CA2815508A1 - Sealing anchor and anchoring system for insulated panel walls - Google Patents

Abstract

Anchoring systems for use in cavity wall structures having an inner wythe constructed of composite panels and a masonry outer wythe are disclosed. The wall anchor is surface-mounted through the panel and secured to the frame for a high-strength interconnection. The wall anchor secures the veneer and provides a seal against the insertion opening, maintaining insulation integrity and limiting thermal transfer. Interconnection with a veneer tie and reinforcement wire within the outer wythe provides a seismic construct.

Description

MLP 7620.CA
SEALING ANCHOR AND ANCHORING SYSTEM FOR INSULATED PANEL
WALLS
BACKGROUND OF THE INVENTION
Field of the Invention [0001] This invention relates to an anchoring system for cavity walls having an inner wythe of insulated panels. More particularly, the invention relates to an insulated panel backup wall and a thermally-isolating, sealing anchoring system for interconnecting the insulated panel wall with a masonry outer wythe. At the outer wythe, the anchoring systems provide veneer ties for angular adjustment, self-leveling and seismic protection. Besides sealing the panels, the anchor seal provides support for the wall anchor and substantially precludes lateral movement.
Description of the Prior Art [0002] Cavity wall construction backup walls take many forms, including dry wall, concrete masonry units, tilt-up poured concrete, and insulating concrete forms. Selection of the backup wall type is dependent upon location, type and size of construction and other varied considerations. Anchors specific to each type of backup wall construction are inserted into the backup wall to properly anchor the outer wythe or veneer in accordance with the building specifications and location.

[0003] In the past, different building specifications and locations resulted in various structural problems such thermal transfer from the inner to the outer wythe, pinpoint loading, high lateral loads from high-wind and seismic forces, and deterioration of cavity wall insulation. Through their inventions, Ronald P. Hohmann, Jr. and Ronald P.
Hohmann of Hohmann and Barnard, Inc., Hauppauge, New York, 11788, have solved these and other varied technical problems relating to differing cavity wall technologies. The Hohmann inventions have been in response to changes in Uniform Building Code provisions and to investigations into the effects of various forces upon cavity wall construction. Exemplary patents include a snap-in wire tie for use in a seismic construction system for a cavity wall (U.S. Patent No. 7,325,366); a self-sealing wall anchor for maintaining insulation integrity (U.S. Patent No. 6,941,717); low-profile side-welded anchors and reinforcement devices for cavity walls (U.S. Patent No. 6,789,365); and high-span and high-strength anchors and reinforcement devices for cavity walls (U.S. Patent No. 6,668,505).

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[0004] Another obstacle in cavity wall construction is compliance with the greater insulation requirements set forth in codes such as the Massachusetts Energy Code, Energy Code Requirement, Chapter 13 (78 CMR, Seventh Edition; Boston, MA). This Code sets forth a required higher R-value insulation which perforce increases the cavity size. To address the Energy Code Requirements, each type of backup wall typically requires a large cavity to house insulation between the backup wall and the veneer. The larger cavities, with the associated thicker insulation, require stronger anchors with concomitantly higher costs.
The present invention solves the construction issues relating to thermal transfer, pinpoint loading, high lateral forces and maintaining the integrity of the high R-value insulation through the use of a novel insulated composite panel and anchoring system therefor.

[0005] Architectural or composite panels date back many years and, as shown in F.B. Brandreth, etal., U.S. Pat. No. 3,310,926, form various types of enclosures. Brandreth describes sandwich-type panel construction with face sheets formed from metal or plastic.
The interior of each panel can be filled with insulating material. Brandreth further describes associated frame members, mullions and sills.

[0006] Panels evolved through the years to become sturdier, more insulative and have reached a technology level that includes the thin composite wall panels detailed in Boyer, U.S. Pat. No. 7,007,433, assigned to Centria, Inc., of Moon Township, Pennsylvania.
Composite panels are generally composed of metal sheet elements or laminates that are integratible with one another to create an interior space for an insulative core of foam or polymer. As shown in Boyer, U.S. Pat. Nos. 6,253,511 and 6,968,659, structures utilizing composite panels are constructed using composite joinery. The resulting building is sturdy and insulative and exhibits an alternative aesthetic to that of traditional brick veneer. The present invention is designed to work in conjunction with the composite panels and wall systems of interconnecting panels.

[0007] Composite panels take many forms including aluminum plate, thin composite panels consisting of two thin aluminum sheets sandwiching a thin plastic interlayer, metal sheets bonded to rigid insulation to create a sandwich panel, fiber-reinforced plastic, stainless steel and terracotta. The impermeable exteriors of the panel ensure that the built-in insulation maintains the R-value during the life of the building, thereby lowering heating and cooling costs. Composite panels are lightweight, weighing as little as 1.6 P.S.F., but structurally strong enough to cover long spans.

[0008] In the past, although composite panels would provide an efficient back-up wall for commercial brick veneer construction, the lack of a proper anchoring system MLP 7620.CA
restricted this practice. The present invention solves the anchoring problem related to the use of composite panels as the inner wythe by providing an anchoring system that seals the anchor entry points, provides a strong interconnection between the composite panels and associated steel frame, and secures the outer wythe to the inner wythe.

[0009] Prior art wall anchors for masonry veneer walls include pronged surface-mounted wall anchors with several formations including an L-shaped backplate.
These systems served well, but insulation integrity issues were known to occur. In the 1980's, an anchor for masonry veneer walls was developed and described in U.S. Patent 4,764,069 by Reinwall et al., which patent is an improvement of the masonry veneer anchor of Lopez, U.S.
Patent 4,473,984. Here the anchors are keyed to elements that are installed using power-rotated drivers to deposit a mounting stud in a cementitious or masonry backup wall. Fittings are then attached to the stud, which include an elongated eye and a wire tie therethrough for disposition in a bed joint of the outer wythe. It is instructive to note that pin-point loading -that is forces concentrated at substantially a single point - developed from this design configuration. This resulted, upon experiencing lateral forces over time, in the loosening of the stud.

[0010] As insulation became thicker, tearing during insertion of these prior art anchors became more prevalent. With tearing, the insulation gapping caused in the insulation permitted air and moisture to infiltrate through the insulation along the pathway formed by the tear. Patchwork attempts to seal the insulation often resulted in additional on-site work and supplies and greater dependency on local workmanship.

[0011] Focus on the thermal characteristics of cavity wall construction is important to ensuring minimized heat transfer through the walls, both for comfort and for energy efficiency of heating, ventilating and air conditioning (HVAC) systems. When the exterior is cold relative to the interior of a heated structure, heat from the interior should be prevented from passing through the outside. Similarly, when the exterior is hot relative to the interior of an air conditioned structure, heat from the exterior should be prevented from passing through to the interior. Providing a seal at the insertion points of the mounting hardware assists in controlling heat transfer and thereby stabilizing HVAC systems.

[0012] In preparing for this application the following additional patents and patent applications came to the attention of the inventors and are believed to be relevant to the further discussion of the prior art:

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Patent Inventor Issue Date 4,021,990 Schwalberg May 10, 1977 4,473,984 Lopez October 2, 1984 4,875,319 Hohmann October 24, 1989 5,392,581 Hatzinikolas February 28, 1995 5,816,008 Hohmann October 6, 1998 5,819,486 Goodings October 13, 1998 6,000,178 Goodings December 14, 1999 6,209,281 Rice April 3, 2001 7,043,884 Moreno May 16, 2006 7,415,803 Bronner August 26, 2008 7,845,137 Hohmann, Jr. December 7, 2010 Publication No. Inventor Date US 2008/0092472 Doerr et al. April 24, 2008 US 2010/0037552 Bronner June 1, 2009 [0013] U.S. 4,021,990 - Schwalber2 - 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. The wall tie is embedded in the exterior wythe and is not attached to a straight wire run.

[0014] U.S. 4,473,984 - Lopez - Issued October 2, 1984 Discloses a curtain-wall masonry anchor system wherein a wall tie is attached to the inner wythe by a self-tapping screw to a metal stud and to the outer wythe by embedment in a corresponding bed joint. The stud is applied through a hole cut into the insulation.

[0015] U.S. 4,875,319 - Hohmann - Issued October 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 '990 and is clipped onto a straight wire run.

[0016] U.S. 5,392,581 - Hatzinikolas et al. - Issued February 28, 1995 Discloses a cavity-wall anchor having a conventional tie wire for mounting in the brick veneer and an L-shaped sheetmetal bracket for mounting vertically between side-by-side blocks and horizontally on atop a course of blocks. The bracket has a slit which is vertically disposed and protrudes into the cavity. The slit provides for a vertically adjustable anchor.

[0017] U.S. 5,816,008 - Hohmann - Issued October 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.

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[0018] U.S. Patent No. 5,819,486 - Goodings - Issued October 13, 1998 Discloses an anchor for use in the installation of a composite building panel. The anchor comprises a wall mounting face, a spacer and two flange receiving grooves. The anchor is mounted to the backup wall with a fastener.

[0019] U.S. Patent No. 6,000,178 - Goodings - Issued December 14, 1999 Describes an apparatus for use in the installation of a composite building panel. The apparatus comprises a corrugated member adhered to the panel to form a back face which locks with the anchor of an adjacent panel.

[0020] U.S. 6,209,281 - Rice - Issued April 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.

[0021] U.S. Patent No. 7,043,884 - Moreno - Issued May 16, 2006 Discloses a cladding system for mounting stone cladding panels on an exterior of a building to form a facade. The panels are mounted on rails which are, in turn, mounted upon vertical mullions which have associated structural anchors.

[0022] U.S. 7,415,803 ¨ Bronner ¨ Issued August 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.

[0023] U.S. 7,845,137 ¨ Hohmann, Jr. ¨ Issued December 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.

[0024] U.S. Patent Publication No. US 2008/0092472 - Doerr et al - Published April 24, 2008 Discloses an anchor assembly for use in joining a masonry structure with a backup wall formed from insulated concrete form blocks. The anchor assembly includes an anchor and a tie.

[0025] U.S. Pub. No. 2010/0037552 ¨ Bronner - Filed June 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.

[0026] None of the above references provide the advancements in anchoring systems and commercial construction as detailed herein. The present novel invention offers a multi-purpose solution by resolving issues relating to thermal transfer, pinpoint loading and high lateral forces, while maintaining insulation integrity through the use of unique seals. By MLP 7620.CA
providing an anchoring system for use with a composite panel backup wall, safety requirements are met and training and construction costs are reduced.

[0027] The present invention provides an all-in-one composite panel backup solution by combining the benefits of composite panels, cavity walls and brick veneer through the use of a novel anchoring system. The single component insulated composite back-up wall panel system eliminates batt insulation, wide cavity spans, exterior gypsum board and building wraps, while enhancing thermal efficiency and moisture control. The one piece construction is lightweight and meets the Massachusetts Energy code. The metal skins provide a superior water drain plain, air barrier and vapor barrier. The anchoring system allows for rapid completion of the construction of the backup wall.

[0028] The anchoring system provides a structurally strong connection between the veneer and the frame, meeting or exceeding code requirements. The present anchoring system resolves past problems relating to thermal transfer, pinpoint loading, high lateral forces and insulation integrity, while simultaneously reducing installation labor and energy costs, thereby saving time and money. The anchoring system self-seals the insertion points.

[0029] None of the prior art provides the present backup solution using composite panels. As will become clear in reviewing the disclosure which follows, the insulated cavity wall structure benefits from the recent developments described herein that leads to solving the problems of constructing a commercial structure efficiently, from both an insulative as well as a cost/time perspective.
BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In the following drawing, the same parts in the various views are afforded the same reference designators.

[0031] FIG. 1 shows a first embodiment of the composite panel anchoring system of this invention and is a perspective view of the anchoring system partially constructed, mounted on the columns and with an attached brick veneer;

[0032] FIG. 2 is a cross sectional view of FIG. 1 showing a fully constructed composite panel anchoring system;

[0033] FIG 3. is a side view of the anchor of FIG. 2 with a veneer tie emplaced within the tie;

[0034] FIG. 4 is a perspective view of an alternative design anchor with a veneer tie emplaced within the veneer tie;

[0035] FIG. 5 is a side view of the anchor of FIG. 4 without the veneer tie;

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[0036] FIG. 6 is a top plan view of the anchor of FIG. 4 without the veneer tie or fastener;

[0037] FIG. 7 is a side view of the anchor of FIG. 4 with drilling cutouts and without the veneer tie;

[0038] FIG. 8 is a perspective view of the second embodiment of this invention showing successive courses of a partially constructed composite panel anchoring system with a veneer tie emplaced within the anchor secured within the inner wythe and mounted on a course of bricks;

[0039] FIG. 9 is a perspective view of the anchor of FIG. 8 without the veneer tie;
and, [0040] FIG. 10 is a top plan view of the anchor of FIG. 8 with a veneer tie emplaced within the anchor and a reinforcement wire set within the veneer tie.
DETAILED DESCRIPTION

[0041] Before entering into the Detailed Descriptions, several terms which will be revisited later are defined. These terms are relevant to discussions of innovations introduced by the improvements of this disclosure that overcome the technical shortcomings of the prior art devices.

[0042] In the embodiments described herein below, the anchoring system hereof provides anchoring devices for composite panel wall systems for usage in a cavity wall as the inner wythe or backup wall. The anchoring system hereof maintains and enhances the connectivity of the architectural composite panels to the frame, while minimizing thermal transfer to and from the cavity thereby maintaining the insulation integrity.

[0043] 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 thermal transfer from the exterior to the interior and from the interior to the exterior. 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 and substantially no loss of heat or air conditioned air from the interior. The present invention is designed to minimize invasiveness into the insulative layer.

[0044] The anchoring system for composite panels described herein addresses issues unique to the art of anchoring masonry veneers in an efficient and insulatively MLP 7620.CA
compliant manner. Unlike any other structure-supporting building materials, wall anchors are relatively small, isolated assemblies that operate individually and in concert to shoulder the burden of severe forces bearing upon massive solid-wall constructs. The construction of brick veneer cavity wall structures face many challenges. Proper insulation, cavity drainage and moisture removal, thermal transfer, pinpoint loading and stability are examples of the challenging areas. The development of an anchoring system for composite panels is in response to these challenges. This invention resolves the structural issues related to the construction of a high-span cavity between the inner and outer wythe, by internalizing and securing the necessary insulation within the composite panel inner wythe. This invention further reduces other costs and elements required to construct a cavity wall system.

[0045] Additionally, 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. The term thermally-isolated anchoring system or anchor as used hereinafter refers to a presently described anchoring system of this invention having a thermally-isolating panel seal which facilitates thermal isolation between the base portion and the panel portion.

[0046] 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.

[0047] This anchoring system, discussed in detail hereinbelow, consists of a composite panel system with a self-sealing anchoring system. The anchor is constructed to be inserted and secured within the inner wythe. The anchor also serves to connect the veneer to the frame. As the outer wythe being anchored is a brick veneer, the anchoring system includes sufficient vertical adjustment so as to avoid any misalignment.

[0048] The present invention is in response to the prior art labor and materials intensive cavity wall construction. Construction of a cavity wall containing a backup wall or inner wythe and a masonry outer wythe involves numerous components, which in turn require numerous suppliers and subcontractors adding to the time and cost of construction.
Prior art cavity wall structures require an inner wythe of dry wall, masonry wall units, tilt-up MLP 7620.CA
concrete panels or other suitable building materials. The inner wythe is protected with a building wrap or flashing which assists water and moisture removal and often terminates with a drip edge. Once the inner wythe is protected against water and moisture, insulation is then mounted on the exterior of the inner wythe so as to meet the building code requirements.
This cumbersome process requires skilled craftsmen to ensure that each step is undertaken carefully and with appropriate care. Several problems such as thermal transfer, insulation deterioration, pinpoint loading and failures due to high lateral forces are present in the prior art. The present invention streamlines the prior art process and resolves such problems through the use of an anchoring system for composite panels.

[0049] Referring now to Figures 1 through 7, the first embodiment of the present invention shows a surface-mounted thermally-isolating anchoring system for composite panels with a brick veneer outer wythe. The anchoring system for composite panels is referred to generally by the numeral 10. A cavity wall structure 12 is shown having an inner wythe or composite panel backup wall 14 supported on a structural framework or frame, including metal studs or vertical columns 16. The inner wythe 14 is assembled from interengaged individual panels 17 that have a preset thickness determined at time of manufacture of generally, but not limited to, from 2- to 4-inches. The panels 17 are consecutively mounted and are interconnected with high strength fasteners. The cavity wall 12 also includes an outer wythe or veneer 18 of brick 20 construction. Between the inner wythe 14 and the outer wythe 18, a cavity 22 is formed.

[0050] 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 tie of the anchoring system hereof.

[0051] For purposes of discussion, the cavity surface 24 of the inner wythe 14 contains a horizontal line or x-axis 34 and an intersecting vertical line or y-axis 36. A
horizontal line or z-axis 38, normal to the xy-plane, passes through the coordinate origin formed by the intersecting x- and y-axes.

[0052] The composite panel 17 is typically between 12 and 20 feet long, approximately 24 to 36 inches wide, and comprises inner and outer facing sheets 29, 31 and a structural insulative core 39 of foam filling the interior space of the building panel 17 and adhesively connecting the facings sheets 29, 31 to provide a structural panel.
Although the use of a foam is discussed herein, it is to be understood that this represents only one type of MLP 7620.CA
core material that is utilized in a composite building panel. Examples of other types of core material that are substituted for the foam core include polymeric materials and a conventional honeycomb core structure.

[0053] The wall anchor 40 is shown as stud-type anchor with a base portion 41, panel portion 52, and a fastener portion 48. The base portion 41 has a shafting or aperture 43 for housing a fastener 48, and a mounting surface 55 that is adjacent the panel portion 52.
The panel portion 52 is coextensive with the preset thickness of the composite panel 17 and has a shaftway or aperture 50 that runs the length of the panel portion 52 allowing for the insertion and sheathing of the fastener 48. The base portion 41 mounting surface 55 is dimensioned to be larger than the panel portion 52 to seal the opening in the panel 17 and preclude the penetration of air, moisture and water vapor and maintain the insulation integrity. The base portion 41 has two wings 82 that extend into the cavity 22 substantially normal to the base portion 41. The wings 82 each have a veneer tie receptor 83 and face towards the outer wythe 18. The anchor 40 is constructed of galvanized steel, hot dip galvanized steel, stainless steel, bright basic steel, plastic, reinforced plastic, or another similar material. The panel portion 52 optionally contains a notch 54 that is configured to drill through the panel 17 upon installation in the inner wythe 14. The panel 17 may optionally be configured with anchor-receiving channels 84 to assist in interconnecting the anchor 40 with the inner wythe 14. The panel portion 52 is configured for a press fit relationship with and for disposition in the anchor-receiving channel 84.

[0054] The anchor 40 is secured to the inner wythe 14 by a fastener 48 having a self-drilling tip 45, which is disposed in the aperture 43 of the base portion 41 and the shaftway 50 of the panel portion 52. The fastener 48 is affixed to the frame 16. A panel seal 57 is disposed at the junction of the base portion 41 mounting surface 55 and the panel portion 52 providing a thermally-isolating break in the anchor 40. The panel seal 57 has a shaftway 56 therethrough for the fastener 48. The panel seal 57 is a thermally-isolating fitting composed of neoprene or similar material which, upon compression during the anchor installation stabilizes the anchor and limits lateral displacement of the anchor and provides sealing at the opening in the panel 17 which precludes water and vapor penetration into the inner wythe 14. The anchor 40 is optionally manufactured as a single construct.

[0055] The fastener head 47 and seals the panel shaftway 50 and the base portion aperture 43. The fastener head 47 has a larger circumference than the base portion aperture 43 to ensure that the fastener 48 will not be displaced within the aperture 43. The head 47 is adjacent a fastener body 63 which is sheathed by the panel portion 52 upon insertion to limit MLP 7620.CA
insulation 26 tearing. The wall anchor 40 is fastened to the column or frame 16. The anchor 40 is fastened to the column 16 with a fastener 48 thereby creating a high-strength connection with the anchor 40 and the frame 16. Although other fastening means are compatible, the fastener 48 is typically a bolt with a head with a washer mounted under the bolt head. To restrict directional movement, the base portion 41 optionally contains a patterned interlocking portion 73 abutting the aperture opposite the mounting surface 55 and the fastener head 47 is complementarily patterned to form an interlocking portion 75 configured to engage with the base portion 41 interlocking portion 73.

[0056] The anchoring system 10 further includes a veneer tie 44. Although various veneer ties work in conjunction with the 'wall anchor 40, including the use of a connection bar and apertured veneer ties (not shown) or a box or Byna-Tie threadedly mounted through the free end aperture (not shown), the veneer tie 44 shown is a wire formative pintle device manufactured by Hohmann & Barnard, Inc., Hauppauge, NY 11788. The veneer tie 44, is shown in FIGS. 1 and 2 as being emplaced on the course of bricks 20 in preparation for embedment in the mortar of the bed joint 32. The veneer tie 44 is fixedly disposed in an x-z plane of the bed joint 32 and is constructed to adjustably position with the longitudinal axis substantially horizontal and to interengage with the wall anchor 40. The dimensional relationship between the wall anchor 40 and the veneer tie 44 limits the axial movement of the construct. The veneer tie receptor 83 is slightly larger horizontally than the diameter of the veneer tie 44. The veneer tie receptor 83 is designed to accept a veneer tie 44 threadedly therethrough and limit horizontal and vertical movement.

[0057] The veneer tie 44 is a wire formative and has an insertion end 67 adapted for embedment in the bed joint 32. The insertion end 67 optionally has a swaged side leg 159 for interconnection with a reinforcement wire 171 as shown in FIG. 10. Upon installation of the anchoring system 10 with an interconnected reinforcement wire 171 in the outer wythe 14, the anchoring system 10 provides a high degree of seismic protection. The veneer tie 44 is vertically adjustable to a substantially horizontal position and upon installation, maintains continuous positive interengagement with the wall anchor 40.

[0058] The description which follows is a second embodiment of the surface-mounted anchoring system for cavity walls of this invention. For ease of comprehension, wherever possible, similar parts use reference designators 100 units higher than those above.
Thus, the inner wythe or backup wall 114 of the second embodiment is analogous to the backup wall 14 of the first embodiment. As in the first embodiment, shown in FIG. 1, a cavity wall structure is formed. Referring now to Figures 8 through 10, the second MLP 7620.CA
embodiment of the present invention shows the anchoring system for composite panels with a brick veneer outer wythe. The anchoring system for composite panels is referred to generally by the numeral 110. A cavity wall structure 112 is shown having an inner wythe or composite panel backup wall 114 supported on a structural framework or frame, including metal studs or vertical columns 116. The inner wythe 114 is assembled from interengaged individual panels 117 having adjacent panel ends that form a vertical juncture (not shown).
The cavity wall 112 also includes an outer wythe or facing 118 of brick 120 construction.
Between the inner wythe 114 and the outer wythe 118, a cavity 122 is formed.
100591 Successive bed joints 130 and 132 are substantially planar and horizontally disposed and, in accord with building standards, are 0.375-inch (approx.) in height.
Selective ones of bed joints 130 and 132, which are formed between courses of bricks 120, are constructed to receive therewithin the insertion portion of the veneer tie of the anchoring system hereof.
[00601 For purposes of discussion, the cavity surface 124 of the inner wythe 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.
100611 The composite panel 114 is typically between 12 and 20 feet long, approximately 24 to 36 inches wide, and 2- to 4-inches thick, and comprises inner and outer facing sheets and a structural insulative core 123 of foam filling the interior space of the building panel 114 and adhesively connecting the facings sheets to provide a structural panel.
Although the use of a foam is discussed herein, it is to be understood that this represents only one type of core material that are utilized in a composite building panel.
Examples of other types of core material that are substituted for the foam core include polymeric materials and a conventional honeycomb core structure.
10062] The wall anchor 140 is shown as stud-type anchor with a base portion and a fastener 148. The base portion 141 has an aperture 143 for housing a fastener 148 and a mounting surface 155. The base portion 141 mounting surface 155 is dimensioned to be larger than the fastener 148 to seal the opening in the panel 117 and preclude the penetration of air, moisture and water vapor and maintain the insulation integrity. The base portion 141 has two wings 182 that extend into the cavity 122 substantially normal to the base portion 141. The wings 182 each have a veneer tie receptor 183 and face towards the outer wythe 118. The anchor 140 is constructed of galvanized steel, hot dip galvanized steel, stainless steel, bright basic steel, plastic, reinforced plastic or another similar material.

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[0063] The anchor 140 is secured to the inner wythe by fastener 148 having a self-drilling tip 147, which is disposed in the aperture 143 of the base portion.
The fastener 148 is affixed to the frame 116. A panel seal 157 is disposed on the base portion 141 mounting surface 155 providing a thermally-isolating break in the anchor 140. The panel seal 157 has a shaftway 156 therethrough to sheath the fastener 148. The panel seal 157 is a thermally-isolating fitting composed of neoprene or similar material which, upon compression during the anchor installation stabilizes the anchor and limits lateral displacement of the anchor and provides sealing at the opening in the panel 117 which precludes water and vapor penetration into the inner wythe 114.
[0064] The fastener head 147 seals the seal shaftway 156 and the base portion aperture 143. The fastener head 147 has a larger circumference than the base portion aperture 143 to ensure that the fastener 148 will not be displaced within the aperture 143. The head 147 is adjacent a fastener body 163. The wall anchor 140 is fastened to the column or frame 116. The anchor 140 is fastened to the column 116 with a fastener 148 thereby creating a high-strength connection with the anchor 140 and the frame 116. Although other fastening means are compatible, the fastener 148 is typically a bolt with a head with a washer mounted under the bolt head. To restrict directional movement, the base portion 141 optionally contains a patterned interlocking portion 173 abutting the aperture 143 opposite the mounting surface and the fastener head 147 is complimentarily patterned to form an interlocking portion 175 configured to engage with the base portion 141 interlocking portion 173.
[0065] The anchoring system further includes a veneer tie 144. Although various veneer ties work in conjunction with the wall anchor 140, including the use of a connection bar and apertured veneer ties (not shown) or a box or Byna-Tie threadedly mounted through the free end aperture (not shown), the veneer tie 144 shown is a wire formative pintle device manufactured by Hohmann & Barnard, Inc., Hauppauge, NY 11788. The veneer tie 144, is shown in FIG. 8 as being emplaced on the course of bricks 120 in preparation for embedment in the mortar of the bed joint 130. The veneer tie 144 is fixedly disposed in an x-z plane of the bed joint 130 and is constructed to adjustably position with the longitudinal axis substantially horizontal and to interengage with the wall anchor 140. The dimensional relationship between the wall anchor 140 and the veneer tie 144 limits the axial movement of the construct. The veneer tie receptor 183 is slightly larger horizontally than the diameter of the veneer tie 144. The veneer tie receptor 183 is designed to accept a veneer tie 144 threadedly therethrough and limit horizontal and vertical movement.

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[0066] The veneer tie 144 is a wire formative and has an insertion portion or end 167 adapted for embedment in the bed joint 130, a pair of side leg portions 169 that are coextensive with and substantially perpendicular and co-planar with the insertion portion 167, and a pair of pintle portions 180 coextensive with the side leg portions 169.
The pintle portions 180 are configured to be vertically disposed for insertion through the receptor portions 183. To create a seismic construct, the anchoring system 110 includes a reinforcement wire 171 disposed in the bed joint 130 and interconnected with a swage 181 in the side leg portion 169. The veneer tie 144 is vertically adjustable to a substantially horizontal position and upon installation, maintains continuous positive interengagement with the wall anchor 140.
[0067] The anchoring system for composite panels set forth above solves the problems of the prior art by providing a universal all-in-one solution to thermal transfer, pinpoint loading, high lateral forces and maintaining insulation integrity.
The novel use of a composite panel backup wall with an integral veneer anchor saves material and labor costs while providing a superior cavity wall structure.
[0068] The above description of the thermally-isolating anchoring system of this invention sets forth various described configurations and applications thereof in corresponding anchoring systems. Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirement of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.

Claims (20)

1. A high-strength anchoring system for use in a cavity wall, said cavity wall having an inner wythe formed from a plurality of composite panels mounted on a frame, said composite panels having a preset thickness, and an outer wythe formed from a plurality of successive masonry courses with a bed joint between each two adjacent courses, said inner wythe and said outer wythe in a spaced apart relationship the one with the other forming a cavity therebetween, said anchoring system comprising, in combination:
a wall anchor surface-mounted in said inner wythe, said wall anchor further comprising:
a panel portion coextensive with said preset thickness of said composite panel, said panel portion having a shaftway therethrough to sheath a fastener;
a base portion having an aperture, a mounting surface adjacent said panel portion, said mounting surface precluding penetration of air, moisture and water vapor through said inner wythe, and two wings extending into said cavity substantially normal to said base portion, said two wings each having a veneer tie receptor;
and, a fastener for disposition in said aperture of said base portion and said shaftway of said panel portion, said fastener affixing said wall anchor to said frame;
and, a veneer tie interlockingly connected with each said veneer tie receptor and configured for embedment in said bed joint of said outer wythe.

2. An anchoring system as described in Claim 1, wherein said anchoring system further comprises a panel seal having a shaftway therethrough to sheath said fastener, said seal abutting said base mounting surface.

3. An anchoring system as described in Claim 2, wherein said panel seal is a thermally isolating neoprene fitting which, upon compression during said wall anchor installation, stabilizes said wall anchor thereby limiting lateral displacement of said wall anchor and sealing said opening in said panel, precluding water and vapor penetration through said inner wythe.

4. An anchoring system as described in Claim 3, wherein said base portion further comprises a patterned interlocking portion abutting said aperture opposite said mounting surface and said fastener further comprises a head with a patterned interlocking portion configured to engage with said base portion interlocking portion and restrict multidirectional rotation.

5. An anchoring system as described in Claim 4, wherein said veneer tie is a wire formative, said veneer tie further comprises:
an insertion portion adapted for disposition in said bed joint of said outer wythe, said insertion portion having a swaged side leg; and, a reinforcement wire disposed in said swaged side leg of said veneer tie, whereby, upon installation of said anchoring system with an interconnected reinforcement wire in said outer wythe, said system provides a high degree of seismic protection.

6. An anchoring system as described in Claim 5, wherein said fastener further comprises a self-drilling tip.

7. An anchoring system as described in Claim 6, wherein said panel portion further comprises a notch, said notch configured to drill through said panel upon insertion in said inner wythe.

8. An anchoring system as described in Claim 1, wherein said wall anchor is constructed of material selected from a group consisting of galvanized steel, hot dip galvanized steel, stainless steel, bright basic steel, plastic and reinforced plastic.

9. A high-strength anchoring system for use in a cavity wall, said cavity wall having an inner wythe formed from a plurality of composite panels mounted on a frame, and an outer wythe formed from a plurality of successive masonry courses with a bed joint between each two adjacent courses, said inner wythe and said outer wythe in a spaced apart relationship the one with the other forming a cavity therebetween, said anchoring system comprising, in combination:
a wall anchor surface-mounted in said inner wythe, said wall anchor further comprising:
a base portion having an aperture, a mounting surface precluding penetration of air, moisture and water vapor through said inner wythe, a patterned interlocking portion abutting said aperture opposite said mounting surface, and two wings extending into said cavity substantially normal to said base portion, said two wings each having a veneer tie receptor; and, a fastener for disposition in said aperture of said base portion, said fastener disposed in said inner wythe affixing said wall anchor to said inner wythe;
and, a veneer tie interlockingly connected with said base veneer tie receptor and configured for embedment in said bed joint of said outer wythe.

10. An anchoring system as described in Claim 9, wherein said fastener further comprises:
a fastener head having a patterned interlocking portion configured to engage with said base portion;
a fastener shaft adjacent said head, said fastener shaft for insertion and securement within said inner wythe; and a fastener tip adjacent said shaft and opposite said head, said fastener head configured to be self-drilling.

11. An anchoring system as described in Claim 10, wherein said anchoring system further comprises a panel seal having a shaftway therethrough to sheath said fastener, said seal abutting said base mounting surface.

12. An anchoring system as described in Claim 11, wherein said panel seal is a thermally isolating neoprene fitting which, upon compression during said wall anchor installation, stabilizes said wall anchor thereby limiting lateral displacement of said wall anchor and sealing said opening in said panel precluding water and vapor penetration through said inner wythe.

13. An anchoring system as described in Claim 12, wherein said veneer tie further comprises:
an insertion portion configured for insertion into said bed joint of said outer wythe;
a pair of side leg portions coextensive, substantially perpendicular and co-planar with said insertion portion; and, a pair of pintle portions coextensive with said pair of side leg portions and upon installation configured to be vertically disposed for insertion through said receptor portion, said veneer tie being vertically adjustable to a substantially horizontal position.

14. An anchoring system as described in Claim 13, wherein said anchoring system further comprises:
a reinforcement wire disposed in said bed joint; and, wherein said veneer tie insertion portion has a swaged side leg for interconnection with said reinforcement wire;
whereby, upon installation of said anchoring system with an interconnected reinforcing wire in said outer wythe, said system provides a high degree of seismic protection.

15. An anchoring system as described in Claim 1, wherein said frame is a metal column, and wherein said wall anchor is constructed of material selected from a group consisting of galvanized steel, hot dip galvanized steel, stainless steel, and bright basic steel.

16. A high-strength anchoring system for use in a cavity wall, said cavity wall having an inner wythe formed from a plurality of composite panels mounted on a frame, said composite panels having a preset thickness and anchor-receiving channels therethrough, and an outer wythe formed from a plurality of successive masonry courses with a bed joint between each two adjacent courses, said inner wythe and said outer wythe in a spaced apart relationship the one with the other forming a cavity therebetween, said anchoring system comprising, in combination:
a surface-mounted wall anchor being a single construct, said wall anchor further comprising:
a panel portion configured for a press fit relationship with and for disposition in said anchor-receiving channel, said panel portion having a shaftway therethrough to sheath a fastener; and, a base portion having an aperture, a mounting surface adjacent said panel portion, said mounting surface precluding penetration of air, moisture and water vapor through said inner wythe, a patterned interlocking portion abutting said aperture opposite said mounting surface, and two wings extending into said cavity substantially normal to said base portion, said two wings each having a veneer tie receptor;
a panel seal abutting said base mounting surface;
a fastener for disposition in said aperture of said base portion, said shaftway of said panel portion, and said shaftway of said panel seal, said fastener affixing said wall anchor to said inner wythe, said fastener having a head with a patterned interlocking portion configured to engage with said base portion to restrict rotational movement of said base portion; and, a wire formative veneer tie interlockingly connected with each said base veneer tie receptor and configured for embedment in said bed joint of said outer wythe.

17. An anchoring system as described in Claim 16, wherein said panel seal is a thermally isolating neoprene fitting which, upon compression during said wall anchor installation, stabilizes said wall anchor thereby limiting lateral displacement of said wall anchor and sealing said anchor-receiving channel, precluding water and vapor penetration through said inner wythe.

18. An anchoring system as described in Claim 17, wherein said veneer tie insertion portion further comprises a swaged side leg; and wherein said anchoring system further comprises a reinforcement wire disposed in said swaged side leg of said veneer tie, whereby, upon installation of said anchoring system with an interconnected reinforcement wire in said outer wythe, said system provides a high degree of seismic protection.

19. An anchoring system as described in Claim 18, wherein said fastener further comprises a self-drilling tip.

20. An anchoring system as described in Claim 16, wherein said panel portion further comprises a notch, said notch configured to drill through said panel upon insertion in said inner wythe thereby forming said anchor-receiving channel.