U.S. patent application number 10/846081 was filed with the patent office on 2004-11-25 for masonry tie for cavity wall construction.
Invention is credited to Collins, P. Michael, Schaefer, Steven E..
Application Number | 20040231270 10/846081 |
Document ID | / |
Family ID | 33452468 |
Filed Date | 2004-11-25 |
United States Patent
Application |
20040231270 |
Kind Code |
A1 |
Collins, P. Michael ; et
al. |
November 25, 2004 |
Masonry tie for cavity wall construction
Abstract
A masonry wall tie for anchoring a masonry wall to an inner wall
of a cavity wall construction includes a base channel member having
a pair of spaced generally parallel side walls and an anchor clip
configured for engaging the base channel member. A slot is formed
in each of the channel side walls. Each slot has an
outwardly-extending lip bordering the slot. The base member is
fastened to the outer surface of the inner wall. The anchor clip
has a pair of oppositely projecting arms, each of which is seated
in one of the slots in the side walls. The length of the slots
determines the height adjustment of the anchor clip when engaged
with the base channel member. The anchor clip spans the gap between
the two walls in the cavity wall construction and the brace of the
clip is seated within the mortar joint between the bricks or other
masonry units on the outer wall.
Inventors: |
Collins, P. Michael;
(Cincinnati, OH) ; Schaefer, Steven E.;
(Cincinnati, OH) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Family ID: |
33452468 |
Appl. No.: |
10/846081 |
Filed: |
May 14, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60472605 |
May 22, 2003 |
|
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Current U.S.
Class: |
52/506.01 |
Current CPC
Class: |
E04B 1/4178
20130101 |
Class at
Publication: |
052/506.01 |
International
Class: |
E04C 003/30 |
Claims
We claim:
1. A wall tie assembly for securing an outer masonry wall structure
to an adjacent inner wall structure, comprising: a base channel
member adapted to be mounted to the inner wall structure, said base
channel member having at least one side wall joined to a spine
adapted to be juxtaposed to the inner wall structure; an elongated
slot formed in said at least one side wall; a lip bordering said
elongated slot and extending from said at least one side wall; and
an anchor clip having a first end adapted to be slidably coupled to
said base channel member along said elongated slot and a second end
adapted to be coupled to the outer masonry wall structure thereby
securing the masonry wall structure to the adjacent inner wall
structure.
2. The wall tie assembly of claim 1 further comprising at least one
aperture in said spine, said at least one aperture adapted to
receive a fastening member for securing said base channel member to
the inner wall structure.
3. The wall tie assembly of claim 1 further comprising a pair of
said side walls spaced from each other.
4. The wall tie assembly of claim 3 wherein an elongated slot is
formed in each of said side walls.
5. The wall tie assembly of claim 1 wherein said elongated slot
extends generally parallel to said at least one side wall.
6. The wall tie assembly of claim 1 wherein said spine is generally
perpendicular to said at least one side wall.
7. The wall tie assembly of claim 1 wherein said lip is generally
perpendicular to said associated side wall.
8. The wall tie assembly of claim 1 wherein said lip extends
generally outwardly from an outer surface of said at least one side
wall.
9. The wall tie assembly of claim 1 wherein said lip has a
generally oval configuration.
10. The wall tie assembly of claim 1 wherein said at least one side
wall further comprises an outwardly extending flange along at least
a portion of a distal edge of said at least one side wall.
11. The wall tie assembly of claim 1 wherein said spine further
comprises an outwardly extending flange along a top and bottom end
of said spine.
12. The wall tie assembly of claim 1 wherein said anchor clip
comprises: at least one outwardly extending clip arm adapted to be
inserted into said elongated slot in said at least one side wall
and moveable along said elongated slot so as to adjust the position
of said anchor clip relative to said base channel member; a leg
member coupled to said clip arm at one end thereof; and a brace
coupled to said leg member opposite said clip arm and adapted to be
embedded in the masonry wall structure.
13. The wall tie assembly of claim 12 wherein said anchor clip
comprises two outwardly and opposite extending clip arms.
14. The wall tie assembly of claim 12 wherein said brace is
rectangularly shaped.
15. The wall tie assembly of claim 12 wherein said anchor clip is
formed from metal wire stock.
16. The wall tie assembly of claim 1 wherein said base channel
member is formed from sheet metal.
17. A wall tie assembly for securing an outer masonry wall
structure to an adjacent inner wall structure, comprising: a base
channel member adapted to be mounted to the inner wall structure,
said base channel member comprising: (a) a pair of spaced and
generally parallel side walls; (b) a spine joining said side walls
along at least a portion of a proximal edge of said side walls,
said spine being generally perpendicular to each said side wall and
further including at least one aperture adapted to receive a
fastening member for securing said base channel member to the
adjacent inner wall structure; (c) an elongated slot formed in each
of said side walls and extending generally parallel to said side
walls; (d) an outwardly extending lip bordering said elongated slot
in each said side wall and extending generally perpendicular to an
outer surface of each said side wall; an anchor clip comprising:
(a) a pair of oppositely projecting clip arms each of which is
adapted to be inserted into one of said slots in said base channel
member and moveable along said elongated slots; (b) a leg member
coupled to said clip arms at one end thereof; and (c) a generally
rectangular brace coupled to said leg member opposite said clip
arms and adapted to be embedded in the outer masonry wall structure
to thereby secure the outer masonry wall structure to the adjacent
inner wall structure.
18. A cavity wall construction, comprising: an inner wall having an
outer face; an outer wall having an inner face confronting the
outer face of the inner wall and generally being parallel to and
spaced from the inner wall so as to define a cavity therebetween,
said outer wall comprising courses of masonry units held together
with mortar; a plurality of wall tie assemblies joining the inner
wall to the outer wall, each wall tie assembly comprising: a base
channel member mounted to the outer face of the inner wall, said
base channel member having at least one side wall joined to a spine
along at least a portion of a proximal edge of said at least one
side wall; an elongated slot formed in said at least one side wall;
a lip bordering said elongated slot and extending from said at
least one side wall; and an anchor clip spanning the cavity between
said inner and outer walls, said anchor clip having a first end
slidably coupled to said base channel member along said elongated
slot and a second end embedded in the mortar between adjacent
courses of mortar units thereby securing the outer wall to the
inner wall.
19. The cavity wall construction of claim 18 further comprising at
least one aperture in said spine, said at least one aperture
adapted to receive a fastening member for securing said wall tie to
the inner wall structure.
20. The cavity wall construction of claim 18 further comprising a
pair of said side walls spaced from each other.
21. The cavity wall construction of claim 20 wherein an elongated
slot is formed in each of said side walls.
22. The cavity wall construction of claim 18 wherein said elongated
slot extends generally parallel to said at least one side wall.
23. The cavity wall construction of claim 18 wherein said spine is
generally perpendicular to said at least one side wall.
24. The cavity wall construction of claim 18 wherein said lip is
generally perpendicular to said at least one side wall.
25. The cavity wall construction of claim 18 wherein said lip
extends generally outwardly from an outer surface of said at least
one side wall.
26. The cavity wall construction of claim 18 wherein said lip has a
generally oval configuration.
27. The cavity wall construction of claim 18 wherein said at least
one side wall further comprises an outwardly extending flange along
at least a portion of a distal edge of said at least one side
wall.
28. The cavity wall construction of claim 18 wherein said spine
further comprises an outwardly extending flange along a top and
bottom end of said spine.
29. The cavity wall construction of claim 18 wherein said anchor
clip comprises: at least one outwardly extending clip arm adapted
to be inserted into said elongated slot in said at least one side
wall and moveable along said elongated slot so as to adjust the
position of said anchor clip relative to said base channel member;
a leg member coupled to said clip arm at one end thereof; and a
brace coupled to said leg member opposite said clip arm and adapted
to be embedded in the outer wall.
30. The cavity wall construction of claim 29 wherein said tie
member comprises two oppositely extending clip arms.
31. The cavity wall construction of claim 29 wherein said brace is
rectangularly shaped.
32. The cavity wall construction of claim 29 wherein said tie
member is formed from metal wire stock.
33. The cavity wall construction of claim 18 wherein said base
channel member is formed from sheet metal.
Description
[0001] This claims the benefit of U.S. Provisional Application Ser.
No. 60/472,605, filed May 22, 2003 and hereby incorporated by
reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates to brick veneer/cavity wall
construction and, more particularly, to a device used to anchor the
outer wall to the inner wall in a cavity wall system.
[0003] Wall systems having a masonry exterior or outer wall are
typically constructed of at least one vertical layer of masonry and
at least a second vertical layer of a material forming a back-up
system. The back-up system or inner wall may be constructed of
lumber or of a concrete masonry unit. A space is often provided in
such wall systems (e.g., cavity wall systems) between the brick and
back-up system.
[0004] The outer wall and the inner wall are interconnected by wall
ties in an effort to provide a completed structure having good
rigidity and resistance to wind loading, sagging, and other
environmental effects. Typically such wall tie systems include an
anchor member mounted to the inner wall and a wire tie coupled to
the anchor member and spanning the cavity to be embedded in the
outer masonry wall.
[0005] Known wall tie systems suffer many disadvantages and
drawbacks in that there is a tendency for the wire tie to fracture
or break during installation due to the stresses formed in the wall
tie as it is flexed and manipulated. Moreover, the anchors and wire
ties tend to fracture or twist out of shape after the construction
of the walls due to uneven settling of the inner and outer walls
causing the facing wall to be inadequately supported. In addition,
a number of agencies have recently expressed serious concern
regarding the potential for corrosion and failure of the masonry
wall ties due to the exposure of the anchors and wire ties to
moisture which is present in the cavity between the back-up wall
and the masonry veneer.
[0006] While it is highly desirable to provide for a robust wall
tie system to properly anchor the outer wall, the commonly utilized
systems require numerous anchor and wire tie sets spaced on the
inner and outer walls. While many known wall ties are hugely
successful, they require a significant quantity of material which
increases with wall size giving rise to increasing costs. The goal
of added strength has led to added anchor material further
increasing costs.
[0007] Wall ties are well known. But some such wall ties are
expensive, and do not operate to adequately increase the strength
of the cavity wall structure. A principal object of this invention
is to provide an anchor and wire tie arrangement which is robust
and economical.
[0008] Another object is to provide a wall tie assembly in which,
in one embodiment, an anchor channel extends over a length on the
inner wall so as to develop a wall tie of great strength and ease
of installation.
[0009] Still another object is to provide a wall tie apparatus
which is inexpensive, yet which provides great strength and
rigidity during a long service life.
SUMMARY OF THE INVENTION
[0010] This invention addresses these and other problems in the
prior art and provides an apparatus which allows for simple
installation of the masonry wall tie system and robust support for
the outer wall in a more economically efficient manner.
[0011] A masonry wall tie for anchoring a masonry veneer wall to a
backup wall of a cavity wall construction according to one
embodiment of this invention includes a base channel member having
a pair of spaced generally parallel channel side walls and an
anchor clip configured for engaging the base channel member. A slot
is formed in at least one, and preferably both, channel side walls.
Each slot has an outwardly-extending lip that is tapered, flared or
beveled for added strength. The slots are aligned generally
vertical relative to the masonry veneer wall and face one another.
The base member is screwed or otherwise fastened to the outer
surface of the backup or inner wall.
[0012] The anchor clip has at least one, and preferably a pair, of
oppositely projecting arms, each of which is seated in the slot of
a corresponding channel side wall. The anchor clip is engaged with
the slots by orienting the arms vertically, placing the arms in the
gap between the channel side walls, and rotating the anchor clip
ninety-degrees so that the arms enter the slots. The length of the
slots offers height adjustment of the anchor clip when engaged with
the base channel member.
[0013] The anchor clip spans the cavity between the inner and outer
walls in the cavity wall construction and the head portion or brace
of the clip is seated within the mortar joint between the bricks or
other masonry units on the outer wall. The brace is an elongated
loop having a generally rectangular shape that lies generally in
the same plane as the arms. The base channel member is fabricated
from sheet metal and the anchor clip is formed from metal rod or
wire stock.
[0014] As a result of this invention, the base channel member is
fabricated from much less expensive and thinner gauge metal while
offering greater strength than known systems. Even though the base
channel member is made from thinner metal, the outwardly-extending
lips bordering the slots provide added strength and a robust, yet
economical, solution to the problems associated with known wall tie
systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The objectives and features of the invention will become
more readily apparent from the following detailed description taken
in conjunction with the accompanying drawings in which:
[0016] FIG. 1 is a cross-sectional view of a cavity wall system
incorporating an exemplary embodiment of a wall tie of this
invention;
[0017] FIG. 2 is perspective view of an anchor clip and a base
channel member of the masonry wall tie according to an exemplary
embodiment of this invention;
[0018] FIG. 3 is a view similar to FIG. 2 with the clip and anchor
channel member coupled together;
[0019] FIG. 4 is a cross-sectional view taken along line 3-3 of
FIG. 3; and
[0020] FIG. 5 is a perspective view partially broken away showing
the embodiment of FIG. 2 being installed in a cavity wall
system.
DESCRIPTION OF THE INVENTION
[0021] Referring to FIG. 1, an exemplary cavity wall 10 is shown
and includes a brick veneer outer wall 12 and an inner wall 14. The
brick veneer 12 is constructed from a plurality of bricks or blocks
16 arranged in a pattern to construct the wall 12. Each brick 16 is
of a substantially rectangular shape having a uniform length,
height and depth. The brick veneer 12 is built up by placing one
layer 18 of bricks 16 over another layer 18, with the upper layer
vertically offset from the lower layer by a distance of
approximately one-half the length of a brick 16. Thus, a brick 16
on one layer 18 is positioned directly over the space between two
bricks 16, 16 on the layer 18 immediately beneath it or above it.
The spaces 20 between adjacent bricks 16 and the spaces 22 between
adjacent layers or courses 18, 18 of bricks 16 are filled with
mortar 24. Alternatively, the veneer 12 may be stone or other
masonry units with mortar 24 in the joints or spaces 20, 22.
[0022] The interior wall 14 includes wood framing 26, dry wall and
insulation, weather proofing membrane, flashing (not shown) and an
outer sheathing layer 28 as is customary. Of course, other
materials may be used. In any event, the building wall is
constructed so that there is a small cavity or airspace A between
the inner surface of the outer wall 12 and the outer surface of the
interior wall 14. The airspace or cavity A between the inner
surface of the outer wall 12 and the outer surface of the interior
wall 14 is usually at least about one to two inches deep, although
the exact dimension may vary depending upon the nature of the
construction and local building code requirements. A wall tie
assembly, generally shown at 29, spans cavity A to secure the outer
masonry wall to the inner wall.
[0023] Referring to FIGS. 2-3, a wall tie assembly 29 comprises a
base channel member 30 and an anchor clip 32 according to a
presently preferred embodiment of this invention are shown. The
base channel member 30 has a generally U-shaped configuration with
a pair of spaced channel side walls 34, 34 generally parallel to
each other and joined together along a proximal edge by a spine or
bite portion 36 of the member 30. The spine 36 has a generally
T-shaped flange 38 projecting outwardly at both the top and bottom
end of the base channel member 30. As shown generally in FIGS. 4-5,
the spine 36 of the base channel member 30 is designed and adapted
for being juxtaposed against the outer face of the inner wall 14.
In one presently preferred embodiment, the side walls 34 are spaced
approximately one-half inch from each other and the lateral
dimension of the T-shaped flange 38 is approximately seven-eighths
of an inch. The width of the channel side walls 34 is approximately
three-fourths of an inch. The base channel member 30 preferably has
a material thickness of approximately 20 to 22 gauge and the
overall height of the base channel member 30 is approximately six
inches. The thickness of the base channel member 30 material in
many locales is controlled by applicable building codes and other
requirements and is typically required to be 16 to 18 gauge.
However, due to the configuration of the base channel member 30 of
this invention, thinner material for the member 30 provides for
comparable strength and performance of members of thicker material.
Moreover, the material thickness should be adjusted to accommodate
specific applications (residential, commercial, etc.), environments
and other use requirements.
[0024] A pair of spaced holes or apertures 40 are provided in the
spine 36 through which mechanical fasteners 42 such as screws,
nails, tacks or other devices can be inserted to mount the base
channel member 30 on the outer surface of the inner wall 14.
Preferably, the base channel member 30 is aligned with one of the
studs 26 of the inner wall 14 and the mechanical fastener 42
projects through the sheathing member 28 and into the studs 26 for
a secure base channel member 30 attachment.
[0025] The channel side walls 34 are generally mirror images of one
another and each include an outwardly turned flange 44 on a
terminal or distal edge thereof as shown particularly in FIGS. 2-4.
In one presently preferred embodiment, the flange 44 is
approximately three-sixteenths of an inch in width and extends the
entire height of the channel side wall 34. Advantageously, a slot
46 is formed in each side wall 34 and extends generally parallel to
each side wall. Each side wall 34 further includes an outwardly
tapered or flared lip 48. In one embodiment, lips 44 project
outwardly from an exterior surface of the channel side walls 34 in
a generally oval configuration. In one presently preferred
embodiment, lips 48 project approximately 0.074 inches outwardly
from the side walls 34 and are formed form the material of the side
wall 34 vacated or bent to form the slot 46. The dimensions of the
lips 48 depend at least in part upon the size of the oval slot 46
from which the lip 48 material is formed. Likewise, the size of the
slot 46 depends at least in part upon the size of the anchor clip
32 to be inserted therein. The lips 48 provide significant added
strength to the base channel member 30 and the wall tie system 29
according to this invention. While the lips 48 are shown in FIGS.
2-5 as projecting outwardly from the associated side wall 34, other
configurations and embodiments are possible within the scope of
this invention. Preferably, the slot 46 is bounded, at least
partially, by an area of material that has increased depth relative
to the remainder of the member 30.
[0026] The opening of each slot 46 is sized and configured to
receive and capture therein one of two oppositely projecting arms
50 on the terminal portions of the anchor clip 32. The arms 50 are
oriented generally perpendicularly to an adjoining anchor clip leg
52. A leg 52 is connected to a brace 54 portion of the clip 32. In
one presently preferred embodiment, the brace 54 of the anchor clip
32 is rectangular and about four inches in length and approximately
three-fourths of an inch in width. Preferably, the anchor clip 32
is formed from metal rod or wire stock of 9 gauge stock or about
one-eighth inch in diameter and the distance from the clip arms 50
to the brace 54 is about four inches. As previously stated, the
slots 46 must be sized and configured to accept the lip arms 50
therein accounting for appropriate tolerances, coatings and other
factors.
[0027] In use, the base channel member 30 is mounted to the inner
wall 14 of the cavity wall system 10 in a generally vertical
orientation and preferably secured to the studs 26 of the inner
wall 14. The anchor clip 32 is engaged with the slots 46 by
initially orienting the clip arms 50 generally vertically and
inserting the clip arms 50 between the channel side walls 34. The
anchor clip 32 is then rotated into a generally horizontal
orientation as shown in FIGS. 2 and 3 so that the clip arms 50 are
inserted into the respective slots 46 in the side walls 34 of the
base channel member 30. The length of the slots 46 provide for
ready adjustment of the height of the clip 32 relative to the base
channel member 30 so that as the outer wall 12 is being
constructed, the brace 54 of the clip 32 is inserted atop one of
the bricks 16 and embedded in the mortar 24 between adjacent
courses 18 of the outer wall 12. As shown in FIGS. 1 and 5, the leg
52 of the clip 32 spans the cavity A between the inner and outer
walls 12, 14 and the brace 54 and an adjacent portion of the leg 52
are embedded in the mortar 24 between the brick courses 18.
Advantageously, because of the length of the slots 46 in the base
channel member 30, the clip 32, when engaged therewith, can readily
be inserted between adjacent bricks 16 in a range of different
courses 18 (see FIG. 5). In other words, the base channel member 30
does not need to be repositioned on the inner wall 14 for the clip
32 to be embedded between the bricks in upper, lower or
intermediate courses 18. This provides significant efficiency and
versatility for the wall tie system according to this invention.
Moreover, because of the lip 48 surrounding each slot 46, the
strength with which the clip 32 and base channel member 30 secures
the outer wall 12 to the inner wall 14 is significantly increased
while still utilizing a thinner and less expensive material for the
base channel member 30. For example, 20 gauge metal can be utilized
for the base channel member 30 while providing strength comparable
to a 12 gauge material with the associated cost benefits of
utilizing a thinner material for the base channel member 30.
[0028] As a result, the wall tie assembly according to this
invention provides increased strength, versatility and ease of
installation with lower material costs and associated economic
impact over known systems.
[0029] From the above disclosure of the general principles of the
present invention and the preceding detailed description of at
least one preferred embodiment, those skilled in the art will
readily comprehend the various modifications to which this
invention is susceptible. Therefore, we desire to be limited only
by the scope of the following claims and equivalents thereof.
* * * * *