U.S. patent application number 15/533782 was filed with the patent office on 2017-12-21 for thermally broken anchor and assembly including the same.
This patent application is currently assigned to Dow Corning Corporation. The applicant listed for this patent is Dow Corning Corporation. Invention is credited to Lawrence Donald CARBARY, Jary D. JENSEN.
Application Number | 20170362816 15/533782 |
Document ID | / |
Family ID | 55168394 |
Filed Date | 2017-12-21 |
United States Patent
Application |
20170362816 |
Kind Code |
A1 |
CARBARY; Lawrence Donald ;
et al. |
December 21, 2017 |
THERMALLY BROKEN ANCHOR AND ASSEMBLY INCLUDING THE SAME
Abstract
An anchor for securing together interior and exterior building
components includes a first end having an outer side for engaging
the interior building component and an inner side opposite the
outer side. The anchor further includes a second end having an
outer side and an inner side opposite the outer side of the second
end for engaging the exterior building component. A thermal break
for reducing thermal bridging between the exterior and interior
building components is disposed in a space between the inner sides
of the ends and has a first coupling surface bonded to the inner
side of the first end and a second coupling surface bonded to the
inner side of the second end. An assembly includes the anchor for
securing together the interior and exterior building
components.
Inventors: |
CARBARY; Lawrence Donald;
(Midland, MI) ; JENSEN; Jary D.; (Sanford,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dow Corning Corporation |
Midland |
MI |
US |
|
|
Assignee: |
Dow Corning Corporation
Midland
MI
|
Family ID: |
55168394 |
Appl. No.: |
15/533782 |
Filed: |
December 16, 2015 |
PCT Filed: |
December 16, 2015 |
PCT NO: |
PCT/US2015/066097 |
371 Date: |
June 7, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62093032 |
Dec 17, 2014 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/7608 20130101;
Y02A 30/261 20180101; E04B 1/40 20130101; Y02B 30/94 20130101; Y02B
30/90 20130101; E04F 13/0801 20130101; Y02A 30/00 20180101 |
International
Class: |
E04B 1/41 20060101
E04B001/41; E04F 13/08 20060101 E04F013/08; E04B 1/76 20060101
E04B001/76 |
Claims
1. An assembly for a structure, said assembly comprising: an
interior building component; an exterior building component spaced
from said interior building component; and an anchor disposed
between said building components to secure said exterior building
component to said interior building component, said anchor
comprising; a first end having an outer side for engaging said
interior building component and an inner side opposite said outer
side of said first end; a second end having an outer side for
engaging said exterior building component and an inner side
opposite said outer side of said second end, said inner sides of
said ends facing each other with a space defined therebetween; and
a thermal break disposed in the space, with said thermal break
having a first coupling surface bonded to said inner side of said
first end and a second coupling surface opposite said first
coupling surface and bonded to said inner side of said second end;
wherein a thermal conductivity of said thermal break is lower than
a thermal conductivity of at least one of said ends to reduce
thermal bridging between said building components while said
building components are subject to a temperature difference between
said building components.
2-14. (canceled)
15. A structure comprising said assembly as set forth in claim
1.
16. An anchor for securing an exterior building component to an
interior building component, said anchor comprising: a first end
having an outer side for engaging the interior building component
and an inner side opposite said outer side of said first end; a
second end having an outer side for engaging the exterior building
component and an inner side opposite said outer side of said second
end, said inner sides of said ends facing each other with a space
defined therebetween; and a thermal break disposed in the space,
said thermal break having a first coupling surface bonded to said
inner side of said first end and a second coupling surface opposite
said first coupling surface and bonded to said inner side of said
second end; wherein a thermal conductivity of said thermal break is
lower than a thermal conductivity of at least one of said ends to
reduce thermal bridging between the building components while the
building components are subject to a temperature difference between
the building components.
17. The anchor as set forth in claim 16, wherein said thermal break
adhesively bonds said ends together.
18. The anchor as set forth in claim 16, wherein said thermal break
exclusively bonds said ends together.
19. The anchor as set forth in claim 16, wherein the thermal
conductivity of said thermal break is lower than the thermal
conductivity of each of said ends.
20. The anchor as set forth in claim 16, wherein: i) said thermal
break comprises a polymeric material; ii) each of said ends
comprises a metallic material; or iii) both i) and ii).
21. The anchor as set forth in claim 16, wherein said thermal break
comprises a silicone, alternatively comprises a silicone
rubber.
22. The anchor as set forth in claim 16, wherein said thermal break
comprises an epoxy, alternatively comprises an epoxy adhesive.
23. The anchor as set forth in claim 16, wherein said thermal break
comprises an elastomer selected from the group consisting of
thermoplastic elastomers, unsaturated rubbers, saturated rubbers,
and mixtures thereof.
24. The anchor as set forth in claim 23, wherein said thermal break
comprises a thermoplastic elastomer selected from the group
consisting of styrenic block copolymers, polyolefins, elastomeric
alloys, polyurethanes, copolyesters, polyamides, and mixtures
thereof.
25. The anchor as set forth in claim 23, wherein said thermal break
comprises a unsaturated rubber selected from the group consisting
of polyisoprenes, polybutadienes, chloroprenes, butyl rubbers,
styrene-butadienes, nitrile rubbers, and mixtures thereof.
26. The anchor as set forth in claim 23, wherein said thermal break
comprises a saturated rubber selected from the group consisting of
ethylene propylene rubber, ethylene propylene diene rubber,
epichlorohydrin rubber, polyacrylic rubber, silicone rubber,
fluorosilicone rubber, fluoroelastomers, perfluoroelastomers,
polyether block amides, chlorosulfonated polyethylene,
ethylene-vinyl acetate, and mixtures thereof.
27. The anchor as set forth in claim 16, wherein each of said ends
comprises iron, alternatively comprises steel.
28. The anchor as set forth in claim 16, wherein said thermal break
has a cross-sectional area of from about 1 to about 800 square
centimeters (cm.sup.2) or about 0.5 to about 120 square inches
(in.sup.2).
29. The anchor as set forth in claim 16, wherein said thermal break
has an average thickness of from about 1 to about 50 millimeters
(mm) or about 0.05 to about 2 inches (in).
30. The anchor as set forth in claim 16, wherein said inner sides
are configured to mechanically catch in the event of fire burning
away said thermal break.
31. A method of securing an exterior building component to an
interior building component spaced from the exterior building
component, said method comprising the steps of: providing an
anchor; attaching the anchor to one of the building components to
form a sub-assembly; and connecting the sub-assembly and the
remaining building component to secure the exterior building
component to the interior building component; wherein the anchor is
as set forth in claim 16.
32. The anchor as set forth in claim 16, wherein each of said inner
sides includes a catch structure, and wherein said catch structures
are complimentary with and spaced apart from each other.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 62/093,032, filed Dec. 17, 2014, the content of
which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to an anchor and to
an assembly for a structure, more specifically to an anchor and to
an assembly comprising interior and exterior building components,
with the anchor disposed between the building components and having
a thermal break for reducing thermal bridging between the building
components while the building components are subject to a
temperature difference between the building components.
DESCRIPTION OF THE RELATED ART
[0003] In many commercial or industrial buildings, L- or Z-brackets
are used to mechanically attach external building components (e.g.
cladding) to internal building components (e.g. structural walls or
sub-frames). A continuous span of insulation is often in contact
with at least the internal building component. The brackets pass
through seams in the insulation so that the external component can
be attached to the brackets, which were previously attached to the
interior building component. The brackets transfer climactic loads
(e.g. wind loads) of the environment from the external building
component to the internal building component. The brackets must be
strong enough to support climactic loads and also weight of the
external building component(s). Therefore, the brackets are often
formed from metal (e.g. steel or aluminum). Unfortunately, since
the aforementioned brackets are formed from metal, they act as
direct thermal shorts between the exterior and interior building
components. Various systems have been proposed in an effort to
reduce heat transfer (i.e., heat loss or gain) between building
components.
[0004] One system utilizes a ThermaStop.TM. thermal isolation
system, which is commercially available from Knight Wall Systems of
Deer Park, Wash. The ThermaStop.TM. system utilizes 55 AL-ZN-coated
steel brackets with plastic bases and integral 1/8-inch plastic
washers. While the ThermaStop.TM. system has a relatively narrow
cross-section, the cross-section is formed from steel which passes
through insulation and acts as a direct thermal short.
[0005] Another system utilizes a CASCADIA CLIP.RTM., which is
commercially available from Cascadia Windows Ltd. of Langley, BC,
Canada. The CASCADIA CLIP.RTM. is a fiberglass girt spacer, and is
illustrated in U.S. Design Pat. No. D666,894 S to Bombino et al.
and U.S. Patent Application Publication No. US2013/0174506 A1 to
Bombino et al. While formed from fiberglass, the CASCADIA CLIP.RTM.
relies on conventional metal fasteners (e.g. lag screws) that act
as direct thermal shorts. In addition, the CASCADIA CLIP.RTM. can
be difficult and time consuming to install.
[0006] Another system utilizes a thermal insulation material (TIM),
which is commercially available from FABREEKA.RTM. of Boston, Mass.
The TIM is manufactured from a fiberglass-reinforced laminate
composite. While formed from fiberglass, the TIM is a merely a pad
used between flanged steel connections. The steel connections must
be connected via conventional metal fasteners (e.g. bolts) that act
as direct thermal shorts. In addition, the TIM can be difficult and
time consuming to install.
[0007] Yet another system utilizes a POS-I-TIE.RTM.
ThermalClip.RTM., which is commercially available from Heckmann
Building Products, Inc. of Melrose Park, Ill. The ThermalClip.RTM.
is formed from polyphenylsulfone (PPSU), has a snap on design, and
is described in U.S. Patent Application Publication No.
US2013/0232909 A1 to Curtis et al. The ThermalClip.RTM. is used in
masonry construction. While formed from PPSU, the ThermalClip.RTM.
relies on conventional metal wire ties that can act as direct
thermal shorts. In addition, the ThermalClip.RTM. can be difficult
and time consuming to install.
[0008] In view of the foregoing, there remains an opportunity to
provide systems that reduce or negate heat transfer. There also
remains an opportunity to provide systems that are easier and less
time consuming to install.
SUMMARY OF THE INVENTION
[0009] An anchor is disclosed. The anchor is useful for securing an
exterior building component to an interior building component. The
anchor comprises a first end having an outer side for engaging the
interior building component. The anchor also comprises an inner
side opposite the outer side of the first end. The anchor further
comprises a second end having an outer side for engaging the
exterior building component. The anchor yet further comprises an
inner side opposite the outer side of the second end. The inner
sides of the ends face each other. A space is defined between the
inner sides of the ends. A thermal break is disposed in the space.
The thermal break has a first coupling surface bonded to the inner
side of the first end. The thermal break also has a second coupling
surface opposite the first coupling surface and bonded to the inner
side of the second end. Thermal conductivity of the thermal break
is lower than thermal conductivity of at least one of the ends. The
thermal break generally reduces thermal bridging between the
building components while the building components are subject to a
temperature difference between the building components.
[0010] An assembly is also disclosed. The assembly comprises the
interior and exterior building components, which are spaced from
each other to define the space. The anchor is disposed between the
building components. The anchor secures the exterior building
component to the interior building component, and generally reduces
thermal bridging therebetween. The assembly is useful for a
structure, such as for a building.
[0011] A method is also disclosed. The method entails securing the
exterior building component to the interior building component. The
method comprises the steps of providing the anchor and attaching
the anchor to one of the building components to form a
sub-assembly. The method further comprises the step of connecting
the sub-assembly and the remaining building component to secure the
building components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Other advantages of the disclosure will be readily
appreciated, as the same becomes better understood by reference to
the following detailed description when considered in connection
with the accompanying drawings wherein:
[0013] FIG. 1A is a perspective view of an anchor of the
disclosure;
[0014] FIG. 1B is an exploded perspective view of the anchor in
FIG. 1A;
[0015] FIG. 2 is a perspective view of another anchor of the
disclosure;
[0016] FIG. 3 is a photograph of a portion of an assembly having
exterior and interior building components, clips, and rigid foam
insulation; and
[0017] FIG. 4 is a side view of an assembly having an exterior
building component and interior building components and the anchor
according to FIG. 2 used for securing the exterior building
component to the interior building component;
[0018] FIG. 5 is a side section view of an anchor in accordance
with another embodiment of the disclosure including a catch
structures positioned within a thermal break;
[0019] FIG. 6 is a side section view of the anchor of FIG. 5 in
which the thermal break is removed and wherein the catch structures
are interlocked and engaged to one another.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring to the Figures, wherein like numerals indicate
like parts throughout the several views, an anchor is shown
generally at 20. The anchor 20 is useful for securing an exterior
building component 46 to an interior building component 48. The
building components 46, 48 are described further below and
illustrated in FIGS. 3-6.
[0021] The anchor 20 comprises a first end 22 having an outer side
24. The outer side 24 is useful for engaging the interior building
component 46. The anchor 20 further comprises an inner side 26
opposite the outer side 24 of the first end 22. The first end 22
can be of various sizes, dimensions, and shapes. Referring to FIG.
1, the first end 22 is generally configured as a T-bracket. As
shown in FIG. 2, the first end 22 is generally configured as a
flat-bracket. While the T- and flat-bracket configurations (or
designs) are shown, the first end 22 can be of various
configurations and is not limited to a particular one.
[0022] The anchor 20 further comprises a second end 28 having an
outer side 30. The outer side 30 is useful for engaging the
exterior building component. The anchor 20 yet further comprises an
inner side 32 opposite the outer side 30 of the second end 28. The
second end 28 can be of various sizes, dimensions, and shapes. As
shown in FIGS. 1 and 2, the second end 28 is generally configured
as a T-bracket. While the T-bracket configuration is shown, the
second end 28 can be of various configurations and is not limited
to a particular one. The second end 28 can be the same as or
different from the first end 22. For example, the ends 22,28 may be
mirror images of each other as best shown in FIG. 1B, or different
from each other as shown in FIG. 2.
[0023] The inner sides 26, 32 of the ends 22, 28 generally face
each other. Typically, the inner sides 26, 32 are substantially
parallel each other; however, this is not required. A space 34 is
generally defined between the inner sides 26, 32 of the ends 22,
28. The space 34 can be of various dimensions.
[0024] Other configurations, designs, or profiles that may be
utilized for at least one of the ends 22,28, and/or for the anchor
itself 20, include those that mimic conventional L-brackets,
Z-brackets, U-brackets, C-brackets, I-brackets, H-brackets,
hanging-brackets, hat-brackets, stirrup-brackets, flat-brackets,
split-bend-anchors, etc. The anchor 20 can be configured to mimic
various types of conventional anchors utilized in construction for
securing building components together. The anchor 20 may also be
referred to as a tie, clip, or bracket. A person of ordinary skill
in the art can select an appropriate configuration of the ends 22,
28, and/or the anchor 20 based on use, location, load, etc., of the
anchor 20.
[0025] Optionally, the ends 22, 28 can individually define at least
one hole 36. The hole 36 can be of various sizes, dimensions, and
shapes. The hole 36 can be used for attaching the first end 22 to
the interior building component and/or for attaching the second end
28 to the exterior building component. The hole 36 can be used in
combination with a fastener. Examples of suitable fasteners
include, but are not limited to, bolts, screws, pins, ties, nails,
rivets, adhesives, etc. The disclosure is not limited to a
particular type of fastener. The hole(s) 36 can be pre- or
post-formed in the end(s) 22, 28, e.g. by casting, machining,
stamping, drilling, etc.
[0026] Typically, each of the ends 22, 28 individually comprise a
rigid material. Examples of suitable rigid materials include, but
are not limited to, metallic materials, polymeric materials,
composite materials, and combinations thereof. In various
embodiments, each of the ends 22, 28 comprise a metallic material.
In these embodiments, each of the ends 22, 28 can individually
comprise an elemental metal or an alloy thereof. Examples of
suitable metals include, but are not limited to, transition and
post-transition metals, such as iron, copper, aluminum, zinc, etc.
In certain embodiments, each of the ends 22, 28 comprise iron. In
specific embodiments, each of the ends 22, 28 comprise steel.
Various grades of steel (SAE Steel Grades) can be used to form the
ends 22, 28, such as 200 or 300 series stainless steel. In a
specific embodiment, SAE Steel Grade 304 stainless steel is used to
form each of the ends 22, 28. A person of ordinary skill in the art
can select an appropriate material for each of the ends 22, 28
based on use, location, load, etc., of the anchor 20.
[0027] A thermal break 38 is disposed in the space 34. The thermal
break 38 has a first coupling surface 40 bonded to the inner side
26 of the first end 22. The thermal break 38 also has a second
coupling surface 42 opposite the first coupling surface 40. The
second coupling surface 42 is bonded to the inner side 32 of the
second end 28.
[0028] Typically, the thermal break 38 adhesively bonds the ends
22, 28 together. Said another way, the first coupling surface 40 is
generally adhered to the inner side 26 of the first end 22, and the
second coupling surface 42 is generally adhered to the inner side
32 of the second end 28 during normal usage. Adhesion is generally
the tendency of dissimilar surfaces to cling to one another. In
further embodiments, the thermal break 38 exclusively bonds the
ends 22, 28 together. In these embodiments, the anchor 20 is free
of supplemental means for connecting the ends 22, 28 together. In
other words, the ends 22, 28 are attached together exclusively by
the thermal break 38 and nothing more. Examples of such
supplemental means include, but are not limited to, fasteners such
as bolts, pins, screws, etc.
[0029] The thermal break 38 can be of various dimensions. As best
shown in FIG. 1B, the thermal break 38 generally has a height (H),
width (W), and thickness (T). Each of the height (H), width (W),
and thickness (T) of the thermal break 38 can be uniform or can
vary. A person of ordinary skill in the art can select an
appropriate height (H), width (W), and thickness (T) of the thermal
break 38 based on use, location, load, etc., of the anchor 20.
[0030] The thermal break 38 can have various cross-sectional areas,
as generally defined by its height (H) and width (W). In various
embodiments, the thermal break 38 has a cross-sectional area (H*W)
of from about 1 to about 800, about 1 to about 300, about 1 to
about 200, about 5 to about 100, about 5 to about 50, about 10 to
about 40, about 20 to about 40, or about 30 square centimeters
(cm.sup.2), or any subrange between about 1 and about 800 cm.sup.2.
Alternatively, the thermal break 38 can have a cross-sectional area
(H*W) of from about 0.5 to about 120 square inches (in.sup.2)
(3.23-774 cm.sup.2), about 0.5 to about 80 in.sup.2 (3.23-516
cm.sup.2), about 2 to about 40 in.sup.2 (12.9-258 cm.sup.2), about
2 to about 20 in.sup.2 (12.9-129 cm.sup.2), about 4 to about 16
in.sup.2 (25.8-103.2 cm.sup.2), about 8 to about 16 in.sup.2
(50.6-103.2 cm.sup.2), or about 12 in.sup.2 (77 cm.sup.2), or any
subrange between about 0.5 and about 120 in.sup.2, (3.23-774
cm.sup.2). A person of ordinary skill in the art can select an
appropriate cross-sectional area (H*W) of the thermal break 38
based on use, location, load, etc., of the anchor 20.
[0031] The thermal break 38 can have various average thicknesses,
as generally defined by its thickness (T). In various embodiments,
the thermal break 38 has an average thickness (T) of from about 1
to about 50, about 1 to about 40, about 1 to about 30, about 1 to
about 20, about 2 to about 10, about 4 to about 8, or about 6,
millimeters (mm), or any subrange from about 1 to about 40 mm.
Alternatively, the thermal break 38 has an average thickness (T) of
from about 0.05 to about 2 inches (in) (1.27-50.8 mm), about 0.05
to about 1.5 in (1.27-38.1 mm), about 0.05 to about 1.25 in
(1.27-31.75 mm), about 0.05 to about 1 in (1.27-25.4 mm), about 0.1
to about 0.75 in (2.54-19.05 mm), about 0.25 to about 0.5 in
(6.35-12.7 mm), or about 0.25 in (6.35 mm), or any subrange from
about 0.05 to about 2 in (1.27-50.8 mm). A person of ordinary skill
in the art can select an appropriate average thickness (T) of the
thermal break 38 based on use, location, load, thermal performance
requirements, etc., of the anchor 20.
[0032] Optionally, at least a portion of the thermal break 38 can
be molded over at least a portion of at least one of the ends 22,
28. While not required, it is thought that overmolding may be
useful to increase strength (e.g. sheer strength) of the anchor 20.
Optionally, at least one of the inner sides 26, 32 of the ends 22,
28 can include one or more surface protrusions. While not required,
it is thought that surface protrusions may be useful to increase
strength (e.g. sheer strength) of the anchor 20. Surprisingly, it
has been found that strength of the anchor 20 is still adequate
even when the inner sides 26, 32 of the ends 22, 28 are
substantially smooth (e.g. prior to disposing or forming the
thermal break 38). A person of ordinary skill in the art can select
an appropriate option (e.g. overmolding and/or protrusions) based
on use, location, load, etc., of the anchor 20.
[0033] The thermal break 38 typically comprises a rigid,
semi-rigid, semi-flexible, or flexible material. It is thought that
such a material can allow for varying degrees of movement between
the ends 22, 28 of the anchor 20. For example, some amount of
settling, flexing, expansion, and/or contraction can occur with
certain building components. Exterior building components are
especially prone to movement when subject to climatic loads (e.g.
wind load) and/or variations in temperature (e.g. when exposed to
sunlight on a cool/cold day). Other types (or forms) of load
include dead, live, building, environmental, and gravity loads, and
the disclosure is not limited to a particular one.
[0034] Typically, the thermal break 38 is formed from a material
different from at least one of the ends 22, 28 more typically
different from both of the ends 22, 28. In various embodiments, the
thermal break 38 comprises a polymeric material. Various types of
polymer chemistries can be utilized to form the thermal break 38,
including, but not limited to, elastomers (or rubber), silicone or
silicone rubber, or rigid materials such as epoxies or epoxy
adhesives.
[0035] In various embodiments, the thermal break 38 comprises an
elastomer (or rubber). Examples of suitable elastomers include, but
are not limited to, thermoplastic elastomers (TPEs), unsaturated
rubbers, saturated rubbers, and mixtures thereof.
[0036] Specific examples of suitable TPEs include, but are not
limited to, styrenic block copolymers, polyolefins, elastomeric
alloys, polyurethanes, copolyesters, and polyamides. Mixtures of
TPEs may also be used. In certain embodiments, the thermal break 38
is formed from a polyurethane (e.g. a thermoplastic polyurethane,
or TPU).
[0037] Specific examples of suitable unsaturated rubbers include,
but are not limited to, those that can be cured by sulfur
vulcanization such as polyisoprenes, polybutadienes, chloroprenes,
butyl rubbers, styrene-butadienes, and nitrile rubbers. Certain
unsaturated rubbers can also be cured by means other than by sulfur
vulcanization. Mixtures of unsaturated rubbers may also be
used.
[0038] Specific examples of suitable saturated rubbers include, but
are not limited to, ethylene propylene rubber (EPM), ethylene
propylene diene rubber (EPDM), epichlorohydrin rubber, polyacrylic
rubber, silicone rubber, fluorosilicone rubber, fluoroelastomers,
perfluoroelastomers, polyether block amides, chlorosulfonated
polyethylene, and ethylene-vinyl acetate. Mixtures of saturated
rubbers may also be used. In certain embodiments, the thermal break
38 is formed from EPDM.
[0039] In various embodiments, the thermal break 38 comprises
silicone. In further embodiments, the thermal break 38 comprises
silicone rubber. The silicone rubber may also be referred to as a
silicone elastomer. Various types of silicone rubbers can be used
to form the thermal break 38. The silicone rubber may be cured, for
example, by an addition cure system, a condensation cure system, or
a peroxide cure system.
[0040] In various embodiments, the silicone rubber is cured by a
heat cure system. Heat cure systems typically rely on addition cure
mechanisms using platinum-based catalysts or peroxide cure
mechanisms to facilitate cure. The curing process can be
accelerated by adding heat and/or pressure. Examples of suitable
silicone rubbers include those commercially available from Dow
Corning Corporation of Midland, Mich., such as SILASTIC.RTM.
Silicone Rubbers (e.g. SILASTIC.RTM. TR-70 Silicone Rubber).
[0041] Alternatively, the thermal break 38 is formed from a
condensation cured silicone structural adhesive or condensation
cured silicone structural sealant which forms a suitable
elastomeric material upon curing. Examples of suitable silicone
structural adhesive or condensation cured silicone structural
sealant include those commercially available from Dow Corning
Corporation of Midland, Mich., for example DOW CORNING.RTM.
Silicone Structural Sealants (e.g. DOW CORNING.RTM. 995 Silicone
Structural Sealant).
[0042] In various embodiments, the thermal break 38 comprises an
epoxy or an epoxy adhesive. In certain of these embodiments, the
epoxy or epoxy adhesive cures to form a rigid material that
provides and maintains sufficient adherence and desired adhesive
strength to the respective inner sides 26, 32 of the first and
second end 22, 28 during usage.
[0043] In embodiments where the thermal break 38 comprises a
polymeric material, e.g. elastomers, silicone or epoxy, the thermal
break 38 generally has a very low thermal conductivity. For
example, the thermal break 38 can have a thermal conductivity that
is over 2, 5, 10, 25, 50, or 100 times less than that of metallic
materials such as steel. The thermal break 38, and therefore the
anchor 20, can be configured to have a fail safe flame resistance.
For example, the anchor 20 can be configured to have a mechanical
catch that will allow the ends 22, 28 to maintain structural
engagement in the event a fire burns away the polymeric thermal
break 38. This is evaluated by testing to NFPA 285 (National Fire
Protection Association Test 285--Standard First Test Method for
Evaluation of Fire Propagation Characteristics of Exterior
Non-Load-Bearing Wall Assemblies Containing Combustible Components
(copies of test available from NFPA of Quincy, Mass.)). The anchor
20 can also be configured to be tolerant in "freeze-thaw"
conditions, and/or be configured to be tolerant of alkalines in
mortar.
[0044] The anchor 20 can be made by various manufacturing methods,
and the disclosure is not limited to a particular one. In certain
embodiments, the anchor 20 is made by injection molding. In these
embodiments, the material utilized to form the thermal break 38
(e.g. a silicone composition) is injected between the ends 22, 28
while in a mold. Heat and/or pressure can be utilized to accelerate
cure of certain materials, e.g. silicone rubber. Other molding
methods can also be used, such as compression molding. A person of
ordinary skill in the art can select an appropriate method of
manufacture based on the materials used to form the anchor 20.
[0045] An assembly (shown as 50 in the alternative embodiments of
FIGS. 3-6, respectively). The assembly 50 is useful for a
structure, and can be used in the construction industry. The
structure is typically a building, and the disclosure is not
limited to a particular one. Examples of buildings include, but are
not limited to, residential, commercial, and industrial buildings,
such as single story, mid-rise, and high-rise buildings.
[0046] The assembly 50 includes an interior building component
(shown as 48 in FIGS. 3-6, respectively). The interior building
component 48 can be any type of conventional interior building
component, and the disclosure is not limited to a particular one.
Examples of suitable interior building components include, but are
not limited to, studs, beams, rails, joists, ties, trusses, mounts,
braces, frames, walls, and supports. The interior building
component can include one or more of the prior examples.
[0047] The assembly 50 further includes an exterior building
component (shown as 46 in FIGS. 3-6, respectively) spaced from the
interior building component 48. The exterior building component 46
can be any type of conventional exterior building component, and
the disclosure is not limited to a particular one. Examples of
suitable exterior building components include, but are not limited
to, rain screens, curtain walls, bricks, masonry, stones, timbers,
panels, siding, facades, cladding, girts, rails, walls, sills,
lintels, headers, and mullions. The exterior building component can
include one or more of the prior examples. The examples listed
above for the interior and exterior building components is not an
all inclusive list. Further, that which is described as an interior
building component may also be used as an exterior building
component and vice versa. The disclosure is not limited to a
particular designation of the building components.
[0048] The assembly 50 further includes the anchor 20 as described
in FIGS. 1-2 above. The anchor 20 is disposed between the interior
48 and exterior building components. The anchor 20 generally
secures the exterior building component 46 to the interior building
component 48 (or vice versa).
[0049] Optionally, the assembly 50 can further include one or more
conventional building components. The disclosure is not limited to
a particular type or number of conventional building components. In
various embodiments, the assembly further comprises at least one
fastener. Examples of suitable fasteners include, but are not
limited to, bolts, screws, pins, nails, rivets, adhesives, etc. The
disclosure is not limited to a particular type of fastener. If
used, the fastener is generally used in connection with the hole
36. Further, if used, the fastener 36 generally does not
operatively connect the ends 22, 28 together, e.g. by spanning
between the ends 22, 28.
[0050] In various embodiments, the assembly 50 further includes
insulation. The insulation can be disposed around the anchor 20,
between the anchor 20 and at least one of the building components,
and/or between the building components. Examples of suitable types
of insulation include, but are not limited to, batts and blankets,
loose-fill Insulation, structural insulated panels (SIPs), spray
foam, vacuum insulated panels (VIPs), etc. Further examples of
suitable types of insulation include, but are not limited to,
fiberglass, mineral wool, glass wool, rock wool, cotton, expanded
polystyrene (EPS), extruded polystyrene (XPS), polyisocyanurate
("polyiso"), open- or closed-cell polyurethane foam, cellulose,
aerogel, etc. Optionally, one or more fasteners may be used to hold
the insulation in place, such as stick pins, clips, etc. The
disclosure is not limited to a particular type of insulation or
fastener thereof.
[0051] Thermal conductivity of the thermal break 38 is lower than
thermal conductivity of at least one of the ends 22, 28. In certain
embodiments, thermal conductivity of the thermal break 38 is lower
than the thermal conductivity of each (or both) of the ends 22, 28.
The thermal break 38 may also be referred to as a thermal barrier.
The lower thermal conductivity of the thermal break 38 generally
reduces thermal bridging between the building components while the
interior and exterior building components are subject to a
temperature difference between the building components. In general,
the thermal break 38 reduces or prevents the flow of thermal energy
between the ends 22, 28, and therefore, reduces or prevents the
flow of thermal energy (or heat transfer) between the interior and
exterior building component. The disclosure is not limited to a
particular direction of thermal energy flow (i.e., inward, outward,
or neutral).
[0052] A thermal bridge (also referred to as a cold bridge or
thermal short), is a fundamental of heat transfer where a
penetration of an insulation layer by a highly conductive or
non-insulating material takes place in the separation between the
interior (or conditioned space) and exterior environments of a
building assembly (also referred to as the building enclosure,
building envelope, or thermal envelope). Thermal bridging is
created when materials that are poor thermal insulators come into
contact, allowing heat to flow through the path of least thermal
resistance created, although nearby layers of material separated by
insulation and or by airspace allow little heat transfer. For
example, sun shades anchored to the side of a building typically go
through the insulation and their anchorage creates a thermal bridge
to the building's interior.
[0053] In general, insulation around a thermal bridge is of little
help in preventing heat loss or gain due to thermal bridging. As an
example, if thermal bridges at balconies of a building are not
taken care of, the balconies can act as "cooling fins". Such
cooling fins conduct heat off the building and cool rooms adjacent
to the balconies. A wall with a thermal bridge may be analogized to
a bucket with a hole in it. Adding insulation without breaking
thermal bridges is like increasing the thickness of the walls of
the bucket but not plugging the hole. In various embodiments
utilizing insulation, the only part that breaks the insulation
layer is the thermal break 38. In this way, foam wall boards for
example, can be used in a way that provides truly continuous
insulation.
[0054] A method is also disclosed. The method is useful for
securing the exterior building component 46 to the interior
building component 48. The method includes the step of providing
the anchor 20. The method further includes the step of attaching
the anchor 20 to one of the building components to form a
sub-assembly. For example, the anchor 20 can be attached to the
interior building component 48 or to the exterior building
component 46 to form the sub-assembly.
[0055] The method yet further comprises the step of connecting the
sub-assembly and the remaining building component to secure the
exterior building component 46 to the interior building component
48. For example, the exterior building component 46 can be attached
to a sub-assembly including the anchor 20 and the interior building
component 48. Conversely, the interior building component 48 can be
attached to a sub-assembly including the anchor 20 and the exterior
building component 46. One or more fasteners may be utilized for
such attachment.
[0056] One or more anchors 20 can be utilized to attach the
building components 46, 48 of a structure. A person of ordinary
skill in the art can select an appropriate number of anchors 20
based on the use, location, load, etc., of the anchors 20. The same
can be said for determining the size, configuration, and location
of the anchors 20. The anchor 20 should be of a sufficient size to
support the exterior building component 46 from both climactic and
gravity loads. The anchor 20 can be designed based on end
application. In certain embodiments, the anchor 20 and/or the
assembly 50 can be designed to be fire safe by including additional
mechanical clips that engage when and if the polymeric thermal
break material 38 is burned away in a fire, wherein this system can
be verified with testing to NFPA 285.
[0057] Referring to FIG. 3, a photograph of a portion of an
assembly 50 is illustrated as having exterior building components
46, interior building components 48, clips 56, and rigid foam
insulation 60 is shown. The assembly 50 is just one example of a
possible configuration of an assembly in which the anchor 20 of the
disclosure can be utilized, e.g. in place of, or in addition to,
the clips 56.
[0058] FIG. 4 illustrate an exploded view of another embodiment of
an assembly 50 that includes the anchor 20 according to FIG. 2
disposed between an exterior building component 46 and an interior
building component 48 for securing the exterior building component
46 to the interior building component 48.
[0059] In FIG. 4, the outer side 24 of a first end 22 of the anchor
20 is positioned against an outer surface 156 of the exterior
building component 46. A fastener 165, shown herein as a screw 165,
is inserted through a respective hole 36 and secures the second end
28 to the exterior building component 46. Additional fasteners 165
are also inserted through the holes 36 in the second end 28 to
secure the interior building component 48 to the second end 28.
[0060] As also illustrated in FIG. 4, a thermal break 38 is
disposed in the space 34 between the first end 22 and the second
end 28. The thermal break 38 has a first coupling surface 40 bonded
to the inner side 26 of the first end 22. The thermal break 38 also
has a second coupling surface 42 opposite the first coupling
surface 40. The second coupling surface 42 is bonded to the inner
side 32 of the second end 28. In this embodiment, as described
above, the thermal conductivity of the thermal break 38 is lower
than the thermal conductivity of at least one of the ends 22,28 to
reduce thermal bridging between the exterior building component 46
and the interior building component 48 while such building
components 46,48 are subject to temperature differences. Rigid foam
insulation (not shown) may also be positioned between the exterior
building component 46 and the interior building component 48 in a
space between the interior building component 46 and the exterior
building component 48 and adjacent to the space 34 not defined by
the anchor 20.
[0061] In another embodiment of the present invention, as
illustrated in FIGS. 5 and 6, the assembly 50 includes wherein the
inner side 26, 32 of each of the first and second ends 22, 28 of an
anchor 20 in accordance with another embodiment of the invention
are configured to include a catch structure 72, 74 that are
complementary with each other. The catch structures 72, 74 are
designed to mechanically interlock, or engage one another, in the
event of a fire burning away the thermal break 38 or other
situations in which the thermal break 38 is removed. As such, in
FIG. 5, wherein the thermal break 38 is present, the catch
structures 72, 74 are positioned in such a manner that they are
spaced apart from each other and within the thermal break 38. If
the thermal break 38 is burned away or otherwise removed, such as
shown in FIG. 6, the catch structures 72, 74 engage or otherwise
mechanically interlock with each other in a manner such that the
positioning of the exterior building components relative to the
interior building components that are secured by the anchor 20 is
maintained.
[0062] The following examples, illustrating the anchor 20 of the
disclosure, are intended to illustrate and not to limit the
invention.
EXAMPLES
[0063] Examples of the anchor are made by injection molding.
Configuration of the anchors can be appreciated with reference to
FIG. 1. A mold is configured to make 5 anchors at the same time.
First and second ends are loaded into the mold. There are 5 pairs
of the ends. The inner sides of the ends of each pair are spaced
apart by about 0.25 inches (0.635 cm). Each end is a 1 inch (2.54
cm) T-bracket, and is formed from 304 stainless steel. A silicone
composition is injected between the inner sides to form a thermal
break between each pair of the ends. The thermal break adhesively
couples each pair the ends together. The silicone composition is
illustrated in Table I below.
TABLE-US-00001 TABLE I Component CAS Number Wt. % Dimethyl
siloxane, dimethylvinyl- 68083-19-2 40.0-60.0 terminated
Trimethylated silica 68909-20-6 30.0-50.0 Dimethyl, methylvinyl
siloxane, 68083-18-1 7.0-13.0 dimethylvinyl-terminated Dimethyl,
methylhydrogen siloxane 68037-59-2 1.0-5.0 Dimethylcyclosiloxanes
None 1.0-5.0
[0064] The silicone composition in Table I is classified as an
addition cure silicone rubber typically cured using a
platinum-based catalyst. The mold is heated to facilitate curing.
After molding, the thermal breaks have a Shore A hardness of about
70 (ASTM D2240-05(2010)). The silicone rubber of the thermal break
has excellent adhesive and cohesive strength.
[0065] The anchors can be used to form various assemblies for a
structure. For example, if the exterior building component of a
structure is subject to a windload of upwards of 50 pounds per
square foot (2394.01 Pascal), one skilled in the art can determine
the size and number of anchors required to achieve a desired wind
load per anchor design. If an anchor is placed every 32 square feet
(e.g. 8 feet.times.4 feet (i.e., approximately 2.44
meters.times.1.22 meters, or 2.97 square meters)), each anchor will
be subject to about 1600 pounds wind load (7116.8 newtons). The
single anchor would have to have a minimum breaking load of 6,400
pounds (about 28,467.2 newtons) for a 4:1 safety factor. For
example, if the anchor has an ultimate breaking strength of 350
pounds per square inch (2.4 megapascals), the above-mentioned 4:1
safety factor would therefore require a 20 square inch
cross-section (about 129 square centimeters).
[0066] It is to be understood that the appended claims are not
limited to express and particular compounds, compositions, or
methods described in the detailed description, which may vary
between particular embodiments which fall within the scope of the
appended claims. With respect to any Markush groups relied upon
herein for describing particular features or aspects of various
embodiments, it is to be appreciated that different, special,
and/or unexpected results may be obtained from each member of the
respective Markush group independent from all other Markush
members. Each member of a Markush group may be relied upon
individually and or in combination and provides adequate support
for specific embodiments within the scope of the appended
claims.
[0067] It is also to be understood that any ranges and subranges
relied upon in describing various embodiments of the present
invention independently and collectively fall within the scope of
the appended claims, and are understood to describe and contemplate
all ranges including whole and/or fractional values therein, even
if such values are not expressly written herein. One of skill in
the art readily recognizes that the enumerated ranges and subranges
sufficiently describe and enable various embodiments of the present
invention, and such ranges and subranges may be further delineated
into relevant halves, thirds, quarters, fifths, and so on. As just
one example, a range "of from 0.1 to 0.9" may be further delineated
into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e.,
from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which
individually and collectively are within the scope of the appended
claims, and may be relied upon individually and/or collectively and
provide adequate support for specific embodiments within the scope
of the appended claims. In addition, with respect to the language
which defines or modifies a range, such as "at least," "greater
than," "less than," "no more than," and the like, it is to be
understood that such language includes subranges and/or an upper or
lower limit. As another example, a range of "at least 10"
inherently includes a subrange of from at least 10 to 35, a
subrange of from at least 10 to 25, a subrange of from 25 to 35,
and so on, and each subrange may be relied upon individually and/or
collectively and provides adequate support for specific embodiments
within the scope of the appended claims. Finally, an individual
number within a disclosed range may be relied upon and provides
adequate support for specific embodiments within the scope of the
appended claims. For example, a range "of from 1 to 9" includes
various individual integers, such as 3, as well as individual
numbers including a decimal point (or fraction), such as 4.1, which
may be relied upon and provide adequate support for specific
embodiments within the scope of the appended claims.
[0068] The present invention has been described herein in an
illustrative manner, and it is to be understood that the
terminology which has been used is intended to be in the nature of
words of description rather than of limitation. Many modifications
and variations of the present invention are possible in light of
the above teachings. The present invention may be practiced
otherwise than as specifically described within the scope of the
appended claims. The subject matter of all combinations of
independent and dependent claims, both single and multiple
dependent, is herein expressly contemplated.
* * * * *