Brick tie gap connector

Abstract

A sheet metal connector is provided for connecting a brick wall to a second structural member, the connector is received in the mortar joint of the brick wall and is connected to second structural member. The connector is provided with zones of controlled bending and controlled stiffness to allow for controlled bending of the connector in the field.

Claims

1. A connection between a wall having a mortar joint and a structural member made with a connector, the connection comprising: a. the wall having the mortar joint; b. the structural member having a substantially vertically disposed surface, c. the connector, the connector having a mortar joint attachment portion at least a portion of which is received in the mortar joint of the wall and a structural member attachment portion attached to the structural member, the structural member attachment portion has a main body and at the end of the main body the structural member attachment portion is joined to an extending portion, the extending portion extending away from the substantially vertically disposed surface of the structural member and extending to the wall having the mortar joint, the extending portion including the mortar joint attachment portion, the connector having a longitudinal axis that extends along the mortar joint attachment portion and to and along the structural member attachment portion, wherein; d. the connector includes one or more controlled stiffness zones where the connector is formed with one or more strengthening portions, one or more controlled bending zones where the connector is adapted to be more easily bent transversely to the longitudinal axis than the connector is bent transversely to the longitudinal axis in the one or more controlled stiffness zones, and one or more calibrated stiffness zones where the connector is adapted to be bent more easily than the connector is bent in the one or more controlled stiffness zones transversely to the longitudinal axis and where the connector is adapted to be bent less easily than in the one or more controlled bending zones transversely to the longitudinal axis.

2. The connection of claim 1, wherein: the structural member attachment portion interfaces with and is attached to the substantially vertically disposed surface of the structural member.

3. The connection of claim 1, wherein: one or more bends transverse to the axis of the connector are formed in the connector in the one or more controlled bending zones.

4. The connection of claim 1, wherein: one of the one or more controlled bending zones is provided between the structural member attachment portion and the extending portion and has a bend.

5. The connection of claim 4, wherein: the connector is formed with a fastener opening in the structural member attachment portion close to the bend between the extending portion and the structural member attachment portion.

6. The connection of claim 1, wherein: one or more bends transverse to the axis of the connector are formed in the connector in the one or more controlled stiffness zones.

7. The connection of claim 1, wherein: the one or more calibrated stiffness zones are bracketed by at least two of the one or more controlled stiffness zones.

8. The connection of claim 1, wherein: the one or more calibrated stiffness zones are provided in the extending portion of the connector.

9. The connection of claim 1, wherein: a. the wall is separated from the structural member such that there is a space between the structural member and the wall; and b. the one or more calibrated stiffness zones are provided in the extending portion of the connector that is disposed in the space between the structural member and the wall.

10. The connection of claim 1, wherein: at least one of the one or more strengthening portions extends from one of the one or more controlled stiffness zone into one of the one or more calibrated stiffness zones.

11. The connection of claim 1, wherein: the mortar joint attachment portion has one or more strengthening portions that extend along the longitudinal axis of the connector.

12. The connection of claim 11, wherein: the one or more strengthening portions are generally parallel, thin extending embossments.

13. The connection of claim 12, wherein: the one or more extending embossments have ends closer to the structural attachment portion and are joined together by one or more angled transitioning embossments that come together to form one or more connecting embossments.

14. The connection of claim 13, wherein: the one or more connecting embossments extend through at least one of the one or more calibrated stiffness zones in the extending portion.

15. The connection of claim 14, wherein: a. the wall is separated from the structural member such that there is a space between the structural member and the wall; and b. portions of the one or more strengthening portions are provided in the extending portion of the connector that is disposed in the space between the structural member and the wall; c. the one or more connecting embossments extend to the strengthening portions provided in the extending portion of the connector that is disposed in the space between the structural member and the wall.

16. The connection of claim 15, wherein: one of the one or more strengthening portions having a portion that is disposed in the space between the structural member and the wall is formed with an opening through the connector.

17. The connection of claim 11, wherein: a. the wall is separated from the structural member such that there is a space between the structural member and the wall; and b. portions of the one or more strengthening portions are provided in the extending portion of the connector that is disposed in the space between the structural member and the wall; and c. portions of the strengthening portions are provided in the mortar joint.

18. The connection of claim 17, wherein: the one or more strengthening portions with portions in the mortar joint and portions in the extending portion of the connector that is disposed in the space between the structural member and the wall are generally parallel, thin extending embossments.

19. The connection of claim 1, wherein: a. the wall is separated from the structural member such that there is a space between the structural member and the wall; and b. the one or more calibrated stiffness zones are provided only in the extending portion of the connector that is disposed in the space between the structural member and the wall.

20. The connection of claim 19, wherein: the one or more calibrated stiffness zones are bracketed by at least two of the one or more controlled stiffness zones.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a connector according to the present invention.

(2) FIG. 2 is a perspective view of the connector of FIG. 1 bent into an alternate shape.

(3) FIG. 3 is a top view of the connector of FIG. 1.

(4) FIG. 4 is a bottom view of the connector of FIG. 1.

(5) FIG. 5 is back end view of the connector of FIG. 1.

(6) FIG. 6 is a front end view of the connector of FIG. 1.

(7) FIG. 7 is a side elevation view of the connector of FIG. 1.

(8) FIG. 8 is a side elevation view of the connector as bent and shown in FIG. 2.

(9) FIG. 9 is a side, cross-sectional view of the connection of the present invention, showing the connector bent into an alternate shape as in FIG. 2.

(10) FIG. 10 is a perspective view of an alternate connector according to the present invention.

(11) FIG. 11 is a perspective view of the connector of FIG. 10 bent into an alternate shape.

(12) FIG. 12 is a perspective of an alternate connector according to the present invention.

(13) FIG. 13 is a perspective view of an alternate arrangement of the connector according to the present invention.

(14) FIG. 14 is a perspective view of a connector according to the present invention.

(15) FIG. 15 is a perspective view of the connector of FIG. 14 bent into an alternate shape.

(16) FIG. 16 is a top view of the connector of FIG. 14.

(17) FIG. 17 is a bottom view of the connector of FIG. 14.

(18) FIG. 18 is back end view of the connector of FIG. 14.

(19) FIG. 19 is a front end view of the connector of FIG. 14.

(20) FIG. 20 is a side elevation view of the connector of FIG. 14.

(21) FIG. 21 is a side elevation view of the connector as bent and shown in FIG. 15.

(22) FIG. 22 is a side, cross-sectional view of the connection of the present invention, showing the connector bent into an alternate shape as in FIG. 15.

(23) FIG. 23 is an alternate side, cross-sectional view of the connection of the present invention, showing the connector bent into an alternate shape as in FIG. 15.

(24) FIG. 24 is a top view of the connection of FIG. 23, showing portions of the mortar joint attachment portion protruding from the mortar joint.

(25) FIG. 25 is an alternate side, cross-sectional view of the connection of the present invention. The connector is inverted.

(26) FIG. 26 is a perspective of an alternate connector according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

(27) The present invention is a connection between a wall 1 such as a brick wall where elements are joined by mortar and a structural member 2. The connection is designed to resist tension and compression loading between the brick wall 1 and the structural wall 2. Preferably, the brick wall 1 has a mortar 3 joint which can serve as a first fastening, and the second member has a vertically disposed attachment surface 4. As shown in FIG. 9, in one preferred embodiment of the invention, the mortar joint 3 and the attachment surface 4 are disposed generally orthogonally. The brick wall 1 and the structural member 2 are positively joined by the brick tie or connector 5 of the present invention.

(28) The structural member 2 is typically made from wood, but could also be any building material used to create the structural frame of a building or wall such as steel. The structural member 2 can also be a cementitious member or another wall built out of elements joined by mortar.

(29) In order to better define the invention the connector 5 is described as having a longitudinal axis 6 as shown in FIG. 1. As shown in FIG. 9, a first preferred embodiment of the connection of the present invention used to join the brick wall 1 and the structural wall or structural member 2 also includes one or more fasteners 7 received by the elongated connector 5 and the structural member 2.

(30) The elements of the connection are preferably arranged in the following manner. The connection 5 is formed with the wall 1 having the mortar joint 3 and the structural member 2 having a substantially vertically disposed surface 4. The connector 4 has a mortar joint attachment portion 8 received in the mortar joint 3 of the wall 1 and a structural member attachment portion 9 that interfaces with and is attached to the substantially vertically disposed surface 4 of the structural member 2, the structural member attachment portion 9 has a main body 10 and at the end 11 of the main body 10 the structural member attachment portion 9 is joined to an extending portion 12 at a first bend 13. The extending portion 12 extends away from the substantially vertically disposed surface 4 of the structural member and extends to the wall 1 having the mortar joint 3, the extending portion 12 includes the mortar joint attachment portion 8. As noted above, the connector 5 has a longitudinal axis 6 that extends along the mortar joint attachment portion 8 and to and along the structural member attachment portion 9. The connector 5 also includes one or more controlled stiffness zones 14 where the connector 5 is formed with strengthening portions 15, one or more controlled bending zones 16 where the connector 5 is adapted to be more easily bent transversely to the longitudinal axis 6 than the connector 5 can be bent transversely to the longitudinal axis 6 in the controlled stiffness zones 14, and one or more calibrated stiffness zones 17 where the connector 5 can be bent more easily than the connector 5 can be bent in the controlled stiffness zones 14 transversely to the longitudinal axis 6 and where the connector 5 can be bent less easily than in the controlled bending zones 16 transversely to the longitudinal axis 6.

(31) In FIG. 1, the connector 5 is shown before it has been attached to the structural member 2 and before it is has been bent in the field.

(32) In FIG. 2, the connector 5 is shown with a first bend 13 between the structural member attachment portion 9 and the extending portion 12. The connector 5 is also shown with a second bend 18 in the bridge portion 19 of the extending portion 12. The structural member attachment portion 9 is formed with a controlled stiffness zone 14. The portion of the extending portion 12 proximal to the structural member attachment portion 9 is formed with a controlled stiffness zone 14. Between the structural member attachment portion 9 and the extending portion 12, the connector 5 is formed with a controlled bending zone 16 at the first bend 13. The portion of the extending portion 12 distal to the structural member attachment portion 9 is formed with a controlled stiffness zone 14. Between the controlled stiffness zones 14 on the extending portion 12 there is preferably provided at least one calibrated stiffness zone 17 where a second bend 18 can be formed in the connector 5.

(33) The controlled stiffness zone 14 in the structural member attachment portion 9 is preferably formed with two embossments 20 that run along the longitudinal axis 6 of the connector 5. The embossments 20 bracket an opening 21 for the fastener 7 that joins the connector 5 to the structural member 2.

(34) Notches 72 could be formed on either side of the connector 5 at the first bend 13 to further make it easy to bend the connector 4 transverse to the longitudinal axis 6 at the controlled bending zone 16. As shown in FIGS. 7 and 8, the controlled bending zone is a thin portion along the longitudinal axis 6 where there are no strengthening portions 15 in the connector such that general flat metal of the connector 5 is easily bent.

(35) As shown in FIG. 14, the proximal portion of the extending portion 12 can be formed with a deep v-shaped embossment 23 to create a controlled stiffness zone. The v-shaped embossment 23 is formed with weep holes 22 to drain water from the connector. As shown in FIG. 1, the proximal portion of the extending portion 12 could be formed with flanges 73 at the side edges 24 and 25 of the connector 5 to create a controlled stiffness zone 17.

(36) As shown in FIG. 1, the distal portion of the extending portion 12 could be formed with flanges 26 at the side edges 24 and 25 of the connector 5, creating another controlled stiffness zone 14. The flanges 26 extend along the mortar joint attachment portion 8.

(37) At the second bend 18 in the connector 5, additional notches 27 are formed to allow for easier bending of the connector 5. The additional notches 27 interrupt the side edges 24 and 25 of the connector 5 in the extending portion 12. At the second bend 18 of the connector 5, the connector 5 is also provided with a connecting embossment 36 that extends beyond the additional notches 27 into the controlled stiffness zones 14 that bracket the second bend 18. This arrangement of portions makes the area of the connector 5 at the second bend 18 a calibrated stiffness zone 17.

(38) As shown in FIGS. 1 and 2, the mortar joint attachment portion 8 is formed with openings 28 to allow mortar to extend through the connector 5. The edges of the openings 28 are provided with protruding rims 29 to help the connector 5 engage the mortar.

(39) FIG. 9 shows the connection. The mortar joint attachment portion 8 is engaged with the mortar joint. The fastener 7 is driven into the structural member 2 which could be a stud in a structural wall. The structural wall that contains the structural member 2 is shown with a waterproof covering layer 30 and panel 31. A space 32 is provided between the wall 1 and the structural member 2.

(40) As shown in FIG. 14, the bridge portion 19 can be formed with a large v-shaped embossment 23 to strengthen this portion of the extending portion 12 that is not inserted in the mortar joint 3 or attached to the structural member 2. Typically, the connector 5 will be installed with the vertex of the “v” of the embossment 23 disposed upwardly and the sides of the v-shaped embossment 37 extending downwardly. The orientation of the v-shaped embossment 23 allows the bridge portion 19 to shed water that may fall on the connector 5. The v-shaped embossment 23 is preferably formed with weep holes 22 or openings in the connector 5 that allow water to drain from the v-shaped embossment 23 when the connector 5 is installed in an inverted position as is shown in FIG. 25.

(41) As shown in FIG. 14, the mortar joint attachment portion 8 is preferably made with one or more generally parallel, thin extending embossments 38 that extend along the length of the axis 6 of the connector 5. The mortar joint attachment portion 8 is also provided with openings 28 for creating interlock with the mortar of the mortar joint 3. The extending embossments 38, of which there are three preferably, are disposed closer to the structural wall attachment portion 9 then the interlocking openings 28. As shown in FIGS. 10 and 11, portions of these extending embossments 38 can protrude from the mortar joint 3 in certain installations when the gap 32 between the brick wall 1 and the structural member 2 are spaced farther apart than typically, or if the connector 5 is bent substantially to have the mortar joint attachment portion 8 reach into the mortar joint 3. These one or more extending embossments 38 provide strength to those portions of the mortar joint attachment portion 8 that is not embedded in the mortar 3 in the installations shown in FIGS. 23 and 24.

(42) According to the present invention, the extending embossments 38 in the mortar joint attachment portion 8 at their ends closer to the structural attachment portion 9 are preferably joined together by one or more angled transitioning embossments 39 that come together to form the one or more connecting embossments 36, preferably just one, that extend along the axis 6 of the connector from the mortar joint attachment portion 8 to the bridge portion 19 of the extending portion 12. These one or more connecting embossments 36 that extend from the mortar joint attachment portion 8 to the bridge portion 19 of the extending portion 12 are preferably fewer in number than the extending embossments 38 in the mortar joint attachment portion 8. These one or more connecting embossments 36 also extend into the bridge portion 19 that is formed with strengthening embossments 15 or bends. As shown in FIG. 1 this strengthening embossment is a deep v-shaped embossment 23. This extension of the one or more connecting embossments 36 creates a calibrated stiffness zone 17 between the mortar joint attachment portion 8 and the bridge portion 19 of the extending member 12. The one or more connecting embossments 36 and the one or more extending embossments 38 can be the same number, but the one or more connecting embossments 36 and the one or more extending embossments 38 in the mortar joint attachment portion 8 are formed such that it is easier to bend the connector 5 transverse to the axis 6 along the connector 6 at the calibrated stiffness zone 17 between mortar joint attachment portion 8 and the bridge portion 19. The one or more connecting embossments 36 and the strengthening formations 15 in the bridge portion 19 are formed such that it is easier to bend the connector transverse to the axis along the connector at the calibrated stiffness zone 17 between the mortar joint attachment portion 8 and the bridge portion 19.

(43) According to the present invention, the extending embossments 38 in the mortar joint attachment portion 8 are connected by the one or more transitioning embossments 39 to the one or more connecting embossments 36, and the one or more connecting embossments 36 extend into the v-shaped embossment 23 in the bridge portion 19. This connection of the embossments creates a gutter system that will transfer water off of the connector 5 via the weep holes 22 in the v-shaped embossment 23 if the connector is disposed in an inverted position as shown in FIG. 12.

(44) The particular elements used to strengthen the connector 5 and give the connector 5 its characteristic properties also allow the connector 5 to be made with less material which reduces the cost of the connector 5. These elements include making the bridge portion 19 with a single v-shaped embossment 23 that extends the width of the connector 5, making the mortar joint attachment portion 8 with three parallel thin extending embossments 38 and making the mortar joint attachment potion 8 with rimmed openings 29.

(45) FIG. 12 shows a similar connector 5 with a smaller central embossment 36 in the extending portion 12 and without any notches.

(46) FIG. 13 shows a central notch 33 in the extending portion 12, creating a tab 34 that extends from the end 11 of the main body 10 of the structural member attachment portion 9. The opening 21 for the fastener 7 is provided in this tab 34 such that the opening 21 for the fastener 7 is aligned with the first bend 13. An additional embossment 35 is provided in the structural member attachment portion 9.