Prefabricated wall connector

Abstract

An apparatus in which a base member or anchored member is connected to a concrete foundation or anchor member by a connector, the connector having an embedding member and an attachment member connected to the upper end of the embedding member and extending away from the embedding member, the connector attaching to the side of the base member with a fastener.

Description

[Technical Field]

[0001] The present invention provides a connection between an anchoring structural member and an anchored structural member in a building to counteract pull-out and lateral forces between the members. [Background technology]

[0002] Many prior art methods exist for attaching a wall base plate or similar lower support member to the top of a building foundation or other lower anchor structural member to resist pullout forces. One approach is to fasten a threaded anchor bolt to the concrete foundation and pour unhardened concrete around the bolt. A hole is then drilled in the base plate, and the plate is then secured to the foundation with the anchor bolt protruding through the opening in the base plate. A nut and washer are then installed over the bolt to hold the base plate in place. Threaded anchors can also be installed in the foundation after it has been secured by drilling a hole in the foundation and either mechanically attaching the anchor if an expansion anchor or similar anchor is used, or by securing the anchor using a strong adhesive.

[0003] Several sheet metal connectors have been designed to replace or provide an alternative to using threaded anchors to connect a foundation plate or slab to a foundation. Examples of such sheet metal connectors can be found in U.S. Patent Nos. 3,889,441, 3,750,360, 4,413,456, 4,739,598, and 8,484,917. U.S. Patent Nos. 3,889,441 and 3,750,360 are designed with a pair of attachment arms that protrude from the cement or concrete on either side of the foundation plate and then wrap around the top of the foundation plate. The inner arms of the plate, like anchor bolts installed in the foundation, protrude from the top surface of the foundation and can interfere with the finishing process of the foundation or slab to ensure a flat upper surface. U.S. Patent Nos. 4,413,456, 4,739,598, and 8,484,917 teach anchors that protrude from a foundation only near the edge of the foundation to lessen the interference with the foundation finish. These patents teach forming connectors with elongated arms that extend upward from the foundation and bend over and around a relatively thin foundation plate to attach to the top surface of the foundation plate as well as to the sides of the foundation plate to provide a strong connection. However, such connectors typically cannot be used in construction methods in which furring material is attached to the relatively thin foundation plate or substructural members before the foundation plate is attached to the foundation. The furring material interferes with the ability of these anchors to connect to the foundation plate. With the furring blocking access to the top of the base plate, a strong and secure connection between the upper secured structural member and the lower secured structural member cannot be achieved unless an additional shielding member is used that connects to the base plate and further to the mounting member of the anchor. U.S. Patent No. 4,570,403, similar to U.S. Patents Nos. 4,413,456, 4,739,598, and 8,484,917, shows the use of sheet metal anchors with prefabricated walls having relatively tall lower support members with high side surfaces that allow a strong connection to be made through the furring covering the lower support member.

[0004] The present invention improves upon the prior art by providing a connector that can make a strong connection to a relatively thin lower support member and a wall that has a backing that blocks access to the upper surface of the relatively thin lower support member. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 3,889,441 [Patent Document 2] U.S. Patent No. 3,750,360 [Patent Document 3] U.S. Patent No. 4,413,456 [Patent Document 4] U.S. Patent No. 4,739,598 [Patent Document 5] U.S. Patent No. 8,484,917 [Patent Document 6] U.S. Patent No. 4,570,403 Summary of the Invention

[0006] The connector of the present invention provides a cost-effective and convenient method for fastening a relatively thin sill or lower support member of a wall to a concrete foundation or other anchor structural member supporting a wall, particularly when the relatively thin sill is covered by a furring strip that prevents access to the upper surface of the relatively thin sill. The connector of the present invention is provided with a relatively short, yet wide, mounting section that allows for a strong connection using pin fasteners between the mounting member and the side surface of the relatively thin lower support member of the wall.

[0007] The connector of the present invention provides embossments in the attachment member to strengthen the connector and create a localized area of ​​bending between the attachment member and an extension member located between the attachment member and the embedded member.

[0008] The connector of the present invention has an embedment member that provides high resistance to removal from the supporting structural member. The embedment member is provided with multiple legs that are spaced apart from one another so that the cementitious material can completely surround the embedment member without creating any voids between the embedment member and the formwork plate.

[0009] The connectors may be installed before or immediately after the concrete is poured.

[0010] The present invention provides a connector that can be attached to a form for pouring concrete with a flat-head nail that can be easily removed from the connector due to the shape of the connector into which the nail is inserted. The attachment of the connector to the form is only temporary, as the form is removed once the concrete or cement has set. Typically, double-head nails are used to attach prior art connectors to the form so that the nails can be easily removed; however, because double-head nails are designed with protruding portions when used so that they can be more easily removed, they can interfere with the finish of the foundation. Because flat-head nails can be used to attach the connector to the top surface of the formwork, the connector and nail have a low profile at the installation location, and as a result, the connector causes less interference with the finish of the concrete foundation than if double-head nails were used.

[0011] The connectors are shaped and embedded in the concrete in a manner that minimizes exposure of the connectors to the elements after the formwork plate is removed from the concrete foundation to prevent deterioration of the connectors. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a perspective view of a connector of the present invention. [Figure 2] FIG. 2 is a top view of the connector of FIG. 1. [Figure 3] FIG. 2 is a bottom view of the connector of FIG. 1. [Figure 4] FIG. 2 is a front elevational view of the connector of FIG. 1. [Figure 5]FIG. 2 is a rear elevational view of the connector of FIG. 1. [Figure 6] FIG. 2 is a left side elevational view of the connector of FIG. 1. [Figure 7] FIG. 2 is a right side elevation view of the connector of FIG. 1. [Figure 8] 1 is a perspective view of a connection of the present invention with the connector and fastener shown in dotted lines. [Figure 9] 1 is an exploded perspective view of the connection of the present invention with portions of the base removed to show the recessed portion of the connector. [Figure 10] This is a cross-sectional side elevation view of a connection, with the anchored structural member and anchor structural member shown in cross section. The furring strip is shown attached to the base member and to the vertically-disposed studs that make up the anchored structural member. The connector interfaces with the furring strip, and nails are driven through the connector and furring strip into the lower support member. The connector is shown embedded in the concrete foundation and attached to the formwork plate. [Figure 11] 11 is a cross-sectional side elevation view of a connection similar to FIG. 10, showing screws as fasteners making the connection between the connector and the lower support member of the anchored structural member. [Figure 12] FIG. 11 is a cross-sectional side elevation view of a connection similar to FIG. 10, in which the connector is attached directly to the side surface of the lower support member. [Figure 13] 1 is a cross-sectional side view of a connector connected to a foundation formwork member, with the concrete foundation shown in cross section. [Figure 14] FIG. 10 is a perspective view of a modified form of connector attached to a formwork plate. [Figure 15] FIG. 15 is a perspective view of the connector shown in FIG. 14. [Figure 16] FIG. 10 is a perspective view of another modified form of connector. DETAILED DESCRIPTION OF THE INVENTION

[0013] 10, the connector 1 of the present invention is used to secure an anchored structural member or wall 2 to an anchoring structural member, such as a concrete or cementitious foundation 3. Foundation 3 has a top surface 13 and a perimeter surface 104 that meets top surface 13 at an outer edge 105.

[0014] As shown in FIG. 13, the connector 1 is temporarily attached to the formwork member 4 by one or more fasteners, such as nails 6 .

[0015] As shown in FIG. 10 , the anchored structural member or wall 2 is formed with a base or lower support member 21. The lower support member 21 preferably has a bottom surface 22 that rests on the upper surface 13 of the foundation 3, sides 23, and a top surface 24. Furring strips 25 may be attached to the sides 23 of the base 21. Studs 101 extending upward from the base 21 are shown in FIG. 11 . The studs 101 are attached to the base. The furring strips 25 are typically connected to the base 21 and the studs 101, and the furring strips 25 are structural and may provide lateral resistance to the load of the anchored structural member or wall 2.

[0016] As shown in FIG. 1, the connector 1 includes a potting member 7 having a terminal end 8 .

[0017] As shown in Figures 8, 9 and 13, the embedding elements 7 are positioned diagonally downwards within the foundation 3 and extend away from the formwork members or plates 4.

[0018] As shown in FIG. 1, the embedding member 7 has an upper end portion 9 that is attached to an extension member 10 , which in turn is attached to a mounting member 12 .

[0019] As shown in Figure 13, in one type of formwork, when connector 1 is positioned for pouring a concrete foundation, mounting member 12 overlaps upper surface 14 of formwork plate 4, with the general plane of mounting member 12 being in the general plane of upper surface 13 of foundation 3. An alternative embodiment of a connector for attachment to an alternative formwork is shown in Figure 16.

[0020] As shown in FIG. 1 , attachment member 12 connects to extension member 10 at interface 57. Embedded member 7 has an upper terminating edge 106 where it connects to extension member 10. Attachment member 12 is preferably a unitary attachment member connected to extension member 10. As shown in FIGS. 2 and 7 , attachment member 12 is preferably wider than embedment member 7 along a transverse axis 110 of connector 1 that is perpendicular to a longitudinal axis 111 of connector 1. The transverse axis is parallel to the upper terminating edge 106 of embedment member 7.

[0021] 2, in a preferred embodiment, linearly arranged oblong openings 102 are formed in connector 1 along upper termination edge 106 to provide controlled weakening of connector 1 so that it can be bent in the field as needed. These oblong openings 102 are elongated along transverse axis 110 of connector 1.

[0022] As shown in FIG. 1 , preferably, the connector 1 is first formed with the attachment member 12 and extension member 10 as generally planar members and in the same plane, and the embedment member 7 is bent 45 degrees from the extension member 10 at the terminal edge 106 of the embedment member 7. Alternatively, as shown in FIGS. 14 and 15 , the upper portion 9 of the embedment member is bent perpendicularly from the extension member 10, and the remainder of the embedment member 7 is bent 45 degrees relative to the upper portion 9. Alternatively, as shown in FIG. 16 , during concrete pouring using a particular formwork, the upper portion 9 of the embedment member 7 is aligned with the extension member 10, and the remainder of the embedment member 7 is bent 45 degrees relative to the upper portion 9 of the embedment member 7.

[0023] As shown in FIG. 1 , the embedment member 7 is preferably formed as a pair of legs 18 that extend into the foundation 3 when in use. A gap 61 is provided between the legs 18 to allow concrete to surround the legs 18 of the embedment member 7. As shown in FIG. 7 , the legs 18 extend along the longitudinal axis 111 of the connector 1. The multiple legs 18 also help prevent rotation of the connector 1 when a force is applied to the connector 1. The legs 18 have a selected length along the longitudinal axis 111 of the connector 1, and the legs 18 are substantially separated from one another along a substantial portion of their selected length. Each leg 18 has a terminal end 8 disposed inwardly from the outer circumferential surface 104 of the foundation 3, and each said leg 18 extends substantially to the upper end 9 of the embedment member 7. Preferably, the legs 18 of the embedding member 7 extend through the extension member 10 and connect to the integral mounting member 12 at a lower elongated boundary 57 where the integral mounting member 12 connects to the extension member 10, with each leg 18 connecting to the integral mounting member 12 by having a portion that forms the upper end 9 of the embedding member 7 connected to the extension member 10 that is connected to the lower elongated boundary 57 of the integral mounting member 12. As shown in FIG. 1 , the extension member 10 is formed as multiple extension sections that connect the legs 18 to the mounting member 12, and one or more open notches 30 are formed in the extension member 10 between the extension sections. The upper edges of the one or more open notches 30 in the extension member 10 coincide with the boundary 57 between the mounting member 12 and the extension member 10.

[0024] 1, the embedment member 7 is formed with one or more embossments 16 that extend along the longitudinal axis 111 of the connector 1 for a substantial length of the leg 18. The leg 18 is preferably provided with enlarged flow holes 112 to aid in the mechanical coupling of the leg 18 with the cementitious member.

[0025] As shown in FIG. 7, preferably, the distal end 8 of each leg 18 is formed with an angled barb 17 that enhances mechanical engagement with the base 3 .

[0026] As shown in FIG. 12 , the mounting member 12 is formed with fastener openings 19 for driving fasteners 20 therethrough. The fasteners 20 can be nails, as shown in FIG. 10 , or screws, as shown in FIG. 11 . The sides 23 of the base 21 are typically aligned with the outer periphery 104 of the foundation 3. The sides 23 of the base 21 can be covered by the furring material 25, or they may not be covered by the furring material 25. As shown in FIGS. 11 and 12 , the fastener openings 19 in the mounting member 12 are positioned so that they can engage with the sides 23 of the base 21 when the base 21 and furring material 25 are of typical dimensions, regardless of whether the sides 23 of the base 21 are covered by the furring material 25.

[0027] As shown in FIG. 2 , the fastener openings 19 in the mounting member 12 are preferably arranged along a converging line 113 that extends parallel to the transverse axis 110 of the connector 3, with no fastener opening 19 spaced farther from the converging line 113 than the diameter 41 of the fastener opening 19, and preferably the converging line 113 passing through or intersecting all of the fastener openings 19, or passing through or intersecting some of the fastener openings 19 and substantially intersecting the peripheries 42 of the remaining fastener openings 19.

[0028] 1 and 3, in a preferred embodiment of the present invention, the fastener openings 19 of the attachment member 12 are formed with peripheral embossments 26, with each peripheral embossment 26 surrounding or substantially surrounding the fastener opening 19. The peripheral embossments 26 are generally annular protruding members 45 having generally planar base portions 46 that protrude from the generally planar attachment member 12. The peripheral embossments 26 are preferably formed with outer annular peripheral edges 47 that substantially intersect the outer annular peripheral edges 47 of adjacent peripheral embossments 26. As shown in FIG. 1, bridging embossments 48 have base portions of a similar height to the base portions 46 of the peripheral embossments and connect adjacent peripheral embossments 26. As shown in FIG. 1 , the connection of bridging embossment 48 with surrounding embossment 26 creates a continuous embossment 51 surrounding all fastener openings 19, with embossment 51 extending substantially the lateral length of attachment member 12.

[0029] As best seen in FIG. 1, radially inward from the peripheral embossing 26, the attachment member 12 is provided with a protruding member 49 in the form of a conical member having an angled surface 50 that converges at the fastener opening 19.

[0030] In a preferred embodiment, some embossments 26 have lower edges 27 that extend to boundary 57. The embossed portion of mounting member 12 extends a substantial distance of mounting member 12 along longitudinal axis 111 of connector 1. As shown in FIG. 1 , in a preferred embodiment, an upper portion 70 of mounting member 12 near upper edge 71 of mounting member 12 has a non-embossed portion. The embossments 26 resist deformation, and therefore, the lower edges 27 of the embossments 26 that extend to boundary 57 define an area at boundary 57 that is more easily bent than the embossed portion of mounting member 12. When the base material 25 is attached to the base 21 as shown in FIG. 10 and the extension member 10 projects in line with the top surface 13 of the base 3, the user can bend the mounting member 12 upward by bending the connector 1 at the interface 57, where it is relatively easy to bend the connector, as opposed to bending through the embossment 26.

[0031] The connector 1 is preferably formed from a blank of sheet steel which is preferably galvanized.

[0032] Connector 1 is preferably installed before the concrete slab is poured. The anchors are installed as shown in FIG. 13, with one or more nails 6 driven through openings 19 in mounting members 12 and into the top surface 14 of form plate 4. After the concrete is poured and hardens, nails 6 can be removed and form plate 4 can be peeled away from foundation 3, leaving connector 1 embedded in foundation 3.

[0033] As shown in FIG. 12, due to the shape of the embedment members 7 in this particular embodiment, when the formwork plates 4 are removed, only the upper terminal edges 106 of the upper ends 9 of the embedment members 7 are exposed, minimizing exposure of the connectors 1 to the elements, which can cause corrosion of the connectors 1 and weaken the connection.

[0034] To complete the connection, the bottom surface 22 of the lower support member 21 is placed against the top surface 13 of the cementitious foundation 3. If the side surface 23 of the lower support member is not covered by a base material 25 as shown in FIG. 12, the extension member 10 and the mounting member 12 are bent upward 90 degrees at the terminal edge 106 of the embedment member along the side surface 23 of the lower support member or base member 21. The mounting member 12 abuts the side surface 23 of the lower support member 21, and the fasteners 20 are inserted through the mounting member 12 and directly into the side surface 23 of the lower support member 21. If the base material 25 is attached to the lower support member 21 as shown in FIGS. 10 and 11, or if the lower support member 21 overhangs the cementitious member 3, the bending of the connector 1 occurs at the interface 57 between the mounting member 12 and the extension member 10. If the lower portion of the furring strip 25 is not aligned with the top surface 13 of the anchor structural member 3, the extension member can be bent upward to reach the outer side surface 28 of the furring strip 25. The mounting member 12 is bent upward so that the mounting member 12 abuts the side surface 28 of the furring strip 25 and the fasteners 20 pass through the mounting member 12, the furring strip 25, and into the side surface 23 of the lower support member 21. The extension member 10 is preferably formed without deformation or embossing so that the portion of the extension member 10 can be easily bent.

[0035] As shown in Figures 14, 15, and 16, the top portion 9 of the embedment member 7 that attaches to the extension member 10 can be formed at an angle relative to the rest of the embedment member 7 so that the top portion 9 is positioned vertically when attached to the formwork plate 4, the top portion 9 is positioned at a perpendicular angle to the extension member 10 as shown in Figures 14 and 15, or is positioned flush with the extension member 10 as shown in Figure 16. The embodiment of connector 1 shown in Figure 16 is designed for installation into a panelized formwork where the top surface of the formwork plate 4 is positioned significantly above where the top surface 13 of the cementitious member 3 is located. Forming the top portion 9 of the embedment member 7 to be flush with the inside surface of the formwork plate 4 helps to position the connector accurately and in alignment with the inside surface of the formwork plate.

[0036] As shown in FIGS. 14 and 15, the upper portion 70 of the mounting member 12 may be formed with a notch 114 that aids in aligning the mounting member 12 with the outer edge of the form plate 4.

Claims

1. A connection portion that fixes an anchored structural member to an anchor structural member using a connector, a. the anchor structural member is a cementitious foundation having a generally horizontal upper surface and a perimeter surface that meets the upper surface at an outer edge; b. An anchored structural member having a lower support member having an upper surface and a side surface, the side surface of the lower support member being disposed in a substantially parallel relationship with the outer periphery of the concrete foundation. Equipped with c) the connector includes an embedding member that is embedded obliquely relative to the upper surface of the foundation, the embedding member having a plurality of legs each having a selected length along a longitudinal axis of the connector, the legs being substantially separated from one another along a substantial portion of their selected lengths, the embedding member having an upper terminal edge disposed adjacent an outer edge of the foundation and an upper end extending downwardly within the foundation, each of the legs having a terminal end disposed inward from the outer periphery of the foundation, each of the legs extending substantially to the upper end of the embedding member; d) the connector includes an extension member connected to the upper end of the embedding member at the upper terminal edge of the embedding member and extending away from the upper end of the embedding member and the base perimeter surface; e. the connector includes an elongated integral mounting member connected to the extension member and the legs of the embedding member through the extension member, the integral mounting member having a lower elongated border where the integral mounting member connects to the extension member, and each of the legs connects to the integral mounting member by having a portion forming an upper end of the embedding member connected to the extension member which is connected to the lower elongated border of the integral mounting member; f. the integral mounting member is aligned with the side surface of the lower support member; g. fasteners connecting the mounting members to the side surfaces of the lower support members; Connection part.

2. the mounting member is wider than the embedding member along a transverse axis of the connector perpendicular to a longitudinal axis of the connector; The connection according to claim 1 .

3. the extension member is formed as a plurality of extension sections connecting the legs to the mounting member, and one or more open notches are formed in the extension member between the extension sections; The connection according to claim 1 .

4. an upper edge of one or more open notches in the extension member coincides with the interface between the attachment member and the extension member; The connection according to claim 3 .

5. the mounting member of the connector is attached to the lower support member of the anchored structural member only by fasteners that pass through the connector and the side surface of the lower support member; The connection according to claim 1 .

6. a. the extension member extends away from the outer edge of the cementitious foundation and substantially parallel to the upper surface of the cementitious foundation; b. the mounting member extends upwardly and substantially parallel to the outer periphery of the foundation; The connection according to claim 1 .

7. a. the extension member extends away from an outer edge of the cementitious foundation at an angle relative to the top surface of the cementitious foundation; b. the mounting member extends upwardly and substantially parallel to the outer periphery of the foundation; The connection according to claim 1 .

8. a plurality of fastener openings for the fasteners to be received by the mounting member of the connector are formed in the mounting member of the connector, and a plurality of peripheral embossments are formed around the fastener openings; The connection according to claim 1 .

9. a selected peripheral embossment of the plurality of peripheral embossments has a lower edge that is substantially aligned with the interface between the attachment member and the extension member; The connection according to claim 8.

10. the peripheral embossments formed around the fastener opening are connected to one another; The connection according to claim 9.

11. the legs have reinforcing embossments; The connection according to claim 1 .

12. the reinforcing embossments on the legs extend substantially the length of the legs, and the embossments are aligned with the longitudinal axis of the connector. The connection according to claim 11.

13. the upper terminal edge of the upper end of the embedding member substantially coincides with a bend line between the embedding member and the extension member; The connection according to claim 1 .

14. an opening formed in the connector along the bend line between the embedding member and the extension member; The connection of claim 13 further comprising:

15. the opening formed in the connector along the bend line is formed as a laterally elongated opening extending along the bend line between the embedding member and the extension member; The connection according to claim 14.

16. the legs having terminal portions at the distal ends of the legs formed with barbs; The connection according to claim 1 .

17. the legs are formed with enlarged flow openings; The connection according to claim 1 .

18. the mounting member is formed with a plurality of fastener openings for receiving fasteners for attaching the mounting member to the side surface of the lower support member, the fastener openings being arranged along a collection line extending parallel to a transverse axis of the connector, and no fastener opening is spaced from the collection line by more than a diameter of the fastener opening; The connection according to claim 1 .

19. the aggregation line passes through all of the fastener openings; 19. The connection of claim 18.

20. the aggregation line intersects a portion of the plurality of fastener openings and substantially intersects the remaining peripheries of the plurality of fastener openings; 18. The connection according to claim 17.

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