Note: Descriptions are shown in the official language in which they were submitted.
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THERMALLY BROKEN ANCHOR AND ASSEMBLY INCLUDING THE
SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No.
62/093,032, filed December 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 ThermaStopTm thermal isolation system, which is
commercially available from Knight Wall Systems of Deer Park, WA. The
ThermaStopTm system utilizes 55 AL-ZN-coated steel brackets with plastic bases
and
integral 1/8-inch plastic washers. While the ThermaStopTm system has a
relatively
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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 , which is commercially
available from Cascadia Windows Ltd. of Langley, BC, Canada. The CASCADIA
CLIP is a fiberglass girt spacer, and is illustrated in U.S. Design Patent
No.
D666,894 S to Bombino et al. and U.S. Patent Application Publication No.
US2013/0174506 Al to Bombino et al. While formed from fiberglass, the
CASCADIA CLIP relies on conventional metal fasteners (e.g. lag screws) that
act
as direct thermal shorts. In addition, the CASCADIA CLIP can be difficult and
time
consuming to install.
[0006] Another system utilizes a thermal insulation material (TIM), which is
commercially available from FABREEKA of Boston, MA. 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 ThermalClip , which is
commercially available from Heckmann Building Products, Inc. of Melrose Park,
IL.
The ThermalClip is formed from polyphenylsulfone (PPSU), has a snap on
design,
and is described in U.S. Patent Application Publication No. U52013/0232909 Al
to
Curtis et al. The ThermalClip is used in masonry construction. While formed
from
PPSU, the ThermalClip relies on conventional metal wire ties that can act as
direct
thermal shorts. In addition, the ThermalClip 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.
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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] Figure lA is a perspective view of an anchor of the disclosure;
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[0014] Figure 1B is an exploded perspective view of the anchor in Figure 1A;
[0015] Figure 2 is a perspective view of another anchor of the disclosure;
[0016] Figure 3 is a photograph of a portion of an assembly having exterior
and
interior building components, clips, and rigid foam insulation; and
[0017] Figure 4 is a side view of an assembly having an exterior building
component
and interior building components and the anchor according to Figure 2 used for
securing the exterior building component to the interior building component;
[0018] Figure 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] Figure 6 is a side section view of the anchor of Figure 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
Figures 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 Figure 1, the
first end
22 is generally configured as a T-bracket. As shown in Figure 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
Figures 1 and 2, the second end 28 is generally configured as a T-bracket.
While the
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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 Figure 1B, or different from each other as shown
in
Figure 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,
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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
Figure
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 (cm2), or any
subrange
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between about 1 and about 800 cm2. Alternatively, the thermal break 38 can
have a
cross-sectional area (H*W) of from about 0.5 to about 120 square inches (in2)
(3.23 -
774 cm2), about 0.5 to about 80 in2 (3.23 - 516 cm2), about 2 to about 40 in2
(12.9 -
258 cm2), about 2 to about 20 in2 (12.9 - 129 cm2), about 4 to about 16 in2
(25.8 -
103.2 cm2), about 8 to about 16 in2 (50.6 - 103.2 cm2) , or about 12in2 (77
cm2), or
any subrange between about 0.5 and about 120 in2, (3.23 - 774 cm2). 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 - 50.8mm), about 0.05 to about 1.5 in (1.27 - 38.1mm), about 0.05
to about
1.25 in (1.27 - 31.75mm), about 0.05 to about 1 in (1.27 - 25.4mm), about 0.1
to
about 0.75 in (2.54 - 19.05mm), about 0.25 to about 0.5 in (6.35 - 12.7mm), or
about
0.25in (6.35mm), or any subrange from about 0.05 to about 2 in (1.27 -
50.8mm). 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
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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,
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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,
MI,
such as SILASTIC Silicone Rubbers (e.g. SILASTIC 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, MI, for
example
DOW CORNING Silicone Structural Sealants (e.g. DOW CORNING 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
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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, Massachusetts)). 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 Figures 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
Figures 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 Figures 3-6, respectively) spaced from the interior building component
48. The
exterior building component 46 can be any type of conventional exterior
building
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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 Figures
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
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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
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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 Figure 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.
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[0058] Figure 4 illustrate an exploded view of another embodiment of an
assembly 50
that includes the anchor 20 according to Figure 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 Figure 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 Figure 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
Figures 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 Figure
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
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38. If the thermal break 38 is burned away or otherwise removed, such as shown
in
Figure 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 Figure 1. A mold is configured to
make
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 (0.635cm). Each end is a 1 inch (2.54cm) 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 I
Component CAS Number Wt.%
Dimethyl siloxane, dimethylvinyl-terminated 68083-19-2 40.0 - 60.0
Trimethylated silica 68909-20-6 30.0 - 50.0
Dimethyl, methylvinyl siloxane, dimethylvinyl-terminated 68083-18-1
7.0 - 13.0
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 x 4
feet (i.e.,
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approximately 2.44 meters x 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
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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.
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