U.S. patent application number 10/459005 was filed with the patent office on 2004-12-16 for connection and method for setting a composite anchor with an apertured screen in a substrate.
This patent application is currently assigned to Simpson Strong-Tie Company, Inc.. Invention is credited to Hagel, Gerald W., Houck, Joel M..
Application Number | 20040250497 10/459005 |
Document ID | / |
Family ID | 33510708 |
Filed Date | 2004-12-16 |
United States Patent
Application |
20040250497 |
Kind Code |
A1 |
Hagel, Gerald W. ; et
al. |
December 16, 2004 |
CONNECTION AND METHOD FOR SETTING A COMPOSITE ANCHOR WITH AN
APERTURED SCREEN IN A SUBSTRATE
Abstract
A connection, and a method of forming a connection, that
adhesively fixes and bonds a fastening element or anchor in bore
hole, particularly in a soft substrate or substrate with an
interior cavity or void where the anchor is to be set in vertical
wall or set upwardly into a ceiling. To make the connection, an
accessory is used that has the form of a sleeve having a closed or
partially blocked insertion end and an open anchor receiving end
and apertures running along its length. The accessory helps to
ensure that the anchor is surrounded with mortar or adhesive, and
the mortar or adhesive contacts the wall of the bore. The
cylindrical wall of the sleeve has apertures along its length. The
sleeve can be formed with larger apertures formed near the anchor
receiving end of the sleeve and smaller apertures formed near the
insertion end of the sleeve. The sleeve is formed by inserting an
open-ended cylindrical mesh tube into a frame that holds the tube
along its length at a select location. This select location can be
near the insertion end and away from the anchor receiving end. The
sleeve has an external diameter that allows the sleeve to fit into
the bore in the substrate and an internal diameter that is large
enough to receive the anchor that is to be secured in the bore. The
length of the sleeve corresponds or is similar in length to the
embedded length of the anchor. The apertures in the peripheral
surface of the sleeve create passages therethrough for the uncured
adhesive.
Inventors: |
Hagel, Gerald W.; (Lombard,
IL) ; Houck, Joel M.; (Lansing, IL) |
Correspondence
Address: |
JAMES R. CYPHER
405 14TH STREET
SUITE 1607
OAKLAND
CA
94612
|
Assignee: |
Simpson Strong-Tie Company,
Inc.
|
Family ID: |
33510708 |
Appl. No.: |
10/459005 |
Filed: |
June 10, 2003 |
Current U.S.
Class: |
52/698 |
Current CPC
Class: |
Y10S 411/93 20130101;
F16B 13/146 20130101; E04G 23/0207 20130101 |
Class at
Publication: |
052/698 |
International
Class: |
E04B 001/38 |
Claims
1. a connection comprising: a. a substrate having a bore therein;
b. a sleeve received by the bore, the sleeve being formed from two
distinct and separately formed members that are assembled together
to create the sleeve, the first member being a frame, defining an
interior area enclosed by the frame and an exterior area, the frame
comprising an insertion end, a first axial section, and an anchor
receiving end, the first axial section having openings formed
therein, the second member being a tube having apertures formed
therein, the tube being received by the frame, such that at least a
portion of the tube overlaps a portion of the first axial section,
such that a material disposed within the interior area enclosed by
frame and at the first axial section, if forced radially outwardly,
would pass through the apertures in the tube, and through the
openings in the frame to reach the exterior of the frame; c. an
adhesive disposed within the interior area of the frame and along
portions of the exterior area of the frame, and in contact with the
substrate; d. an anchor received by the frame and having a portion
received within the interior area of the frame and in contact with
the adhesive in the interior of the frame, the adhesive
substantially surrounding and contacting the portion of the anchor
received within the interior of the frame.
2. The connection of claim 1, wherein the frame further comprises:
a second axial section having openings formed therein.
3. The connection of claim 2, wherein: the openings formed in the
second axial section are of a different size than the openings
formed in the first axial section.
4. The connection of claim 3, wherein: the openings formed in the
second axial section are larger than the apertures in the tube.
5. The connection of claim 1, wherein: the insertion end of the
frame is substantially closed so that the adhesive in the interior
of the frame cannot pass through the insertion end of the frame to
reach the exterior of the frame.
6. The connection of claim 1, wherein the first axial section of
the frame comprises: a plurality of spaced-apart staves joined
together by ribs, creating the openings in the first axial
section.
7. The connection of claim 6, wherein: the ribs are preferably
annular hoops.
8. The connection of claim 1, wherein: the apertures in the tube
are smaller than the openings in the first axial section of the
frame.
9. The connection of claim 1, wherein: the tube is of similar
length as the first axial section of the frame.
10. The connection of claim 1, wherein: the frame is formed with an
abutment at said anchor receiving end.
11. The connection of claim 1, wherein: the frame and the tube are
cylindrical members.
12. The connection of claim 1, further comprising: a cap attached
to the anchor receiving end of the frame.
13. The connection of claim 12, wherein: the cap is formed with
resilient flaps that allow the anchor to be inserted through the
cap when the cap is a placed over the anchor receiving end of the
frame.
14. A method for making a connection between an anchor and a
substrate, comprising: a. creating an apertured screen by inserting
a separately formed tube, the tube having apertures formed therein,
into a separately formed frame, the frame comprising an insertion
end, a first axial section, and an anchor receiving end, and the
first axial section having openings therein, the tube being
inserted into the frame in such a manner that the apertures in the
tube overlap with the openings in the first axial section of the
frame, b. filling the screen with an adhesive; c. inserting the
screen into a bore in the substrate; d. inserting the anchor into
the screen after the screen has been filled with adhesive and after
the screen has been inserted into the bore, such that the adhesive
is extruded out of the screen through the apertures in the
separately formed tube and the openings in the separately formed
frame, such that the adhesive contacts the substrate, and such that
a portion of the anchor is received within the frame and the
adhesive substantially surrounds and contacts the portion of the
anchor received within the interior of the frame.
15. The method of claim 14, wherein the frame further comprises: a
second axial section having openings formed therein.
16. The method of claim 15, wherein: the openings formed in the
second axial section are of a different size than the openings
formed in the first axial section.
17. The method of claim 16, wherein: the openings formed in the
second axial section are larger than the apertures in the tube.
18. The method of claim 14, wherein: the insertion end of the frame
is substantially closed so that the adhesive in the interior of the
frame cannot pass through the insertion end of the frame to reach
the exterior of the frame.
19. The method of claim 14, wherein the first axial section of the
frame comprises: a plurality of spaced-apart staves joined together
by ribs, creating the openings in the first axial section.
20. The method of claim 19, wherein: the ribs are preferably
annular hoops.
21. The method of claim 14, wherein: the apertures in the tube are
smaller than the openings in the first axial section of the
frame.
22. The method of claim 14, wherein: the tube is of similar length
as the first axial section of the frame.
23. The method of claim 14, wherein: the frame is formed with an
abutment at said anchor receiving end.
24. The method of claim 14, wherein: the frame and the tube are
cylindrical members.
25. The method of claim 14, further comprising: a cap attached to
the anchor receiving end of the frame.
26. The [connection] method of claim 25, wherein: the cap is formed
with resilient flaps that allow the anchor to be inserted through
the cap when the cap is a placed over the anchor receiving end of
the frame.
27. The connection of claim 4, wherein: the apertures in the tube
are smaller than the openings in the first axial section of the
frame.
28. The connection of claim 27, further comprising: a cap attached
to the anchor receiving end of the frame.
29. The connection of claim 28, wherein: the cap is formed with
resilient flaps that allow the anchor to be inserted through the
cap when the cap is a placed over the anchor receiving end of the
frame.
30. The method of claim 17, wherein: the apertures in the tube are
smaller than the openings in the first axial section of the
frame.
31. The method of claim 30, further comprising: a cap attached to
the anchor receiving end of the frame.
32. The method of claim 31, wherein: the cap is formed with
resilient flaps that allow the anchor to be inserted through the
cap when the cap is a placed over the anchor receiving end of the
frame.
33. The connection of claim 2, wherein: the first and second axial
sections of the frame are formed such that if the anchor is
inserted into the frame, the adhesive is radially extruded through
the first and second axial sections at different rates.
34. The method of claim 15, wherein: the first and second axial
sections of the frame are formed such that when the anchor is
inserted into the frame, the adhesive is radially extruded through
the first and second axial sections at different rates.
35. A connection comprising: a. a substrate having a bore therein;
b. a sleeve received by the bore, the sleeve being formed from two
distinct and separately formed members that are assembled together
to create the sleeve, the first member being a frame, defining an
interior area enclosed by the frame and an exterior area, the frame
comprising an insertion end, a first axial section, a second axial
section, and an anchor receiving end, the first axial section
having openings formed therein, the second axial section having
openings formed therein, the second member being a tube, the tube
being received by the frame, such that at least a portion of the
tube overlaps a portion of the first axial section; c. an adhesive
disposed within the interior area of the frame and along portions
of the exterior area of the frame, and in contact with the
substrate; d. an anchor received by the frame and having a portion
received within the interior area of the frame and in contact with
the adhesive in the interior of the frame, the adhesive
substantially surrounding and contacting the portion of the anchor
received within the interior of the frame.
Description
BACKGROUND
[0001] The present invention relates to an improved connection
between an anchor or fastening element and a substrate, such as
masonry, cement or stone, using an adhesive or mortar compound to
make the connection, and more particularly, provides an improved
apertured or porous sleeve-shaped member for use with the anchor
and the adhesive.
[0002] It has been found that using an apertured sleeve with an
adhesively set anchor (sometimes called a composite anchor) in a
bore can improve the connection between the anchor and the
substrate in certain situations. Apertured sleeves are useful when
the anchor is set in the side face of a wall or upwardly into the
bottom face of a ceiling. Typically, the anchor used with an
apertured sleeve is a threaded steel rod, although any post of any
material can be used. Other anchors that may be used include rebar
and tubular steel.
[0003] When using an adhesive or mortar to set an anchor in a bore,
it is important that the anchor be completely surrounded by the
adhesive or mortar and that the adhesive or mortar completely fill
the space between the anchor and the wall of the bore, such that
there are no air pockets. This creates a strong bond between the
anchor and the substrate and protects the anchor from corrosion.
This condition is generally easily achieved without the use of an
apertured sleeve, when the bore is made in a foundation or floor
and the adhesive is inserted into the bore from above. The adhesive
flows easily to the bottom of the bore, and when the bottom of the
bore is reached, it starts to fill the bore, spreading
circumferentially to the wall of the bore, generally a cylinder.
However, injecting adhesive so as to sufficiently fill a bore when
the bore is disposed horizontally, as in a wall, or upwardly, as in
a ceiling, can be very difficult.
[0004] Apertured sleeves assist with the placement of the adhesive
in these situations in a number of ways. They help measure how much
adhesive needs to be used with an anchor of selected dimensions,
and they help the adhesive to reach the upper surfaces of the bore,
and keep the adhesive relatively close to the anchor.
[0005] Measurement of the adhesive is achieved by first selecting
the length of the sleeve so that it is only slightly longer than
that part of the anchor that will be embedded in the substrate.
Second, measurement is achieved by closing the end of the sleeve
that is inserted into the bore, although it may have apertures like
the rest of the sleeve. Generally, the apertured cylindrical sleeve
also has a diameter smaller than that of the bore, and larger than
that of the anchor. Generally, the sleeve is small enough to slip
easily into the bore and large enough to slip easily over the
anchor. The apertures in the sleeve are dimensioned to work with
particular adhesives. The apertures need to allow uncured adhesive
to flow through them when forced under pressure, as when an anchor
is inserted into a sleeve filled with adhesive, but also need to
slow the flow of adhesive that is merely being inserted in the
sleeve during a filling operation. The apertures also need to be
spaced sufficiently close so that the adhesive will substantially
cover the sleeve where it can escape from the sleeve through the
apertures.
[0006] With a sleeve formed in this fashion, it is a simple matter
to fill or charge the sleeve with adhesives outside of the bore,
and then insert the sleeve into the bore. In this manner, an
appropriate amount of adhesive is delivered into the bore for a
particular anchor. Because the inserted end of the sleeve is closed
or partially blocked, the adhesive does not easily flow further
into the bore, and if an anchor is inserted quickly into the sleeve
and the bore, there will be little opportunity for the adhesive to
flow back out of the front opening of the bore. Thus a selected
amount of adhesive is collected and situated in the bore and
prevented from flowing away from the anchor, and thus will
uniformly spread and surround the anchor, filling the clearance or
space between the wall of the bore and the outer surface of the
anchor, creating a strong connection between the substrate and the
anchor along its entire length.
[0007] Apertured sleeves are also especially useful when the anchor
is set in a hollow substrate or a substrate with an internal open
space or spaces such as concrete block or concrete masonry units
(CMU). The screen-type sleeve serves to keep the hardenable mass
close to the anchor.
[0008] Concrete blocks are generally cement and/or concrete formed
into rectangular cells. Concrete blocks and concrete masonry units
are hollow rather than solid rectangular blocks. A typical concrete
block or CMU is generally a rectangular block with 4 full sides or
shells surrounding a cavity that opens outwardly through the top
and bottom surfaces. Wider concrete blocks and concrete masonry
units may be formed with a web that divides the cavity and spans
the distance from one side of the block to the other. The walls of
the concrete block or CMU can be narrow or thicken depending on the
strength needed for the block.
[0009] Setting an anchor in a substrate having interior voids such
as a concrete block wall or in a masonry wall having an air space
between a facade of bricks and the concrete supporting wall creates
further difficulties for the insertion of adhesives. Not only can
the adhesive flow too far into the bore away from the anchor, and
drip down from the upper surfaces of the bore, but it can literally
fall into the void completely away from the anchor.
[0010] Since it is likely that void in the wall or the cavity in
the concrete block is too large for there to be any bonding of the
anchor to the substrate by means of the adhesive along substantial
portions of its length, the attachment of the portions of the
anchor situated in the bore in the wall or shell of the concrete
block or the lines of masonry units becomes very crucial. As
mentioned above, the apertured sleeve helps distribute the adhesive
uniformly around the anchor making sure that as much contact with
the masonry substrate is achieved as is possible. Also the
apertured sleeve helps protect the anchor from the elements by
keeping it surrounded with adhesive, even in portions of the
substrate where there is a large cavity and no bond can be created
between the substrate and the anchor.
[0011] Setting an anchor in a substrate with a void or hollow
interior area also creates additional difficulties for creating a
strong connection that the current invention seeks to address. With
substrates that have voids, it is especially important that a
strong bond be made between the substrate and the anchor where that
bond is possible. One way of increasing the chance that enough
adhesive will fill the space between the anchor and the substrate
is to direct the adhesive through various areas of the sleeve along
its axial length where the substrate is expected to be by
increasing the aperature size or the porosity of the sleeve in
those areas with respect to the aperture size in other areas. Thus
in the areas with larger aperture size the adhesive will more
easily flow through the sleeve and is more likely to reach the
substrate.
[0012] According to U.S. Pat. No. 4,790,114, granted to Gene Falco,
when an anchor exerts ram pressure on an adhesive within a sleeve
with a uniform porosity over their axial length more adhesive is
pushed radially outward from the sleeve at the distal or insertion
end than is extruded from the insertion or proximal end, resulting
in a conically tapering displacement of adhesive with the base of
the cone being at the distal or insertion end. See U.S. Pat. No.
4,790,114 at column 1, line 34 through 57. According to Falco, "the
[adhesive] material moves freely and uniformly toward the leading
edge rather than in a significantly radially[sp] direction through
the sleeve."
[0013] To combat this problem, Falco in U.S. Pat. No. 4,790,114
teaches a sleeve with an axial section at the trailing end of the
screen with a mesh size that is larger than the mesh size of an
axial section at the leading end of the screen. The larger mesh
size at the trailing end means less resistance to radial extrusion
of the adhesive, and, thus, less ram pressure is needed to push
adhesive radially outward through the screen, so that enough
adhesive will exit the screen at the trailing section and is thus
likely to reach the peripheral wall of the bore and bond with the
anchor with the substrate, creating a stronger connection.
[0014] Falco in U.S. Pat. No. 4,790,114 achieves a screen with two
different mesh sizes by bonding two different tubes of two
different mesh sizes with a lapping seam and welding , braising or
otherwise joining them together.
[0015] This is a labor intensive operation that does not lend
itself well to automation and insuring quality control through a
run of parts. There exists a need in the art to create a sleeve
with axial sections having different resitances to radial extrusion
of the adhesive that is cost effective to produce and can insure
uniform quality among parts.
[0016] The object of the present invention is to provide a
composite anchor capable of being mass produced at a reasonable
price, as well as a composite anchor which is easy to handle and
has a high resistance to extraction.
OBJECTS OF THE INVENTION
[0017] It is an object of the present invention to improve the
adhesive setting of anchors in substrates, and to ensure the
creation of a dependable, strong and safe bond between the anchor
and the substrate.
[0018] It is an object of the present invention to create a
connection between an anchor and a substrate by means of a sleeve
formed from two separate and distinct members: a cylindrical frame
and a tube, both having apertures or openings.
[0019] It is a further object of the present invention to create an
apertured or perforated sleeve, having different aperture
dimensions at different areas along its length that is economical
to produce.
[0020] It is a further object of the present invention to create an
apertured or perforated sleeve that cannot be pushed too deeply
into a bore.
[0021] It is a further object of the present invention to provide
an accessory sleeve that is divided along its axial length into at
least two axial sections, in one section of which perforations are
provided, in total, having a path of less resistance to radial
extrusion than in the other section, thus enabling selection of
relatively different amounts of adhesive material to be extruded
from the selected axial sections. Preferably, the axial section
with the least resistance to radial extrusion is located at the
trailing or proximal end of the sleeve where the initial ram action
occurs.
[0022] The sleeve achieves two axial sections each with a different
resistance to radial extrusion or with a different porosity by
forming a frame that receives a mesh tube only along part of its
length. The mesh tube has a given porosity along its length. The
frame, where it receives the mesh tube, has very large openings
between staves and connecting ribs, such that the except where the
ribs of the frame, overlie the mesh tube, the mesh tube determines
the rate at which the adhesive is radially extruded. Meanwhile the
frame in the axial portion where it does not overlie the mesh tube
has apertures formed in it that are a different porosity than that
of the mesh tube. These apertures determine the radial flow of
adhesive through the sleeve, thus producing a different rate of
radial extrusion from the mesh tube.
[0023] According to the present invention, there may be any number
of different axial sections each with a different resistance to
extrusion of the adhesive, some even without openings. The
preferred embodiment is designed to effectively have two axial
sections with different radial extrusion rates.
[0024] It is also an object of the present invention to provide an
improved method of setting an anchor with an apertured sleeve and
an adhesive in a substrate. According to the improved method an
apertured screen is created by inserting a separately formed tube
into a separately formed frame. The wall of the tube has apertures
formed therein. The frame has a first axial section having openings
therein. The tube is inserted into the frame in such a manner that
the apertures in the tube overlap with the openings in the first
axial section of the frame. The screen is filled with adhesive. The
screen is inserted into a bore in the substrate. An anchor is
inserted into the screen after the screen has been filled with
adhesive and after the screen has been inserted into the bore, such
that the adhesive is extruded out of the screen through the
apertures in the separately formed tube and the openings in the
separately formed frame, such that the adhesive contacts the bore
of the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of the individual frame, tube
and plug of the present invention before they are assembled to
create the sleeve.
[0026] FIG. 2 is a perspective view of the sleeve of the present
invention with the cap attached to the anchor receiving end of the
frame.
[0027] FIG. 3 is a front view of the frame of the present invention
with the plug attached to the insertion end of the frame. The tube
has not been inserted into the frame.
[0028] FIG. 4 is a top view of the frame of FIG. 3.
[0029] FIG. 5 is a bottom view of the frame of FIG. 3.
[0030] FIG. 6A is an end view of the mesh tube.
[0031] FIG. 6B is an end view of an alternate mesh tube.
[0032] FIG. 7A is a front view of a mesh tube.
[0033] FIG. 7B is a front view of an alternate mesh tube.
[0034] FIG. 8A is a sectional front view of the sleeve of the
present invention.
[0035] FIG. 8B is a sectional front view of the sleeve of the
present invention with the cap attached to the anchor receiving end
of the frame.
[0036] FIG. 8C is a sectional front view of the sleeve of the
present invention being filled with adhesive, according to the
method of the present invention.
[0037] FIG. 8D is a sectional front view of the sleeve of the
present invention being filled with adhesive, according to the
method of the present invention.
[0038] FIG. 8E is a sectional front view of the sleeve of the
present invention filled with adhesive and inserted through two
oppositely disposed shells of a into a hollow concrete masonry
unit.
[0039] FIG. 8F is a sectional front view of the sleeve of the
present invention filled with adhesive and inserted through two
oppositely disposed shells of a hollow concrete masonry unit,
having received an anchor so that the adhesive is forced out of the
apertures in the sleeve to bond with the shells of the concrete
masonry unit.
[0040] FIG. 9 is a sectional front view of the sleeve of the
present invention filled with adhesive and inserted through one
shell of a hollow concrete masonry unit, having received an anchor
so that the adhesive is forced out of the apertures in the sleeve
to bond with the shell of the concrete masonry unit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] As shown in FIG. 8F, the present invention relates to a
connection, and a method of forming a connection, between a
substrate 1 and an anchor 2 by means of adhesive 3. The substrate 1
is formed with a bore 4 therein. To facilitate the connection
between the anchor 2 and the substrate 1 a special porous sleeve 5
is used.
[0042] The sleeve 5 is received by the bore 4 in the substrate 1.
As shown best in FIG. 1, the sleeve 5 is formed from two distinct
and separately formed members: a frame 6 and a tube 7. The two
individual members 6 and 7 are assembled together to create the
sleeve 5 for the connection.
[0043] The first member is a frame 6 that defines an interior area
8 enclosed by the frame 6, see FIGS. 3 and 4, and an exterior area
9, see FIG. 8F. As shown in FIG. 4, the frame 6 has an internal
surface 10 and an external surface 11. The frame 6 is preferably
cylindrical.
[0044] As shown in FIG. 3, the frame 6 can be considered to have a
number of different portions. The end of the frame 6 that is
inserted first into the bore is called the distal or insertion end
12. In the preferred embodiment, directly following the insertion
end 12 is the first or leading axial section 13, although the
leading axial section 13, as defined, does not need to directly
follow the insertion end 12 to be able practice the invention. The
first axial section 13 of the frame 6 is formed with openings 14
therein. The end of the frame 6 that will be visible when the
sleeve 5 is inserted into the bore 4 is called the trailing or
anchor receiving end 15.
[0045] As shown in FIGS. 7A and 7B, the second distinct and
separate member is a tube 7 having apertures 16 formed therein. The
tube 7 is preferably cylindrical.
[0046] As shown in FIGS. 1 and 2, to create the connection, the
tube 7 is received by the frame 6, such that at least a portion of
the tube 7 overlaps a portion of the leading axial section 13.
Because there are openings 14 in the leading axial section 13 and
apertures 16 in the tube 7, a fluid material disposed within the
interior area 8 enclosed by frame 6 and at the leading axial
section 13 could be forced radially outwardly through the apertures
16 in the cylindrical tube 7, and through the openings 14 in the
leading axial section 13 of the frame 6 to reach the exterior 9 of
the frame 6. In fact, as shown in FIG. 8F, to make the connection,
an adhesive 3 is disposed within the interior area 8 of the frame 6
and due to the insertion of the anchor 2 into the sleeve 5 before
the adhesive 3 has set, the adhesive 3 is forced out of the frame 6
through the apertures 16 in the tube 7 and the openings 14 in the
leading axial section 13 of the frame 6.
[0047] The adhesive 3 is also disposed along portions of the
exterior area 9 of the frame 6, and in contact with the bore 4 in
the substrate 1. Preferably, the adhesive 3 is extruded out of the
sleeve 5 and into contact with the bore 4 in the substrate 1 by
operation of the insertion of the anchor 2 into the sleeve 5. The
anchor 2 through contact with the adhesive 3 becomes bonded to the
substrate 1 when the adhesive 3 sets.
[0048] In the preferred form of the connection, the adhesive 3
completely surrounds and is in complete contact with the portion of
the anchor 2 inserted into the frame 6. Similarly, where there are
openings 14 in the frame 6, the adhesive surrounds the portion of
the sleeve 5 inserted into the bore 4 in the substrate 1. Thus, the
adhesive 3 substantially surrounds and contacts the interior and
exterior surfaces 10 and 11 of the frame 6, pervades the apertures
16 in the tube 7 and the openings 14 in the leading axial section
13 of the frame 6, and bonds with the walls 17 of the bore 4.
[0049] As shown in FIGS. 1 and 2, in the preferred form of the
sleeve 5, the frame 6 is further formed with-a second axial section
18. The second axial section 18 has openings 19 formed therein.
Preferably, the second axial section 18 follows the leading axial
section 13, thus it is also called the trailing axial section 18,
i.e. it is disposed between the leading axial section 13 and the
anchor receiving end 15 of the frame 6. Preferably, the openings 19
formed in the trailing axial section 18 are of a different size
than the openings 14 formed in the first axial section 13, and the
apertures 16 in the tube 7.
[0050] The anchor 2 or fastener can be a rod, bolt, dowel, post,
bar, rebar, pin or some other elongated member. The anchor 2 can be
smooth, threaded, or have some other surface contour. As shown in
FIG. 8F, the preferred anchor 2 is an all thread rod, having
threads 20. The anchor 2 can have similar leading and trailing ends
21 -and 22, respectively, as shown in FIG. 8F, or the trailing end
22 that juts out from the substrate 1 could be formed with a hook
or some other shape to enable it to be used as a special purpose
support for something to be hung from the anchor 2.
[0051] The anchor or fastener 2 is preferably made of metal, such
as steel, but the particular material can vary so long as the
desired load characteristics are achieved. The anchor 2 could be
made from a fiber composite, a plastic, a ceramic or wood.
[0052] The preferred sleeve 5 is an axially extending generally
cylindrical hollow body.
[0053] The sleeve 5 can be of any length, depending on the anchor 2
and bore 4 with which it will be used.
[0054] As is best shown in FIGS. 1 and 2, in the preferred
embodiment, the sleeve 5 is formed from at least two separate and
physically distinct pieces that are combined together to form the
final sleeve 5. In the preferred embodiment the sleeve 5 is made up
of at least a cylindrical frame 6, and a separate mesh tube 7 that
are assembled together.
[0055] In the preferred embodiment, the frame 6 has an insertion
end 12, a leading axial section 13, a trailing axial section 18,
and an anchor receiving end 15.
[0056] As is shown in FIG. 1, in the preferred embodiment, the
insertion end 12 of the frame 6 is open, and receives a plug 23
that will completely close off the insertion end 12 of the frame 6,
once the mesh tube 7 has been received in the frame 6. In the
preferred embodiment, when the sleeve 5 is ready to be inserted in
the bore 4 in the substrate and be filled with adhesive 3, the
insertion end 12 of the frame 6 is substantially closed or sealed
so that the adhesive 3 in the interior 8 of the frame 6 cannot pass
through the insertion end 12 of the frame 6 to reach the exterior 9
of the frame 6.
[0057] As is shown in FIGS. 1, 2 and 3, in the preferred
embodiment, the leading axial section 13 of the frame 6 has a
plurality of spaced-apart staves 24 running from the insertion end
12 to the trailing axial section 18, joined together at points
along the length of the frame 6 by ribs 25. The ribs 25 are
preferably annular hoops. The openings 14 in the leading axial
section 13 are created between the spaced-apart staves 24 and the
ribs 25.
[0058] In the preferred embodiment, these openings 14 in the
leading axial section of the frame 6 are relatively large compared
to the apertures 16 in the tube 7.
[0059] In the preferred embodiment, the spaced-apart staves 24 that
extend axially along the frame 6 are joined by ribs 25 at the ends
of the staves 24 and at intervals along the staves 24.
[0060] In the preferred embodiment, as shown in FIG. 1, the
preferred frame has four staves 24. The preferred embodiment has at
least one annular rib 15 spaced between the insertion end 12 and
the trailing axial section 18, and more depending on the length of
the sleeve 5.
[0061] In the preferred embodiment, the trailing axial section 18
is also cylindrical, but instead of having large open areas, it has
a plurality of small apertures or openings 19.
[0062] As is shown in FIG. 1, in the preferred embodiment, the
apertures are laid-out in a rectangular grid as shown in FIG. 1.
The preferred openings 19 are square openings. As is best shown in
FIG. 3, in one embodiment, the sides 26 that define the square
openings 19 are 0.038" long, and are separated by members that are
0.030" wide.
[0063] In the preferred embodiment, after the trailing axial
section 18, the sleeve 5 ends at the anchor receiving end 15.
[0064] The other separate member of the preferred multi-component
sleeve 5 is the mesh tube 7.
[0065] The mesh tube 7 is preferably formed from a synthetic fabric
or mesh netting, preferably nylon, or some other material such as
polyester, polypropylene, polyethylene or some other thermal formed
material. The mesh tube 7 could also be formed from a perforated
plastic or metal sheet.
[0066] The mesh tube 7 is preferably made by cutting a strip from
stock mesh netting. The strip of mesh netting is then rolled about
its longitudinal axis and secured to itself at one or;more
locations or, preferably, along its entire length by an adhesive,
hot melt, heat or ultrasonic welding, as is shown in FIGS. 7a and
7b. Preferably, there is very little overlap when the mesh is
rolled on itself. Alternatively, the mesh tube can be manufactured
in a continuous operation.
[0067] The apertures 16 of a select size in the mesh tube 7 are
preferably uniformly distributed over the surface of the tube 7.
The size of the apertures 16 or mesh count of the mesh tube 7 will
depend on the adhesive or mortar to be used. The inventors have
found that a mesh tube 7 with a mesh count of 30 per inch and an
open area of 22% is the preferred mesh for use with an adhesive
product sold under the mark Acrylic-Tie.TM. by Simpson Strong-Tie
Company, Inc., the assignee of the present invention. The mesh
tubes shown in FIGS. 7A and 7B show alternate orientations of the
preferred rectangular mesh.
[0068] As shown in FIGS. 4, 6A, 6B and 8A, the mesh tube 7 is
inserted into the frame 6. Preferably, the mesh tube 7 has an outer
diameter 27 that closely matches the interior diameter-28 of
leading axial section 13 of the frame 6.
[0069] The sleeve 5 is manufactured by separately forming the frame
6 and the mesh tube 7, and then inserting the mesh tube 7 into the
frame 6.
[0070] The mesh tube 7 is preferably inserted through the insertion
end 12 of the frame 6.
[0071] As shown in FIG. 8A, in the preferred embodiment, the
internal surface 10 of the frame 6 is preferably formed with a
plurality of shoulders 29 at the beginning of the trailing axial
section 18 of the frame. The mesh tube 7 is preferably the length
of the leading axial section of the frame 13, and when it is
inserted fully into the frame 6, and stopped by the shoulders 29 on
the inner diameter 28 of the frame 6 it does not protrude from the
insertion end 12 of the frame 6.
[0072] In the preferred method of making the sleeve 5, a plug 23 is
then attached to the insertion end 12 of the frame 6 by sonic or
heat welding, trapping the mesh tube 7 in the frame 6 between the
shoulders 29 and the plug 23.
[0073] As shown in FIG. 2, in the preferred embodiment, once the
mesh tube 7 is inserted within the frame 6, the screen 5 is
provided with relatively small apertures 16 and 19 substantially
along the whole of its length.
[0074] In the preferred embodiment, the sleeve 5 has a greater open
area or higher porosity at its rear or trailing axial section 18
than at its forward or leading axial section 13 to allow for
selectively higher rates of radial extrusion of the adhesive 3 at
the rear of the sleeve 5. The porosity could be reversed, the rear
section could have no pores at all, or the length of the screen 5
could be divided in more than just two segments of differing
porosity. More than one mesh tube 7 could be received by the
sleeve, and where a plurality of mesh tubes 7 are used, the
porosity of the mesh tubes 7 could vary. Tubes could also be
inserted in the frame that do not have apertures.
[0075] The use of a frame 6 that receives one or more mesh tubes 7
allows for a simple means to create a sleeve 5 with varying
porosity or resistance to radial extrusion of a fluid material out
of the sleeve 5 under ram action along various segments of the
sleeve 5.
[0076] As shown in FIG. 8E and 9, in the preferred embodiment of
the sleeve 5 designed for use with concrete masonry units 30 having
thin webs 31 or shells, the trailing axial section 18, having less
resistance to radial extrusion of the adhesive 3, does not extend
too far along the sleeve 5. The trailing axial section 18 is
preferably, approximately the depth of the web 31 or shell when the
sleeve 6 is used in a hollow concrete masonry unit 30 or other
substrate 1 having an initial web 31 and then a large cavity
32.
[0077] The sleeve 5 is made of a relatively stiff but resilient
material. The material may be metal, but it is preferably made from
plastic. The cylindrical frame 6 is preferably made of
polypropylene, polyethylene, nylon, polyester, polyurethane, ABS
plastic or any similar thermal formed material.
[0078] As is shown in FIG. 8F, the material of the frame 5 is stiff
enough to enable the elongate sleeve or screen 6, even when it is
filled with mortar or some other adhesive 3, to bridge a void or
cavity 32 in a hollow substrate 1 such as concrete masonry unit 30.
Longer screens 3 meant to span long voids 32 will need to be made
from very stiff material; however, the inventors contemplate that
typical screens will be from 3.5" to 8" long, and these can be made
from polypropylene or polyethylene.
[0079] As shown in FIGS. 8E and 8F, when used in a concrete masonry
unit or hollow block 30, and the uses desires to set the anchor in
both the first web 31 and the second web 33 of the concrete masonry
unit 30, the screen 5 needs to be stiff enough, when filled with
mortar 3 to be inserted into a first bore or tunnel 4 formed in a
first web 31 of a hollow block 30, extend across an interior cavity
32 of the hollow block 30 and be received in second aperture formed
in the second opposite web 33 of the hollow block 30. During the
insertion, the user will not be able to see the second aperture 34
formed in the second opposite web 33 of the hollow block 30.
[0080] Preferably, the screen 5 has a generally uniform diameter
along its length. As shown in FIGS. 5 and 8E,the screen has an
outer diameter 35 selected to cooperate with the diameter of the
bore 4 or aperture in the substrate 1 or the first and second bores
or apertures 4 and 34 in the first and second webs 31 and 33 of a
hollow substrate 30. As shown in FIGS. 4 and 8F, the effective
inner diameter of the sleeve 28 is selected to cooperate with the
external diameter 36 of the anchor 2.
[0081] The insertion or distal end 12 of the frame 6 is preferably
closed or substantially closed so that the uncured adhesive 3 is
prevented from leaving the intended zone of adhesive bonding. When
a fastener or anchor 2 is inserted into the cylindrical screen 5,
the adhesive 3 disposed within the screen 5 will be prevented from
being axially discharged from the distal end 12 of the sleeve 5 and
will be discharged radially through the apertures and openings 14,
16 and 19 in the sleeve 5.
[0082] As shown in FIG. 8F, the frame 6 is preferably formed with
an abutment 37 at its anchor receiving or proximal end 15 which
determines the depth to which the sleeve 5 can be driven or
inserted into the hole 4. This abutment or stop 37 may be formed by
providing an annular flange at the anchor receiving end 15, or as
is shown in FIG. 1, in the preferred embodiment, a pair of
oppositely disposed flanges 38 at the anchor receiving end 15 of
the frame 6.
[0083] As is shown in FIG. 1, a cap 39 is preferably formed
integral with the proximal end 15 of the frame 6. The cap 39 is
formed with resilient flaps 40 so that when it is attached to the
frame 6, an anchor or fastener 2 may still be inserted into the
sleeve 6. The cap 39 with flaps 40 helps prevent the adhesive 3
from being extruded out of the sleeve 5 through the proximal end 15
when the anchor 2 is inserted into the sleeve 5.
[0084] The substrate 1 is preferably masonry or concrete. The
substrate could also be rock, metal, plastic, a composite or some
other material.
[0085] The bore 4 in the substrate 1 or apertures 4 and 34 in the
webs 31 and 33, if a hollow substrate 30 is used, are generally
cylindrical tunnels with a peripheral/cylindrical wall 17. The bore
4 can be a blind tunnel. The bore 4 can also be a through-hole or
aperture if the bore is formed in the first web 31 of a substrate 1
having a hollow interior 32, such as with concrete masonry units
30. If the substrate 1 is soft, or porous, the peripheral wall 17
of the bore 4 may have large cavities.
[0086] A typical hollow substrate 1 is a wall of a building made up
of concrete masonry units 30. Concrete masonry units 30 typically
come in widths of 6", 8", 10" or and 12". They come in different
weights. The face shell or webs 31 and 33 of the concrete masonry
30 unit get thicker as the width of the concrete masonry unit gets
larger.
[0087] The inventors have designed selected screens 5 for use with
concrete masonry units 30 of different sizes. The inventors have
found that a nominal 3.5" length screen is optimally used with a 6"
concrete masonry unit for insertion into only the front web or
shell 31 of the concrete masonry unit 30.
[0088] With respect to the adhesive 3, preferably, the apertures 16
in the mesh tube 7 and the openings 19 in the second axial section
18 are designed to be used with a specific adhesive or hardenable
mass 3. The characteristics of the adhesive 3 determine the size of
the apertures 16 of the mesh tube 7 and the size of the apertures
19 in the second axial section 18 of the frame 6. These
characteristics include viscosity and the particle size of the
filler in the adhesive 3. Preferably, the aperture sizes are chosen
for a specific adhesive compound 3 so that the adhesive 3 does not
flow or just barely flows through the screen 5 when initially
injected into the screen 5 before insertion into the apertures or
bore 4, due to the viscosity of the adhesive 3. The consistency of
the adhesive 3 and the dimensions of the relatively small apertures
16 and 19 of the sleeve 5 should be so interrelated that the mortar
3 can only barely flow out of the sleeve 5 by itself when initially
injected into the sleeve 5, but can be forced out through the
apertures 16 and 19 by the bolt 2 when it is introduced into the
sleeve 5, and substantially surrounds the circumference of the
sleeve 5.
[0089] The adhesive 3 is preferably a construction adhesive, such
as a polymerizing system. Typical systems include the free radical
polymerization of unsaturated polyester resins, the free radical
polymerization of acrylates, and the free radical polymerization of
epoxyacrylates. The adhesive 3 can be a vinyl ester, an acrylic, an
epoxy, a polyester, resin, grout, cement mortar or any other
adhesive system which can be placed into the sleeve 5, allow for
the insertion of the sleeve 5 filled with the adhesive system 3 to
be inserted into the bore 4 or apertures 4 and 34, allow for an
anchor or fastener 2 to be positioned in the sleeve 5, and then
harden or set-up to bond the anchor 2 with the substrate 1.
[0090] The adhesive 3 is preferably a two-part adhesive, the first
part consisting primarily of one or more polymerizable monomers or
compounds, and the second part consisting of an initiator or other
hardening agent. The components are stored separately, and when
mixed the adhesive 3 sets. Preferably, the adhesive 3 is stored
separately and then mixed just before insertion into the sleeve 5.
A preferred means of accomplishing this is using a two-part
container that can be loaded into an injection gun. The container
has a static mixing nozzle where the components are mixed as they
are extruded from the container by the piston of the mixing gun,
with the mixed components be inserted immediately upon mixing into
the sleeve 5.
[0091] The container could also have means for mixing the
components in the container such as a rupturable or frangible
barrier between the components that can be broken when the
components are ready to be mixed such as by a impeller that would
then help mix the components.
[0092] The components of the adhesive 3 could also be stored in a
flexible casing that could be inserted into the sleeve 5. The
casing and the barrier between the two components could be broken
by the anchor 2 being inserted into the sleeve 5 with rotating of
the anchor 2 accomplishing the mixing, although this method is not
preferred. Methods of introducing the adhesive 3 into the sleeve 5
are also known in the art where the resin is placed in the sleeve
5, and a hardener or initiator is carried on a fibrous sheath on
the anchor 2, wherein, when the anchor 2 is inserted into the
sleeve, the hardener on the sheath comes into contact with the
resin and setting begins. In these methods the anchor 2 is rotated
in the sleeve 5 to produce mixing. This method is also not
preferred.
[0093] Various additives, known in the art, such as fillers,
inhibitors, stabilizers, catalysts, thixotropic agents,
plasticizers, pigments, and cross-linking agents can be included in
the adhesive system 3, depending on its type.
[0094] For a hollow substrate, such as a a concrete masonry unit
30, the substrate is prepared by forming aligned apertures 4 and 34
in the first and second webs 31 and 33 of the hollow substrate 30.
Using a drill, a first aperture 4 is formed in the first web 31 of
the substrate 30. The drill is then inserted further, extending
across the interior cavity 32 of the hollow substrate 30, and a
second aperture 34 is blind drilled in a second opposite web 33 of
the hollow substrate 30.
[0095] A substrate 1 with a large interior cavity 32 could be a
hollow concrete block 30, or it could be two walls of masonry
members such as rows of bricks spaced apart from each other, to
name two common examples.
[0096] The bores or apertures 4 and 34 in the substrate 30, are
then cleaned of debris, usually with a brush.
[0097] The preferred screen 5, formed by inserting a separately
formed tube 7 into the insertion end 12 of a separately formed
frame 6, and sealing the insertion end 12 of the frame with a plug
23, is then completely filled with an adhesive 3 through the
trailing end or proximal end 15. An injection gun is typically used
for this filling procedure, and the screen 5 can be filled with a
cap 39 having an opening for receiving the nozzle 41 of an
injection gun in place if desired. See FIGS. 8C and 8D.
[0098] The apertures 16 in the mesh tube 7 and the apertures 19 in
the trailing axial section 18 in the frame 6 are of a selected size
with respect to the adhesive 3 selected so that the adhesive 3 does
not come too far out of the apertures 16 and 19.
[0099] After the screen 5 has been filled with adhesive 3, it is
inserted, distal end first 12, through the first aperture 4 within
the web 31, across the hollow interior 32 of the hollow substrate
30, and into the second aperture 34 in the second web 33.
[0100] The fastener or anchor 2 is inserted into the screen 5 so as
to exert ram pressure on the adhesive mass 3 and extrude the
adhesive or mortar 3 out of the apertures 14, 16 and 19 of the
screen 5 (the larger openings 14 in the leading axial section 13 of
the frame 6, the apertures 19 in the trailing axial section 18 of
the frame 6, and the apertures 16 in the mesh tube 7) to bond with
the substrate 30 and secure the bolt 2 thereto upon setting. The
skirt or flaps 40 on the end cap 39 help to keep mortar or adhesive
3 from extruding out the trailing end of the sleeve 15, and they
also help center the anchor 2 in the sleeve 5.
[0101] Where the cavity 32 in the substrate 30 interfaces with the
aperture or bore 4, a positive lock will be afforded by the
hardenable mass or adhesive 3 spreading along the web 31 into the
cavity 32 in the substrate 30 and then setting.
[0102] Depending on the orientation of the anchor 2, and
particularly if the anchor 2 is set in a ceiling or roof, the
anchor or fastener 2 will need to be held in place while the
adhesive 3 sets and hardens.
[0103] The screen 5 can also be used for bonding an anchor 2 to
just the outer shell or first web 31 of a hollow wall 30. The
installation is similar to that described above. The inventors have
tested the inventive screen 5 in a 10" on hollow concrete masonry
unit 30, bonding the anchor to only the outer shell 31 of the
concrete masonry unit 30 in the center of the shell or web 31.
[0104] Using a drill with a {fraction (9/16)}" drill bit, a first
aperture 4 was formed in the first web 31 of the concrete masonry
unit 30. The aperture was then cleaned of debris.
[0105] A 3.5" long screen 5 formed according to the preferred
embodiment of the present invention was selected. The internal
diameter 28 of the frame was 0.475". The mesh tube 7 had an outside
diameter 27 of approximately 0.470", a length of 2.45" and a
thickness of 0.020".
[0106] The screen 5 was completely filled with an acrylic-based
adhesive sold under the brand Acrylic-Tie.TM. through the trailing
end or proximal end 15 of the frame 6. After the screen 5 was
filled with adhesive 3, it was inserted, distal end first 12,
through the first aperture 4 within the outer shell or web 31 of
the hollow concrete block 30 which was approximately 1.7"
thick.
[0107] A 3/8" diameter Grade B7 All Thread Rod anchor 3 was
inserted into the screen 5 so as to exert ram pressure on the
adhesive mass 3 and extrude the adhesive 3 out of the apertures
apertures 14, 16 and 19 of the screen 5 (the larger openings 14 in
the leading axial section 13 of the frame 6, the apertures 19 in
the trailing axial section 18 of the frame 6, and the apertures 16
in the mesh tube 7) to bond with the substrate 30 and secure the
bolt 2 thereto upon setting.
[0108] The screen can also be used in a solid substrate 1. A bore 4
is drilled a selected depth in the solid substrate, and otherwise
the installation is similar to that described above and is not
repeated.
* * * * *