Masonry Veneer Hanger Assembly for Concealed Shelf Angle Support

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Solution Overview

Problem

In contemporary building construction, the use of masonry veneer with shelf angles poses challenges such as trapped moisture leading to rusting and mortar obstruction, which complicates drainage and visual aesthetics, especially in non-planar wall configurations where excess mortar falls between the veneer and insulation, obstructing weep holes and requiring innovative support solutions.

Innovation Solution

A two-part, separable masonry veneer support hanger assembly that mounts to a masonry support shelf angle, featuring a hook-like design with a crotch mechanism to securely engage the shelf angle, allowing for easy installation and load transfer while accommodating re-bar and mortar, and a foot profiled to conform to the masonry veneer, ensuring secure attachment without visible fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If shelf angles are mounted close to the wall structure to reduce spacing, then the visual appearance is improved and structural efficiency is enhanced, but moisture trapping and rusting occur due to inadequate drainage pathways

Engineering Contradiction:

Improvespacing between shelf angle and wall structureVSAvoidmoisture trapping and rusting

Core Design Contradiction:

ShapeVSObject-affected harmful factors

Solution Approach 1:

The support system is divided into modular components: mounting brackets attached to the wall structure, shelf angles spanning between brackets, and drainage channels integrated into the shelf angle design. This segmentation allows each component to perform its specific function while maintaining close spacing without moisture accumulation

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Drainage channels and weep holes act as intermediary pathways between the shelf angle and wall structure, providing a controlled route for moisture egress. These intermediaries prevent direct contact between trapped moisture and the shelf angle, eliminating rusting while maintaining aesthetic close spacing

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If shelf angles are spaced far from the wall structure to allow drainage, then moisture-related issues are reduced, but the visual appearance deteriorates and structural efficiency is reduced

Engineering Contradiction:

Improvemoisture drainageVSAvoidspacing between shelf angle and wall structure

Core Design Contradiction:

Object-affected harmful factorsVSShape

Solution Approach 1:

Instead of relying solely on horizontal spacing for drainage, the solution introduces a vertical dimension through integrated drainage channels and weep holes in the shelf angle design. This allows effective moisture drainage while maintaining minimal horizontal spacing for aesthetic and structural efficiency

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of manufacture

If masonry veneer is installed directly against the sheathing, then construction simplicity is improved, but excess mortar blocks drainage pathways and causes rusting

Engineering Contradiction:

Improveconstruction simplicityVSAvoidmortar obstruction of drainage

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The shelf angle with integrated drainage channels is installed before masonry veneer application, establishing a predetermined drainage pathway. This preliminary action ensures that even when veneer is installed directly against sheathing, excess mortar cannot block the pre-formed drainage channels, preventing rusting while maintaining construction simplicity

Inventive Principle:

Principle #10Preliminary action

4Strength

If support brackets are visible to provide structural support, then structural function is ensured, but visual aesthetics deteriorate

Engineering Contradiction:

Improvestructural support capabilityVSAvoidvisual appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The mounting brackets are designed with differentiated local qualities: the structural attachment portion remains visible and robust for strength, while the portion near the shelf angle incorporates aesthetic finishes or is positioned to be less conspicuous. This local differentiation maintains structural capability while improving overall visual appearance

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12134889B2Support bracket hanger assembly and method

Publication Date: 2024.11.05 FERO CORP

AI summary

A masonry veneer support assembly for mounting masonry veneer to supporting wall structure has a shelf angle, and first and second shelf angle mounting brackets. Each shelf angle mounting bracket has an upwardly extending back that mounts to the supporting wall structure, and a web extending forwardly away from the wall structure. The web has first and second shelf angle mounting seats formed therein. The first shelf angle mounting seat is upwardly spaced from the second shelf angle mounting seat. Hangers in the form of two-part separable brackets are provided to permit masonry veneer to be mounted underneath the shelf angle, thereby concealing it from view.