inner wythe  114  and for interconnection with veneer tie  144 . 
         [0080]    The veneer tie  144  is a box Byna-Tie® device manufactured by Hohmann &amp; Barnard, Inc., Hauppauge, N.Y. 11788. The veneer tie  144  is shown in  FIG. 4  as being emplaced on a course of bricks  120  in preparation for embedment in the mortar bed joints  130  and  132 . In this embodiment, the system includes a wall anchor  140  and a veneer tie  144 . 
         [0081]    But for the structure of the driver portion  166 , the wall anchor  140  is like wall anchor  40  just described. Here, the driven end  152  is again a self-drilling screw portion  156  with a first and a second shaft portion  158  and  160 , respectively, of increasing diameter. The internal seal  164  and the external seal  170  are at flanges  162  and  168 . The driver portion  166  is capable of being driven using a conventional chuck into the anchor-receiving channel  148  and, after being rotated to align with the bed joint  130 , collar  167  is locked in place. The collar  167 , which has two apertures  169  for accommodating the veneer tie  144 , has the effect of spreading stresses experienced during use and further reducing pin-point loading as opposite force vectors cancel one another. The veneer tie  144  has two side legs  176  and  178  and an insertion portion  180 . 
         [0082]    The description which follows is a third embodiment of the anchoring system for insulated cavity walls of this invention. For ease of comprehension, whenever possible similar parts use reference designators 200 units higher than those in the first embodiment. Referring now to  FIGS. 7 through 10 , the third embodiment is shown and referred to generally by the numeral  210 . 
         [0083]    A cavity wall structure  212  is shown having an inner wythe or backup wall  214  with sheetrock or wallboard  216  mounted on metal studs or columns  217  and an outer wythe or facing wall  218  of brick  220  is formed. The cavity  222  has attached to the exterior surface  224  of the inner wythe  214  an air/vapor barrier  225  and insulation  226 . The air/vapor barrier  225  and the wallboard  216  together form the exterior layer  228  of the inner wythe  214 , which exterior layer  228  has the insulation  226  disposed thereon. 
         [0084]    Successive bed joints  230  and  232  are substantially planar and horizontally disposed and, in accord with building standards, are 0.375-inch (approx.) in height. Selective ones of bed joints  230  and  232 , which are formed between courses of bricks  220 , are constructed to receive therewithin the insertion portion of the veneer anchor hereof. Being threadedly mounted in the inner wythe, the wall anchor is supported thereby and, as described in greater detail hereinbelow, is configured to minimize air and moisture penetration around the wall anchor/inner wythe interface. For purposes of discussion, the cavity surface  224  of the inner wythe  214  contains a horizontal line or x-axis  234  and intersecting vertical line or y-axis  236 . A horizontal line or z-axis  238 , normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes. A wall anchor  240  is shown with a rear leg portion  242 . The wall anchor  240 , while shown as a unitary structure of high-strength steel may be manufactured as an assemblage of several distinct parts. 
         [0085]    The veneer tie  244  is a self-leveling tie and corrects slight misalignment between wall anchor and bed joint levels. The veneer tie  244  is shown in  FIGS. 8 ,  9  and  10  as being emplaced on a course of bricks  220  in preparation for embedment in the mortar of bed joint  230 . As shown in this embodiment, the system does not include a wire or outer wythe reinforcement ( 46 ,  FIG. 1 ), but could easily be modified to incorporate the same. 
         [0086]    At intervals along a horizontal surface  224 , wall anchors  240  are driven into place in the anchor-receiving channels  248 . The wall anchors  240  are positioned on surface  224  so that the longitudinal axis  250  of wall anchor  240  is normal and taps into masonry backup wall  214 . As best shown in  FIGS. 9 and 10 , the wall anchor  240  extends from a driven end  252  to a driver end  254 . The driven end  252  is constructed with a self-drilling screw portion  256 . 
         [0087]    Contiguous with screw portion  256  is a dual-diameter barrel with a smaller diameter barrel or shaft portion  258  toward the driven end  252  and a larger diameter barrel or shaft portion  260  toward the driver end  254 . At the juncture of barrel portions  258  and  260 , a flange  262  is formed and a stabilizing neoprene fitting or internal seal  264  is emplaced thereat. When fully driven into masonry inner wythe  214 , the internal seal  264  and barrel portion  260  of wall anchor  240  are drawn into the insulation  226 . Further the seal  264  abuts the insertion point precluding air and moisture penetration thereinto. 
         [0088]    At the driving end  254 , a driver portion  266  adjoins larger diameter barrel or shaft portion  260  forming a flange  268  therebetween and another stabilizing neoprene fitting or external seal  270  is emplaced thereat. Upon installation into rigid insulation, the larger barrel portion  260  is forced into a press fit relationship with anchor-receiving channel  248 . Stabilization of this stud-type wall anchor  240  is attained by barrel portion  260  and internal neoprene fitting  264  completely filling the channel  248  with external neoprene fitting  270 , capping the opening  272  of channel  248  into cavity  222 , and clamping wall anchor  240  in place. With stabilizing fitting or external seal  270  in place the insulation integrity within the cavity wall is maintained. 
         [0089]    Here, the veneer tie  244  is a wire formative having a rear leg  242  set at an angle to the front legs. In this embodiment, the driver portion  266  has an elongated aperture  272  for the interlacing of veneer tie  244 . From the rear leg  242 , two side legs  276  and  278  extend to and, at the front portion thereof, are part of insertion portion  280 . Because of the angular displacement, one of the side legs extends upwardly to the insertion portion; and the other, downwardly. The insertion portion  280  is constructed with two front legs  282  and  284  adjoining side legs  276  and  278 , respectively. The veneer tie  244  is self-leveling as, upon insertion into bed joint  230 , the position along rear leg  242  of aperture  274  is established. 
         [0090]    The description which follows is a fourth embodiment of the anchor utilizing thermally-isolated tubules for cavity walls of this invention. For ease of comprehension, wherever possible similar parts use reference designators 300 units higher than those above. Thus, the self-drilling screw portion  356  of the fourth embodiment is analogous to the self-tapping screw portion  56  of the first embodiment. Referring now to  FIGS. 11 through 13 , the fourth embodiment of the anchor is shown and is referred to generally by the numeral  310 . As in the first embodiment, a wall structure similar to that shown in  FIG. 1  is used herein. Optionally, a masonry inner wythe is used (not shown). Here, the anchoring system has a surface-mounted wall anchor with a thermally-isolating tubule and a dual sealing anchor base with a single—or double—aperture receptor for connection to a veneer tie. 
         [0091]    The anchoring system  310  is surface mounted to the exterior surface  324  of the inner wythe  314 . In this embodiment like the previous one, insulation  326  is disposed on wallboard  316  which is, in turn, mounted on columns  317 . Successive bed joints  330  which are substantially planar and horizontally disposed and formed between courses of bricks  320  forming the outer wythe, are constructed to receive therewithin the insertion portion of the anchoring system construct hereof. Being surface mounted onto the inner wythe  314 , the anchoring system  310  is constructed cooperatively therewith, and as described in greater detail below, is configured for disposition in the anchor-receiving channel  321 . 
         [0092]    An anchoring system  310  is shown which has a wall anchor  340  which penetrates the rigid insulation  326  and the wallboard  316 . The wall anchor  340  is constructed for surface mounting on inner wythe  314  and for interconnection with an interlocking veneer tie  344  which, in turn, optionally receives a reinforcement wire  346  therewithin to form a seismic construct. 
         [0093]    The wall anchor  340  has a stepped cylinder body  341  with the steps extending along a common longitudinal axis  347 . The stepped cylinder body  341  is installed within the anchor—receiving channel  321  for a press fit relationship. The stepped cylinder body has a shaftway  386  to sheath a fastener  356 . The stepped cylinder  341  is constructed from sheet metal selected from hot dipped galvanized, stainless steel, bright basic steel or a similar metal. 
         [0094]    At intervals along the outer wythe surface  324 , the anchors  340  are surface-mounted using mounting hardware such as fasteners or self-tapping screws  356  inserted through the stepped cylinder  341 . In this structure, the stepped cylinder  341  sheaths the exterior of mounting hardware  356 . The fastener  356  is thermally-isolated from the anchor  340  through the use of a thermally-isolating washer or stepped cylinder seal  388  composed of a material such as neoprene which is disposed at the juncture of the fastener shaft  390  and the fastener head  392 . The fastener head  392  and stepped cylinder seal  388  together have a larger circumference than the stepped cylinder  341  opening to ensure that upon disposition of the fastener  356  in the shaftway  386  appropriate thermal isolation is achieved. Opposite the fastener head  392  and adjacent to the fastener shaft  390  is a self-tapping or self-drilling tip  394  which, upon installation, attaches the anchor  340  to inner wythe  314 . 
         [0095]    The stepped cylinder  341  is cylindrical and constructed of sheet metal. A shaftway  386  extends through the length of the stepped cylinder  341  allowing for the insertion and sheathing of the fastener  356 . The stepped cylinder body  341  contains a wallboard step  396  having a configured open end  397  which, when inserted within the outer wythe  314 , is disposed adjacent the wallboard or the dry wall  316  and contains an insulation step  391  which, when inserted within the anchor-receiving channel  321 , is disposed adjacent the insulation  326 . A wallboard seal  398  is placed on the stepped cylinder  341  at the shoulder or juncture  354  of the wallboard step  396  and the insulation step  391  to minimize thermal transfer between the inner wythe  314  and the anchoring system  310 . An insulation step  391  is adjacent to the wallboard step  396  and, upon insertion, is dimensioned to be substantially coextensive with the insulation  326 . An insulation seal  393  is disposed on the insulation step  391  at the junction of the insulation step  391  and the anchor receptor step  395 . The anchor receptor step  395  contains a flanged end  387  that prohibits the anchor receptor portion  389  from being removed from the flanged end  387 . The insulation seal  393 , wallboard seal  398 , and stepped cylinder seal  388  are thermally-isolating washers or neoprene fittings which, upon compression during wall anchor  340  installation stabilize the wall anchor  340  and limit lateral displacement of the wall anchor  340  and further seal the opening in the anchor-receiving channel precluding water and vapor penetration through the inner wythe  314 . 
         [0096]    To secure the anchor receptor portion  389  on the stepped cylinder  341 , the anchor receptor step  395  has a smaller diameter than the insulation step  391  which secures the anchor receptor portion  389  against the flanged end  387  and the insulation step  391 . Alternatively, the anchor receptor step  395  contains a retaining clip slot  373  adjacent the insulation step  391 . A retaining clip  377  is inserted in the retaining clip slot  373  to secure the anchor receptor portion  389  against the flanged end  387 . 
         [0097]    The anchor receptor portion  389  has one or more elongated apertures  375  for connection and interlocking with the veneer tie  344 . The elongated apertures or aperture receptors  375  are substantially parallel to each other and are constructed to be within the predetermined dimensions to limit veneer tie  314  movement in accordance with the building code requirements. The apertured receptors  375  are slightly elongated horizontally than the diameter of the veneer tie  314 . The veneer tie (as shown in more detail in the first embodiment)  344  has a rear leg  342  or other connection component for insertion in the anchor receptor portion  389 . The insertion portion  380  of the veneer tie  344  has a swaged side leg  386  for connection with a reinforcement wire  346 . The veneer tie  344  upon installation is embedded in the bed joint  330  of the outer wythe  320 . 
         [0098]    Upon insertion of the anchor  340  into the layers of the inner wythe  314 , the anchor receptor portion  389  rests snugly against the opening formed by the insertion of the anchor  314  and serves to provide further sealing of the insertion opening in the insulation  326  precluding the passage of air and moisture into and from the wall cavity. This construct maintains the insulation integrity. 
         [0099]    In the above description of anchoring systems for insulated cavity walls of this invention various configurations are described and applications thereof in corresponding settings are provided. Because varying and different embodiments may be made within the scope of the inventive concept herein taught and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense. Thus minor changes may be made without departing from the spirit of the invention.

Technology Category: e