Thermally Coated Wall Anchor for Cavity Wall Thermal Break

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Solution Overview

Problem

Existing anchoring systems in cavity walls, made from thermally conductive metals, compromise the thermal insulation by creating thermal bridges and facilitating heat transfer, leading to heating and cooling losses and condensation buildup, which can cause corrosion and mold growth.

Innovation Solution

A thermally-isolating coated wall anchor system with a novel coating that reduces thermal conductivity and provides a thermal break, using materials like thermoplastics, thermosets, and non-porous finishes to minimize heat transfer while maintaining structural integrity and seismic resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If thermally conductive metal anchoring systems are used, then structural strength and seismic resistance are improved, but thermal insulation performance deteriorates due to thermal bridge formation

Engineering Contradiction:

Improvestructural strengthVSAvoidthermal energy loss

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

A thermally-isolating coating is applied as an intermediary layer between the thermally conductive metal wall anchor and the surrounding cavity wall components. This coating acts as a thermal barrier that interrupts the thermal thread while allowing the metal anchor to maintain its structural function for seismic and wind resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The anchoring system transitions from a single-material metal construction to a composite structure consisting of a metal core providing structural strength and a thermally-isolating coating providing thermal protection. This composite approach allows simultaneous achievement of both structural integrity and thermal insulation.

Inventive Principle:

Principle #40Composite materials

2Reliability

If metal wall anchors are used to connect veneer ties, then anchoring reliability is improved, but condensation buildup increases due to thermal transfer

Engineering Contradiction:

Improveanchoring reliabilityVSAvoidcondensation buildup

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The thermally-isolating coating serves as a mediator that prevents direct thermal contact between the metal anchor and the cavity environment. By blocking heat transfer through the anchor, the coating eliminates the temperature differential that causes condensation while preserving the anchor's mechanical reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of energy

If thermally-isolating coated wall anchors are used, then thermal insulation performance is improved, but device complexity increases due to coating application

Engineering Contradiction:

Improvethermal energy lossVSAvoidmanufacturing complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The solution changes the thermal conductivity parameter of the wall anchor by applying a coating layer with low thermal conductivity. This parameter modification allows the existing metal anchor design to maintain its structural properties while achieving the desired thermal insulation performance.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional metal anchoring systems are used, then manufacturing simplicity is maintained, but heat transfer through the building envelope increases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidheat transfer

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The harmful thermal conductivity property is extracted from the wall anchor system by applying a thermally-isolating coating. This extraction removes the unwanted heat transfer capability while preserving the essential mechanical anchoring function, achieving energy efficiency without significantly complicating manufacturing.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The thermally-isolating coated wall anchor system effectively reduces thermal conductivity and heat transfer, maintaining insulation integrity and preventing condensation buildup, thereby enhancing energy efficiency and structural stability.

Implementation Method 1

The use of the specially designed and thermally-protected wall anchors of the present invention lowers the underlying metal thermal conductivities, thereby reducing thermal transfer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9624659B2Thermally coated wall anchor and anchoring systems with in-cavity thermal breaks for cavity walls

Publication Date: 2017.04.18 HOHMANN & BARNARD INC

AI summary

Thermally-isolating wall anchors and reinforcement devices and anchoring systems employing the same are disclosed for use in masonry cavity walls. A thermally-isolating coating is applied to the wall anchor, which is interconnected with a wire formative veneer tie. The thermally-isolating coating is selected from a distinct grouping of materials, that are applied using a specific variety of methods, in one or more layers and cured and cross-linked to provide high-strength adhesion. The thermally-coated wall anchors provide an in-cavity thermal break that severs the thermal threads running throughout the cavity wall structure, reducing the U- and K-values of the anchoring system by thermally-isolating the metal components.