U.S. patent application number 11/179980 was filed with the patent office on 2007-01-18 for composite wall tie system and method.
Invention is credited to Earl Smith.
Application Number | 20070011964 11/179980 |
Document ID | / |
Family ID | 37660366 |
Filed Date | 2007-01-18 |
United States Patent
Application |
20070011964 |
Kind Code |
A1 |
Smith; Earl |
January 18, 2007 |
Composite wall tie system and method
Abstract
A composite wall tie structure is disclosed for supporting or
anchoring building materials to a building structure. The composite
wall tie has a vertical leg for affixation to a building structure
and a horizontal leg for placement in the mortar between courses of
building materials. The horizontal portion of the wall tie has
bristle-like protuberances and/or perforations thereon for
anchoring the leg within mortar. The materials of construction of
the wall tie are preferably selected from composites that are
moisture impermeable and corrosion resistant. The wall tie system
may also comprise a mounting and alignment bracket attached to the
vertical legs of multiple wall ties at regular horizontal intervals
to accommodate the secure attachment of wall ties to wall
studs.
Inventors: |
Smith; Earl; (Virginia
Beach, VA) |
Correspondence
Address: |
David J. Bolduc
4805 Pleasure House Ct. #102
Virginia Beach
VA
23455
US
|
Family ID: |
37660366 |
Appl. No.: |
11/179980 |
Filed: |
July 12, 2005 |
Current U.S.
Class: |
52/285.3 |
Current CPC
Class: |
E04B 1/4178
20130101 |
Class at
Publication: |
052/285.3 |
International
Class: |
E04B 1/38 20060101
E04B001/38 |
Claims
1. A wall tie member for securing building materials to a building
structure, comprising: a vertical leg having a top portion and a
bottom portion and a front face and a back face; and a horizontal
leg having a front edge, a back edge, a right edge and a left edge
and a top face and a bottom face; said vertical leg bottom portion
being rigidly affixed to said horizontal leg back edge, thereby
defining a substantially L-shaped member; said top face or said
bottom face of said horizontal leg having an adhesion enhancing
surface for anchoring said horizontal leg within mortar connecting
building materials; said adhesion enhancing surface comprising a
plurality of spaced apart protuberances on said top face or said
bottom face of said horizontal leg; wherein said vertical leg is
configured to be attached to an underlying building structure; and
wherein said horizontal leg is configured to be anchored within
said mortar connecting building materials exterior to said
underlying building structure; and wherein the material of
construction of said vertical leg and horizontal leg comprises a
corrosion resistant, moisture impermeable composite material.
2. A wall tie member according to claim 1, further comprising: a
substrate having a vertical portion between said front and back
faces of said vertical leg and a horizontal portion between said
top and bottom faces of said horizontal leg; and wherein a bottom
portion of said vertical portion of said substrate is rigidly
connected to a back portion of said horizontal portion of said
substrate; and wherein said substrate is configured to transfer a
load exerted on said horizontal leg by said building materials
through said horizontal portion of said substrate to said vertical
portion of said substrate and to said vertical leg and said
underlying building structure.
3. A wall tie member according to claim 1, wherein said adhesion
enhancing surface of said horizontal leg further comprises: at
least one perforation hole extending through said horizontal leg
from said top face to said bottom face of said horizontal leg for
allowing adhesion of mortar between said top face and said bottom
face of said horizontal leg.
4. A wall tie member according to claim 2, further comprising: at
least one perforation hole extending through said horizontal leg
from said top surface to said bottom surface of said horizontal leg
and said horizontal portion of said substrate for allowing adhesion
of mortar between said top surface and said bottom surface of said
horizontal leg. wherein said at least one perforation hole through
said substrate has a peripheral surface covered by said composite
material.
5. A wall tie member according to claim 1, further comprising: a
plurality of affixation holes extending through from said front
surface to said back surface of said vertical leg for allowing
attachment of said vertical leg to a plurality of affixation
locations on said underlying building structure; and a plurality of
fasteners adapted to be placed through said plurality of affixation
holes and attachment to said underlying building structure.
6. A wall tie member according to claim 2, further comprising: a
plurality of affixation holes extending through from said front
surface to said back surface of said vertical leg and said vertical
portion of said substrate for allowing attachment of said vertical
leg to a plurality of affixation locations on said underlying
building structure; and a plurality of fasteners adapted to be
placed through said plurality of affixation holes and attachment to
said underlying building structure; wherein said plurality of
affixation holes through said substrate has a peripheral surface
covered by said composite material.
7. A wall tie member according to claim 1, wherein said composite
material is selected from the group moisture impermeable, corrosion
resistant, high strength composite materials consisting of:
Acrylonitrile/Methylacrylate copolymer; Regenerated Cellulose; CA;
CAB; Cyclo-olefin copolymer; E-CTFE; ETFE; EP; FKM; PAN; ABS; PA
4,6; PA 6; PA 6,6; PA 6,6 30% GFR; PA 11; PA 12; PAI; Polyaramid
Polyparaphenylene terephthalamide; Polyaramid Polymetaphenylene
isophthalamide; PBI; PBT; PBT 30% GFR; PC; Polycarbonate-30% Glass
Fibre Filled; PCTFE; PEEK; PEI; PES; Polyethylene-Carbon filled;
HDPE; LDPE; UHMW PE; PEN; PET, PETP; PHB; PHB92/PHV 8; PI; PMMA;
Acrylic; Polymethylpentene; POMC; POMH; Polyphenyleneoxide PPO
(modified), PPE (modified); PPO 30% GFR; PPS; PPS-40% GFR;
Polyphenylsulphone; PP; PS; PS-X-Linked; PTFE; PTFE 75/Glass 25;
PTFE 25% GF; UPVC; PVF; PVDC; PVDF; Silicone Elastomer; Teflon;
Teflon PFA; iron; steel; aluminum; tin; titanium; beryllium;
carbon; carbon fibers; concrete; glass reinforced plastics; carbon
fiber reinforced plastics; and mixtures, oxides and alloys
thereof.
8. A wall tie member according to claim 2, wherein said composite
material is selected from the group moisture impermeable, corrosion
resistant, high strength composite materials consisting of:
Acrylonitrile/Methylacrylate copolymer; Regenerated Cellulose; CA;
CAB; Cyclo-olefin copolymer; E-CTFE; ETFE; EP; FKM; PAN; ABS; PA
4,6; PA 6; PA 6,6; PA 6,6 30% GFR; PA 11; PA 12; PAI; Polyaramid
Polyparaphenylene terephthalamide; Polyaramid Polymetaphenylene
isophthalamide; PBI; PBT; PBT 30% GFR; PC; Polycarbonate-30% Glass
Fibre Filled; PCTFE; PEEK; PEI; PES; Polyethylene-Carbon filled;
HDPE; LDPE; UHMW PE; PEN; PET, PETP; PHB; PHB92/PHV 8; PI; PMMA;
Acrylic; Polymethylpentene; POMC; POMH; Polyphenyleneoxide PPO
(modified), PPE (modified); PPO 30% GFR; PPS; PPS-40% GFR;
Polyphenylsulphone; PP; PS; PS-X-Linked; PTFE; PTFE 75/Glass 25;
PTFE 25% GF; UPVC; PVF; PVDC; PVDF; Silicone Elastomer; Teflon; and
Teflon PFA; and wherein the material of construction of said
substrate is selected from the group of high strength materials
including: iron; steel; aluminum; tin; titanium; beryllium; carbon;
carbon fibers; concrete; glass reinforced plastics; carbon fiber
reinforced plastics; and mixtures, oxides and alloys thereof.
9. A wall tie member according to claim 1, wherein said horizontal
leg further comprises: an adhesion enhancing surface on said front
edge, said right edge and said left edge, said top face or said
bottom face of said horizontal leg, for anchoring said horizontal
leg within mortar connecting building materials; said adhesion
enhancing surface comprising a plurality of spaced apart
protuberances on said front edge, said right edge and said left
edge, said top face or said bottom face of said horizontal leg.
10. A wall tie member according to claim 9, wherein said adhesion
enhancing surface of said horizontal leg further comprises: at
least one perforation hole extending through said horizontal leg
from said top face to said bottom face of said horizontal leg for
allowing adhesion of mortar between said top face and said bottom
face of said horizontal leg.
11. A wall tie system comprising: a plurality of wall ties, each of
said wall ties comprising: a vertical leg having a top portion and
a bottom portion and a front face and a back face; and a horizontal
leg having a front edge, a back edge, a right edge and a left edge
and a top face and a bottom face; said vertical leg bottom portion
being rigidly affixed to said horizontal leg back edge, thereby
defining a substantially L-shaped member; said top face or said
bottom face of said horizontal leg having an adhesion enhancing
surface for anchoring said horizontal leg within mortar connecting
building materials; said adhesion enhancing surface comprising a
plurality of spaced apart protuberances on said top face or said
bottom face of said horizontal leg; wherein said vertical leg is
configured to be attached to an underlying building structure; and
wherein said horizontal leg is configured to be anchored within
said mortar connecting building materials exterior to said
underlying building structure; and wherein the material of
construction of said vertical leg and horizontal leg comprises a
corrosion resistant, moisture impermeable composite material; and
an alignment and mounting bracket having a front face and a back
face and a horizontal length; said alignment and mounting bracket
comprising a horizontal strip of corrosion resistant, moisture
impermeable thermoplastic material; wherein said back face of said
vertical leg of each of said of wall ties is affixed to said
alignment and mounting bracket at regular spaced intervals along
said horizontal length of said alignment and mounting bracket.
12. The wall tie system according to claim 11, wherein said
alignment and mounting bracket further comprises: an angled portion
along said horizontal length of said alignment and mounting
bracket; said angled portion being adapted to span a corner portion
of said underlying building structure.
13. The wall tie system according to claim 11, further comprising:
a substrate having a vertical portion between said front and back
faces of said vertical leg and a horizontal portion between said
top and bottom faces of said horizontal leg; and wherein a bottom
portion of said vertical portion of said substrate is rigidly
connected to a back portion of said horizontal portion of said
substrate; and wherein said substrate is configured to transfer a
load exerted on said horizontal leg by said building materials
through said horizontal portion of said substrate to said vertical
portion of said substrate and to said vertical leg and said
underlying building structure.
14. The wall tie system according to claim 11, wherein said
adhesion enhancing surface of said horizontal leg further
comprises: at least one perforation hole extending through said
horizontal leg from said top face to said bottom face of said
horizontal leg for allowing adhesion of mortar between said top
face and said bottom face of said horizontal leg.
15. The wall tie system according to claim 13, further comprising:
at least one perforation hole extending through said horizontal leg
from said top surface to said bottom surface of said horizontal leg
and said horizontal portion of said substrate for allowing adhesion
of mortar between said top surface and said bottom surface of said
horizontal leg. wherein said at least one perforation hole through
said substrate has a peripheral surface covered by said composite
material.
16. The wall tie system according to claim 11, further comprising:
a plurality of affixation holes extending through from said front
surface to said back surface of said vertical leg for allowing
attachment of said vertical leg to a plurality of affixation
locations on said underlying building structure; and a plurality of
fasteners adapted to be placed through said plurality of affixation
holes and attachment to said underlying building structure.
17. The wall tie system according to claim 13, further comprising:
a plurality of affixation holes extending through from said front
surface to said back surface of said vertical leg and said vertical
portion of said substrate for allowing attachment of said vertical
leg to a plurality of affixation locations on said underlying
building structure; and a plurality of fasteners adapted to be
placed through said plurality of affixation holes and attachment to
said underlying building structure; wherein said plurality of
affixation holes through said substrate has a peripheral surface
covered by said composite material.
18. The wall tie system according to claim 11, wherein said
composite material is selected from the group moisture impermeable,
corrosion resistant, high strength composite materials consisting
of: Acrylonitrile/Methylacrylate copolymer; Regenerated Cellulose;
CA; CAB; Cyclo-olefin copolymer; E-CTFE; ETFE; EP; FKM; PAN; ABS;
PA 4,6; PA 6; PA 6,6; PA 6,6 30% GFR; PA 11; PA 12; PAI; Polyaramid
Polyparaphenylene terephthalamide; Polyaramid Polymetaphenylene
isophthalamide; PBI; PBT; PBT 30% GFR; PC; Polycarbonate-30% Glass
Fibre Filled; PCTFE; PEEK; PEI; PES; Polyethylene-Carbon filled;
HDPE; LDPE; UHMW PE; PEN; PET, PETP; PHB; PHB92/PHV 8; P1; PMMA;
Acrylic; Polymethylpentene; POMC; POMH; Polyphenyleneoxide PPO
(modified), PPE (modified); PPO 30% GFR; PPS; PPS-40% GFR;
Polyphenylsulphone; PP; PS; PS-X-Linked; PTFE; PTFE 75/Glass 25;
PTFE 25% GF; UPVC; PVF; PVDC; PVDF; Silicone Elastomer; Teflon;
Teflon PFA; iron; steel; aluminum; tin; titanium; beryllium;
carbon; carbon fibers; concrete; glass reinforced plastics; carbon
fiber reinforced plastics; and mixtures, oxides and alloys
thereof.
19. The wall tie system according to claim 13, wherein said
thermoplastic material is selected from the group moisture
impermeable, corrosion resistant, high strength composite materials
consisting of: Acrylonitrile/Methylacrylate copolymer; Regenerated
Cellulose; CA; CAB; Cyclo-olefin copolymer; E-CTFE; ETFE; EP; FKM;
PAN; ABS; PA 4,6; PA 6; PA 6,6; PA 6,6 30% GFR; PA 11; PA 12; PAI;
Polyaramid Polyparaphenylene terephthalamide; Polyaramid
Polymetaphenylene isophthalamide; PBI; PBT; PBT 30% GFR; PC;
Polycarbonate-30% Glass Fibre Filled; PCTFE; PEEK; PEI; PES;
Polyethylene-Carbon filled; HDPE; LDPE; UHMW PE; PEN; PET, PETP;
PHB; PHB92/PHV 8; P1; PMMA; Acrylic; Polymethylpentene; POMC; POMH;
Polyphenyleneoxide PPO (modified), PPE (modified); PPO 30% GFR;
PPS; PPS-40% GFR; Polyphenylsulphone; PP; PS; PS-X-Linked; PTFE;
PTFE 75/Glass 25; PTFE 25% GF; UPVC; PVF; PVDC; PVDF; Silicone
Elastomer; Teflon; and Teflon PFA; and wherein the material of
construction of said substrate is selected from the group of high
strength materials including: iron; steel; aluminum; tin; titanium;
beryllium; carbon; carbon fibers; concrete; glass reinforced
plastics; carbon fiber reinforced plastics; and mixtures, oxides
and alloys thereof.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a wall tie system for
supporting bricks and other veneers on a building structure. More
specifically, the present invention comprises a composite wall tie
that is lighter and more corrosion resistant as compared to
conventional metallic brick wall ties. In the composite wall tie
system, a series of wall ties are secured at regular intervals to a
supporting bracket designed to best distribute, align and affix a
series of wall ties to a building structure.
[0003] 2. Description of the Prior Art
[0004] Brick and concrete structures are common in the prior art.
Many structures are built from brick, concrete and the like because
of their many advantages including: durability and strength; fire
resistance; temperature and sound insulation; general
attractiveness; and ease of maintenance, i.e., elimination of the
rotting, denting, warping, rusting, splitting, peeling, and fading
associated with wooden structures, as well as a deterrent to wood
consuming insects such as termites.
[0005] It should be understood that the facing material described
hereinafter as brick can also be concrete, cinderblock, stone,
granite, slate, mortar and other structural materials and veneers
and combinations thereof. It is necessary when building a brick
structure for the brickwork to be supported periodically so that it
does not fall away from the building structure. Methods for
accomplishing this support include the use of masonry headers and
metallic brick ties, which are used to secure the non load-bearing
brick veneer to a load bearing frame. The headers, bonders or wall
ties are attached to the primary structure such as a wood studded
structure, a reinforced concrete frame or to a steel framed
structure, to which the load is transferred.
[0006] Use of wall ties has grown since testing has shown that
metal-tied walls are more resistant to water penetration than were
masonry-bonded walls. Bonders or headers, used in masonry-bonded
walls may provide direct paths for possible water penetration.
Testing also indicated that the compressive strength of metal-tied
cavity walls and solid walls, and the transverse strength of
metal-tied solid walls were comparable to those of masonry-bonded
walls. The use of wall ties has continued to increase over the
years due to a trend away from massive, multi-course masonry walls
to relatively thin masonry cavity walls, double-course walls and
veneers. Investigation into the performance of masonry-bonded walls
in which the bonded courses are of different materials indicates
frequent shear failures in the headers. The use of backing systems
other than masonry, i.e., steel, concrete and wood, has also
rendered bonding with masonry headers impossible, leading to the
development of a number of different metal tie systems.
[0007] Typically, wall ties perform three primary functions between
a course of brick and its backing or another course of masonry: 1)
provide a connection, 2) transfer lateral loads, 3) permit in-plane
movement to accommodate differential movements and, in some cases,
restrain differential movement. In addition to these primary
functions, metal ties (as joint reinforcement) may also be required
to serve as horizontal structural reinforcement or provide
longitudinal continuity.
[0008] For a tie system to fulfill these functions, it must: 1) be
securely attached to both masonry courses or the brick veneer and
its backing, 2) have sufficient stiffness to transfer lateral loads
with minimal deformations, 3) have a minimum amount of mechanical
play, 4) be corrosion-resistant and 5) be easily installed to
reduce installation errors and damage to the tie system. This
listing is far from complete; special project conditions, unusual
details and special building code requirements must also be
considered. Availability and cost are always factors in product
specifications. However, cost should not have a major influence on
the selection of a wall tie system since the cost of ties is
typically a very small part of the total wall cost.
[0009] There are a number of different wall tie systems available
for brick masonry wall systems. One type of wall tie system is the
unit tie system which include rectangular "box" ties, "Z" ties and
corrugated ties. Rectangular and "Z" ties are usually fabricated
from cold-drawn steel wire and are available for use in more
corrosive environments. Rectangular and "Z" ties are used to bond
walls constructed of two or more masonry wythes. "Z" ties should
only be used to bond walls constructed with solid units (not less
than 75% solid) or grouted units. Rectangular ties may be used with
either solid or hollow units. Such wire ties should not have a bend
or dip: Bends in the tie reduce the capacity of the tie to transfer
lateral load and also facilitate water transfer. Corrugated sheet
steel ties are typically manufactured from steel sheet and are also
available in stainless steel. Corrugated ties are typically used in
low-rise, residential veneer over wood frame construction.
[0010] Another type of wall tie system available for brick masonry
wall systems includes continuous horizontal joint reinforcement
systems. Continuous horizontal joint reinforcement is typically
made from 8-11 gage wire, or 3/16 in. diameter wire, in lengths of
10 to 12 ft. The most common configurations are the ladder, truss,
and tab types. Joint reinforcement may be used in multi-wythe solid
walls, masonry cavity walls, brick veneer with masonry backing, and
grouted masonry walls. As with wire ties, the cross wires should be
without dips. Truss-type joint reinforcement is not recommended for
use in cavity walls or brick veneer with masonry backing. The
configuration of the truss diagonals can restrain differential
movement between wythes and possibly result in bowing of the
walls.
[0011] Another type of wall tie system is the adjustable tie system
which was developed to accommodate the use of face brick whose bed
joints did not align vertically with interior masonry wythes and
has been extended to ties used to attach brick to other systems,
resulting in the use of both adjustable unit ties and adjustable
ties with joint reinforcement. Adjustable unit ties typically
include typically two-piece systems, consisting of a single or
double eye and pintle arrangement. The advantages offered by
adjustable tie systems are not without possible problems: 1)
Mislocation of adjustable ties placed prior to construction of
facing wythes, if extreme, can render the ties useless. 2)
Adjustable ties may encourage less than perfect layout of the wall
system since a built-in adjustment allowance is available. 3) Large
variations in construction tolerances may not allow full engagement
of ties installed before facing wythes are constructed. 4)
Improperly positioned ties may result in large vertical tie
eccentricity. 5) The structural performance of some adjustable ties
in regard to strength and stiffness is less than that of standard
unit ties or joint reinforcement.
[0012] The most common types of wall ties used in modern
residential buildings of cement block and brick masonry
construction have traditionally been fabricated of a thin L-shaped
corrugated metal bracket. They are generally made of steel, tin or
aluminum because these materials are durable and inexpensive. The
wall tie is typically nailed or otherwise secured to the vertical
studs or header (building frame) with the horizontal section placed
on the course of bricks below it. One or more courses of brick are
then placed on the horizontal section of the wall tie and are
secured thereto with mortar. One particular size of wall tie
commonly used measures 4 inches tall by 31/2 inches per leg, and
are of 1/32 to 1/16 inch thick metal. Some metal wall ties are
protected against corrosion by hot-dip galvanizing. The density of
the galvanization will depend on the corrosive level of the
environment, however stainless steel can also be used in highly
corrosive environments. The wall ties may also be protected from
corrosion with paint or some other coating that protects exposed
areas from corrosion.
[0013] Typically, the sizing and spacing of wall ties has been
based largely on empirical information and the designer's judgment.
Typically, wall ties are installed at not less than one per three
square feet of wall area, not more than 32 inches apart
horizontally, and not more than 16 inches apart vertically. Since
wood stud framing is usually on 16'' centers, the limit of 32'' on
center horizontally would permit one tie in every other stud, but
the one tie per three square feet requirement would then limit the
vertical spacing to 13 inches, which would require that ties be
installed in every fourth course of brick, unnecessarily slowing
down the mason. Therefore, in order to comply with standards and
maximize mason productivity, it is suggested that a wall tie be
attached to each stud (at 16'' or 24'' off center) not to exceed
every 16'' vertically (6 courses for 21/4'' high units (modular and
standard) and 5 courses for 23/4'' high units (queen, princess,
king, engineer, and Norwegian).
[0014] Questions concerning strength, stiffness, corrosion and the
effects of these on the long-term performance of wall ties have
been posed. Selection of a tie system to function properly under
these conditions is further complicated by the vast number of tie
types available and the variety of materials from which they are
fabricated. Some tie systems, however, are poorly designed and do
not provide adequate load transfer for brick masonry.
[0015] Thus, one problem with metal wall ties is that the metal
bends or deforms under a sufficient load. The deformation of the
wall ties will cause the brickwork to come away from the underlying
support structure. The deformation of the member will cause cracks
and weakening of the brick structure, necessitating eventual
replacement of the wall ties and brickwork. The deformation of the
wall tie will also cause cracks, weakening and eventual failure of
the brick tie, also causing cracks or failure of the brickwork. The
cracks in the brickwork will also cause moisture to enter beneath
the brickwork thereby damaging the underlying structure and
exposing it to wood infesting insects.
[0016] It is another problem with a metal wall tie that by its
nature, steel (or other metals) is corrosive. Corrosion of the
metal wall tie can cause cracks to extend up from the ends of the
wall ties. The corrosion product of steel will occupy 10 to 20
times as much space as the steel itself. This expansion generates
tremendous pressure when confined. As mentioned herein above, this
bending from compression is capable of breaking apart the brick
masonry, or lifting the brick, thereby necessitating replacement of
the wall tie and brickwork. The corrosion of the member will also
cause cracks and weakening and eventual failure of the brick tie,
also causing cracks or failure of the brickwork. The cracks in the
brickwork will also cause moisture to enter beneath the brickwork
thereby damaging the underlying structure and exposing it to wood
infesting insects. To repair this problem, it is often necessary to
replace the wall tie with a new one. Typically, three to four
courses of the exterior brick masonry must be removed in order to
perform this repair. This is very expensive.
[0017] It is another problem with metal wall ties that metal by its
very nature will expand and contract due to thermal expansion. This
thermal expansion will inevitably cause any protective coatings
such as paint or galvanization to be decimated over time and allow
the underlying metal to be exposed to moisture, thereby causing
corrosion. Furthermore, because these coatings are relatively thin,
they are easily damaged during shipping and installation of the
wall tie. Many wall ties are shipped as a straight corrugated
strip, which is bent before installation. This bending inherently
cracks the coating at the weakest point of the wall tie. Only a
small amount of exposed metal is necessary to commence the
corrosion process in large areas of the wall tie.
[0018] Furthermore, corrosion of the metal wall tie creates greater
problems. By their nature brick and concrete are very porous. Water
can easily permeate the typical brick or concrete block. This is
the reason drainage devices (called weep holes) are typically built
into these veneers in order to prevent accumulation of moisture
between the veneer and the underlying structure of the building.
Accumulation of moisture can cause damage to the underlying wooden
or metal structure. However, some moisture is still retained
between the veneer and the structure. This inevitably leads to
corrosion of exposed metal members in the structure, i.e., the
metal wall ties. When the wall ties fail, the brick veneer loses
another anchor point on the underlying structure, which can cause
the brickwork to come away from the structure, cause cracks, or
even completely collapse.
[0019] Therefore, a need exists for a new and improved wall tie
system that can be fabricated from materials, which have sufficient
structural strength, as well as being resistant to corrosion.
[0020] The prior art includes a variety of wall tie assembles. For
example, U.S. Pat. No. 6,212,841 to Plume entitled "Brick Tie, in
Moulded Plastic," describes a brick-tie that is constructed as a
one-piece molding in plastic. The molding has a vertical arm, which
is secured to the stud by a nail, and a horizontal arm, which is
mortared between courses of bricks. The nail is located near the
junction between the arms, and the junction is chunky enough to be
inflexible. The bridge, which spans the space between the bricks
and the stud, is also thick enough to be inflexible. Although
device of Plume attempts to provide for a lightweight, corrosion
resistant structure, the device of Plume still does not provide for
a wall tie with sufficient structural strength for its intended
purpose.
[0021] U.S. Pat. No. 5,035,099 to Lapish entitled "Wall Tie,"
discloses a wall tie connector for masonry-veneer that has a
ductile attachment plate for attachment to a support frame or to
the masonry. The wall tie has a pair of protruding apertured
flanges in which a ductile bar with a keying portion is keyed into
an aperture to prevent rotation about its longitudinal axis. A
retaining tie member is slideably mounted on the bar, and is
connectable to masonry veneer or to a support member. The ductile
attachment plate may have secondary flanges orthogonal to the main
apertures flanges, and so arranged as to penetrate an insulation
layer or to key into a masonry wall. Although device of Lapish
attempts to provide a structurally durable yet flexible member, the
device of Lapish still does not provide for a wall tie having a
lightweight, corrosion resistant structure with sufficient
structural strength for its intended purpose.
[0022] Thus, the prior art devices identified above suffer a host
of disadvantages. None of the devices above provide for a wall tie
structure that is both lightweight yet structurally rigid while
also being corrosion resistant. A plastic wall tie as described
above is not suffucuently structurally rigid, and metallic or
galvanized structures still are not corrosion resistant as the
galvanization is easily damaged during transport and
installation.
[0023] Accordingly, it is an object of the present invention to
provide a new and useful wall tie structure.
[0024] Another object of the present invention is to provide a wall
tie structure that is made of composite materials such that it is
lightweight compared to prior art wall tie.
[0025] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials that have sufficient structural strength to
support or anchor the brickwork thereon.
[0026] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials and is simple and relatively inexpensive to
fabricate.
[0027] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials having a rigidifying means affixed thereto or
therein.
[0028] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials such that it is moisture impermeable.
[0029] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials such that it is corrosion resistant.
[0030] Another object of the present invention is to provide a wall
tie structure of the above-described character wherein the wall
ties are affixed to a spacing and alignment member.
[0031] The foregoing and other objects of the present invention, as
well as the invention itself, may be more fully understood from the
following description when read in conjunction with the
accompanying drawings.
SUMMARY OF THE INVENTION
[0032] In accordance with the present invention, a new and useful
lightweight moisture impermeable wall tie structure is disclosed.
The wall tie is fabricated as an L-shaped member using composite
materials. The wall tie may be rigidified using additional
stiffening materials within a thermoplastic matrix. The invention
further comprises a spacing and alignment member along which
multiple wall ties are affixed at spaced apart intervals to
accommodate the alignment and affixation of multiple wall ties
according to the space between wall studs.
[0033] Accordingly, it is an object of the present invention to
provide a new and useful wall tie structure.
[0034] Another object of the present invention is to provide a wall
tie structure that is made of composite materials such that it is
lightweight compared to prior art wall ties.
[0035] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials that have sufficient structural strength to
support or anchor the brickwork thereon.
[0036] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials and is simple and relatively inexpensive to
fabricate.
[0037] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials having a rigidifying means affixed thereto,
thereby minimizing or preventing fatigue and breakage of the wall
tie.
[0038] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials such that it is moisture impermeable.
[0039] Another object of the present invention is to provide a wall
tie structure of the above-described character that is formed of
composite materials such that it is corrosion resistant.
[0040] Additional objects and advantages of the invention will be
set forth in part in the description that follows, and in part will
be obvious from the description, or may be learned by practice of
the invention. The objects and advantages of the invention will be
obtained by means of instrumentalities in combinations particularly
pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] The accompanying drawings illustrate a complete embodiment
of the invention according to the best modes so far devised, and in
which:
[0042] FIG. 1 is a perspective view a prior art corrugated
galvanized wall tie.
[0043] FIG. 2 is a side view of a prior art wall tie showing the
operable relationship between the wall tie, the underlying
structure and the brickwork anchored/supported thereby.
[0044] FIG. 3 is an elevation view showing a brick veneer structure
and (in ghost) wall studs and wall ties thereunder showing an
incorrect installation of wall ties.
[0045] FIG. 4 is an elevation view showing a brick veneer structure
and (in ghost) wall studs and wall ties thereunder showing a
correct installation of wall ties.
[0046] FIG. 5 is a front elevation view showing the preferred
embodiment of the composite wall tie of the present invention.
[0047] FIG. 6 is a plan view of the composite wall tie in FIG.
5.
[0048] FIG. 7 is a cross-sectional side elevation view along line
7-7 of the composite wall tie of FIG. 5.
[0049] FIG. 8 is a cross-sectional side elevation view showing wall
tie having an interior frame encased in a composite material.
[0050] FIG. 9 is a cross-sectional side elevation view showing wall
tie having an interior frame encased in a composite material and
showing the composite material in the perforation and affixation
hole.
[0051] FIG. 10 is a cross-sectional view of a preferred
configuration of an angled affixation hole with fastener and
sealant.
[0052] FIG. 11 is a front elevation view of multiple wall ties
mounted on the horizontal alignment and mounting bracket.
[0053] FIG. 12 is a front elevation view of an alternate embodiment
of multiple wall ties mounted on the horizontal alignment and
mounting bracket.
[0054] FIG. 13 is a plan view of multiple wall ties mounted on the
outside of a right angle mounting bracket.
[0055] FIG. 14 is a plan view of multiple wall ties mounted on the
outside of a right angle mounting bracket.
[0056] FIG. 15 is a plan view of multiple wall ties mounted on an
obtuse angle bracket, on the exterior or the interior sides (in
ghost) of the angled bracket.
[0057] FIG. 16 is a plan view of multiple wall ties mounted on an
acute angle bracket, on the exterior or the interior sides (in
ghost) of the angled bracket. I
[0058] FIG. 17 is a plan view of multiple wall ties mounted on an
arcuate bracket on the exterior or the interior sides (in ghost) of
the rounded, arc-shaped bracket.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0059] Referring now to the figures where similar parts are
numbered the same throughout. FIG. 1 is a perspective view of a
typical embodiment of bent corrugated metal strip used as a wall
tie in the prior art. As mentioned herein above, the metal strip
typically comprises a thin steel, tin or aluminum strip having an
L-shaped cross-section. The dimensions of the unbent wall tie are
approximately 029 inch (22 gauge) thick, by 7/8'' wide by 61/2 inch
long. FIG. 2 shows the typical configuration of a prior art wall
tie affixed to a building structure and having bricks and mortar
supported or anchored therewith.
[0060] Referring now to FIGS. 3-4: FIGS. 3-4 are elevation views of
a masonry veneer with the wall studs and wall ties shown in ghost
therebehind. FIG. 3 shows a generally random distribution of wall
ties affixed to the structure underlying the brick veneer. As can
be seen, some wall ties are affixed to the structure, but are not
attached to the wall studs thereunder. The does not provide
appreciable support or anchoring to the brick veneer. Furthermore,
as is seen in FIG. 3, the wall ties are spaced unevenly and do not
provide the required support of not less than one per three square
feet of wall area, not more than 32 inches apart horizontally, and
not more than 16 inches apart vertically. In order to comply with
standards and maximize mason productivity, the wall ties should be
attached to each stud (at 16'' or 24'' off center) not to exceed
every 16'' vertically (6 courses for 21/4'' high units (modular and
standard) and 5 courses for 23/4'' high units, as is shown in FIG.
4.
[0061] Referring now to FIGS. 5-10: In these embodiments, the wall
tie 1 comprises a composite structure having a generally L-shaped
cross-section. The wall tie 1 has a vertical leg 20 which is
affixed to the underlying structure (building header or wall stud)
and which is rigidly attached to a horizontal leg 10, about which
bricks and mortar are laid. The dimensions are 1/40-1/8 inches and
preferably at least 0.023-0.040 inch (17-30 gauge) thick, by
0.75-2.5 inch wide for each leg and a length between 3-5 inches for
the vertical leg 20 and 2-3 inches for the horizontal leg 10. In
the preferred embodiment, the vertical leg 20 is 4 inches tall by 2
inches wide and the horizontal leg 10 is 3 inches long and 2 inches
wide.
[0062] The materials of construction of the vertical leg 20 and
horizontal leg 10 of the wall tie 1 are preferably composite
materials that are lightweight (relative to the prior art steel
composition). In the preferred embodiment of the invention, the
primary material of construction of the wall tie 1 is preferably a
thermoplastic material that is lightweight and has a high tensile
strength. Examples of such preferred thermoplastics includes
Acrylic, ABS (and glass fiber reinforced ABS), Acetyl Copolymer (AC
and glass reinforced AC), High Density PolyEthylene (HDPE), Ultra
High Molecular Weight PolyEthylene (UHMPE), Nylon (including heat
stabilized, impact modified, glass-filled, polyamide and copolymer
flame retardant nylons, and combinations thereof), Polycarbonate,
Polypropelene, Polyimide (PI and glass fiber reinforced PI),
Polyamide-Imide, Polystyrene, Teflon.TM., and Epoxies.
[0063] More specifically, the substances that may be used as a
composite construction of or coating for a composite wall tie
include: Acrylonitrile/Methylacrylate copolymer; Regenerated
Cellulose; Cellulose Acetate (CA); Cellulose Acetate Butyrate
(CAB); Cyclo-olefin copolymer; Ethylene-Chlorotrifluoroethylene
copolymer (E-CTFE); Ethylene-Tetrafluoroethylene Copolymer (ETFE);
Fluorinated Ethylene Propylene Copolymer (FEP);
Polyacrylamide/acrylate Hydrogel;
Hexafluoropropylenevinylidenefluoride copolymer (FKM);
Polyacrylonitrile (PAN); Polyacrylonitrile-butadiene-styrene (ABS);
Polyamide-Nylon 4,6 (PA 4,6); Polyamide-Nylon 6 (PA 6);
Polyamide-Nylon 6,6 (PA 6,6); Polyamide-Nylon 6,6-30% Glass Fiber
Reinforced (PA 6,6 30% GFR); Polyamide-Nylon 11 (PA 11);
Polyamide-Nylon 12 (PA 12); Polyamide/imide (PAI); Polyaramid
Polyparaphenylene terephthalamide; Polyaramid Polymetaphenylene
isophthalamide; Polybenzimidazole (PBI); Polybutylene terephthalate
(PBT); Polybutylene terephthalate-30% Glass Fiber Reinforced (PBT
30% GFR); Polycarbonate (PC); Polycarbonate-30% Glass Fibre Filled;
Polychlorotrifluoroethylene (PCTFE); Polyetheretherketone (PEEK);
Polyetherimide (PEI); Polyethersulfone (PES); Polyethylene-Carbon
filled; Polyethylene-High density (HDPE); Polyethylene-Low Density
(LDPE); Polyethylene-Ultra High molecular Weight (UHMW PE);
Polyethylene naphthalate (PEN); Polyethylene terephthalate
Polyester, (PET, PETP); Polyhydroxybutyrate-Biopolymer (PHB);
Polyhydroxybutyrate/Polyhydroxyvalerate 8%-Biopolymer (PHB92/PHV
8); Polyimide (PI); Polymethylmethacrylate (PMMA); Acrylic;
Polymethylpentene; Polyoxymethylene-Copolymer Acetal-Copolymer
(POMC); Polyoxymethylene-Homopolymer Acetal-Homopolymer (POMH);
Polyphenyleneoxide PPO (modified), PPE (modified);
Polyphenyleneoxide (modified), 30% Glass Fiber Reinforced (PPO 30%
GFR); Polyphenylenesulfide (PPS); Polyphenylenesulfide-40% Glass
Fiber Reinforced (PPS-40% GFR); Polyphenylsulphone; Polypropylene
(PP); Polystyrene (PS); High Impact Conductive Polystyrene;
Polystyrene-Cross-linked (PS-X-Linked); Polytetrafluoroethylene
(PTFE); Polytetrafluoroethylene coated Glass Fabric (PTFE 75/Glass
25); Polytetrafluoroethylene filled with Glass (PTFE 25% GF);
Polyvinylchloride-Unplasticized (UPVC); Polyvinylfluoride (PVF);
Polyvinylidenechloride (PVDC); Polyvinylidenefluoride (PVDF);
Silicone Elastomer; and Tetrafluoroethylene-perfluoro(alkoxy vinyl
ether)-Copolymer PFA. (Teflon PFA).
[0064] As an example of the properties of HDPE which make it
desirable as a material for a light-weight corrosion resistant
(moisture impermeable) material of construction for a wall tie
structure are the following properties: HDPE has a density of
0.0338-0.0348 lb/in.sup.3 (0.948 g/cc); Water Absorption of 0.01%;
Moisture Vapor Transmission of 0.965 cc-mil/100 in.sup.2-24 hr-atm;
Tensile Strength of 3480-6530 psi (30 Mpa); Yield Strength of
2180-4350 psi (21.9 Mpa); a Tensile Modulus 116-144 ksi (0.86 Gpa);
a Flexural Modulus of 72.5-220 ksi (0.928 Gpa); a linear
Coefficient of Thermal Expansion (CTE) at 20.degree. C. of 77.8
.mu.in/in; and a Melting Point of 255-268.degree. F. (130.degree.
C.). Thus desirable physical properties include low density for
light weight (0.5-3.0 g/cc); Low Water absorption (less than 0.1%);
a low CTE (less than 250 .mu.in/in); relatively high melting point
(more than 160.degree. F./60.degree. C.); High tensile strength of
(15-100 Mpa); High Yield Strength (5-40 Mpa); a relatively high
Tensile Modulus (0.5-2.5 Gpa); a relatively high Flexural Modulus
(0.7-4.0 Gpa).
[0065] Each of the horizontal legs 10 and vertical legs 20 has
opposing surfaces that provide functionality to the composite wall
tie 1 structure. The horizontal leg 10 has a top face 10b and a
bottom opposing face 10a, a front edge 10c and rear edge 10d, as
well as left and right side edges 10e, 10f. The bottom face 10a and
top face 10b of the horizontal leg 10 are substantially flat and
these faces 10a, 10b are situated between the bricks and/or mortar
of the wall anchored thereby. The front edge 10c, left edge 10e and
right edge 10f and also situated within the mortar between vertical
courses of bricks and adjacent bricks in a course. The vertical
legs 20 have front 20a and back 20b opposing faces. The back face
20b of the vertical leg 20 is substantially flat and abuts the
underlying building structure to which it is attached. The front
face 20a of the vertical leg 20 is adjacent to the bricks that are
laid around the top face 10b and the bottom face 10a of the
horizontal leg 10. The vertical leg also has a top portion 20c and
a bottom portion 20d, which bottom portion 20d is rigidly attached
to the rear edge 10d of the horizontal leg 10.
[0066] Referring to FIGS. 8-9: In order to increase the tensile and
flexural strength of the lightweight composite wall tie 1 and
comply with certain building codes, another embodiment of the
composite wall tie 2 may also include a substrate 200 comprising
metal frame/substrate or other interior support member located
between the front and back faces 20a, 20b of the vertical leg 20
and between the top and bottom faces 10b, 10a of the horizontal leg
10. More specifically, in this embodiment of a composite wall tie 2
a solid interior frame or substrate 200, comprises a vertical
substrate leg 220 rigidly attached to a horizontal substrate leg
210 constructed as described above, which is located between the
front and back faces 20a, 20b of the (plastic) vertical leg 20 and
between the top and bottom faces 10b, 10a of the (plastic)
horizontal leg 10. A metallic substrate 200 also allows for simple
detection of the placement of the wall tie 2 by magnetic means,
thereby facilitating location and repair of any wall ties 2 that
need repair or replacement.
[0067] The material of construction of the substrate 200 may be
selected from the group of high tensile and flexural strength
metals such as iron, steel, aluminum, tin, titanium, beryllium and
mixtures, oxides and metal alloys. The material of construction of
the substrate may also be selected from the group of high strength
materials such as carbon, carbon fibers, concrete and glass
reinforced or carbon fiber reinforced plastics and other materials
having high tensile and flexural strength. Furthermore, the
substrate may include various combinations of the aforementioned
metallic and/or other composite materials.
[0068] The interior support structure may include for example solid
substrates (vertical and horizontal legs 220, 210 of the substrate
rigidly affixed to each other) which are encased in or coated with
the aforementioned thermoplastic material. Furthermore, rather than
a solid interior frame 200, the substrate 200 or support structure
may include a mesh, wire frame or particulate composite disposition
of the aforementioned materials of composition. In addition, in
order to comply with building codes, the substrate and/or composite
may also comprise fire and/or heat resistant compositions including
asbestos and/or carbon.
[0069] As mentioned herein above in one embodiment of the
invention, the lightweight composite material (primarily a
thermoplastic substance) may be used alone or may be used to encase
an interior support structure 200. Preferably the thermoplastic is
applied to the support structure 200 by spray coating. However, the
materials may be combined by insertion of the support structure 200
within an extruded plastic casing. The thermoplastic may also be
heated to enhance adhesion of the casing (vertical and horizontal
legs 20, 10) to the internal support structure 200. The thickness
of the casing is preferably sufficient to prevent permeation of
moisture therethrough and onto the support structure to prevent
oxidation of the internal structure 200. Preferably, the casing has
a thickness of at least 0.005-0.015 inch thickness and the interior
support 200 has a thickness ranging between 0.005 to 0.025 inch
thickness. Preferably the overall thickness of the wall tie legs
10, 20 is 0.025-0.040 inch However, the horizontal leg 10 and the
vertical leg 20 may range in thickness from as little as 0.015 inch
to as much as 0.10 inch depending on the materials of construction
of the wall tie 1, 2 and their load bearing capabilities.
[0070] Referring again to FIGS. 5-7. In yet another embodiment of a
wall tie 3, the material of construction of the horizontal leg 10
and vertical leg 20 may be selected from the group of high tensile
and flexural strength and preferably non-corrosive metals such as
iron, steel, stainless steel, aluminum, tin, titanium, beryllium
and mixtures, oxides and alloys of those metals. The material of
construction of the wall tie 3 may also be selected from the group
of high strength materials such as carbon, carbon fibers, concrete
and glass reinforced or carbon fiber reinforced plastics and other
materials having high tensile and flexural strength. Furthermore,
the wall tie 3 may include various combinations of the
aforementioned metallic and/or other composite materials. As used
herein, the description of the further components of the wall tie 1
apply equally to the second and third embodiments of the wall tie,
2, 3.
[0071] In an exemplary embodiment, the above described wall tie 1,
2, 3 is used with a course of typical bricks. Modular bricks have
typical nominal dimensions of 4 inches in width (31/2-35/8 inch) by
8 inches in length (71/2-75/8 inch) and nominal heights of 22/3,
31/5 and 4 inches, and a joint thickness (for mortar) of 3/8 to 1/2
inch. Multiple wall ties 1, 2, 3 are preferably secured to the
underlying building structure to be 16 inches (on center) apart to
anchor alternate bricks (15 inches) with a 3/8 to 1/2 inch of
mortar between each adjoining brick side face. Each wall tie 1-3 is
situated between two vertically adjacent bricks with 1/4-1/2 inch
of mortar between the brick bottom and top faces adjacent the top
face 10b and bottom face 10a of the horizontal leg 10 of the wall
tie 1-3.
[0072] Referring to FIGS. 5-7 and 9-10: In order to affix the wall
tie 1-3 to the underlying building structure, affixation holes 40
are provided through the vertical leg 20 of the wall tie 1, 2, 3.
The holes 40 allow placement of a fastener 45 therethrough to allow
for said fastener 45 to secure the vertical leg 20 of the wall tie
1, 2 to the underlying structure. Preferably, the affixation holes
40 also have the thermoplastic composite on the faces 40a of the
holes 40 (on the hole faces 40a normal to the front and back faces
20a, 20b of the vertical leg 20) to prevent moisture from
contacting the substrate 200 in the reinforced wall tie 2, thereby
preventing oxidation of the substrate 200. The fastener 45
preferably comprises a nail of 4-6 inches in length and 3/16- 5/16
inch diameter. They are preferably hot-dipped, galvanized or
plastic coated metallic fasteners 45. The fastener 45 may also
comprise a barbed nail or a screw and may also comprise a strong
plastic or Teflon fastener 45 that can withstand a hammer drive
into the structure.
[0073] There are preferably at least two affixation holes 40
through the vertical leg 20 of the wall tie 1-3 on opposing ends of
the vertical leg 20 of the wall tie 1, i.e. one each hole 40 in the
top portion 20c and bottom portion 20d of the vertical leg 20. Wall
studs (2.times.4 or 2.times.6 boards forming part of the building
frame which are typically spaced 16 inches on center) provide a
more secure attachment of the wall tie 1 to the underlying building
structure. The central axis of the securing/affixation holes 40 may
be normal to the front and back faces 20a, 20b of the vertical leg
20 of the wall tie 1 (as well as the abutting face of the
underlying building structure). However, in the preferred
embodiment of the invention, the securing holes 40 have an axis
relating to the face of the underlying structure at substantially
45 degrees. More specifically, the holes 40 are related to the
abutting face of the underlying building structure "downwardly"
(approximately 45 degrees off vertical) to provide for greater load
transference and a secure attachment from the wall tie 1 to the
fastener 45 and from the fastener 45 to the vertical leg 20,
through the fastener 45 and to underlying building structure. The
angle of the axis between the affixation hole 40 and the face of
the underlying structure can vary between 115 degrees and 15
degrees off vertical, but is preferably 45 degrees off
vertical.
[0074] To enhance the moisture impermeability of the wall tie 1
structure and further prevent corrosion, the affixation holes 40
are preferably filled with a self-sealing substance 47 between the
fastener 45 and the interior (composite/plastic coated) walls 40a
of the affixation holes 40. The self-sealing substance 47
preferably comprises tar, but may also include rubber, silicone,
and other moisture impermeable sealing compounds. Also to prevent
the onset of corrosion, the materials of construction of the
fasteners 45, which may be nails, screws or other anchors are
preferably selected from the variety of corrosion resistant
materials including galvanized metal, Teflon.TM., polyester, and
the materials of construction listed herein above as the composite
materials of construction of the wall tie structure. Thus, when the
fastener 45 is affixed through the affixation hole 40 to the
underlying building structure, the self sealing substance 47 forms
a moisture impermeable layer between the fastener 45 and the
affixation hole 40 as well as a moisture impermeable barrier
between the fastener 45, upper wall tie 1 leg and the underlying
building structure. Furthermore, the wall tie 1 may be
prefabricated with the fasteners 45 already partially imbedded
within the sealing compound 47 in the affixation holes 40 in order
to provide ease of installation.
[0075] Referring to FIGS. 5-7 and 9: To enhance adhesion of the
mortar and/or bricks to the surfaces of the wall tie 1-3, i.e., the
faces of vertically adjacent bricks, the bottom face 10a and top
face 10b of the horizontal leg 10 are preferably textured such as a
sanded, corrugated, dimpled and/or perforated texture. Such
texturing enhances adhesion of mortar thereto and/or therethrough
to provide a firm anchorage of the mortar and bricks to the faces
of the horizontal leg 10. More specifically, the wall tie
preferably has adhesion enhancing surfaces on and/or the top and
bottom faces 10b, 10a of the horizontal leg 10 of the wall tie 1
comprising perforations 50 and bristles 60, i.e., spaced apart
raised bumps or protuberances.
[0076] Referring again to FIGS. 5-7 and 9: One or more surfaces of
the horizontal leg 10 of the wall tie are fabricated so as to
enhance the adhesion of the mortar and thereby adjacent bricks to
those surfaces. More specifically, the bottom face 10a and top face
10b of the horizontal leg 10 have raised surfaces thereon
comprising spaced apart bumps or protuberances and most
specifically stiff bristles 60. The texture of the bristles 60 is
that of a stiff brush or comb raised above the underlying surfaces
of the horizontal leg 10. Each protuberance 60 or bristle is
essentially cylindrical with a diameter of 10-50 mils and 10 mils
to 1/8 inch in length. While the bristles are preferably
cylindrical, they may also comprise other geometric prisms, i.e.,
circular, elliptical, rectangular, triangular, pentagonal,
hexagonal and other regular and irregular polygonal prisms. The
combed surface covers 10-60 percent of the top face 10b and/or
bottom face 10a of the horizontal leg 10. Preferably the bristles
60 cover 40 to 50 percent of the opposing top and bottom faces 10b,
10a of the leg. Furthermore, the front edge 10d and/or left and
right side edges 10e, 10f of the horizontal leg 10 may also have
protuberances 60 there on to enhance adhesion in and to the mortar
and to restrict movement of the horizontal leg 10 within the mortar
between adjacent bricks. The protuberances 60 on the front and side
edges of the horizontal leg 10 comprise one or more bristles 60
spaced apart in one or two rows of protuberances along these
smaller edges 10c, 10e, 10f. Furthermore, the top and bottom faces
10b, 10a and front and side edges 10c, 10e, 10f as well as the
protuberances 60 may further be textured such as a sanded,
corrugated, dimpled and/or perforated texture.
[0077] Referring again to FIGS. 5-7 and 9: The horizontal leg 10
preferably also has perforations, i.e., holes 50 therethrough
running between the top and bottom faces 10b, 10a of the horizontal
leg 10 of the wall tie 1 or 2 or 3. These holes 50 provide an
additional interior surface to which the mortar can adhere within
the horizontal leg 10 of the wall tie 1, thereby providing and even
stronger anchoring of the wall tie 1 to the mortar between adjacent
bricks. Furthermore the holes 50 allow any accumulated moisture in
the bricks and/or mortar to drain out from the brick and/or mortar
through the wall tie 1 structure. Draining of moisture prevents
accumulation of moisture in the veneer thereby minimizing moisture
damage to the wall tie 1 and the underlying structure to which the
wall tie 1 is affixed. There is preferably at least one hole 50
through the horizontal leg 10 of the wall tie 1, and more
preferably a plurality of holes 50 through the horizontal leg 10 of
the wall tie 1. Preferably the holes 50 in the horizontal leg 10
are essentially cylindrical with a diameter of 10-50 mils and 10
mils to 1/8 inch in length, i.e., the thickness of the horizontal
leg 10. The holes extend through 10-60 percent the horizontal leg
10 from the top face 10b to bottom face 10a. Most preferably, and
to ensure the strength of the horizontal leg 10 is not compromised,
the holes 50 extend through only 10-30 percent of the horizontal
leg 10. The holes 50 may be spaced at regular intervals or may be
randomly distributed through the horizontal leg 10 of the wall tie
1.
[0078] Referring to FIG. 9: In the embodiments of the wall tie 2
having a substrate 200 therein, preferably the holes 50 also extend
through the substrate 200 and also have the thermoplastic composite
on the faces 50a of the holes 50 (on the hole faces 50a normal to
the top and bottom faces 10b, 10a of the horizontal leg 10) to
prevent moisture from contacting the substrate 200, thereby
preventing oxidation of the substrate 200 within the composite wall
tie 2.
[0079] Referring now to FIGS. 11-12: In the composite wall tie
system, a series of wall ties 1, 2 are secured at regular intervals
to a spacing, alignment and supporting bracket 100 comprising a
strip of material designed to best distribute, align and affix a
series of wall ties 1, 2 to a building structure. The materials of
construction of the bracket 100 are described above in the
materials of construction of the wall tie 1. The strip is
preferably one inch in height, i.e., in the longer dimension of the
vertical leg 20, and 1/40 to 1/4 inch thick, i.e., in the dimension
normal to the front and rear faces 20a, 20b of the vertical leg 20.
The supporting bracket 100 comprises a strip of composite material
to which the back faces 20b of the vertical leg 20 of the wall ties
1 are affixed. Alternately and preferably, the bracket strip 100 is
integral with a portion of the vertical leg 20 of the wall tie 1
such that the front and back sides of the strip 100 are flush and
integral with the front and back faces 20a, 20b of the vertical leg
20 of the wall tie 1 thereby allowing the back face 100b of the
strip 100 and the back face 20b of the vertical leg 20 to be flush
with the surface of the building structure to which it is attached.
The bracket 100 is preferably four feet long in order to be
compatible with the four foot widths of plywood that are used in
building structures. However, the composite wall tie system may
comprise any number of wall ties evenly spaced on a longer bracket
strip and may even comprise a flexible strip 100 packaged in a
roll.
[0080] As is shown in FIGS. 11-12, the strip 100 may be located
anywhere along the back 20b of the vertical leg 20. As is shown in
FIG. 11, the bracket 100 may be located on the bottom portion 20d
of the vertical leg 20, either flush with the bottom, i.e.,
adjacent the rear edge 10c of the horizontal leg 10, or above that
edge. Likewise, as is shown in FIG. 12, the bracket 100 may be
located on the top portion 20c of the vertical leg 20, either flush
with the top edge or below that edge. Most preferably, the strip
100 is located in the bottom portion 20d of the vertical leg, and
above the lower affixation hole 40 so as not to interfere with the
affixation of the wall tie 1 to the building structure.
Alternately, the affixation hole 40 may also extend through the
bracket 100. The wall ties 1, 2 are preferably spaced 16 inches
apart on center in order for them to be affixed to wall studs which
are typically 16 inches apart on center in a typical building
structure. In some structures or portions of structures the studs
are spaced apart by 20 inches on center. Therefore in another
embodiment of the wall tie system with the bracket, the wall ties
are spaced apart by twenty inches on center.
[0081] Referring now to FIGS. 13-17: While most wall ties are
installed in straight lines, i.e., along a horizontal line on a
planar wall of a building structure, it is also within the scope of
this invention to have wall ties spaced apart on a bracket spanning
angles for the corners or rounded portions of a building structure.
In FIGS. 13 and 14 the wall ties 1, 2 are shown attached to a right
angle bracket 101, on the exterior and the interior sides of the
angled bracket 101 respectively. In FIG. 15 the wall ties 1, 2 are
shown attached to an obtuse angle bracket 102, on the exterior or
the interior sides (in ghost) of the angled bracket 102. In FIG. 16
the wall ties 1, 2 are shown attached to an acute angle bracket
103, on the exterior or the interior sides (in ghost) of the angled
bracket 103. In FIG. 17 the wall ties 1, 2 are shown attached to an
arcuate bracket 104, on the exterior or the interior sides (in
ghost) of the rounded, arc-shaped bracket 104.
[0082] In each of the angled brackets of FIGS. 13-16, the bracket
has an angled portion 110 which conforms to the angle of the
underlying building structure. In the angled brackets 101-103, the
brackets may have a rigid angled shape 110 of solid construction.
Alternately, the brackets 101-103 may have a prefabricated crimp
120 therein to allow the bracket 101-103 to be bent into a variety
of angles from acute to obtuse to right angles to conform to any
desired angle of the underlying building structure. In the rounded
bracket 104 of FIG. 17 the bracket 104 may be fabricated from rigid
materials with a variety of curvatures, but most preferably on
rounded surfaces uses flexible bracket material suited to conform
to any rounded surface.
[0083] While the principles of the invention have now been made
clear in illustrated embodiments, there will immediately be obvious
to those skilled in the art, many modifications of structure,
proportions, elements, materials, and components used in the
invention, which are particularly adapted for specific environments
and application requirements without departing from those
principles. Therefore, by the appended claims, the applicants
intend to cover any modifications and other embodiments as
incorporate those features which constitute the essential features
of this invention.
* * * * *