CA2971211A1

CA2971211A1 - Thermally broken anchor and assembly including the same

Info

Publication number: CA2971211A1
Application number: CA2971211A
Authority: CA
Inventors: Lawrence Donald Carbary; Jary D. Jensen
Original assignee: Dow Corning Corp
Current assignee: Dow Silicones Corp
Priority date: 2014-12-17
Filing date: 2015-12-16
Publication date: 2016-06-23
Also published as: KR20170082602A; US20170362816A1; EP3234278A1; CN107109847A; WO2016100514A1

Abstract

An anchor 20 for securing together interior 48 and exterior building components 46 includes a first end 22 having an outer side 24 for engaging the interior building component and an inner side 26 opposite the outer side 24. The anchor further includes a second end 28 having an outer side 30 and an inner side 32 opposite the outer side of the second end for engaging the exterior building component. A thermal break 38 for reducing thermal bridging between the exterior and interior building components is disposed in a space 34 between the inner sides of the ends and has a first coupling surface 40 bonded to the inner side of the first end and a second coupling surface 42 bonded to the inner side of the second end. An assembly 50 includes the anchor 20 for securing together the interior and exterior building components 46, 48.

Description

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 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.

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;

14 [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 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 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 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 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 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, 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 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 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 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 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.

[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 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 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., 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 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.

Claims

What is claimed is:

1. An assembly 50 for a structure, said assembly comprising:
an interior building component 48;
an exterior building component 46 spaced from said interior building component 48; and an anchor 20 disposed between said building components 46, 48 to secure said exterior building component 46 to said interior building component 48, said anchor 20 comprising;
a first end 22 having an outer side 24 for engaging said interior building component 48 and an inner side 26 opposite said outer side 24 of said first end 22;
a second end 28 having an outer side 30 for engaging said exterior building component and an inner side 32 opposite said outer side 30 of said second end 28, said inner sides 26, 32 of said ends 22, 28 facing each other with a space 34 defined therebetween; and a thermal break 38 disposed in the space 34, with said thermal break 38 having a first coupling surface 40 bonded to said inner side 26 of said first end 22 and a second coupling surface 42 opposite said first coupling surface 40 and bonded to said inner side 32 of said second end 28;
wherein a thermal conductivity of said thermal break 38 is lower than a thermal conductivity of at least one of said ends 22, 28 to reduce thermal bridging between said building components 46, 48 while said building components 46, 48 are subject to a temperature difference between said building components 46, 48.

2. The assembly 50 as set forth in claim 1, wherein said thermal break 38 adhesively bonds said ends 22, 28 together.

3. The assembly 50 as set forth in claim 1 or 2, wherein said thermal break exclusively bonds said ends 22, 28 together.

4. The assembly 50 as set forth in any one of claims 1 through 3, wherein the thermal conductivity of said thermal break 38 is lower than the thermal conductivity of each of said ends 22, 28.

5. The assembly 50 as set forth in any one of claims 1 through 4, wherein:
i) said thermal break 38 comprises a polymeric material;
ii) each of said ends 22, 28 comprises a metallic material; or iii) both i) and ii).

6. The assembly 50 as set forth in any one of claims 1 through 5, wherein said thermal break 38 comprises silicone, alternatively silicone rubber.

7. The assembly 50 as set forth in any one of claims 1 through 5, wherein said thermal break 38 comprises epoxy, alternatively an epoxy adhesive.

8. The assembly 50 as set forth in any one of claims 1 through 5, wherein said thermal break 38 comprises an elastomer selected from the group consisting of thermoplastic elastomers, unsaturated rubbers, saturated rubbers, and mixtures thereof

9. The assembly 50 as set forth in claim 8, wherein said thermoplastic elastomer is selected from the group consisting of styrenic block copolymers, polyolefins, elastomeric alloys, polyurethanes, copolyesters, polyamides, and mixtures thereof.

10. The assembly 50 as set forth in claim 8 or claim 9, wherein said unsaturated rubber is selected from the group consisting of polyisoprenes, polybutadienes, chloroprenes, butyl rubbers, styrene-butadienes, nitrile rubbers, and mixtures thereof

11. The assembly 50 as set forth in any one of claims 8 through 10, wherein said saturated rubber is 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

12. The assembly 50 as set forth in any one of claims 1 through 11, wherein each of said ends 22, 28 comprises iron, alternatively steel.

13. The assembly 50 as set forth in any one claims 1 through 12, wherein said thermal break 38 has a cross-sectional area of from about 1 to about 800 square centimeters (cm2).

14. The assembly 50 as set forth in any one claims 1 through 13, wherein said thermal break 38 has an average thickness of from about 1 to about 50 millimeters (mm).

15. A structure comprising said assembly 50 as set forth in any one of claims 1 through 14.

16. An anchor 20 for securing an exterior building component 46 to an interior building component 48, said anchor 20 comprising:
a first end 22 having an outer side 24 for engaging the interior building component 48 and an inner side 26 opposite said outer side 24 of said first end 22;
a second end 28 having an outer side 30 for engaging the exterior building component 46 and an inner side 32 opposite said outer side 30 of said second end 28, said inner sides 26, 32 of said ends 22, 28 facing each other with a space defined therebetween; and a thermal break 38 disposed in the space, said thermal break 38 having a first coupling surface 40 bonded to said inner side 26 of said first end 22 and a second coupling surface 42 opposite said first coupling surface 40 and bonded to said inner side 32 of said second end 28;
wherein a thermal conductivity of said thermal break 38 is lower than a thermal conductivity of at least one of said ends 22, 28 to reduce thermal bridging between the building components 46, 48 while the building components 46, 48 are subject to a temperature difference between the building components 46, 48.

17. The anchor 20 as set forth in claim 16, wherein said thermal break 38 adhesively bonds said ends 22, 28 together.

18. The anchor 20 as set forth in claim 16 or 17, wherein said thermal break 38 exclusively bonds said ends 22, 28 together.

19. The anchor 20 as set forth in any one of claims 16 through 18, wherein the thermal conductivity of said thermal break 38 is lower than the thermal conductivity of each of said ends 22, 28.

20. The anchor 20 as set forth in any one of claims 16 through 19, wherein:
i) said thermal break 38 comprises a polymeric material;
ii) each of said ends 22, 28 comprises a metallic material; or iii) both i) and ii).

21. The anchor 20 as set forth in any one of claims 16 through 20, wherein said thermal break 38 comprises silicone, alternatively silicone rubber.

22. The anchor 20 as set forth in any one of claims 16 through 20, wherein said thermal break 38 comprises comprises epoxy, alternatively an epoxy adhesive.

23. The anchor 20 as set forth in any one of claims 16 through 20, wherein said thermal break 38 comprises an elastomer selected from the group consisting of thermoplastic elastomers, unsaturated rubbers, saturated rubbers, and mixtures thereof

24. The anchor 20 as set forth in claim 23, wherein said thermoplastic elastomer is selected from the group consisting of styrenic block copolymers, polyolefins, elastomeric alloys, polyurethanes, copolyesters, polyamides, and mixtures thereof

25. The anchor 20 as set forth in claim 23 or claim 24, wherein said unsaturated rubber is selected from the group consisting of polyisoprenes, polybutadienes, chloroprenes, butyl rubbers, styrene-butadienes, nitrile rubbers, and mixtures thereof

26. The anchor 20 as set forth in any one of claims 23 through 25, wherein said saturated rubber is 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 20 as set forth in any one of claims 16 through 26, wherein each of said ends 22, 28 comprises iron, alternatively steel.

28. The anchor 20 as set forth in any one of claims 16 through 27, wherein said thermal break 38 has a cross-sectional area of from about 1 to about 800 square centimeters (cm2) (or about 0.5 to about 120 square inches (in2)).

29. The anchor 20 as set forth in any one of claims 16 through 28, wherein said thermal break 38 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 20 as set forth in any one of claims 16 to 29, wherein the inner side mechanically catches the outer side in the event of fire burning away the polymeric thermal break 38.

31. A method of securing an exterior building component 46 to an interior building component 48 spaced from the exterior building component 46, said method comprising the steps of:
providing an anchor 20;
attaching the anchor 20 to one of the building components 46 or 48 to form a sub-assembly; and connecting the sub-assembly and the remaining building component 46 or 48 to secure the exterior building component 46 to the interior building component 48;
wherein the anchor 20 is as set forth in any one of claims 16 through 30.